Table of Contents
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MACHINE IDENTIFICATION............................ 1-1
FRAME SERIAL NUMBER ......................... 1-1
ENGINE SERIAL NUMBER........................ 1-1
IMPORTANT INFORMATION .......................... 1-2
DISASSEMBLY........................................... 1-2
ALL REPLACEMENT PARTS..................... 1-2
GASKETS, OIL SEALS, AND O-RINGS..... 1-3
PINS............................................................ 1-3
BEARINGS AND OIL SEALS ..................... 1-3
CIRCLIPS ................................................... 1-3
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................................................... 1-3
SPECIAL TOOLS ............................................. 1-4
FOR TUNE UP............................................ 1-4
FOR ENGINE SERVICE............................. 1-4
FOR POWER TRAIN SERVICE ................. 1-7
FOR FUEL INJECTION SERVICE ............. 1-8
FOR ELECTRICAL SERVICE .................... 1-8
CHAPTER 2.
INTRODUCTION............................................... 2-1
THE EMISSION CONTROL SYSTEM.............. 2-1
LUBRICATION CHART.................................... 2-2
ENGINE ............................................................ 2-4
SPARK PLUGS........................................... 2-4
FUEL LINE INSPECTION........................... 2-4
COOLING SYSTEM.................................... 2-5
VALVE CLEARANCE ADJUSTMENT ........ 2-7
SYNCHRONIZATION ............................... 2-13
ENGINE IDLE SPEED ADJUSTMENT..... 2-14
ADJUSTMENT.......................................... 2-15
(T.O.R.S.) CHECK .................................... 2-16
MEASUREMENT ...................................... 2-17
ENGINE OIL LEVEL INSPECTION .......... 2-19
ENGINE OIL REPLACEMENT ................. 2-20
INSPECTION ............................................ 2-23
INSPECTION ............................................ 2-23
ELEMENT ................................................. 2-24
EXHAUST SYSTEM INSPECTION .......... 2-25
POWER TRAIN............................................... 2-26
SHEAVE OFFSET ADJUSTMENT ........... 2-26
DRIVE V-BELT.......................................... 2-28
ENGAGEMENT SPEED CHECK.............. 2-29
PARKING BRAKE ADJUSTMENT............ 2-29
BRAKE FLUID LEVEL INSPECTION ....... 2-30
BRAKE PAD INSPECTION....................... 2-31
BRAKE HOSE INSPECTION.................... 2-32
SYSTEM) .................................................. 2-32
DRIVE CHAIN ........................................... 2-33
TRACK TENSION ADJUSTMENT............ 2-35
SLIDE RUNNER INSPECTION ................ 2-37
MAXIMIZING DRIVE TRACK LIFE ........... 2-37
CHASSIS ........................................................ 2-39
SKI/SKI RUNNER ..................................... 2-39
STEERING SYSTEM ................................ 2-39
LUBRICATION .......................................... 2-41
ELECTRICAL ................................................. 2-42
HEADLIGHT BEAM ADJUSTMENT ......... 2-42
BATTERY INSPECTION........................... 2-42
FUSE INSPECTION.................................. 2-48
TUNING .......................................................... 2-50
CLUTCH.................................................... 2-50
GEAR SELECTION................................... 2-55
FRONT SUSPENSION ............................. 2-61
REAR SUSPENSION................................ 2-63
CHAPTER 3.
COWLINGS ...................................................... 3-1
PZ50/PZ50GT/PZ50FX/PZ50M .................. 3-1
PZ50VT/PZ50MP ........................................ 3-3
STEERING ........................................................ 3-4
PZ50W/PZ50GT/PZ50FX/PZ50M............... 3-4
PZ50VT/PZ50MP ........................................ 3-6
REMOVAL................................................. 3-10
INSPECTION ............................................ 3-10
INSTALLATION......................................... 3-11
SKI .................................................................. 3-14
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