User Manuals: Yamaha PZ50GTW Snowmobile

Manuals and User Guides for Yamaha PZ50GTW Snowmobile. We have 3 Yamaha PZ50GTW Snowmobile manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha PZ50GTW Service Manual (424 pages)

Yamaha Motorcycles Service manual

Brand: Yamaha | Category: Motorcycle | Size: 17.24 MB

How to Use this Manual
3
Periodic Inspection and
4
Table of Contents
6
Chapter 1. General Information

10
Machine Identification

10
- Frame Serial Number
  10
- Engine Serial Number
  10
Important Information

11
- Preparation for Removal and Disassembly
  11
- All Replacement Parts
  11
- Gaskets, Oil Seals, and O-Rings
  12
- Lock Washers/Plates and Cotter Pins
  12
- Bearings and Oil Seals
  12
- Circlips
  12
- Loctite
  12
Special Tools

13
- For Tune up
  13
- For Engine Service
  13
- For Power Train Service
  16
- For Fuel Injection Service
  17
- For Electrical Service
  17
Chapter 2

19
Periodic Inspection and Adjustment

19
Introduction

19
Periodic Maintenance Chart for the Emission Control System

19
General Maintenance and Lubrication Chart

20
Engine

22
- Spark Plugs
  22
- Fuel Line Inspection
  22
- Cooling System
  23
- Valve Clearance Adjustment
  26
- Throttle Body Synchronization
  31
- Engine Idle Speed Adjustment
  32
- Throttle Cable Free Play Adjustment
  33
- Throttle Override System (T.o.r.s.) Check
  34
- Compression Pressure Measurement
  35
- Engine Oil Level Inspection
  37
- Engine Oil Replacement
  38
- Cylinder Head Breather Hose Inspection
  41
- Throttle Body Joints Inspection
  41
- Checking the Air Filter Element
  42
- Exhaust System Inspection
  43
Power Train

44
- Sheave Offset Adjustment
  44
- Drive V-Belt
  46
- Engagement Speed Check
  47
- Parking Brake Adjustment
  47
- Brake Fluid Level Inspection
  48
- Brake Pad Inspection
  49
- Brake Hose Inspection
  50
- Air Bleeding (Hydraulic Brake System)
  50
- Drive Chain
  51
- Track Tension Adjustment
  54
- Slide Runner Inspection
  55
- Maximizing Drive Track Life
  55
Chassis

57
- Ski/Ski Runner
  57
- Steering System
  57
- Lubrication
  59
Electrical

60
- Headlight Beam Adjustment
  60
- Battery Inspection
  60
- Fuse Inspection
  67
Tuning

68
- Clutch
  68
- Gear Selection
  74
- Front Suspension
  79
- Rear Suspension
  82
Chapter 3

88
Chassis

88
Cowlings

88
- Pz50/Pz50Gt/Pz50Fx/Pz50M
  88
- Pz50Vt/Pz50Mp
  90
Steering

91
- Pz50Vt/Pz50Mp
  93
- Removal
  97
- Inspection
  97
- Installation
  98
Ski

101
- PZ50/PZ50GT/PZ50FX/PZ50VT "Usa/Canada
  101
- PZ50VT "Europe"/Pz50Mp
  102
  - Pz50M
    103
  - Inspection
    104
Front Suspension

105
- Pz50/Pz50Fx/Pz50M
  105
- Pz50Gt/Pz50Vt/Pz50Mp
  107
- Handling Notes
  109
- Inspection
  109
- Installation
  110
Chapter 4. Power Train

112
Primary Sheave and Drive V-Belt

112
- Removal
  114
- Disassembly
  114
- Inspection
  115
- Assembly
  117
- Installation
  120
Secondary Sheave

121
- Disassembly
  123
- Inspection
  123
- Assembly
  124
- Installation
  125
Drive Chain

126
- Removal
  127
- Inspection
  127
- Installation
  129
Secondary Shaft

130
- Pz50
  130
- Removal
  131
- Inspection
  131
- Installation
  131
- Secondary Shaft and Drive Chain Installation
  133
Secondary Shaft and Reverse Gear Case

134
- Pz50Gt/Pz50Fx/Pz50M/Pz50Vt/Pz50Mp
  134
- Removal
  138
- Inspection
  139
- Assembly
  139
- Installation
  140
- Secondary Shaft and Drive Chain Installation
  141
Brake

142
- Brake Pad Replacement
  144
- Brake Caliper Disassembly
  147
- Brake Caliper Inspection and Repair
  147
- Brake Caliper Assembly
  148
- Brake Caliper Installation
  148
- Inspection
  150
- Brake Master Cylinder Assembly
  150
- Installation
  150
Slide Rail Suspension

151
- Pz50/Pz50Gt/Pz50Fx/Pz50M
  151
- Pz50Vt/Pz50Mp
  156
- Removal
  162
- Inspection
  162
- Assembly
  162
- Installation
  166
Front Axle and Track

167
- Inspection
  168
- Installation
  168
Chapter 5. Engine

170
Seat and Fuel Tank

170
- Pz50/Pz50Gt/Pz50Fx/Pz50M
  170
Backrest and Passenger Seat

172
- Pz50Vt/Pz50Mp
  172
Rider Seat and Fuel Tank

174
- Pz50Vt/Pz50Mp
  174
- Removal
  176
- Installation
  177
Exhaust Pipe and Muffler

178
- Pz50/Pz50Gt/Pz50Fx/Pz50M
  178
- Pz50Vt/Pz50Mp
  179
- Installation
  180
Oil Tank

181
Engine Assembly

182
- Hose and Leads
  182
- Engine Assembly
  183
- Removal
  185
- Installation
  185
Camshafts

187
- Cylinder Head Cover
  187
- Camshafts
  188
- Removal
  189
- Inspection
  190
- Installation
  194
Cylinder Head

197
- Removal
  198
- Inspection
  198
- Installation
  199
Valves and Valve Springs

202
- Removal
  202
- Inspection
  203
- Installation
  207
A.C. Magneto Rotor and Starter Clutch

210
- Removal
  211
- Inspection
  212
- Installation
  213
Oil Pan and Oil Pump

215
- Removal
  218
- Inspection
  218
- Installation
  219
Balancer

221
- Removal
  223
- Inspection
  224
- Installation
  224
Crankcase

227
- Connecting Rods and Pistons
  228
- Crankshaft
  229
- Removal
  230
- Inspection
  232
- Installation
  242
Chapter 6. Cooling System

248
Radiator and Heat Exchanger

248
- Inspection
  250
- Installation
  251
Thermostat

252
- Inspection
  253
- Installation
  253
Water Pump

255
- Disassembly
  257
- Inspection
  257
- Assembly
  258
- Installation
  259
Chapter 7. Fuel Injection System

261
Fuel Injection System

261
- Ecu Self-Diagnostic Function
  264
- Self-Diagnostic Function Table
  264
- Troubleshooting Chart
  266
- Diagnostic Mode
  267
- Troubleshooting Details
  274
- Oil Pressure Switch
  288
- Intake Air Temperature Sensor
  288
Throttle Body

289
- Injectors
  290
- Inspection
  291
- Pressure Regulator Operation
  291
- Inspection and Adjustment
  292
Chapter 8. Electrical

295
Switch Inspection

295
- Inspecting a Switch Shown in the Manual
  295
Ignition System

296
- Circuit Diagram
  297
- Troubleshooting
  298
- Ignition Spark Gap
  300
- Ignition Coil
  300
- Crankshaft Position Sensor
  301
- Throttle Override System (T.o.r.s.)
  302
- Engine Stop Switch
  303
- Throttle Switch
  303
- Main Switch
  304
Electrical Starting System

305
- Troubleshooting
  306
- Starter Motor
  308
Charging System

314
- Troubleshooting
  314
- Battery
  315
- A.C. Magneto
  315
Lighting System

317
- Circuit Diagram
  317
- Troubleshooting
  318
- Bulb(S)
  320
- Headlight Beam Switch
  320
- Headlight Relay
  321
- Load Control Relay
  321
Signal System

323
- Circuit Diagram
  323
- Troubleshooting
  324
- Brake Light Switch
  332
- Drive Position Switch and Reverse Position Switch (Pz50Gt/Pz50Fx/Pz50M/Pz50Vt/ Pz50Mp)
  332
- DC Back Buzzer (Pz50Gt/Pz50Fx/ Pz50M/Pz50Vt/Pz50Mp)
  332
- Coolant Temperature Sensor
  333
- Oil Level Switch
  334
- Fuel Sender
  334
- Speed Sensor
  335
- Knock Sensor
  335
Grip Warmer System

337
- Circuit Diagram
  337
- Troubleshooting
  338
- Grip and Thumb Warmer
  340
- Grip/Thumb Warmer Adjustment Switch
  340
- Passenger Grip Warmer (Pz50Vt)
  341
- Passenger Grip Warmer Switch (Pz50Vt)
  341
- Passenger Grip Warmer Relay (Pz50Vt/Pz50Mp)
  342
Cooling System (Pz50M/Pz50Vt/Pz50Mp)

345
- Circuit Diagram
  345
- Troubleshooting
  346
- Radiator Fan Motor
  347
- Radiator Fan Motor Relay
  347
Drive/Reverse Selecting System (Pz50Gt/Pz50Fx/Pz50M/Pz50Vt/Pz50Mp)

348
- Circuit Diagram
  349
- Troubleshooting
  350
- Gear Motor
  351
- Gear Motor Relay 1
  352
- Gear Motor Relay 2
  352
- Gear Motor Relay 3
  353
Chapter 9. Specifications

354
General Specifications

354
Maintenance Specifications

358
- Engine
  358
- Power Train
  363
- Chassis
  369
- Electrical
  371
Tightening Torque

374
- Engine
  374
- Power Train
  376
General Torque Specifications

380
Definition of Units

380
Cable Routing

382

Yamaha PZ50GTW Owner's Manual (104 pages)

Brand: Yamaha | Category: Snowmobiles | Size: 6.21 MB

Table of Contents
6
Yamaha Motor Corporation, U.s.a. Snowmobile Limited Warranty

8
- Change of Address
  10
Yamaha Extended Service (Y.e.s.)

11
Location of the Important Labels

12
Safety Information

14
Description

17
Control Functions

20
- Main Switch
  20
- Throttle Lever
  20
- Engine Overheating Prevention System
  21
- Throttle Override System (T.O.R.S.)
  21
- Speedometer Unit
  23
- High Beam Indicator Light
  24
- Fuel Meter and Grip/Thumb Warmer Level Indicator
  24
- Fuel Level Warning Indicator
  25
- Oil Level Warning Indicator
  25
- Low Coolant Temperature Indicator Light
  26
- Drive "D" and Reverse "R" Indicator Lights
  26
- Knock Control System "KCS" Indicator Light
  26
- Coolant Temperature Warning Indicator
  27
- Self-Diagnostic System
  27
- Engine Stop Switch
  28
- Drive Select Switch
  28
- Brake Lever
  29
- Parking Brake Lever
  29
- Headlight Beam Switch
  30
- Grip/Thumb Warmer Adjustment Switch
  30
- Passenger Grip Warmer Switch
  30
- Auxiliary DC Jack
  31
- Shroud Latches
  31
- Shroud and Covers
  32
- Drive Guard
  33
- V-Belt Holder
  33
- Backrest
  34
- Storage Compartment
  34
- Rear Carrier
  34
Pre-Operation Checks

35
- Fuel
  35
- Engine Oil
  36
- Engine Oil Level
  37
- Coolant
  38
- Throttle Lever
  39
- Throttle Override System (T.O.R.S.)
  39
- Brake
  40
- Brake Fluid Leakage
  41
- V-Belt
  41
- Drive Guard
  42
- Drive Track
  42
- 51-MM (2.0-In) High-Profile Pattern Drive Track
  42
- Slide Runners
  43
- Skis and Ski Runners
  43
- Steering System
  44
- Lights
  44
- Air Filter
  44
- Fittings and Fasteners
  44
- Tool Kit and Recommended Equipment
  45
Operation

46
- Starting the Engine
  46
- Break-In
  47
- Riding Your Snowmobile
  48
- Getting to Know Your Snowmobile
  48
- Learning to Ride Your Snowmobile
  48
- To Start out and Accelerate
  48
- Braking
  48
- Turning
  49
- Riding Uphill
  49
- Riding Downhill
  50
- Traversing a Slope
  50
- Ice or Icy Surface
  50
- Hard-Packed Snow
  51
- Operation on Surfaces Other than Snow or Ice
  51
- Maximizing Drive Track Life
  52
- Strap
  53
- Driving
  53
- Stopping the Engine
  55
- Transporting
  55
Periodic Maintenance

56
- Periodic Maintenance Chart for the Emission Control System
  56
- General Maintenance and Lubrication Chart
  57
- Tool Kit
  60
- Removing and Installing the Shroud and Covers
  61
- Checking the Spark Plugs
  64
- Adjusting the Engine Idling Speed
  66
- Adjusting the Throttle Cable
  66
- Checking the Throttle Cable
  66
- Adjusting the High-Altitude Settings
  67
- Adjusting the Valve Clearance
  67
- Changing the Engine Oil
  68
- Cooling System
  70
- Replacing the V-Belt
  72
- Checking the Drive Chain Housing Oil Level and the Drive Chain Tension
  73
- Checking the Brake Pads
  74
- Checking the Parking Brake Pads
  75
- Checking the Brake Fluid Level
  75
- Changing the Brake Fluid
  76
- Suspension
  76
- Adjusting the Drive Track
  84
- Aligning the Skis
  86
- Lubrication
  87
- Replacing a Headlight Bulb
  88
- Adjusting the Headlight Beams
  89
- Battery
  89
- Replacing a Fuse
  90
Troubleshooting

91
Storage

94
Specifications

96
- Dimensions
  96
- Engine
  96
- Chassis
  97
- Electric
  98

Yamaha PZ50GTW Service Manual (30 pages)

Brand: Yamaha | Category: Snowmobiles | Size: 0.55 MB

How to Use this Manual
3
Table of Contents
6
Chapter 1. General Information

10
Machine Identification

10
- Frame Serial Number
  10
- Engine Serial Number
  10
Important Information

11
- Preparation for Removal and Disassembly
  11
- All Replacement Parts
  11
- Gaskets, Oil Seals, and O-Rings
  12
- Lock Washers/Plates and Cotter Pins
  12
- Bearings and Oil Seals
  12
- Circlips
  12
- Loctite
  12
Special Tools

13
- For Tune up
  13
- For Engine Service
  13
- For Power Train Service
  16
- For Fuel Injection Service
  17
- For Electrical Service
  17
Chapter 2

19
Periodic Inspection and Adjustment

19
Introduction

19
Periodic Maintenance Chart for the Emission Control System

19
General Maintenance and Lubrication Chart

20
Chapter 3

22
- Spark Plugs
  22
- Fuel Line Inspection
  22
- Cooling System
  23
- Valve Clearance Adjustment
  27
Engine

22

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User Manuals: Yamaha PZ50GTW Snowmobile

Yamaha PZ50GTW Service Manual (424 pages)

Table of Contents

Chapter 1. General Information

Machine Identification

Important Information

Special Tools

Chapter 2

Periodic Inspection and Adjustment

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Engine

Power Train

Chassis

Electrical

Tuning

Chapter 3

Chassis

Cowlings

Steering

Ski

Front Suspension

Chapter 4. Power Train

Primary Sheave and Drive V-Belt

Secondary Sheave

Drive Chain

Secondary Shaft

Secondary Shaft and Reverse Gear Case

Brake

Slide Rail Suspension

Front Axle and Track

Chapter 5. Engine

Seat and Fuel Tank

Backrest and Passenger Seat

Rider Seat and Fuel Tank

Exhaust Pipe and Muffler

Oil Tank

Engine Assembly

Camshafts

Cylinder Head

Valves and Valve Springs

A.C. Magneto Rotor and Starter Clutch

Oil Pan and Oil Pump

Balancer

Crankcase

Chapter 6. Cooling System

Radiator and Heat Exchanger

Thermostat

Water Pump

Chapter 7. Fuel Injection System

Fuel Injection System

Throttle Body

Chapter 8. Electrical

Switch Inspection

Ignition System

Electrical Starting System

Charging System

Lighting System

Signal System

Grip Warmer System

Cooling System (Pz50M/Pz50Vt/Pz50Mp)

Drive/Reverse Selecting System (Pz50Gt/Pz50Fx/Pz50M/Pz50Vt/Pz50Mp)

Chapter 9. Specifications

General Specifications

Maintenance Specifications

Tightening Torque

General Torque Specifications

Definition of Units

Cable Routing

Yamaha PZ50GTW Owner's Manual (104 pages)

Table of Contents

Yamaha Motor Corporation, U.s.a. Snowmobile Limited Warranty

Yamaha Extended Service (Y.e.s.)

Location of the Important Labels

Safety Information

Description

Control Functions

Pre-Operation Checks

Operation