Related Manuals for Yamaha PZ50W
Summary of Contents for Yamaha PZ50W
- Page 1 SERVICE MANUAL PZ50W PZ50GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW LIT-12618-02-58 8GC-28197-10...
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Page 3: How To Use This Manual
NOTICE HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and Particularly important information is distinguished in their qualified mechanics. It is not possible to put an this manual by the following notations: entire mechanic’s education into one manual, so it... - Page 4 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment POWR 3 Chassis CHAS 4 Power train 5 Engine 6 Cooling system 7 Fuel injection system...
- Page 5 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL ELEC SPECIFICATIONS SPEC...
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Page 6: Table Of Contents
PZ50/PZ50GT/PZ50FX/PZ50M ....3-1 THROTTLE BODY PZ50VT/PZ50MP ........3-3 SYNCHRONIZATION ....... 2-13 ENGINE IDLE SPEED ADJUSTMENT..2-14 STEERING ............3-4 THROTTLE CABLE FREE PLAY PZ50W/PZ50GT/PZ50FX/PZ50M....3-4 ADJUSTMENT.......... 2-15 PZ50VT/PZ50MP ........3-6 THROTTLE OVERRIDE SYSTEM REMOVAL..........3-10 (T.O.R.S.) CHECK ........2-16 INSPECTION ..........3-10 COMPRESSION PRESSURE INSTALLATION......... - Page 7 PZ50VT “Europe”/PZ50MP....... 3-15 BRAKE CALIPER ASSEMBLY ....4-37 PZ50M ............3-16 BRAKE CALIPER INSTALLATION ... 4-37 INSPECTION ..........3-17 INSPECTION ..........4-39 BRAKE MASTER CYLINDER FRONT SUSPENSION ........3-18 ASSEMBLY..........4-39 PZ50/PZ50FX/PZ50M....... 3-18 INSTALLATION......... 4-39 PZ50GT/PZ50VT/PZ50MP ....... 3-20 HANDLING NOTES ........3-22 SLIDE RAIL SUSPENSION......
- Page 8 CYLINDER HEAD........... 5-28 CHAPTER 7. REMOVAL ..........5-29 FUEL INJECTION SYSTEM INSPECTION ..........5-29 INSTALLATION ........5-30 FUEL INJECTION SYSTEM ......7-1 VALVES AND VALVE SPRINGS....5-32 WIRING DIAGRAM ........7-2 REMOVAL ..........5-33 ECU SELF-DIAGNOSTIC FUNCTION ..7-4 INSPECTION ..........5-34 SELF-DIAGNOSTIC FUNCTION TABLE..
- Page 9 LIGHTING SYSTEM ........8-22 CHAPTER 9. CIRCUIT DIAGRAM........8-22 SPECIFICATIONS TROUBLESHOOTING......8-24 BULB(S)............ 8-26 HEADLIGHT BEAM SWITCH ....8-26 GENERAL SPECIFICATIONS......9-1 HEADLIGHT RELAY......... 8-27 LOAD CONTROL RELAY......8-27 MAINTENANCE SPECIFICATIONS....9-5 ENGINE ............9-5 SIGNAL SYSTEM........... 8-28 POWER TRAIN......... 9-10 CIRCUIT DIAGRAM........
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Page 10: Chapter 1. General Information
MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number 1 is located on the left-hand side of the crank- case. -
Page 11: Important Information
ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments. -
Page 12: Gaskets, Oil Seals, And O-Rings
IMPORTANT INFORMATION INFO GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. -
Page 13: Special Tools
SPECIAL TOOLS INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: •... - Page 14 SPECIAL TOOLS INFO • Cooling system tester P/N: YU-24460-01 90890-01325 • Adapter P/N: YU-33984 90890-01352 This tester and its adapter are used for checking the cooling system. • Oil filter wrench P/N: YM-01469 90890-01469 This tool is needed to loosen or tighten the oil filter cartridge. •...
- Page 15 SPECIAL TOOLS INFO • 40 and 50 mm bearing driver P/N: YM-04058 90890-04058 • Mechanical seal installer P/N: YM-04145 90890-04145 These tools are used to install the water pump seal. • Rotor holding tool P/N: YU-01235 90890-01235 This tool is used to hold the camshaft sprocket. •...
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Page 16: For Power Train Service
• Engine mount spacer wrench P/N: YS-01516 90890-01516 Used to turn the engine mounting bolts when removing/installing engine. • Yamaha bond No. 1215 P/N: 90890-85505 ® (Three Bond No.1215 This bond is used to seal two mating surfaces (e.g., crankcase mating sur- faces.) -
Page 17: For Fuel Injection Service
SPECIAL TOOLS INFO • Clutch bushing press P/N: YS-42424 This tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sheave bush and torque cam bush). • Track clip installer P/N: YS-91045-C 90890-01721 This tool is used for installing the track clip. FOR FUEL INJECTION SERVICE •... - Page 18 SPECIAL TOOLS INFO • Digital circuit tester P/N: YU-A1927 90890-03174 This instrument is necessary for checking the electrical componenets.
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Page 19: Periodic Inspection And Adjustment
Replace if necessary. ∗ Idle speed Check and adjust engine idle speed. ∗ Fuel injection Adjust synchronization. Check for leakage. ∗ Exhaust system Tighten or replace gasket if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer. -
Page 20: General Maintenance And Lubrication Chart
Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary. Lubricate with specified grease. ∗ Steering column bearing Lubricate with specified grease. ∗ Ski and front suspension Lubricate with specified grease. ∗ It is recommended that these items be serviced by a Yamaha dealer. - Page 21 Tool kit and recommended Check for proper placement. equipment ∗ It is recommended that these items be serviced by a Yamaha dealer. NOTE: Brake system: • After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regularly check the brake fluid level and add fluid if necessary.
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Page 22: Engine
INSP SPARK PLUGS/FUEL LINE INSPECTION ENGINE SPARK PLUGS 1. Remove: • Fuel tank Refer to “SEAT AND FUEL TANK” in CHAP- TER 5. (PZ50/PZ50GT/PZ50FX/PZ50M) Refer to “RIDER SEAT AND FUEL TANK” in CHAPTER 5. (PZ50VT/PZ50MP) 2. Remove: • Spark plug caps •... -
Page 23: Cooling System
INSP COOLING SYSTEM COOLING SYSTEM Coolant replacement NOTE: The coolant should be changed at least every sea- son. 1. Place the machine on a level surface. 2. Remove: • Right side panel • Right side cover Refer to “COWLINGS” in CHAPTER 3. 3. - Page 24 INSP COOLING SYSTEM 7. Connect: • Radiator outlet hose 1 8. Fill: • Cooling system Recommended coolant: High quality silicate-free ethylene glycol antifreeze containing corro- sion inhibitors Coolant mixing ratio (coolant:water): 3:2 (60%:40%) Total amount: PZ50/PZ50GT/PZ50FX/PZ50M 3.6 L (3.17 Imp qt, 3.81 US qt) PZ50VT/PZ50MP 3.7 L (3.26 Imp qt, 3.91 US qt) CAUTION:...
- Page 25 INSP COOLING SYSTEM/VALVE CLEARANCE ADJUSTMENT Air bleeding steps: • Remove the cap 1 on the radiator outlet pipe 1. • While slowly adding coolant to the coolant filler, drain the coolant until no more air bubbles appear. • Install the cap 1. •...
- Page 26 INSP VALVE CLEARANCE ADJUSTMENT 3. Remove: • Cylinder head cover Refer to “CAMSHAFTS” in CHAPTER 5. • Timing mark accessing screw 1 • Crankshaft end accessing screw 2 4. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in)
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Page 27: Valve Clearance Adjustment
INSP VALVE CLEARANCE ADJUSTMENT 5. Remove: • Intake camshaft • Exhaust camshaft NOTE: • Refer to “CAMSHAFTS” in CHAPTER 5. • When removing the timing chain and camshafts, fasten a wire to the timing chain to retrieve it if it falls into the crankcase. - Page 28 INSP VALVE CLEARANCE ADJUSTMENT EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) Rounded value = 150 • Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.
- Page 29 INSP VALVE CLEARANCE ADJUSTMENT VALVE PAD SELECTION TABLE INTAKE Measured INSTALLED PAD NUMBER clearance ↓ 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 ~ 0.07...
- Page 30 INSP VALVE CLEARANCE ADJUSTMENT • Install the new valve pad 1 and the valve lifter NOTE: • Apply molybdenum disulfide oil to the valve pad and the valve lifter. • The valve lifter must turn smoothly when rotated by hand. •...