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Cover_SMB.fm Page 1 Thursday, July 27, 2006 9:56 AM SERVICE MANUAL PZ50W PZ50GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN U.S.A. 2006.
NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical concepts and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use.
1 ILLUSTRATED SYMBOLS (Refer to the illustration) 2 INSP ADJ GEN INFO 3 Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 4 1 2 3 4 5 6 7 8 9 POWR TR CHAS 5 6 COOL ENG 7 General information Periodic inspection and adjustment Chassis Power train Engine Cooling system Fuel injection system Electrical Specifications 8 FI ELEC – + 9 SPEC 0 A Illustrated symbols 0 to F are used to identify the specifications which appear. B T. R.
INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM GEN INFO 1 INSP ADJ 2 CHAS 3 POWR TR 4 ENG 5 COOL 6 FI 7 – ELECTRICAL SPECIFICATIONS + ELEC 8 SPEC 9
CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION............................ 1-1 FRAME SERIAL NUMBER ......................... 1-1 ENGINE SERIAL NUMBER........................ 1-1 IMPORTANT INFORMATION .......................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY........................................... 1-2 ALL REPLACEMENT PARTS..................... 1-2 GASKETS, OIL SEALS, AND O-RINGS..... 1-3 LOCK WASHERS/PLATES AND COTTER PINS............................................................
PZ50VT “Europe”/PZ50MP....................... 3-15 PZ50M ...................................................... 3-16 INSPECTION ............................................ 3-17 FRONT SUSPENSION ................................... 3-18 PZ50/PZ50FX/PZ50M............................... 3-18 PZ50GT/PZ50VT/PZ50MP ....................... 3-20 HANDLING NOTES .................................. 3-22 INSPECTION ............................................ 3-22 INSTALLATION ........................................
CYLINDER HEAD........................................... 5-28 REMOVAL ................................................ 5-29 INSPECTION ............................................ 5-29 INSTALLATION ........................................ 5-30 VALVES AND VALVE SPRINGS................... 5-32 REMOVAL ................................................ 5-33 INSPECTION ............................................ 5-34 INSTALLATION ........................................ 5-38 A.C.
LIGHTING SYSTEM ....................................... 8-22 CIRCUIT DIAGRAM.................................. 8-22 TROUBLESHOOTING.............................. 8-24 BULB(S).................................................... 8-26 HEADLIGHT BEAM SWITCH ................... 8-26 HEADLIGHT RELAY................................. 8-27 LOAD CONTROL RELAY......................... 8-27 SIGNAL SYSTEM........................................... 8-28 CIRCUIT DIAGRAM..................................
MACHINE IDENTIFICATION GEN 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 crankcase. NOTE: Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. While cleaning, take care to protect the electrical parts, such as relays, switches, motor, resistors, controllers, etc., from high pressure water splashes. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling the machine, keep mated parts together.
IMPORTANT INFORMATION GEN 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. LOCK WASHERS/PLATES AND COTTER PINS All lock washers/plates 1 and cotter pins must be replaced if they are removed.
SPECIAL TOOLS GEN 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: • Be sure to use the correct part number when ordering the tool, since the part number may differ according to country. • For USA and Canada, use part number starting with “YB-”, “YM-”, “YU-” or “YS-”. • For others, use part number starting with “90890-”.
SPECIAL TOOLS GEN 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. • Vacuum gauge P/N: YU-44456 90890-03094 This guide is used to synchronize the carburetors. • Compression gauge P/N: YU-33223 (compression gage) 90890-03081 These tools are used to measure engine compression.
SPECIAL TOOLS GEN 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. • Valve guide remover (ø4) P/N: YM-04111 90890-04111 This tool is used to remove or install the valve guides. • Valve guide installer (ø4) P/N: YM-04112 90890-04112 This tool is used to install the valve guides.
SPECIAL TOOLS GEN INFO • Dynamic spark tester P/N: YM-34487 • Ignition checker P/N: 90890-06754 This tool is used to check the ignition system component. • 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 surfaces.
SPECIAL TOOLS GEN 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 • Mity vac P/N: YS-42423 90890-06756 This tool is used to measure the vacuum pressure. • Fuel pressure adapter P/N: YM-03176 90890-03176 This tool is needed to measure fuel pressure.
SPECIAL TOOLS GEN INFO • Digital circuit tester P/N: YU-A1927 90890-03174 This instrument is necessary for checking the electrical componenets.
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INSP ADJ PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.
GENERAL MAINTENANCE AND LUBRICATION CHART INSP ADJ GENERAL MAINTENANCE AND LUBRICATION CHART Item Engine oil ∗ Engine oil filter cartridge Fuel Engine coolant Pre-operation check (Daily) Remarks Every Seasonally or 4,000 km (2,500 mi) (200 hr) Check oil level. ∗ Replace. Every 20,000 km (12,000 mi) Replace. Check fuel level. Check coolant level. ∗ Air bleed the cooling system if necessary. Throttle lever (handlebar side) Check operation. ∗ Repair if necessary. Throttle override system (T.O.R.S.
GENERAL MAINTENANCE AND LUBRICATION CHART Item ∗ Suspension component Pre-operation check (Daily) Remarks INSP ADJ Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 4,000 km (2,500 mi) (200 hr) Lubricate with specified grease. Lubricate with specified grease. ∗ Parking brake cable end and lever end/throttle cable Check cable damage. end Replace if necessary. Shroud and covers Make sure that the shroud and covers are securely fastened. Fittings and fasteners Check tightness.
SPARK PLUGS/FUEL LINE INSPECTION INSP ADJ ENGINE SPARK PLUGS 1. Remove: • Fuel tank Refer to “SEAT AND FUEL TANK” in CHAPTER 5. (PZ50/PZ50GT/PZ50FX/PZ50M) Refer to “RIDER SEAT AND FUEL TANK” in CHAPTER 5. (PZ50VT/PZ50MP) 2. Remove: • Spark plug caps • Spark plugs 3. Inspect: • Electrodes 1 Damage/wear → Replace the spark plug. • Insulator color 2 Abnormal color → Replace the spark plug Normal color is medium-to-light tan. 4. Measure: • Spark plug gap a Out of specification → Regap.
COOLING SYSTEM INSP ADJ COOLING SYSTEM Coolant replacement NOTE: The coolant should be changed at least every season. 1. Place the machine on a level surface. 2. Remove: • Right side panel • Right side cover Refer to “COWLINGS” in CHAPTER 3. 3. Remove: • Coolant filler cap 1 1 WARNING Do not remove the coolant filler cap 1 when the engine is hot. Pressurized scalding hot fluid and steam may be blown out, which could cause serious injury.
COOLING SYSTEM INSP ADJ 7. Connect: • Radiator outlet hose 1 8. Fill: • Cooling system Recommended coolant: High quality silicate-free ethylene glycol antifreeze containing corrosion 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: • Hard water or salt water is harmful to engine parts. If soft water is not available, use boiled or distilled water.
COOLING SYSTEM/VALVE CLEARANCE ADJUSTMENT INSP ADJ 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. • Add coolant to the full level a. • Install the coolant filler cap. Apply and lock the parking brake. Start the engine and run it at approximately 1,700 ~ 3,500 r/min until the coolant circulates (approximately 3 ~ 5 minutes).
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. 1 2 b INSP ADJ Valve clearance (cold): Intake valve: 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Exhaust valve: 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) a Checking steps: • Turn the crankshaft counterclockwise. • When piston #1 is at TDC on the compression stroke, align the TDC mark a on the A.
VALVE CLEARANCE ADJUSTMENT INSP ADJ 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. 6. Adjust: • Valve clearance Adjustment steps: • Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3. NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.
VALVE CLEARANCE ADJUSTMENT INSP ADJ 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. NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect.
INSP ADJ VALVE CLEARANCE ADJUSTMENT VALVE PAD SELECTION TABLE INTAKE Measured clearance exa → ↓ 0.00 ~ 0.02 0.03 ~ 0.07 0.08 ~ 0.10 0.11 ~ 0.20 0.21 ~ 0.25 0.26 ~ 0.30 0.31 ~ 0.35 0.36 ~ 0.40 0.41 ~ 0.45 0.46 ~ 0.50 0.51 ~ 0.55 0.56 ~ 0.60 0.61 ~ 0.65 0.66 ~ 0.70 0.71 ~ 0.75 0.76 ~ 0.80 0.81 ~ 0.85 0.86 ~ 0.90 0.91 ~ 0.95 0.96 ~ 1.00 1.01 ~ 1.05 1.06 ~ 1.10 1.11 ~ 1.15 1.16 ~ 1.20 1.21 ~ 1.25 1.26 ~ 1.30 1.31 ~ 1.35 1.36 ~ 1.
VALVE CLEARANCE ADJUSTMENT INSP ADJ • Install the new valve pad 1 and the valve lifter 2. NOTE: • Apply molybdenum disulfide oil to the valve pad and the valve lifter. • The valve lifter must turn smoothly when rotated by hand. • Install the valve lifter and the valve pad in the correct place. 2 1 • Install the exhaust and intake camshafts, timing chain and camshaft caps. T. Camshaft cap bolt: 9 Nm (0.9 m · kg, 6.5 ft · lb) R. NOTE: • Refer to “CAMSHAFTS” in CHAPTER 5.
THROTTLE BODY SYNCHRONIZATION INSP ADJ THROTTLE BODY SYNCHRONIZATION NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idle speed should be properly adjusted. 1. Remove: • Headlight assembly (PZ50/PZ50GT/PZ50FX/ PZ50M) • Air filter case assembly Refer to “COWLINGS” in CHAPTER 3. 2. Remove: • Vacuum cap 1 1 3. Install: • Vacuum gauge 1 1 Vacuum gauge: 90890-03094, YU-44456 4. Install: • Air filter case Refer to “COWLINGS” in CHAPTER 3. 5.
THROTTLE BODY SYNCHRONIZATION/ ENGINE IDLE SPEED ADJUSTMENT INSP ADJ Adjustment steps: • Synchronize throttle body #1 and throttle body #2 by turning the synchronizing screws 1 in either direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. 1 Vacuum pressure at engine idling speed: 20.27 ~ 22.93 kPa (0.20 ~ 0.23 kg/cm2, 2.88 ~ 3.
ENGINE IDLE SPEED ADJUSTMENT/ THROTTLE CABLE FREE PLAY ADJUSTMENT INSP ADJ 3. Adjust: • Engine idle speed Adjustment steps: • Remove the rubber cap 1. • Turn the idle adjusting screw 2 in or out until the specified engine idle speed is obtained. Turning in → Idle speed is increased. Turning out → Idle speed is decreased. 1 NOTE: After adjusting the engine idle speed, the throttle cable free play should be adjusted.
THROTTLE CABLE FREE PLAY ADJUSTMENT/ THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK INSP ADJ • Tighten the locknut. NOTE: If the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. (PZ50/ PZ50GT/PZ50FX/PZ50M) Handlebar side adjustment steps: (PZ50/PZ50GT/PZ50FX/PZ50M) • Loosen the locknut 1. • Turn the adjusting nut 2 in or out until the specified free play is obtained. 2 1 Turning in → Free play is increased.
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK/ COMPRESSION PRESSURE MEASUREMENT INSP ADJ WARNING If the engine does not run between 2,800 and 3,000 r/min, stop the engine by turning the main switch to the “OFF” position and check the electrical system. COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance Out of specification → Adjust. Refer to “VALVE CLEARANCE ADJUSTMENT”. 2.
COMPRESSION PRESSURE MEASUREMENT INSP ADJ 6. Measure: • Compression pressure Above the maximum pressure → Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure → Squirt a few drops of oil into the affected cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into cylinder) Reading Diagnosis Higher than without oil Piston ring(-s) wear or damage → Repair.
ENGINE OIL LEVEL INSPECTION INSP ADJ ENGINE OIL LEVEL INSPECTION 1. Inspect: • Engine oil level CAUTION: Do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the air filter and the engine could be damaged. Inspection steps: • Place the snowmobile on a level surface and apply the parking brake. • Start the engine, warm it up for 10 ~ 15 minutes, and then turn off. • Remove the right side cover. Refer to “COWLINGS” in CHAPTER 3.
ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT INSP ADJ • Start the engine, warm it up for several minutes, and then turn it off. • Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. CAUTION: • Use only 4-stroke engine oil. • Engine oil also lubricates the starter clutch. In order to prevent clutch slippage, do not mix any chemical additives with the oil or use oils of a higher grade than “CD”.
ENGINE OIL REPLACEMENT INSP ADJ 8. Remove: • Cylinder head cap 1 1 9. Remove: • Oil pan engine oil drain bolt 1 1 10. Remove: • Oil tank engine oil drain bolt 1 11. Drain: • Engine oil (completely from the oil pan and oil tank) 12. If the oil filter cartridge is also to be replaced, perform the following procedure. 1 Replacement steps: • Remove the air filter case. Refer to “COWLINGS” in CHAPTER 3. • Remove the oil filter bolts 1. • Remove the oil filter cartridge 2 with an oil filter wrench 3.
ENGINE OIL REPLACEMENT INSP ADJ • Apply a thin coat of engine oil onto the O-ring 4 of the new oil filter cartridge. 4 CAUTION: Make sure that the O-ring 4 is positioned correctly in the groove of the oil filter cartridge. • Tighten the new oil filter cartridge to specification with an oil filter wrench. T. Oil filter cartridge: 17 Nm (1.7 m · kg, 12 ft · lb) R. • Tighten the oil cooler bolts to specification. T. R. Oil cooler bolt: 10 Nm (1.0 m · kg, 7.2 ft · lb) LOCTITE® 13.
ENGINE OIL REPLACEMENT/CYLINDER HEAD BREATHER HOSE INSPECTION/THROTTLE BODY JOINTS INSPECTION INSP ADJ 17. Inspect: • Engine oil pressure 1 Inspection steps: • Remove the exhaust pipe joint upper cover. Refer to “EXHAUST PIPE AND MUFFLER” in CHAPTER 5. • Slightly loosen the oil gallery bolt 1. • Install the fuel tank. Refer to “SEAT AND FUEL TANK” in CHAPTER 5. (PZ50/PZ50GT/PZ50FX/PZ50M) Refer to “RIDER SEAT AND FUEL TANK” in CHAPTER 5.
CHECKING THE AIR FILTER ELEMENT INSP ADJ CHECKING THE AIR FILTER ELEMENT 1. Remove: • Air filter case cover Refer to “COWLINGS” in CHAPTER 3. 2. Lift up the air filter element frame and remove the air filter element. 3. Clean: • Air filter element NOTE: Remove the snow. 4. Inspect: • Air filter element Damage/clogs → Replace. 5.
EXHAUST SYSTEM INSPECTION INSP ADJ EXHAUST SYSTEM INSPECTION 3 9 1. Remove: • Fuel tank Refer to “SEAT AND FUEL TANK” in CHAPTER 5. (PZ50/PZ50GT/PZ50FX/PZ50M) Refer to “RIDER SEAT AND FUEL TANK” in CHAPTER 5. (PZ50VT/PZ50MP) 2. Inspect: • Exhaust pipe joints 1 • Exhaust pipe/muffler assembly 2 • Exhaust pipe bands 3 • Muffler end cover 4 (PZ50/PZ50GT/PZ50FX/ PZ50M) • Muffler damper holder 5 • Muffler damper 6 Cracks/damage → Replace. • Gasket 7 • Gaskets 8 Exhaust gas leaks → Replace. 3.
SHEAVE OFFSET ADJUSTMENT INSP ADJ POWER TRAIN SHEAVE OFFSET ADJUSTMENT 1. Remove: • Left side panel • Left side cover Refer to “COWLINGS” in CHAPTER 3. 2. Remove: • Drive V-belt 3. Measure: • Sheave offset a Use a straightedge that is approximately 470 mm (18.5 in) long, 20 mm (0.79 in) wide, and 4 mm (0.16 in) thick. Out of specification → Adjust. Sheave offset: 14.5 ~ 17.5 mm (0.57 ~ 0.69 in) NOTE: Push the secondary sheave inward towards the frame, and then measure the sheave offset. 4.
SHEAVE OFFSET ADJUSTMENT • Install the secondary sheave bolt and washer. INSP ADJ sheave, secondary T. Secondary sheave bolt: 60 Nm (6.0 m · kg, 43 ft · lb) R. • Recheck the sheave offset. If out of specification, repeat the above steps. NOTE: When adjusting the sheave offset, the secondary sheave free play (clearance) should be adjusted. 5. Measure: • Secondary sheave free play (clearance) a Use a feeler gauge. Out of specification → Adjust. Secondary sheave free play (clearance): 1.0 ~ 2.0 mm (0.
DRIVE V-BELT INSP ADJ DRIVE V-BELT a a WARNING When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm (–0.02 in) below the edge a. If the V-belt is not positioned correctly, the clutch engagement speed will be changed. The machine may move unexpectedly when the engine is started. New belt width: 34.1 mm (1.34 in) Belt wear limit width: 32.5 mm (1.28 in) 1. Inspect: • Drive V-belt Cracks/damage/wear → Replace.
ENGAGEMENT SPEED CHECK/ PARKING BRAKE ADJUSTMENT INSP ADJ ENGAGEMENT SPEED CHECK 1. Place the machine on a level surface of hardpacked snow. 2. Inspect: • Clutch engagement speed Inspection steps: • Start the engine, and open the throttle lever gradually. • Check the engine speed when the machine starts moving forward. Out of specification → Adjust the primary sheave.
PARKING BRAKE ADJUSTMENT/ BRAKE FLUID LEVEL INSPECTION INSP ADJ 3. Adjust: • Parking brake cable 2 Adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 in or out until the specified distance a is obtained. a 1 Turning in → Distance a is increased. Turning out → Distance a is decreased. • Tighten the locknut. 4. Measure: • Brake pad clearance (a + b) Out of specification → Adjust. Brake pad clearance (a + b): 1.5 ~ 2.0 mm (0.059 ~ 0.079 in) 5.
BRAKE FLUID LEVEL INSPECTION/ BRAKE PAD INSPECTION INSP ADJ NOTE: For a correct reading of the brake fluid level, make sure that the top of the handlebar brake master cylinder reservoir is horizontal. CAUTION: Brake fluid may corrode painted surfaces or plastic parts. Always clean up spilled fluid immediately. WARNING • Use only the designated brake fluid. Other fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of fluid.
BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) INSP ADJ BRAKE HOSE INSPECTION 1. Inspect: • Brake hose Cracks/damage/wear → Replace. 2. Check: • Fluid leakage Apply the brake lever several times. Fluid leakage → Replace the defective parts. AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) WARNING Bleed the brake system in the following cases: • The system has been disassembled. • A brake hose is loosened or removed. • The brake fluid has been very low. • Brake operation is faulty.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ DRIVE CHAIN INSP ADJ j. Tighten the bleed screw. T. Bleed screw: 6 Nm (0.6 m · kg, 4.3 ft · lb) R. NOTE: If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. k. Add brake fluid to the proper level. Refer to “BRAKE FLUID LEVEL INSPECTION”. WARNING After bleeding the brake system, check the brake operation.
DRIVE CHAIN INSP ADJ • Remove the dipstick and check that the oil reaches the bottom of the dipstick. If the oil does not reach the bottom of the dipstick, add sufficient oil to raise it to the correct level. Recommended oil: Gear oil “GL-3” 75W or 80W CAUTION: Make sure that no foreign material enters the drive chain housing. • Reinstall the dipstick 1. NOTE: b Align the notch a of the dipstick handle with the projection b of the drive chain housing.
DRIVE CHAIN/TRACK TENSION ADJUSTMENT INSP ADJ Chain slack adjustment 1. Adjust: • Drive chain slack 1 2 Adjustment steps: • Loosen the locknut 1. • Turn the adjusting bolt 2 clockwise until it is finger tight, and then loosen it 1/4 turn. • Hold the adjusting bolt 2 in place while tightening the chain adjusting locknut 1. T. Drive chain adjusting locknut: 25 Nm (2.5 m · kg, 18 ft · lb) R.
TRACK TENSION ADJUSTMENT INSP ADJ 3. Adjust: • Track deflection Adjustment steps: a. Place the machine onto a suitable stand to raise the track off of the ground. b. Loosen the rear axle nut 1. c. Start the engine and rotate the track once or twice. Stop the engine. d. Check the track alignment with the slide runner 2. If the alignment is incorrect, turn the left and right adjusters to adjust.
SLIDE RUNNER INSPECTION/ MAXIMIZING DRIVE TRACK LIFE INSP ADJ SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner 1 Cracks/damage/wear → Replace. 2. Measure: • Slide runner wear limit a Out of specification → Replace. Slide runner wear limit: 10.5 mm (0.41 in) MAXIMIZING DRIVE TRACK LIFE Recommendations Track tension During initial break-in, the new drive track will tend to stretch quickly as the track settles. Be sure to correct the track tension and alignment frequently.
MAXIMIZING DRIVE TRACK LIFE INSP ADJ Off-trail riding Avoid off-trail riding until there is sufficient snow coverage. It generally takes several feet of snow to provide a good overall base to properly cover debris, such as rocks, logs, etc. If snow coverage is not sufficient, stay on trails to avoid impact damage to the drive track. Studded track In general, track life will be shortened when studs are installed.
SKI/SKI RUNNER/STEERING SYSTEM INSP ADJ CHASSIS SKI/SKI RUNNER 1. Inspect: • Ski • Ski runner Damage/wear → Replace. • Ski runner thickness a • Plastic ski thickness b Out of specification → Replace. Ski runner wear limit: 6 mm (0.24 in) Plastic ski wear limit: PZ50/PZ50GT/PZ50FX/PZ50VT “USA/Canada”: 13 mm (0.51 in) PZ50M/PZ50VT “Europe”/PZ50MP: 24 mm (0.
STEERING SYSTEM INSP ADJ Toe-out adjustment 1. Place the machine on a level surface. 2. Measure: • Ski toe-out (a – c) • Ski stance b Point the skis forward. Out of specification → Adjust. Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) Ski stance (center to center): PZ50/PZ50GT/PZ50FX/PZ50VT/ PZ50MP: 1,080 mm (42.5 in) PZ50M: 980 mm (38.6 in) 3. Adjust: • Ski toe-out 2 2 1 1 LT Adjustment steps: • Remove the air filter case assembly. Refer to “COWLINGS” in CHAPTER 3. • Loosen the locknuts (tie-rods) 1.
LUBRICATION INSP ADJ LUBRICATION Brake lever, throttle lever and throttle cable end 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. Recommended lubricant: ESSO Beacon 325 Grease or Aeroshell Grease #7A WARNING Apply a dab of grease onto only the end of the cables. Do not grease the throttle cables. They could freeze and cause a loss of control. Rear suspension 1. Use a grease gun to inject grease into the nipples. 2. Apply grease to the pivoting parts.
HEADLIGHT BEAM ADJUSTMENT/BATTERY INSPECTION INSP ADJ ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine in front of a wall at the recommended distance D. Refer to the table below. 3. Measure the distance H from the floor to the center of the headlight and place a mark on the wall at that height. 4. With a person sitting on the machine, apply the parking brake, start the engine and let it idle. 5.
BATTERY INSPECTION INSP ADJ First aid in case of bodily contact: External • SKIN – Wash with water. • EYES – Flush with water for 15 minutes and get immediate medical attention. Internal • Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention. CAUTION: • This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate.
BATTERY INSPECTION INSP ADJ 4. Inspect: • Battery charge Inspection steps: • Connect a pocket tester to the battery terminals. Positive tester probe → positive battery terminal Negative tester probe → negative battery terminal NOTE: • The charge state of a MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). • No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
BATTERY INSPECTION INSP ADJ 5. Charge: • Battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. CAUTION: • Make sure that the battery vent is free of obstructions. • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
INSP ADJ BATTERY INSPECTION Charging method using a variable voltage charger Charger AMP meter Measure the open-circuit voltage prior to charging. Connect a charged and AMP meter to the battery and start charging. YES Make sure that the current is higher than the standard charging current written on the battery. NOTE: Voltage should be measured 30 minutes after the machine is stopped. NOTE: Set the charging voltage at 16 ~ 17 V. (If the setting is lower, charging will be insufficient.
INSP ADJ BATTERY INSPECTION Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. YES Make sure that the current is higher than the standard charging current written on the battery. Charge the battery until the battery’s charging voltage is 15 V. NO This type of battery charger cannot charge the MF battery.
BATTERY INSPECTION/FUSE INSPECTION INSP ADJ 6. Install: • Battery 7. Connect: • Battery leads (to the battery terminals) 1 2 CAUTION: First, connect the positive battery lead 1, then the negative battery lead 2. 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • Battery terminals Recommended lubricant: Dielectric grease FUSE INSPECTION The following procedure applies to all of the fuses.
FUSE INSPECTION INSP ADJ 3. Replace: • Blown fuse 9 Replacing steps: • Set the main switch to “OFF”. • Install a new fuse of the correct amperage. • Set the main switch to “ON” and verify if the electrical circuit is operational. • If the fuse immediately blows again, check the electrical circuit. 1 2 Item 9 9 7 6 5 4 3 9 7 6 5 4 3 9 9 Amperage Q’ty 1 Main fuse 40 A 1 2 Fuel injection system fuse 10 A 1 3 Headlight fuse 20 A 1 4 Signal fuse 7.
CLUTCH INSP ADJ TUNING CLUTCH L Blue High altitude Specifications P Pink R Red Model: PZ50/PZ50FX ~ 800 m (~ 2,500 ft) È Elevation 600 ~ 1,400 m (2,000 ~ 4,500 ft) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) É Engine idle speed 1,800 ± 100 r/min ← ← ← ← Ê Engagement r/min Approx. 3,900 r/min ← ← ← Approx. 4,000 r/min ← ← Ë Shift r/min Approx.
CLUTCH INSP ADJ L Blue P Pink R Red Specifications Model: PZ50GT ~ 800 m (~ 2,500 ft) È Elevation 600 ~ 1,400 m (2,000 ~ 4,500 ft) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) É Engine idle speed 1,800 ± 100 r/min ← ← ← ← Ê Engagement r/min Approx. 3,900 r/min ← ← ← Approx. 4,000 r/min ← ← ← Ë Shift r/min Approx.
CLUTCH INSP ADJ G Green R Red Y Yellow Specifications Model: PZ50M ~ 800 m (~ 2,500 ft) È Elevation 600 ~ 1,400 m (2,000 ~ 4,500 ft) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) É Engine idle speed 1,800 ± 100 r/min ← ← ← ← Ê Engagement r/min Approx. 4,100 r/min ← ← Approx. 4,300 r/min ← ← ← ← Ë Shift r/min Approx.
CLUTCH INSP ADJ L Blue Specifications Y Yellow Model: PZ50VT “USA/Canada” ~ 800 m (~ 2,500 ft) È Elevation 600 ~ 1,400 m (2,000 ~ 4,500 ft) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) É Engine idle speed 1,800 ± 100 r/min ← ← ← ← Ê Engagement r/min Approx. 3,500 r/min ← ← ← Approx. 3,700 r/min ← ← ← Ë Shift r/min Approx.
CLUTCH INSP ADJ Go Gold Specifications L Blue Model: PZ50VT “Europe”/PZ50MP ~ 800 m (~ 2,500 ft) È Elevation 600 ~ 1,400 m (2,000 ~ 4,500 ft) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) É Engine idle speed 1,800 ± 100 r/min ← ← ← ← Ê Engagement r/min Approx. 3,100 r/min ← ← ← Approx. 3,200 r/min ← ← Ë Shift r/min Approx.
CLUTCH/GEAR SELECTION INSP ADJ The clutch may require tuning depending upon where the machine will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop. Clutch shifting speed is defined as the engine speed reached when the machine has travelled 800 m (2,500 ft) after being started at full-throttle from a dead stop.
GEAR SELECTION INSP ADJ 1 Chain and sprocket part number È Parts name É Teeth & links Ê Parts no.
GEAR SELECTION INSP ADJ 4 Secondary spring twist angle 90508-55007 (Red) È Seat 1 2 3 4 C 35° 65° 95° 5° A 45° 75° 105° 15° B 55° 85° 115° 25° É Sheave 90508-55012 (Brown)/90508-58007 (Blue)/90508-60015 (Yellow) È Seat 1 2 3 4 C 40° 70° 100° 10° A 50° 80° 110° 20° B 60° 90° 120° 30° É Sheave 5 Torque cam (secondary spring seat) 2 È Identification mark 89N01 1 3 4 É Effects Ê Part no.
GEAR SELECTION 6 Primary spring INSP ADJ È Spring identification color code É Spring rate color Ê Preload color Ë Parts No. Ì Spring rate N/mm (kg/mm) Í Preload N/mm (kg) Î Color Ï Wire gauge mm (in) Ð Outside diameter mm (in) Ñ No. of coils Ò Free length mm (in) 90501-481J1 9.8 (1.0) 196 (20) Silver-Blue-Silver 4.8 (0.189) 60 (2.362) 5.16 85.4 (3.362) 90501-487G8 14.7 (1.5) 147 (15) Gold 4.8 (0.189) 60 (2.362) 4.19 75.4 (2.969) 90501-507G2 14.7 (1.
GEAR SELECTION INSP ADJ 7 Clutch weight É Weight g (oz) without bush and rivets 8BU-17605-20 45.41 (1.603) 8DN-17605-30 39.76 (1.404) 8ES-17605-00 54.63 (1.928) 8FA-17605-10 63.81 (2.251) 8FN-17605-00 75.28 (2.657) 8FP-17605-00 67.81 (2.394) 8FS-17605-00 65.52 (2.313) Ê Shape & ID mark Ë Standard 8BU 10 È Parts No. 8DN 10 PZ50M 8ES 00 8FA 00 8FN 00 8 FP 00 8 FS 00 8G C 00 8GC-17605-00 47.28 (1.
GEAR SELECTION INSP ADJ 8 Weight rivets È Parts No. É Material Ê Length mm (in) Ë Weight g (oz) 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) IN: PZ50VT “Europe”/PZ50MP CENTER, OUT: PZ50VT/ PZ50MP 90261-06034 Steel 13.9 (0.547) 3.6 (0.127) IN: PZ50M “Europe”/PZ50VT “USA/Canada” OUT: PZ50M “Europe” 90261-06019 Steel 13.3 (0.524) 3.1 (0.109) OUT: PZ50/PZ50GT/PZ50FX 90261-06015 Steel 10.3 (0.406) 2.44 (0.
FRONT SUSPENSION INSP ADJ FRONT SUSPENSION È Spring preload 1. Adjust: • Spring preload Adjustment steps: • Loosen the locknut 1. • Turn the spring seat 2 in or out. PZ50GT/PZ50MP É Shorter ← → Longer Preload Harder ← → Softer Length a 2 1 Standard Spring seat distance Min. 205 mm (8.07 in) 215 mm (8.46 in) Max. 215 mm (8.46 in) PZ50VT “Europe” a Ê Standard Spring seat distance Shorter ← → Longer Preload Harder ← → Softer Length a Min. 190 mm (7.48 in) 200 mm (7.87 in) Max.
FRONT SUSPENSION INSP ADJ CAUTION: Be sure that the left and right spring preload are the same. WARNING These shock absorber contain highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assemblies. Do not subject the shock absorber assemblies to flames or high heat, which could cause it to explode. Rebound damping force adjustment (PZ50FX) The rebound damping force can be adjusted by turning the adjuster 1.
FRONT SUSPENSION/REAR SUSPENSION Compression damping force adjustment (PZ50FX) The compression damping force can be adjusted by turning the adjuster 1. b 1 INSP ADJ a Adjuster position 12 clicks out 7 clicks out 2 clicks out Minimum Standard Maximum Turns out b* ← Compression damping force Soft ← → Turns in a → Hard * With the adjuster fully turned lightly in direction a CAUTION: • Do not continue to turn the adjuster in direction a after it stops.
INSP ADJ REAR SUSPENSION È Adjustment steps: • Remove the stopper band bolts 1, nuts and washers. • Adjust the length of the stopper bands 2 by inserting the bolts in different holes. 1 No.1 No.2 No.3 No.4 No.5 2 Standard setting: No. 1 hole (PZ50/PZ50MP) No. 2 holes (PZ50FX) No. 3 holes (PZ50GT/PZ50M) No. 4 holes (PZ50VT) È É • Tighten the stopper band nuts. 1 No.1 No.2 No.3 No.4 T. Stopper band nut: 4 Nm (0.4 m · kg, 2.9 ft · lb) R.
REAR SUSPENSION INSP ADJ Spring preload 1. Adjust: • Spring preload È Adjustment step: Front side • Loosen the locknut 1. • Turn the spring seat 2 in or out. PZ50GT “Europe” Standard Spring seat distance Shorter ← → Longer Preload Harder ← → Softer Length a Min. 175 mm (6.89 in) 185 mm (7.28 in) Max. 185 mm (7.28 in) PZ50FX Standard Spring seat distance Shorter ← → Longer Preload Harder ← → Softer Length a Min. 180 mm (7.09 in) 190 mm (7.48 in) Max. 190 mm (7.
REAR SUSPENSION INSP ADJ • Turn the adjusting ring 3 to the proper position. É PZ50/PZ50GT “USA/Canada”/PZ50M Spring adjuster position Preload 1 2 3 Softer ← Standard 4 5 → Harder 1 PZ50VT “USA/Canada” Spring adjuster position Ê Preload 1 2 3 Softer ← Standard 4 5 → Harder 3 WARNING This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly.
REAR SUSPENSION INSP ADJ Rear suspension damping force adjustment The damping force can be adjusted by turning the adjuster 1. PZ50FX 20 clicks out 11 clicks out Adjuster position Minimum Standard Turns out b* ← Damping force Soft ← 1 click out Maximum → Turns in a → Hard * With the adjuster fully turned lightly in direction a CAUTION: • Do not continue to turn the adjuster in direction a after it stops. The shock absorber can be damaged and damping force adjustments cannot be made.
REAR SUSPENSION INSP ADJ Control rod (PZ50VT/PZ50MP) 1. Adjust: • Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. a Adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 in or out to adjust the control rod stroke. Adjusting position Effect Increase weight transfer 1 2 3 2 1 1 Standard 2 ← 3 → Decrease weight transfer 2 WARNING Never adjust the control rods beyond the maximum range indicated on the rods with red paint 3.
INSP ADJ REAR SUSPENSION 2-up adjusting block (PZ50VT/PZ50MP) 1. Position: • 2-up adjusting blocks Position Spring force Solo (rider only) 2-up (rider and passenger) A B Soft Hard NOTE: Be sure to change the position of the 2-up adjusting blocks when there is no load (rider or cargo) on the snowmobile. A B Positioning steps: • Pull the lock lever 1 and turn the 2-up adjusting block until it is in the desired position. • Release the lock lever.
COWLINGS CHAS CHASSIS COWLINGS PZ50/PZ50GT/PZ50FX/PZ50M 4 È: 8 Nm (0.8 m • kg, 5.
COWLINGS 4 È: 8 Nm (0.8 m • kg, 5.8 ft • lb) CHAS PZ50FX 12 È 1 5 6 2 È 11 3 16 18 15 13 3 7 14 17 19 8 9 È 10 Order 14 15 16 17 18 19 È Job name/Part name Cylinder-#1 intake air pressure sensor coupler Intake air temperature sensor coupler Cylinder head breather hose Oil tank breather hose Air filter case assembly Intake air pressure sensor hose Q’ty 1 1 1 1 1 2 Remarks Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure.
COWLINGS CHAS PZ50VT/PZ50MP È: 8 Nm (0.8 m • kg, 5.
STEERING CHAS STEERING PZ50/PZ50GT/PZ50FX/PZ50M È: 10 Nm (1.0 m • kg, 7.2 ft • lb) É É: 15 Nm (1.5 m • kg, 11 ft • lb) Ê: 16 Nm (1.6 m • kg, 11 ft • lb) 3 Ë: 20 Nm (2.
STEERING È: 10 Nm (1.0 m • kg, 7.2 ft • lb) CHAS É É: 15 Nm (1.5 m • kg, 11 ft • lb) Ê: 16 Nm (1.6 m • kg, 11 ft • lb) 3 Ë: 20 Nm (2.
STEERING CHAS PZ50VT/PZ50MP 19 È: 10 Nm (1.0 m • kg, 7.2 ft • lb) É: 15 Nm (1.5 m • kg, 11 ft • lb) 14 É (4) 15 Ê: 16 Nm (1.6 m • kg, 11 ft • lb) 13 Ë: 20 Nm (2.0 m • kg, 14 ft • lb) Ì: 16 4 È 17 21 Nm (2.
STEERING 19 È: 10 Nm (1.0 m • kg, 7.2 ft • lb) É: 15 Nm (1.5 m • kg, 11 ft • lb) 14 É (4) 15 Ê: 16 Nm (1.6 m • kg, 11 ft • lb) CHAS 16 4 13 Ë: 20 Nm (2.0 m • kg, 14 ft • lb) È 17 Ì: 21 Nm (2.
CHAS STEERING É È: 21 Nm (2.1 m • kg, 15 ft • lb) É: 23 Nm (2.3 m • kg, 17 ft • lb) Ê: 25 Nm (2.5 m • kg, 18 ft • lb) Ë: 28 Nm (2.8 m • kg, 20 ft • lb) Í 4 10 New 2 3 9 10 7 5 Ì: 30 Nm (3.0 m • kg, 22 ft • lb) È Ê Í 19 21 É New 26 23 New Í Î Î 17 Ï New 24 Ê LT È È Ê New Í 13 11 22 14 Ì 23 Ê Ë Ê LT New Î: 38 Nm (3.8 m • kg, 27 ft • lb) 18 Ï: 90 Nm (9.
CHAS STEERING É È: 21 Nm (2.1 m • kg, 15 ft • lb) É: 23 Nm (2.3 m • kg, 17 ft • lb) Ê: 25 Nm (2.5 m • kg, 18 ft • lb) Ë: 28 Nm (2.8 m • kg, 20 ft • lb) Í 4 10 New 2 3 9 10 7 5 Ì: 30 Nm (3.0 m • kg, 22 ft • lb) È Ê Í 19 21 É New 26 23 New Í Î Î 17 Ï New 24 Ê Ê LT È È Ê New Í 13 11 22 21 12 14 Ì 23 Ê LT Ë Ê LT New Î: 38 Nm (3.8 m • kg, 27 ft • lb) 18 Ï: 90 Nm (9.
STEERING CHAS REMOVAL 1. Straighten the lock washer tabs. INSPECTION 1. Inspect: • Handlebar • Steering column Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent column. This may dangerously weaken the column. 2. Inspect: • Bearings (steering column) • Collars • Bearings (pivot arm brackets) Wear/damage → Replace. • Steering column (bearing contact surfaces) Scratches/wear/damage → Replace. 3. Inspect: • Relay rod • Tie rods • Steering shaft Bends/cracks/damage → Replace.
STEERING CHAS INSTALLATION 1. Install: • Tie rod 1 • Locknuts 2 • Joints 3 a b 3 1 2 È 2 È Tie rod part number 3 É É Set length a Ê Tie rod length b 8GC-23830-00 (PZ50/PZ50GT/ PZ50FX/ PZ50VT/ PZ50MP) 504.7 mm (19.87 in) 433.2 mm (17.06 in) 8GP-23830-00 (PZ50M) 464.9 mm (18.30 in) 393.4 mm (15.49 in) 2.
STEERING CHAS 4. Install: • Steering arm 1 1 2 NOTE: Align the punch mark a on the steering arm 1 with the punch mark b on the pivot arm shaft 2. b a 5. Install: • Steering shaft 1 • Locknuts 2 • Joints 3 a b 3 1 2 2 3 È Steering shaft part number É Set length a 8GC-23820-00 311.3 mm (12.26 in) Ê Shaft length b 244.3 mm (9.62 in) CAUTION: Always use new cotter pin. 1 T. R. Steering shaft and steering control arm nut: 21 Nm (2.
CHAS STEERING 7. Adjust: • Skis 1 Adjustment steps: • Temporarily install the handlebar. • Hold the handlebar straight and check that the skis and relay arms are at right angles to the handlebar. • Install the steering linkage alignment plate 1. Steering linkage alignment plate: 90890-01515, YS-01515 • Loosen the locknuts (steering shaft) 2. • Hold the handlebar straight. • Adjust the steering shaft 3 by turning so that the pivot arm shaft and relay arm point right under.
SKI CHAS SKI PZ50/PZ50GT/PZ50FX/PZ50VT “USA/Canada” Order 1 2 3 4 5 6 7 8 9 Job name/Part name Ski removal Cotter pin Nut Bolt Collar Collar Washer Collar Ski stopper Ski Q’ty Remarks Remove the parts in the order listed below. 1 1 1 1 1 2 1 1 1 For installation, reverse the removal procedure.
SKI CHAS PZ50VT “Europe”/PZ50MP Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Ski removal Cotter pin Nut Bolt Collar Collar Washer Collar Ski stopper Ski stopper plate Ski Q’ty Remarks Remove the parts in the order listed below. 1 1 1 1 1 2 1 1 1 1 For installation, reverse the removal procedure.
SKI CHAS PZ50M Order 1 2 3 4 5 6 7 8 9 Job name/Part name Ski removal Cotter pin Nut Bolt Collar Collar Washer Collar Ski stopper Ski Q’ty Remarks Remove the parts in the order listed below. 1 1 1 2 1 2 1 1 1 For installation, reverse the removal procedure.
SKI CHAS INSPECTION 1. Inspect: • Ski • Ski runner • Ski stopper • Ski stopper plate (PZ50VT “Europe”/ PZ50MP) • Ski handle Wear/cracks/damage → Replace. • Mounting bolt • Collar • Collars Wear/damage → Replace.
CHAS FRONT SUSPENSION FRONT SUSPENSION PZ50/PZ50FX/PZ50M È: 28 Nm (2.8 m • kg, 20 ft • lb) Ê: 45 Nm (4.5 m • kg, 32 ft • lb) Ê É: 34 Nm (3.4 m • kg, 24 ft • lb) Ë: 60 Nm (6.0 m • kg, 43 ft • lb) Ê Ì: 65 Nm (6.
CHAS FRONT SUSPENSION È: 28 Nm (2.8 m • kg, 20 ft • lb) É: Ê: 45 Nm (4.5 m • kg, 32 ft • lb) Ê 34 Nm (3.4 m kg, 24 ft • lb) Ë: 60 Nm (6.0 m • kg, 43 ft • lb) • Ê Ì: 65 Nm (6.
FRONT SUSPENSION CHAS PZ50GT/PZ50VT/PZ50MP È: 7 Nm (0.7 m • kg, 5.1 ft • lb) Ë É: 28 Nm (2.8 m • kg, 20 ft • lb) Ê: 34 Nm (3.4 m • kg, 24 ft • lb) Ë 45 Nm (4.5 m • kg, 32 ft • lb) Ë Ì: 60 Nm (6.0 m • kg, 43 ft • lb) Í: 65 Nm (6.
FRONT SUSPENSION È: 7 Nm (0.7 m • kg, 5.1 ft • lb) Ë É: 28 Nm (2.8 m • kg, 20 ft • lb) Ê: 34 Nm (3.4 m • kg, 24 ft • lb) Ë 45 Nm (4.5 m • kg, 32 ft • lb) Ë 2 3 Í Ê 7 Í CHAS Ì: 60 Nm (6.0 m • kg, 43 ft • lb) Í: 65 Nm (6.
FRONT SUSPENSION CHAS HANDLING NOTES WARNING PZ50GT/PZ50FX/PZ50VT “Europe”/PZ50MP This shock absorber contains highly compressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. • Do not tamper or attempt to open the gas chamber. • Do not subject the shock absorber to flames or any other source of high heat.
FRONT SUSPENSION CHAS INSTALLATION È 2 1. Install: • Stabilizer 1 • Bushing 2 • Stabilizer holder 3 1 3 a É CAUTION: 2 3 Always install the stabilizers, bushings, and stabilizer holders in the same positions on both sides of the snowmobile, otherwise poor handling and loss of stability may result. (PZ50GT/ PZ50VT/PZ50MP) 1 NOTE: a b a c a a • Install the stabilizer holder in the direction shown in the illustration.
FRONT SUSPENSION CHAS Ski alignment NOTE: Be sure to verify the spring preload setting before adjusting the ski toe-out since this adjustments may affect the ski toe-out setting. Point the skis straight forward and measure the amount of ski toe-out. È Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) a – b = Toe-out Refer to “STEERING SYSTEM” in CHAPTER 2.
POWR TR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT s È: 1st 2nd 120 Nm (12.0 m • kg, 85 ft • lb) 60 Nm (6.0 m • kg, 43 ft • lb) 2 E È 1 Order 1 2 Q’ty Job name/Part name Primary sheave removal Left side cover V-belt Primary sheave assembly Remarks Remove the parts in the order listed below. Refer to “COWLINGS” in CHAPTER 3. 1 1 For installation, reverse the removal procedure.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR 4 Order 1 2 3 4 5 6 7 8 9 0 A B C D Q’ty Job name/Part name Primary sheave disassembly Primary sheave cap Primary sheave spring Collar Roller Washer Collar Weight Washer Fixed sheave Stopper Sliding sheave Bushing Spider Slider 1 1 3 3 6 3 3 6 1 2 1 1 1 6 Remarks Remove the parts in the order listed below. Left-handed thread. For assembly, reverse the disassembly procedure.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR REMOVAL 1. Remove: • Primary sheave assembly 1 NOTE: Use the primary sheave holder 2 and primary sheave puller 3. Sheave holder: 90890-01701, YS-01880-A Primary sheave puller: 90890-01898, YS-01881-A, YS-01881-1 DISASSEMBLY 1. Remove: • Fixed sheave 1 • Stopper 2 • Sliding sheave 3 • Bushing 4 • Spider 5 Removal steps: • Immerse the primary sheave assembly in 80 ~ 100 °C (176 ~ 212 °F) water for several minutes.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR • Fit the primary sheave assembly onto the adapter and secure the supporting plates 8. NOTE: Securely fit the projections on the adapter into the fixed sheave holes. • Set the bar wrench 9 onto the spider and turn the special tool clockwise to loosen the spider. Clutch spider separator: 90890-01711, YS-28890-C CAUTION: • The spider has a left-handed thread.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR 2. Inspect: • Primary sheave spring 1 Cracks/damage → Replace. 3. Measure: • Primary sheave spring (standard) free length a Out of specification → Replace the primary sheave spring. Primary sheave spring (standard) free length: PZ50/PZ50GT/PZ50FX: 72.1 mm (2.84 in) PZ50M: 74.1 mm (2.92 in) PZ50VT “USA/Canada”: 73.4 mm (2.89 in) PZ50VT “Europe”/PZ50MP: 72.9 mm (2.87 in) NOTE: When changing the primary sheave springs, refer to “GEAR SELECTION” in CHAPTER 2. 4.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR Rivet replacement steps: • Remove old rivet with the appropriate drill. • Insert the rivet 1 from the ID mark 2 side. • Press or peen the rivet head so that the diameter a of the rivet head measures 8.2 mm (0.32 in) or larger. È 6. Measure: • Bushing inside diameter Out of specification → Replace as a set. É Bushing inside diameter: Roller È: New: 9.077 mm (0.357 in) Wear limit: 9.3 mm (0.366 in) Weight É: New: 8.077 mm (0.318 in) Wear limit: 8.3 mm (0.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR 2. Install: • Fixed sheave (onto the spider) NOTE: • Clean the threads. • Apply LOCTITE® #648 to the fixed sheave as shown. CAUTION: LOCTITE® should be applied only to the specified area. Never apply it to the bushings and other areas. a 16 mm (0.63 in) b 30 mm (1.18 in) 3. Install: • Fixed sheave stoppers 1 NOTE: Stopper tapered portion should face fixed sheave. 4.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR • Tighten the spider to specification using the bar wrench 3. T. Spider: 200 Nm (20.0 m · kg, 145 ft · lb) R. CAUTION: The spider has a left-handed thread. WARNING • Do not operate the primary sheave until the LOCTITE® has dried completely. Wait 24 hours before operating the primary sheave. • Since a high torque is required to tighten the spider, make sure the spider, fixed sheave, and special tool are well secured.
PRIMARY SHEAVE AND DRIVE V-BELT POWR TR INSTALLATION 1. Install: • Primary sheave assembly CAUTION: Be sure to remove any oil or grease from the tapered portion of the crankshaft and spider using a cloth dampened with thinner. 2. Apply: • Engine oil (to threads of primary sheave bolt) 3. Tighten: • Primary sheave bolt 1 Tightening steps: • Hold the primary sheave 2 using the primary sheave holder 3 and tighten the primary sheave bolt to specification. 3 1 Sheave holder: 90890-01701, YS-01880-A 2 T.
SECONDARY SHEAVE POWR TR SECONDARY SHEAVE Order Job name/Part name Secondary sheave removal Q’ty Remarks Remove the parts in the order listed below. NOTE: Apply the brake to lock the secondary sheave. V-belt Refer to “PRIMARY SHEAVE AND DRIVE VBELT”. 1 2 Washer Shim (left) 1 — 3 4 Secondary sheave assembly Shim (right) 1 — 5 Washer 1 Refer to “SHEAVE OFFSET ADJUSTMENT” in CHAPTER 2. Refer to “SHEAVE OFFSET ADJUSTMENT” in CHAPTER 2. For installation, reverse the removal procedure.
SECONDARY SHEAVE POWR TR È: 7 Nm (0.7 m • kg, 5.1 ft • lb) New 1 8 2 3 4 7 È 6 5 : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order 1 2 3 4 5 6 7 8 Job name/Part name Secondary sheave disassembly Circlip Washer Spring seat Secondary sheave spring Sliding sheave Washer Fixed sheave Bushing Q’ty Remarks Remove the parts in the order listed below. 1 1 1 1 1 2 1 1 For assembly, reverse the disassembly procedure.
SECONDARY SHEAVE POWR TR DISASSEMBLY WARNING • Use extreme CAUTION when disassembling the secondary sheave since serious injury can occur due to the sudden release of spring tension. Use the sheave compressor to contain the spring tension before removing the spring seat circlip. • Do not attempt this procedure unless you have the proper tools and understand the instructions thoroughly. INSPECTION 1. Inspect: • Sliding sheave • Fixed sheave • Spring seat Cracks/damage → Replace. 2.
SECONDARY SHEAVE POWR TR 5. Measure: • Ramp shoe thickness a Out of specification → Replace the ramp shoe. Wear limit: 1.0 mm (0.04 in) ASSEMBLY 1. Install: • Secondary sheave spring 1 • Spring seat 2 NOTE: Hook the end of the secondary sheave spring into the spring holes in the sliding sheave. Hook the other end of the spring into the holes in the spring seat. Standard spring position: A-1 (PZ50/PZ50GT/PZ50FX/PZ50VT/PZ50MP) B-1 (PZ50M) Installation steps: 1 CAUTION: 2 • Always use a new circlip.
SECONDARY SHEAVE POWR TR INSTALLATION 1. Lubricate: • Splines (fixed sheave) Recommended grease: ESSO beacon 325 grease or Aeroshell grease #7A 2. Tighten: • Secondary sheave bolt T. Secondary sheave bolt: 60 Nm (6.0 m · kg, 43 ft · lb) R. 3. Adjust: • Sheave offset • Secondary sheave free play (clearance) Refer to “SHEAVE OFFSET ADJUSTMENT” in CHAPTER 2.
DRIVE CHAIN POWR TR DRIVE CHAIN È: 16 Nm (1.6 m • kg, 11 ft • lb) É: 24 Nm (2.4 m • kg, 17 ft • lb) Ê: 25 Nm (2.5 m • kg, 18 ft • lb) New 7 Ë: 48 Nm (4.
DRIVE CHAIN POWR TR REMOVAL 1. Remove: • Driven sprocket 1 NOTE: While holding the front axle assembly with spanner wrench 2, loosen the driven sprocket bolt. 1 2 INSPECTION 1. Inspect: • Drive chain cover Cracks/damage → Replace. • Oil seals (drive chain cover) Wear/damage → Replace. • Bearings Pitting/damage → Replace. Replacement steps: • Remove the circlip (drive chain cover). • Remove the bearing using a general bearing puller. • Install the new bearing.
DRIVE CHAIN POWR TR 3. Measure: • 14 link section a of the drive chain Using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b. Out of specification → Replace the drive chain. Maximum 14 link drive chain section length: 133.35 mm (5.25 in) Limit: 137.35 mm (5.41 in) NOTE: • Measure the length between drive chain pin 1 and E as shown. • Perform this measurement at two or three different places. If replacement is necessary, always replace the chain and the sprockets as a set. 4.
DRIVE CHAIN POWR TR INSTALLATION 1. During installation, pay attention to the following. È Make sure that the bearing seals face towards the drive chain as shown. É C3 É Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps. C1 C1 C2 C3 a Be sure to install the spacers in their original positions, otherwise the brake disc and secondary shaft will stick. a 0.2 ~ 0.7 mm (0.008 ~ 0.
SECONDARY SHAFT POWR TR SECONDARY SHAFT PZ50 New 3 4 È: 24 Nm (2.4 m • kg, 17 ft • lb) 2 1 5 È : 1 ESSO beacon 325 grease or Aeroshell grease #7A 1 Order 1 2 3 4 5 Job name/Part name Secondary shaft removal Secondary sheave assembly Drive chain Bearing holder Secondary shaft Circlip Bearing Bearing Q’ty Remarks Remove the parts in the order listed below. Refer to “SECONDARY SHEAVE”. Refer to “DRIVE CHAIN”. 2 1 1 1 1 For installation, reverse the removal procedure.
SECONDARY SHAFT POWR TR REMOVAL 1. Remove: • Drive chain parts Refer to “DRIVE CHAIN”. • Secondary sheave assembly Refer to “SECONDARY SHEAVE”. 2. Remove: • Bearing housing • Secondary shaft 1 1 NOTE: Remove the secondary shaft 1 from the right side of the machine. INSPECTION 1. Inspect: • Secondary shaft 1 Scratches (excessive)/damage → Replace. • Splines 2 Wear/damage → Replace the secondary shaft. • Bearing contact surface 3 Scratches/wear/damage → Replace the secondary shaft. 2.
SECONDARY SHAFT POWR TR 3. Tighten: • Bearing holder bolts 1 T. Bearing holder bolt: 24 Nm (2.4 m · kg, 17 ft · lb) R. 4. Check: • Secondary shaft stiffness 1 CAUTION: When the secondary shaft is operated in periodic motion, and if its movement is heavy, install it again correctly.
SECONDARY SHAFT POWR TR SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION 1. Install: • Secondary shaft • Drive chain parts È 3 Installation steps: • Install the secondary shaft. • Install the drive chain parts. • Install the drive chain, drive sprocket and driven sprocket. • Tighten the bolt 1. a 4 5 T. 2 R. Driven sprocket bolt: 48 Nm (4.8 m · kg, 35 ft · lb) LOCTITE® • Install the drive chain cover 2.
SECONDARY SHAFT AND REVERSE GEAR CASE POWR TR SECONDARY SHAFT AND REVERSE GEAR CASE PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP New 10 11 È: 9 Nm (0.9 m • kg, 6.5 ft • lb) É: 10 Nm (1.0 m • kg, 7.2 ft • lb) 3 Ê: 17 Nm (1.7 m • kg, 12 ft • lb) É Ë: 24 Nm (2.
SECONDARY SHAFT AND REVERSE GEAR CASE New 10 11 È: 9 Nm (0.9 m • kg, 6.5 ft • lb) É: 10 Nm (1.0 m • kg, 7.2 ft • lb) POWR TR 3 Ê: 17 Nm (1.7 m • kg, 12 ft • lb) É Ë: 24 Nm (2.4 m • kg, 17 ft • lb) (4) É New É (3) New 7 4 Ê 8 È New LT 6 1 2 Ë 5 1 LT 9 : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order 6 7 8 9 10 11 Job name/Part name Drive position switch connector Gear motor Shift arm Secondary shaft assembly Circlip Bearing Q’ty 1 1 1 1 1 1 Remarks Disconnect.
SECONDARY SHAFT AND REVERSE GEAR CASE POWR TR È: 6 Nm (0.6 m • kg, 4.3 ft • lb) É: 17 Nm (1.
SECONDARY SHAFT AND REVERSE GEAR CASE POWR TR È: 6 Nm (0.6 m • kg, 4.3 ft • lb) É: 17 Nm (1.7 m • kg, 12 ft • lb) I 6 C New 0 A M New B G F E 1 É D D K New New 5 2 È 3 É J 5 H 7 4 New 8 9 L Order F G H I J K L M Job name/Part name Collar Bearing Left reverse gear case Secondary shaft Bearing Bearing Bearing Bearing : 1 ESSO beacon 325 grease or Aeroshell grease #7A Q’ty 1 1 1 1 1 1 1 1 Remarks For assembly, reverse the disassembly procedure.
SECONDARY SHAFT AND REVERSE GEAR CASE POWR TR REMOVAL 1. Check that the gear motor is in the drive position. NOTE: Before removing the gear motor from the reverse gear case, make sure that the drive position indicator light on the speedometer unit is on. 2. Remove: • Drive chain parts Refer to “DRIVE CHAIN”. • Secondary sheave assembly Refer to “SECONDARY SHEAVE”. 3.
SECONDARY SHAFT AND REVERSE GEAR CASE POWR TR INSPECTION 1. Inspect: • Secondary shaft Scratches (excessive)/damage → Replace. • Splines Wear/damage → Replace the secondary shaft. • Bearing contact surface Scratches/wear/damage → Replace the secondary shaft. Refer to “SECONDARY SHAFT”. 2. Inspect: • Right reverse gear case • Left reverse gear case • Shift fork Pitting/wear/damage → Replace. • Oil seal Wear/damage → Replace. • Bearings Pitting/damage → Replace. 3.
SECONDARY SHAFT AND REVERSE GEAR CASE POWR TR INSTALLATION 1 1. Install: • Secondary shaft assembly Installation steps: • Install the secondary shaft assembly. • Install the secondary shaft assembly bolts 1. • Install the bearing holder bolts 2. • Tighten the secondary shaft assembly bolts 1. 1 T. Secondary shaft assembly bolt: 10 Nm (1.0 m · kg, 7.2 ft · lb) R. • Tighten the bearing holder bolts 2. T. Bearing holder bolt: 24 Nm (2.4 m · kg, 17 ft · lb) R. • Tighten the set bolts 3. 2 T. R.
SECONDARY SHAFT AND REVERSE GEAR CASE POWR TR 3. Install: • Drive chain parts Refer to “DRIVE CHAIN”. 4. Check: • Secondary shaft stiffness CAUTION: When the secondary shaft is operated in periodic motion, and if its movement is heavy, install it again correctly. SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION 1. Install: • Secondary shaft • Drive chain parts Refer to “SECONDARY SHAFT”.
BRAKE POWR TR BRAKE È: 23 Nm (2.
BRAKE POWR TR È: 6 Nm (0.6 m • kg, 4.3 ft • lb) É: 18 Nm (1.8 m • kg, 13 ft • lb) Ê: 48 Nm (4.8 m • kg, 35 ft • lb) È 1 É 4 1 Ê Ê Order 1 2 3 4 3 Job name/Part name Brake pad removal Retaining pin Brake pad Pad spring Brake caliper assembly 2 Q’ty Remarks Remove the parts in the order listed below. 2 2 1 1 For installation, reverse the removal procedure.
BRAKE POWR TR CAUTION: Disc brake components rarely require disassembly. DO NOT: • Do not disassemble components unless absolutely necessary. • Do not use solvents on internal brake components. • Do not use contaminated brake fluid for cleaning. • Use only clean brake fluid. • Do not allow brake fluid to contact the eyes, otherwise eye injury may occur. • Do not allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur.
BRAKE POWR TR 2. Install: • Brake pads • Pad spring 2 1 Installation steps: • Connect a suitable hose 1 tightly to the caliper bleed screw 2. Put the other end of this hose into an open container. • Loosen the caliper bleed screws and push the pistons into the caliper with your finger. • Tighten the caliper bleed screw 2. T. Bleed screw: 6 Nm (0.6 m · kg, 4.3 ft · lb) R. • Install the brake pads and pad spring. 3. Check: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 2. 4.
BRAKE POWR TR 1 È Ë New New 2 6 8 5 3 7 10 9 Ì 8 4 11 7 Ê È: 6 Nm (0.6 m • kg, 4.3 ft • lb) É: 10 Nm (1.0 m • kg, 7.2 ft • lb) Ì Ê: 16 Nm (1.6 m • kg, 12 ft • lb) É Ë: 30 Nm (3.0 m • kg, 22 ft • lb) Ì: 48 Nm (4.
BRAKE POWR TR BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • Pistons • Piston seals Removal steps: • Using a wood of piece, lock the piston. • Blow compressed air into the hose joint opening a to force out the pistons from the caliper body. a WARNING Never try to pry out the pistons.
BRAKE POWR TR 1. Inspect: • Caliper piston Scratches/rust/wear → Replace the caliper assembly. • Caliper cylinder Wear/scratches → Replace the caliper assembly. • Caliper body Cracks/damage → Replace. • Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals whenever a caliper is disassembled. BRAKE CALIPER ASSEMBLY WARNING • All internal parts should be cleaned only with new brake fluid.
BRAKE Order 1 2 3 4 5 6 7 1 2 3 4 Job name/Part name Brake master cylinder removal Brake fluid Left handlebar switch Brake light switch Brake lever Brake hose Holder Parking brake cable Parking brake lever Master cylinder assembly Q’ty 1 1 1 1 1 1 1 POWR TR Remarks Remove the parts in the order listed below. Drain. Refer to “STEERING” in CHAPTER 3. Disconnect. For installation, reverse the removal procedure. Remove the parts in the order listed below.
BRAKE POWR TR INSPECTION 1. Inspect: • Master cylinder 1 Wear/scratches → Replace the master cylinder assembly. • Master cylinder body 2 Cracks/damage → Replace. • Oil delivery passage (master cylinder body) Blow out with compressed air. 2. Inspect: • Master cylinder kit Scratches/wear/damage → Replace as a set. BRAKE MASTER CYLINDER ASSEMBLY WARNING • All internal parts should be cleaned only with new brake fluid. • Internal parts should be lubricated with brake fluid when installed.
SLIDE RAIL SUSPENSION POWR TR SLIDE RAIL SUSPENSION PZ50/PZ50GT/PZ50FX/PZ50M È: 72 Nm (7.2 m • kg, 52 ft • lb) É: 110 Nm (11.0 m • kg, 80 ft • lb) LT É È LT : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order 1 Job name/Part name Slide rail suspension removal Rear axle nut Tension adjuster Slide rail suspension 1 Q’ty Remarks Remove the parts in the order listed below. Loosen. Loosen. 1 For installation, reverse the removal procedure.
SLIDE RAIL SUSPENSION POWR TR È: 4 Nm (0.4 m • kg, 2.9 ft • lb) É: 49 Nm (4.9 m • kg, 35 ft • lb) 8 Ê: 60 Nm (6.0 m • kg, 43 ft • lb) 9 Ë: 110 Nm (11.
SLIDE RAIL SUSPENSION H È POWR TR È: 6 Nm (0.6 m • kg, 4.3 ft • lb) É: 60 Nm (6.0 m • kg, 43 ft • lb) I Ê: 72 Nm (7.2 m • kg, 52 ft • lb) É M K Ê F D J New E L G I J É È Ê H LT G P É O N E New N O P F D É É PZ50M : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order D E F Job name/Part name Suspension wheel Circlip Spring end guide É Ê LT Q’ty 2 2 2 Remarks NOTE: Apply grease to the inner surface of each spring end guide.
SLIDE RAIL SUSPENSION POWR TR È: 35 Nm (3.5 m • kg, 25 ft • lb) É: 49 Nm (4.9 m • kg, 35 ft • lb) Ë Ê: 60 Nm (6.0 m • kg, 43 ft • lb) ] Ë: 72 Nm (7.
POWR TR SLIDE RAIL SUSPENSION È: 60 Nm (6.0 m • kg, 43 ft • lb) É: 75 Nm (7.5 m • kg, 54 ft • lb) b PZ50M È c i e h j d g l f l f c e k i Order b c d e f g h i j k l Job name/Part name Rear axle Guide wheel Guide wheel Collar Tension adjuster Collar Collar Suspension wheel Wheel bracket Shaft Sliding frame È j PZ50M Q’ty 1 2 1 2 2 1 1 2 2 1 2 É PZ50M Remarks For assembly, reverse the disassembly procedure.
POWR TR SLIDE RAIL SUSPENSION PZ50VT/PZ50MP È: 72 Nm (7.2 m • kg, 52 ft • lb) LT È È LT 1 Order 1 Job name/Part name Slide rail suspension removal Rear axle nut Tension adjuster Slide rail suspension Q’ty Remarks Remove the parts in the order listed below. Loosen. Loosen. 1 For installation, reverse the removal procedure.
SLIDE RAIL SUSPENSION 6 A Ë K 7 L 8 59 D M I N Ì H J B É: 6 Nm (0.6 m • kg, 4.3 ft • lb) Ê: 49 Nm (4.9 m • kg, 35 ft • lb) Ë: 60 Nm (6.0 m • kg, 43 ft • lb) Ê I È: 4 Nm (0.4 m • kg, 2.9 ft • lb) É New POWR TR J Ê 8 6 I Ì: 72 Nm (7.
SLIDE RAIL SUSPENSION 6 A Ë B K 7 L 8 59 D M I N Ì H J É: 6 Nm (0.6 m • kg, 4.3 ft • lb) Ê: 49 Nm (4.9 m • kg, 35 ft • lb) Ë: 60 Nm (6.0 m • kg, 43 ft • lb) Ê I È: 4 Nm (0.4 m • kg, 2.9 ft • lb) É New POWR TR J Ê 8 6 I Ì: 72 Nm (7.
SLIDE RAIL SUSPENSION È: 6 Nm (0.6 m • kg, 4.3 ft • lb) É: 9 Nm (0.9 m • kg, 6.5 ft • lb) Ë: 49 Nm (4.9 m • kg, 35 ft • lb) Ì: 60 Nm (6.0 m • kg, 43 ft • lb) Ê: 25 Nm (2.5 m • kg, 18 ft • lb) Í: 72 Nm (7.
SLIDE RAIL SUSPENSION È: 6 Nm (0.6 m • kg, 4.3 ft • lb) É: 9 Nm (0.9 m • kg, 6.5 ft • lb) Ë: 49 Nm (4.9 m • kg, 35 ft • lb) Ì: 60 Nm (6.0 m • kg, 43 ft • lb) Ê: 25 Nm (2.5 m • kg, 18 ft • lb) Í: 72 Nm (7.
SLIDE RAIL SUSPENSION POWR TR È: 75 Nm (7.5 m • kg, 54 ft • lb) r s t w v u y x y x t s È Order r s t u v w x y Job name/Part name Rear axle Guide wheel Collar Collar Guide wheel Collar Tension adjuster Sliding frame Q’ty 1 2 2 1 1 1 2 2 Remarks For assembly, reverse the disassembly procedure.
SLIDE RAIL SUSPENSION POWR TR REMOVAL 2 1. Unhook the torsion spring 1 (PZ50/PZ50GT/PZ50FX/PZ50M) 1 NOTE: For PZ50/PZ50GT/PZ50FX/PZ50M Rotate the spring end guide 2 in the direction of the arrow shown to unhook the end of the torsion spring. INSPECTION 1. Inspect: • Suspension wheel • Guide wheel Cracks/damage → Replace. • Wheel bearing Wheel turns roughly → Replace. 2. Inspect: • Stopper band Frayed/damage → Replace. • Pull rod (PZ50VT/PZ50MP) Bends/damage → Replace.
SLIDE RAIL SUSPENSION POWR TR 2. Install: • Control rods 1 (PZ50VT/PZ50MP) 1 NOTE: Install the control rods with the water drain holes a facing downward. a 3. Install: • Rear pivot arm joint 1 (PZ50/PZ50GT/PZ50FX/PZ50M) b NOTE: Align the punch mark a in the rear pivot arm joint with the punch mark b in the rear pivot arm. a 1 4. Install: • Rear shock absorber 1 (PZ50GT/PZ50FX/PZ50M) È a NOTE: • For PZ50GT/PZ50M: Install the rear shock absorber with the charging valve a facing upward.
SLIDE RAIL SUSPENSION POWR TR 6. Install: • 2-up adjusting block 1 (PZ50VT/PZ50MP) 1 NOTE: a Install the lock lever guide plate 2 as shown in the illustration so that the projection on the plate contacts the projection a on the 2-up adjusting block. Make sure that the 2-up adjusting block is locked in place and the end b of the lock lever is sticking out from the sliding frame.
SLIDE RAIL SUSPENSION POWR TR 7. Install: • Stopper band 1 È a NOTE: b 1 Install the stopper band with a toward the front pivot arm and b toward the shaft. È É Ê Ë Ì PZ50 PZ50GT/PZ50M PZ50FX PZ50VT PZ50MP É T. R. a 1 b a 1 b a 1 a 1 Ê Ë b Ì b 4-54 Stopper band nut: 4 Nm (0.4 m · kg, 2.
SLIDE RAIL SUSPENSION POWR TR INSTALLATION 1. Adjust: • Track tension Refer to “TRACK TENSION ADJUSTMENT” in CHAPTER 2. Control rod part numbers (PZ50VT/PZ50MP) a b c È Control rod 1 É Length a mm (in) Ê Length b mm (in) Ë Length c mm (in) PZ50VT/PZ50MP 242.3 (9.54) 188.7 (7.43) 2.5P × 2 = 5 (0.098P × 2 = 0.
FRONT AXLE AND TRACK POWR TR FRONT AXLE AND TRACK É È: 9 Nm (0.9 m • kg, 6.5 ft • lb) É: 24 Nm (2.4 m • kg, 17 ft • lb) É 1 Ê: 40 Nm (4.
FRONT AXLE AND TRACK POWR TR INSPECTION 1. Inspect: • Track 1 • Slide metal 2 Wear/cracks/damage → Replace. 1 2 2. Inspect: • Sprocket wheels 1 Wear/break/damage → Replace. • Front axle 2 Bends/scratches (excessive)/damage → Replace. 3. Inspect: • Bearing Pitting/damage → Replace. 1 2 INSTALLATION È 1. Install: • Oil seal 1 1 NOTE: Press the oil seal onto the bearing housing as shown. È 2.5 ~ 3.5 mm (0.10 ~ 0.
FRONT AXLE AND TRACK 2. Install: • Sprocket wheels • Guide wheels 2 (1. 7 mm 06 in) È 123.7 mm (4.87 in) 155.2 mm (6.11 in) 60 mm (2.36 in) NOTE: • When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. • Position each sprocket wheel on the axle as shown in the illustration. 122.4 mm (4.82 in) 123 mm (4.84 in) È PZ50/PZ50GT/PZ50FX É PZ50M Ê PZ50VT/PZ50MP 2 (1. 7 mm 06 in) É 4 mm (0.16 in) 122.2 mm (4.81 in) 155.2 mm (6.11 in) POWR TR 4 mm (0.
ENG SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK PZ50/PZ50GT/PZ50FX/PZ50M 7 È: 7 Nm (0.7 m • kg, 5.1 ft • lb) (6) È 9 10 11 É: 10 Nm (1.0 m • kg, 7.
ENG SEAT AND FUEL TANK 7 È: 7 Nm (0.7 m • kg, 5.1 ft • lb) (6) È 9 10 11 É: 10 Nm (1.0 m • kg, 7.2 ft • lb) 12 15 6 8 1 È É (4) É 2 11 13 3 5 3 3 16 4 14 5 Order 11 12 13 14 15 16 Q’ty 6 1 1 2 1 1 Job name/Part name Plastic band Fuel tank assembly Fuel sender coupler Fuel hose Fuel pump Fuel tank lower plate Remarks Disconnect. Disconnect. For installation, reverse the removal procedure.
ENG BACKREST AND PASSENGER SEAT BACKREST AND PASSENGER SEAT PZ50VT/PZ50MP È: 7 Nm (0.7 m • kg, 5.1 ft • lb) É: 8 Nm (0.8 m • kg, 5.8 ft • lb) Ê: 10 Nm (1.0 m • kg, 7.2 ft • lb) Ë: 23 Nm (2.
ENG BACKREST AND PASSENGER SEAT È: 7 Nm (0.7 m • kg, 5.1 ft • lb) É: 8 Nm (0.8 m • kg, 5.8 ft • lb) Ê: 10 Nm (1.0 m • kg, 7.2 ft • lb) Ë: 23 Nm (2.3 m • kg, 17 ft • lb) È È 14 11 15 4 Ë Ë É 8 15 Ë 10 13 3 Ë 12 ËÊ 9 É 1 É (4) 7 6 13 2 Order 11 12 13 14 15 Q’ty 1 1 2 1 2 Job name/Part name Tail/brake light assembly Tail/brake light switch coupler Passenger grip warmer coupler Rear carrier Passenger grip warmer È (4) 5 É Remarks Disconnect. Disconnect.
RIDER SEAT AND FUEL TANK ENG RIDER SEAT AND FUEL TANK PZ50VT/PZ50MP È: 7 Nm (0.7 m • kg, 5.1 ft • lb) É: Ë: 11 Nm (1.1 m • kg, 8.0 ft • lb) 6 8 Nm (0.8 m kg, 5.8 ft • lb) • Ê: 10 Nm (1.0 m • kg, 7.
RIDER SEAT AND FUEL TANK È: 7 Nm (0.7 m • kg, 5.1 ft • lb) ENG Ë: 11 Nm (1.1 m • kg, 8.0 ft • lb) 6 É: 8 Nm (0.8 m • kg, 5.8 ft • lb) Ê: 10 Nm (1.0 m • kg, 7.2 ft • lb) 3 È 9 (6) 8 4 2 5 É 14 7 10 Ê 12 1 11 10 Ë 10 3 13 Order 11 12 13 14 Q’ty 1 1 2 1 Job name/Part name Fuel tank assembly Fuel sender coupler Fuel return hose Fuel pump Remarks Disconnect. Disconnect. For installation, reverse the removal procedure.
RIDER SEAT AND FUEL TANK ENG REMOVAL 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose connector holder • Fuel hose CAUTION: • Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • Although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remaining in it.
RIDER SEAT AND FUEL TANK ENG INSTALLATION 1. Install: • Fuel pump gasket New • Fuel pump • Fuel pump bracket T. Fuel pump nut: 7 Nm (0.7 m · kg, 5.1 ft · lb) R. NOTE: • Do not damage the installation surface of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket. • Install the fuel pump bracket by aligning the projection a on the fuel pump with the projection b on the fuel tank. • Tighten the bolts to the specified torque in the proper tightening sequence as shown.
ENG EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER PZ50/PZ50GT/PZ50FX/PZ50M Ê È: 6 Nm (0.6 m • kg, 4.3 ft • lb) Ê Î É: 8 Nm (0.8 m • kg, 5.8 ft • lb) Ê: 10 Nm (1.0 m • kg, 7.2 ft • lb) 4 Ì Ë: 18 Nm (1.8 m • kg, 13 ft • lb) Ì: 23 Nm (2.3 m • kg, 17 ft • lb) Ê LT 6 7 Ï Ê Ë È 1 Í 10 3 2 9 2 5 7 3 Í: 25 Nm (2.5 m • kg, 18 ft • lb) 11 É Order 1 2 3 4 5 6 7 8 9 10 11 Î: 33 Nm (3.3 m • kg, 24 ft • lb) Ï: 47 Nm (4.
EXHAUST PIPE AND MUFFLER ENG PZ50VT/PZ50MP É 1 È: 6 Nm (0.6 m • kg, 4.3 ft • lb) Ë É: 7 Nm (0.7 m • kg, 5.1 ft • lb) Ê: 8 Nm (0.8 m • kg, 5.8 ft • lb) Ë: 10 Nm (1.0 m • kg, 7.2 ft • lb) Ì: 18 Nm (1.8 m • kg, 13 ft • lb) Í: 25 Nm (2.5 m • kg, 18 ft • lb) Î Ë Î: 33 Nm (3.
EXHAUST PIPE AND MUFFLER ENG INSTALLATION 1. Install: • Muffler damper holder (temporarily) 2. Install: • Exhaust pipe/muffler assembly 1 È NOTE: a Position the exhaust pipe bolt 1 at the rear of the hole a in the seat rail assembly, and then finger tighten it. È Forward 3. Install: • Exhaust pipe band 1 1 T. Exhaust pipe band bolt: 18 Nm (1.8 m · kg, 13 ft · lb) R. 4. Tighten: • Exhaust pipe bolt T. Exhaust pipe bolt: 33 Nm (3.3 m · kg, 24 ft · lb) R. 5.
OIL TANK ENG OIL TANK È: 10 Nm (1.0 m • kg, 7.2 ft • lb) É: 16 Nm (1.6 m • kg, 11 ft • lb) 1 2 6 3 È 5 4 LS New Order 1 2 3 4 5 6 É Job name/Part name Oil tank removal Right side panel Engine oil Q’ty Oil level switch coupler Oil tank breather hose Oil tank inlet hose Oil tank outlet hose Oil tank Oil level gauge 1 1 1 1 1 1 Remarks Remove the parts in the order listed below. Refer to “COWLINGS” in CHAPTER 3. Drain. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 2. Disconnect. Disconnect.
ENGINE ASSEMBLY ENG ENGINE ASSEMBLY HOSE AND LEADS È: 7 Nm (0.7 m • kg, 5.1 ft • lb) 8 È È 1 4 3 2 1 6 9 5 7 Order Job name/Part name Hose and leads removal Coolant Q’ty Engine oil Throttle body Primary sheave Brake disc Radiator/coolant reservoir/thermostat Handlebar/steering shaft Oil tank inlet hose/oil tank outlet hose Fuel tank 5-13 Remarks Remove the parts in the order listed below. Drain. Refer to “COOLING SYSTEM” in CHAPTER 2. Drain. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 2.
ENGINE ASSEMBLY ENG È: 7 Nm (0.7 m • kg, 5.1 ft • lb) 8 È È 4 3 2 1 1 6 9 5 7 Order Job name/Part name Exhaust pipe/muffler assembly Water pump Battery Q’ty 1 2 3 4 5 6 7 8 9 A.C. magneto lead coupler Rectifier/regulator lead coupler Frame ground lead Starter motor lead Knock sensor coupler Sub-wire harness 2 coupler Cam position sensor coupler Ignition coil coupler Speed sensor lead coupler 2 1 1 1 1 1 1 3 1 5-14 Remarks Refer to “EXHAUST PIPE AND MUFFLER”.
ENGINE ASSEMBLY ENG ENGINE ASSEMBLY È: 7 Nm (0.7 m • kg, 5.1 ft • lb) 1 É: 23 Nm (2.3 m • kg, 17 ft • lb) Ê: 25 Nm (2.5 m • kg, 18 ft • lb) Ë Ë: 30 Nm (3.0 m • kg, 22 ft • lb) Ì: 40 Nm (4.
ENGINE ASSEMBLY ENG REMOVAL 1. Remove: • Rear engine mounting nut • Front engine mounting nuts • Washers NOTE: Do not remove the engine mounting bolts. 2. Remove: • Engine assembly 3 Removal steps: • Screw in the engine mounting bolt spacers (front and rear) using the engine mount spacer wrench 1 so that there is a gap between each engine mounting bolt spacer 2 and engine damper 3. 2 1 Engine mount spacer wrench: 90890-01516, YS-01516 • Remove the engine mounting bolts and engine mounting bracket.
ENGINE ASSEMBLY ENG Installation steps: • Install the engine mounting bolt spacer (front left side). • Install the engine assembly, and then install the rear engine mounting bolt spacer. • Install the rear engine mounting bolt and front engine left mounting bolt. • Install the engine mounting bolt spacer (front right side) to the engine mounting bracket. • Install the engine mounting bracket, and then insert a rod a into the bracket hole to align the engine assembly with the bracket. Use a 10 mm (0.
CAMSHAFTS ENG CAMSHAFTS CYLINDER HEAD COVER È: 8 Nm (0.8 m • kg, 5.8 ft • lb) É: 10 Nm (1.0 m • kg, 7.2 ft • lb) Ê: È É 2 1 12 Nm (1.2 m • kg, 8.7 ft • lb) New Ë: 13 Nm (1.3 m • kg, 9.4 ft • lb) 3 Ë LS Ê 4 6 5 New Order 1 2 3 4 5 6 Job name/Part name Cylinder head cover removal Fuel tank Q’ty Cylinder identification sensor Ignition coil Spark plug Cylinder head cover Cylinder head cover gasket Timing chain guide (top side) Remarks Remove the parts in the order listed below.
CAMSHAFTS ENG CAMSHAFTS È: 9 Nm (0.9 m • kg, 6.5 ft • lb) È É: 12 Nm (1.2 m • kg, 8.7 ft • lb) È Ê: 24 Nm (2.
CAMSHAFTS b ENG REMOVAL a 1. Remove: • Timing accessing screw • Crankshaft end accessing screw 2. Align: • “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) NOTE: • Turn the crankshaft counterclockwise. • When piston #1 is at TDC on the compression stroke, align the TDC mark a on the A.C. magneto rotor with the stationary pointer b on the A.C. magneto cover. • TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
CAMSHAFTS ENG 6. Remove: • Intake camshaft sprocket 1 (Use the special tool 2) Rotor holding tool: 90890-01235, YU-01235 INSPECTION 1. Inspect: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • Camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft dimensions: Intake: : a 30.350 mm (1.1949 in) b 22.510 mm (0.8862 in) Exhaust: : a 30.600 mm (1.2047 in) b 22.493 mm (0.8856 in) 3.
CAMSHAFTS ENG 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft-cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) Measurement steps: • Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). • Position a strip of Plastigauge® 1 onto the camshaft journal as shown. • Install the dowel pins and camshaft caps.
CAMSHAFTS ENG 7. Inspect: • Decompression system 1 2 Inspection steps: • Check that the decompressor lever pins 1 projects from the camshaft. • Check that the decompressor cams 2 moves smoothly. 1 8. Inspect: • Timing chain guide (top side) Damage/wear → Replace the timing chain guide. 9.
CAMSHAFTS ENG Assembly steps: • Install the timing chain tensioner spring, timing chain tensioner spring seat, and timing chain tensioner rod 1. • Squeeze the timing chain tensioner clip 2, and then push the timing chain tensioner rod 3 into the timing chain tensioner housing. NOTE: Do not release the timing chain tensioner clip while pushing the rod into the housing, otherwise the rod may be ejected. • Hook the clip 4 to the timing chain tensioner rod 3.
CAMSHAFTS ENG INSTALLATION 1. Install: • Intake camshaft sprocket 1 (with the special tool 2) Rotor holding tool: 90890-01235, YU-01235 • Camshaft sprocket bolts T. Camshaft sprocket bolt: 24 Nm (2.4 m · kg, 17 ft · lb) R. a a NOTE: c b c Make sure that the position to the cylinder #1 cam a and marks b and c on the camshaft sprockets are in the position shown in the illustration. b: Exhaust side “—” c: Intake side “—” d: Cylinder #1 - cam b 2.
CAMSHAFTS ENG 3. Install: • Dowel pins • Intake camshaft cap • Exhaust camshaft cap a NOTE: Install the camshaft caps with the arrow mark a pointing towards the right side of the engine. a 4. Install: • Camshaft cap bolts T. Camshaft cap bolt: 9 Nm (0.9 m · kg, 6.5 ft · lb) R. NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. CAUTION: • Lubricate the camshaft cap bolts with the engine oil.
CAMSHAFTS ENG 7. Inspect: • Timing chain • Check that the timing chain is taut. If the chain is slack, reinstall the timing chain tensioner. NOTE: If the engine is not disassembled, start the engine and check for any abnormal noise. If any abnormal noise is heard, reinstall the timing chain tensioner. b 8. Turn: • Crankshaft (several turns counterclockwise) 9. Inspect: • “I” mark a Make sure the “I” mark a on the A.C. magneto rotor is aligned with the stationary pointer b on the A.C. magneto cover.
ENG CYLINDER HEAD CYLINDER HEAD (6) Ê È 1 E New 2 É New 3 4 4 È: 10 Nm (1.0 m • kg, 7.2 ft • lb) É: 12 Nm (1.2 m • kg, 8.7 ft • lb) Ê: 1st 25 Nm (2.5 m • kg, 18 ft • lb) 2nd 25 Nm (2.5 m • kg, 18 ft • lb) Final Specified angle 175 ~ 185˚ Order 1 2 3 4 Job name/Part name Cylinder head removal Engine Camshafts Timing chain guide (exhaust side) Cylinder head Cylinder head gasket Dowel pin Q’ty Remarks Remove the parts in the order listed below. Refer to “ENGINE ASSEMBLY”. Refer to “CAMSHAFTS”.
CYLINDER HEAD ENG REMOVAL 1. Remove: • Cylinder head bolts 5 3 1 NOTE: Loosen each bolt 1/2 of a turn at a time. After all of the bolt are fully loosened, remove them. 4 2 6 INSPECTION 1. Eliminate: • Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads • valve seats 2. Inspect: • Timing chain guide (exhaust side) Damage/wear → Replace the timing chain guide. 3.
CYLINDER HEAD ENG INSTALLATION 2 New 1. Install: • Dowel pins 1 • Gasket 2 New 1 1 2. Install: • Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 6 2 3. Tighten: • Cylinder head bolts (M10) 4 NOTE: The tightening procedure of the cylinder head bolts is angle controlled, therefore tighten the bolts using the following procedure. 3 1 5 Tightening steps: • Lubricate the cylinder head bolts and washers with engine oil. • Install the washers and cylinder head bolts.
CYLINDER HEAD ENG • Tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence as shown. T. R. Cylinder head bolt (M10): Final: Specified angle 175 ~ 185° WARNING When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the procedure again. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle.
ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS 1 2 3 4 5 3 M New 8 9 1 M 3 2 3 M 4 New 5 8 M 9 10 10 6 7 M M Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Valves and valve springs removal Cylinder head Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Exhaust valve Intake valve Oil seal Lower spring seat Valve guide Q’ty Remarks Remove the parts in the order listed below. Refer to “CYLINDER HEAD”.
VALVES AND VALVE SPRINGS ENG REMOVAL The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • Valve lifter 1 • Valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2.
VALVES AND VALVE SPRINGS ENG 4. Remove: • Upper spring seat 1 • Valve spring 2 • Valve 3 • Valve stem seal 4 • Lower spring seat 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. INSPECTION 1. Measure: • Valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a – Valve stem diameter b Out of specification → Replace the valve guide. Valve-stem-to-valve-guide clearance: Intake: 0.010 ~ 0.037 mm (0.
VALVES AND VALVE SPRINGS ENG • After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (ø4): 90890-04111, YM-04111 Valve guide installer (ø4): 90890-04112, YM-04112 Valve guide reamer (ø4): 90890-04113, YM-04113 3. Eliminate: • Carbon deposits (from the valve face and valve seat) 4.
VALVES AND VALVE SPRINGS ENG 9. Measure: • Valve seat width a Out of specification → Replace the cylinder head. Valve seat width: Intake: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) : 1.6 mm (0.0630 in) Exhaust: 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) : 1.9 mm (0.0748 in) Measurement steps: • Apply Mechanic’s blueing dye (Dykem) 1 onto the valve face. • Install the valve into the cylinder head. • Press the valve through the valve guide and onto the valve seat to make a clear impression.
VALVES AND VALVE SPRINGS ENG • Install the valve into the cylinder head. • Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. • Apply a fine lapping compound to the valve face and repeat the above steps. • After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat.
VALVES AND VALVE SPRINGS ENG 12. Measure: • Compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring force (installed): Intake: 120.7 ~ 138.9 N at 30.13 mm (12.3 ~ 14.2 kg at 30.13 mm, 27.1 ~ 31.2 lb at 1.19 in) Exhaust: 150.6 ~ 173.2 N at 30.50 mm (15.4 ~ 17.7 kg at 30.50 mm, 33.9 ~ 38.9 lb at 1.20 in) 13. Measure: • Valve spring tilt a Out of specification → Replace the valve spring. Maximum valve spring tilt: Intake: 2.5°/1.6 mm (0.
VALVES AND VALVE SPRINGS ENG 2. Lubricate: • Valve stem 1 • Valve stem seal 2 (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide oil 3. Install: • Lower spring seat 1 • Valve stem seal 2 • Valve 3 • Valve spring 4 • Upper spring seat 5 (into the cylinder head) NOTE: • Make sure each valve is installed in its original place. • Install the valve spring with the larger pitch a facing up. b Smaller pitch 4.
VALVES AND VALVE SPRINGS ENG 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad • Valve lifter (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide oil 7. Install: • Valve pad • Valve lifter NOTE: • The valve lifter must move smoothly when rotated with a finger.
A.C. MAGNETO ROTOR AND STARTER CLUTCH ENG A.C. MAGNETO ROTOR AND STARTER CLUTCH i È: 7 Nm (0.7 m • kg, 5.1 ft • lb) Ê: 12 Nm (1.2 m • kg, 8.7 ft • lb) É: 10 Nm (1.0 m • kg, 7.2 ft • lb) Ë: 130 Nm (13.0 m • kg, 94 ft • lb) É È LT 10 Ê (7) 4 3 3 É 5 Ê LT LT 2 New 12 (5) (3) 1 11 Ê Ê LT LT 9 E Ë Order 1 2 3 4 5 6 7 8 9 10 11 12 8 E LT 7 6 E Job name/Part name A.C. magneto rotor and starter clutch removal Engine assembly A.C.
A.C. MAGNETO ROTOR AND STARTER CLUTCH ENG REMOVAL 1. Remove: • A.C. magneto rotor bolt • Washer NOTE: • While holding the A.C. magneto rotor 1 with the sheave holder 2, loosen the magneto rotor bolt. • Do not allow the sheave holder to touch the projection on the A.C. magneto rotor. 2 1 Sheave holder: 90890-01701, YS-01880-A 2. Remove: • A.C.
A.C. MAGNETO ROTOR AND STARTER CLUTCH ENG 3. Remove: • Starter clutch NOTE: • While holding the magneto rotor with the sheave holder, remove the starter clutch bolts 1. • Do not allow the sheave holder to touch the projection on the magneto rotor. Sheave holder: 90890-01701, YS-01880-A INSPECTION 1. Inspect: • Stator coil • Pickup coil Damage → Replace the pickup coil/stator assembly. 2. Inspect: • Starter clutch rollers 1 Damage/wear → Replace. 3.
A.C. MAGNETO ROTOR AND STARTER CLUTCH ENG 4. Inspect: • Starter clutch operation É Installation steps: • Install the starter clutch gear onto the starter clutch and hold the starter clutch. • When turning the starter clutch gear clockwise È, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. • When turning the starter clutch gear counterclockwise É, it should turn freely, otherwise the starter clutch is faulty and must be replaced.
A.C. MAGNETO ROTOR AND STARTER CLUTCH ENG 4. Tighten: • A.C. magneto rotor bolt 1 T. A.C. magneto rotor bolt: 130 Nm (13.0 m · kg, 94 ft · lb) R. NOTE: • Lubricate the A.C. magneto rotor bolt and washer with engine oil. • While holding the A.C. magneto rotor 2 with the sheave holder 3, tighten the magneto rotor bolt. • Do not allow the sheave holder to touch the projection on the magneto rotor. 1 Sheave holder: 90890-01701, YS-01880-A 3 2 5. Apply: • Sealant (onto the A.C.
OIL PAN AND OIL PUMP ENG OIL PAN AND OIL PUMP É Ì 1 New È (13) 2 Ë E 5 New 4 6 New 12 LT LT 13 Ì 7 New Ê 3 New 11 7 10 È: 10 Nm (1.0 m • kg, 7.2 ft • lb) E : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Oil pan and oil pump removal Engine Starter clutch gear É: 12 Nm (1.2 m • kg, 8.7 ft • lb) 9 8 Ê: 15 Nm (1.5 m • kg, 11 ft • lb) Ë: 17 Nm (1.
OIL PAN AND OIL PUMP É ENG New Ì 1 È (13) 2 Ë E 5 New 4 6 New 12 LT LT 13 7 Ì New Ê 3 New 11 7 10 È: 10 Nm (1.0 m • kg, 7.2 ft • lb) E : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order 11 12 13 Job name/Part name Oil pump drive chain Oil pump assembly Dowel pin É: 12 Nm (1.2 m • kg, 8.7 ft • lb) 9 8 Ê: 15 Nm (1.5 m • kg, 11 ft • lb) Ë: 17 Nm (1.7 m • kg, 12 ft • lb) È LT Q’ty 1 1 2 Ì: 30 Nm (3.0 m • kg, 22 ft • lb) Remarks For installation, reverse the removal procedure.
OIL PAN AND OIL PUMP È: 5 Nm (0.5 m • kg, 3.
OIL PAN AND OIL PUMP ENG REMOVAL 1. Remove: • Oil pan NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. INSPECTION 1. Inspect: • Oil pump housing • Oil pump cover Cracks/damage/wear → Replace the defective part(s). 2.
OIL PAN AND OIL PUMP ENG 4. Inspect: • Relief valve body 1 • Relief valve 2 • Spring 3 Damage/wear → Replace the defective part(s). 5. Inspect: • Oil pump driven sprocket Cracks/damage/wear → Replace. 6. inspect: • Oil pump drive chain Damage/stiffness → Replace the chain and sprocket as a set. 7. Inspect: • Check ball seat • Check ball • Spring • Spacer Damage/wear → Replace the defective part(-s). 1 2 3 8. Inspect: • Oil strainer 1 Damage → Replace. Obstruction → Wash and blow out with compressed air.
OIL PAN AND OIL PUMP ENG 3. Install: • Oil pump driven sprocket shaft 1 b NOTE: 1 Align the slit a on the oil pump driven sprocket shaft with the projection b on the oil pump shaft. a 4. Install: • Dowel pins • Gasket New • Oil pan • Oil pan bolts T. Oil pan bolt: 10 Nm (1.0 m · kg, 7.2 ft · lb) R. NOTE: Tighten the oil pan bolts in stages and in a crisscross pattern.
BALANCER ENG BALANCER Ê New 4 15 5 8 LT È 18 Ê 16 19 7 10 6 New 4 9 New Ë 11 13 14 12 2 17 1 3 (2) New È: 10 Nm (1.0 m • kg, 7.2 ft • lb) É: 12 Nm (1.2 m • kg, 8.7 ft • lb) (4) Ê: 50 Nm (5.0 m • kg, 36 ft • lb) New (10) É Ë: 75 Nm (7.5 m • kg, 54 ft • lb) Order Job name/Part name Balancer shaft removal Engine Cylinder head A.C.
BALANCER ENG Ê New 4 15 5 8 LT È 18 Ê 16 19 7 10 6 New 4 9 New Ë 11 13 14 12 2 17 1 3 (2) New È: 10 Nm (1.0 m • kg, 7.2 ft • lb) É: 12 Nm (1.2 m • kg, 8.7 ft • lb) (4) Ê: 50 Nm (5.0 m • kg, 36 ft • lb) New (10) É Ë: 75 Nm (7.5 m • kg, 54 ft • lb) Order 11 12 13 14 15 16 17 18 19 Job name/Part name Circlip Bearing Circlip Bearing Bearing retainer Bearing Bearing Circlip Bearing Q’ty 1 1 1 1 1 1 1 1 1 LT É Remarks For installation, reverse the removal procedure.
BALANCER ENG REMOVAL 1. Straighten the lock washer tab. 2. Loosen: • Right balancer weight nut 1 CAUTION: The right balancer weight nut has left-handed threads. To loosen the nut, turn it clockwise. 1 NOTE: Place an aluminum plate 2 between the teeth of the balancer shaft drive gear 3 and balancer shaft driven gear 4. 4 2 3 3. Straighten the lock washer tabs. 4.
BALANCER ENG INSPECTION 1. Inspect: • Bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2. Inspect: • Balancer shaft drive gear • Balancer shaft driven gear Damage/wear → Replace. 3. Inspect: • Balancer weight Cracks/damage/wear → Replace. 4. Inspect: • Balancer shaft Scratches (excessive)/damage → Replace. • Splines 1 Wear/damage → Replace the secondary shaft. • Bearing contact surface 2 Scratches/wear/damage → Replace the secondary shaft.
BALANCER 3. Install: • Balancer shaft driven gear 1 • Lock washers • Balancer shaft driven gear nut • Right balancer weight nut • Balancer shaft drive gear bolt a c d ENG 1 b NOTE: • Align the punch mark a on the balancer shaft driven gear with the shorter spline b on the balancer shaft end. • Align the punch mark c on the balancer shaft driven gear with the punch mark d on the balancer shaft drive gear. 2 4 4.
BALANCER ENG 5. Tighten: • Primary sheave drive shaft cover bolt T. R. Primary sheave drive shaft cover bolt: 12 Nm (1.2 m · kg, 8.7 ft · lb) LOCTITE® NOTE: Apply LOCTITE® to the bolts (black) indicated by the “ ” marks on the primary sheave drive shaft cover.
CRANKCASE ENG CRANKCASE CRANKCASE È: 12 Nm (1.2 m • kg, 8.7 ft • lb) É: (6) 1st 15 Nm (1.5 m • kg, 11 ft • lb) 2nd 15 Nm (1.5 m • kg, 11 ft • lb) Final Specified angle 65 ~ 70˚ (2) È (5) È É E E 3 E È (2) LT È 2 1 È E E È (3) 4 LT 4 Order Job name/Part name Crankcase removal Engine Cylinder head A.C.
CRANKCASE ENG CONNECTING RODS AND PISTONS È È: 1st 20 Nm (2.0 m • kg, 14 ft • lb) 2nd Specified angle 120 ~ 130˚ 1 M M 2 E 2 6 E E New 3 4 5 9 3 New 8 E 7 E Order 1 2 3 4 5 6 7 8 9 Job name/Part name Connecting rods and pistons removal Connecting rod cap Big end bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring Q’ty Remarks Remove the parts in the order listed below. 2 4 4 2 2 2 2 2 2 For installation, reverse the removal procedure.
CRANKCASE ENG CRANKSHAFT 2 2 E 1 E E 2 2 E 3 Order 1 2 3 Job name/Part name Crankshaft removal Crankshaft Crankshaft journal bearing Upper crankcase Q’ty Remarks Remove the parts in the order listed below. 1 6 1 For installation, reverse the removal procedure.
CRANKCASE ENG REMOVAL È 1. Remove: • Crankcase bolts NOTE: • Loosen the bolts in decreasing numerical order of the embossed numbers on the crankcase. • Loosen each bolt 1/4 of a turn at a time. After all of the bolts are fully loosened, remove them. 19 18 17 È Cylinder head side É Oil pan side É 10 8 3 5 1 2 4 11 9 7 6 12 13 15 14 2. Remove: • Lower crankcase CAUTION: Tap on one side of the crankcase with a softface hammer.
CRANKCASE ENG 5. Remove: • Piston pin clips 1 • Piston pin 2 • Piston 3 • Connecting rod 4 4 3 CAUTION: 2 Do not use a hammer to drive the piston pin out. 1 NOTE: • For reference during installation, put identification marks on the piston crown. • Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller 5.
ENG CRANKCASE INSPECTION 1. Inspect: • Piston wall • Cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: • Measure cylinder bore “C” with the cylinder bore gauge 1. NOTE: Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. Cylinder bore “C” 77.000 ~ 77.010 mm (3.0315 ~ 3.
CRANKCASE ENG 3rd step: • Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) : 0.120 mm (0.0047 in) • If out of specification, replace the cylinder, and the piston and piston rings as a set. 3. Measure: • Piston ring side clearance Use the thickness gauge 1. Out of specification → Replace the piston and piston rings as a set.
CRANKCASE ENG 5. Measure: • Piston ring end gap Out of specification → Replace the piston rings as a set. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring end gap: Top ring: 0.15 ~ 0.25 mm (0.006 ~ 0.010 in) 2nd ring: 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) Oil ring: 0.10 ~ 0.40 mm (0.004 ~ 0.016 in) 6.
CRANKCASE ENG 9. Calculate: • Piston pin to piston pin bore clearance Out of specification → Replace the piston pin and piston as a set. Piston pin to piston pin bore clearance = Piston pin bore size – Piston pin outside diameter Piston pin to piston pin bore clearance: 0.002 ~ 0.022 mm (0.0001 ~ 0.0009 in) : 0.072 mm (0.0028 in) 10. Measure: • Crankshaft runout Use the V-blocks and a dial gauge. Out of specification → Replace the crankshaft. Dial gauge: 90890-03097, YU-03097 Crankshaft runout: 0.
CRANKCASE ENG 12. Measure: • Crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification → Replace the crankshaft journal bearings. Crankshaft-journal-to-crankshaftjournal-bearing clearance: 0.020 ~ 0.044 mm (0.0008 ~ 0.0017 in) Measurement steps: CAUTION: Do not interchange the crankshaft journal bearings.
CRANKCASE ENG • Install the crankshaft journal lower bearings 1 into the lower crankcase and assemble the crankcase halves. NOTE: • Align the projections a of the crankshaft journal lower bearings with the notches b in the crankcase. • Do not move the crankshaft until the clearance measurement has been completed. • Tighten the bolts in the order of the embossed numbers on the crankcase. È T. R. 2 2 2 Crankcase bolt: Bolt 1: 1st: 15 Nm (1.5 m · kg, 11 ft · lb) 2nd: 15 Nm (1.
CRANKCASE ENG 13. Select: • Crankshaft journal bearings (J1 ~ J3) NOTE: J1 J2 • The numbers È stamped into the crankshaft web and the numbers É stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “J1 ~ J3” refer to the bearings shown in the crankshaft illustration. • If “J1 ~ J3” are the same, use the same size for all of the bearings.
CRANKCASE ENG Measurement steps: CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. • Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods. • Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap.
CRANKCASE ENG • Tighten the connecting rod bolts. T. R. Connecting rod bolt: 1st: 20 Nm (2.0 m · kg, 14 ft · lb) Final: Specified angle 120 ~ 130° • Replace the connecting rod bolts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. Tightening steps: • Clean the connecting rod bolts. • Tighten the connecting rod bolts. • Put a mark e on the corner of the connecting rod bolt 1 and the connecting rod 2.
CRANKCASE ENG 15. Select: • Big end bearings (P1 ~ P2) NOTE: • The numbers È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. • “P1” ~ “P2” refer to the bearings shown in the crankshaft illustration.
CRANKCASE ENG INSTALLATION 1. Install: • Crankshaft journal upper bearing (into the upper crankcase) • Crankshaft journal lower bearing (into the lower crankcase) NOTE: • Align the projections a on the crankshaft journal bearings with the notches b in the crankcase. • Be sure to install each crankshaft journal bearing in its original place. 2. Lubricate: • Crankshaft pins • Connecting rod inner surface (with the recommended lubricant) Recommended lubricant: Engine oil 3.
CRANKCASE be È 90˚ ENG 5. Offset: • Piston ring end gaps c a b c d e È 90˚ Top ring 2nd ring Upper oil ring rail Oil ring expander Lower oil ring rail Exhaust side 6. Lubricate: • Piston • Piston rings • Cylinder ad 45˚ Recommended lubricant: Engine oil 7. Lubricate: • Bolt threads • Nut seats (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide grease 8.
CRANKCASE ENG 9. Install: • Big end bearings • Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin). • Connecting rod cap (onto the connecting rod) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. • Be sure to reinstall each big end bearing in its original place. • While compressing the piston rings with piston ring compressor 2, install the connecting rod assembly into the cylinder with the other hand.
CRANKCASE ENG 11. Tighten: • Connecting rod bolts T. R. Connecting rod bolt: 1st: 20 Nm (2.0 m · kg, 14 ft · lb) Final: Specified angle 120 ~ 130° • Replace the connecting rod bolts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. Tightening steps: • Clean the connecting rod bolts. • Tighten the connecting rod bolts. • Put a mark a on the corner of the connecting rod bolt 1 and the connecting rod 2.
CRANKCASE ENG 13. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215: 90890-85505 (Three Bond No.1215®) NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 ~ 3 mm (0.08 ~ 0.12 in) of the crankshaft journal bearings. 14. Install: • Dowel pins 15.
CRANKCASE ENG 17. Install: • Crankcase bolts È NOTE: • Lubricate the bolt threads with engine oil. • Tighten the bolts in the order of the embossed numbers on the crankcase. 2 2 2 T. R. É 53 64 6 5 1 1 1 5 1 1 1 È Cylinder head side É Oil pan side M9 × 105 mm bolts: 1 M6 × 70 mm bolts: 2 M6 × 65 mm bolts: 3 M6 × 50 mm bolts: 4 M6 × 50 mm bolt: 5 (with LOCTITE®) M6 × 35 mm bolts: 6 6 6 3 6 Crankcase bolt: Bolt 1: 1st: 15 Nm (1.5 m · kg, 11 ft · lb) 2nd: 15 Nm (1.
RADIATOR AND HEAT EXCHANGER COOL COOLING SYSTEM RADIATOR AND HEAT EXCHANGER (2) È: 8 Nm (0.8 m • kg, 5.8 ft • lb) É É: 10 Nm (1.0 m • kg, 7.2 ft • lb) 23 1 24 2 7 22 È 19 21 25 4 15 6 3 (3) 5 26 3 20 LS 16 11 New 14 É 18 8 Ê 17 (3) 13 10 É 24 9 12 Ê: 27 Nm (2.
RADIATOR AND HEAT EXCHANGER (2) È: 8 Nm (0.8 m • kg, 5.8 ft • lb) COOL É É: 10 Nm (1.0 m • kg, 7.2 ft • lb) 23 1 24 2 7 22 È 19 21 25 4 15 6 (3) 3 5 26 3 20 LS 16 11 14 É New 18 8 Ê 17 (3) 13 10 É 24 9 12 Ê: 27 Nm (2.
RADIATOR AND HEAT EXCHANGER COOL INSPECTION 1. Inspect: • Coolant hoses • Heat exchanger • Oil cooler • Coolant pipes Cracks/damage → Replace. 2. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: _ Straighten any flattened fins with a thin, flat-head screwdriver. 3. Check: • Radiator fan (PZ50VT/PZ50MP) Damage → Replace. Malfunction → Check and repair. 4.
RADIATOR AND HEAT EXCHANGER COOL INSTALLATION 1. Install: • Heat exchanger Use the rivet gun. 2. Install: • O-ring • Oil cooler 1 T. a 1 R. Oil cooler bolt: 10 Nm (1.0 m · kg, 7.2 ft · lb) LOCTITE® NOTE: Install the oil cooler with the manufacturer’s mark a facing down.
THERMOSTAT COOL THERMOSTAT È È: 10 Nm (1.0 m • kg, 7.2 ft • lb) É: 23 Nm (2.
THERMOSTAT COOL INSPECTION 1. Inspect: • Thermostat Does not open at 80 ~ 84 °C (176 ~ 183 °F) → Replace. Inspection steps: • Suspend the thermostat in a container filled with water. • Slowly heat the water. Place a thermometer in the water. • While stirring the water, observe the thermostat and thermometer’s indicated temperature. 1 2 3 4 È É Ê Thermometer Water Thermostat Container Fully closed Fully open More than 7 mm (0.28 in) NOTE: If the accuracy of the thermostat is in doubt, replace it.
THERMOSTAT COOL 3. Install: • Coolant temperature sensor (to the thermostat housing) T. Coolant temperature sensor: 23 Nm (2.3 m · kg, 17 ft · lb) R. CAUTION: Use extreme care when handling the coolant temperature sensor. Replace any part that was dropped or subjected to a strong impact.
WATER PUMP COOL WATER PUMP È: 12 Nm (1.2 m • kg, 8.7 ft • lb) 3 1 2 New 5 4 LS È Order 1 2 3 4 5 Q’ty Job name/Part name Water pump removal Oil tank Radiator Water pump inlet hose Throttle body outlet hose Water pump outlet hose Water pump assembly O-ring 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “OIL TANK” in CHAPTER 5. Refer to “RADIATOR AND HEAT EXCHANGER”. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure.
WATER PUMP COOL E 3 New 7 8 6 New 5 New 4 2 New 1 Order 1 2 3 4 5 6 7 8 Q’ty Job name/Part name Water pump disassembly Water pump housing cover Gasket Circlip Impeller shaft assembly Water pump seal Oil seal Bearing Water pump housing Remarks Remove the parts in the order listed below. 1 1 2 1 1 1 1 1 For assembly, reverse the disassembly procedure.
WATER PUMP COOL DISASSEMBLY 1. Remove: • Impeller • Water pump seal 1 NOTE: Remove the water pump seal 1 from the inside of the water pump housing 2. 2. Remove: • Bearing 1 • Oil seal 2 NOTE: Remove the bearing 1 and oil seal 2 from the inside of the water pump housing 3. 3. Remove: • Rubber damper holder 1 • Rubber damper 2 (from the impeller, with a thin, flat-head screwdriver) 1 NOTE: 2 Do not scratch the impeller shaft. INSPECTION 1.
WATER PUMP COOL ASSEMBLY 1. Install: • Oil seal 1 New (to the water pump housing) NOTE: • Before installing the oil seal, apply tap water or coolant onto its outer surface. • Install the oil seal with a socket that matches its outside diameter. 2. Install: • Bearing NOTE: Install the bearing with a socket that matches its outside diameter. 3. Install: • Water pump seal New CAUTION: Never apply oil or grease onto the water pump seal surface.
WATER PUMP COOL 4. Install: • Rubber damper holder 1 • Rubber damper 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 1 2 5. Measure: • Impeller shaft tilt Out of specification → Repeat steps (4) and (5). 1 CAUTION: 2 Make sure the rubber damper and rubber damper holder are flush with the impeller. Max. impeller shaft tilt: 0.15 mm (0.0059 in) 1 Straightedge 2 Impeller INSTALLATION 1.
COOL 6-13
FUEL INJECTION SYSTEM FI FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Battery 2 ECU (engine control unit) 3 Fuel injection system relay 4 Cylinder-#2 ignition coil 5 Spark plug 6 Fuel pump 2 1 7 Cylinder identification sensor 8 Cylinder-#1 ignition coil 9 Cylinder-#1 intake air pressure sensor 0 Throttle position sensor A Speed sensor B Injector #1 C Knock sensor 3 45 D Oil pressure switch E Coolant temperature sensor F Crankshaft position sensor G Injector #2 H Cylinder-#2 intake air pressure sens
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FUEL INJECTION SYSTEM 1 4 5 6 7 0 A B C E F G H I J K L M N O P Q R S T U V W X Y Z c e f l m s t u v w y z { | Crankshaft position sensor Main switch Main fuse Load control relay Fuel injection system fuse Battery Diode Engine stop switch Throttle switch Grip warmer Thumb warmer Oil pressure switch Drive position switch *1 Reverse position switch *1 ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Fuel injection system relay Injector #1 Injector #2 Fuel pump Throttl
FUEL INJECTION SYSTEM FI ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and the warning light and self-diagnosis warning indicator come on to alert the rider that a malfunction has occurred in the system.
FUEL INJECTION SYSTEM Fault code No. Item Symptom Able/unable to start Able/unable to drive Able (depending on the number of faulty cylinders) Able (depending on the number of faulty cylinders) Cylinder-#2 ignition coil (faulty ignition) Open circuit detected in the primary lead of the cylinder-#2 ignition coil. Speed sensor No normal signals are received from the speed sensor.
FI FUEL INJECTION SYSTEM TROUBLESHOOTING CHART Engine operation is not normal or the warning light and self-diagnosis warning indicator flash. * Warning light and self-diagnosis warning indicator may not flash even if the engine operation is not normal. The warning light and self-diagnosis warning indi- The warning light and self-diagnosis warning indicator do not come on. cator flash. Check the operation of the following sensors and actuators in the diagnostic mode. (Refer to “Diagnostic mode table”.
FUEL INJECTION SYSTEM FI DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode 1. Turn the main switch off and set the engine stop switch to “RUN”. 2. Disconnect the wire harness coupler from the fuel pump. 3.
FUEL INJECTION SYSTEM FI 6. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the odometer/ tripmeter LCD. • Actuator operation Push the grip warmer side of the grip/thumb warmer adjustment switch to operate the actuator. If the grip warmer side of the switch is pushed again while the actuator is operating, the actuator operation will stop and restart from the beginning. 7.
FUEL INJECTION SYSTEM FI Fault code table Fault code No. Symptom Probable cause of malfunction Diagnostic code No. No normal signals are received from the cylinder identification sensor. • • • • Open or short circuit in wire harness. Defective cylinder identification sensor. Malfunction in ECU. Improperly installed cylinder identification sensor. — No normal signals are received from the crankshaft position sensor. • • • • • Open or short circuit in wire harness.
FUEL INJECTION SYSTEM Fault code No. Symptom FI Probable cause of malfunction Diagnostic code No. 46 Power supply to the fuel injection system is not normal. • Malfunction in the charging system. (Refer to “CHARGING SYSTEM” in CHAPTER 8.) — 50 Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.) • Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.
FUEL INJECTION SYSTEM FI Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: • Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively. • If it is not possible to check the intake air temperature, use the ambient temperature as reference. Diagnostic code No.
FUEL INJECTION SYSTEM Diagnostic code No. Item Data displayed on meter (reference value) Cylinder-#1 ignition coil Actuates the cylinder-#1 ignition coil five times at 1-second intervals and displays the self-diagnosis warning indicator 1 second after the grip warmer side of the grip/ thumb warmer adjustment switch is pushed. Connect an ignition checker. This operation is performed each time the grip warmer side of the switch is pushed.
FI FUEL INJECTION SYSTEM Diagnostic code No. Item Data displayed on meter (reference value) Headlight relay Actuates the headlight relay for five cycles of 5 seconds and displays the self-diagnosis warning indicator 1 second after the grip warmer side of the grip/thumb warmer adjustment switch is pushed. (The relay is on for 2 seconds and off for 3 seconds.) This operation is performed each time the grip warmer side of the switch is pushed.
FUEL INJECTION SYSTEM FI TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display according to the reinstatement method. Fault code No.: Code number displayed on the meter when the engine failed to work normally. (Refer to “Fault code table”.
FUEL INJECTION SYSTEM Fault code No. 12 Symptom FI No normal signals are received from the crankshaft position sensor. Diagnostic code No. – – Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of crankshaft position sensor. Check for looseness or pinching. Cranking the engine. 2 Connections Crankshaft position sensor coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom FI Cylinder-#1 intake air pressure sensor: open or short circuit detected. Diagnostic code No. 03 (cylinder-#1 intake air pressure sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder-#1 intake air pressure sensor coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out. Check the locking condition of the couplers.
FUEL INJECTION SYSTEM Fault code No. 14 Symptom FI Cylinder-#1 intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. 03 (cylinder-#1 intake air pressure sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Cylinder-#1 intake air pressure sensor hose is detached, clogged, kinked, or pinched. Cylinder-#1 intake air pressure sensor malfunction at intermediate electrical potential.
FUEL INJECTION SYSTEM Fault code No. 16 Symptom FI Stuck throttle position sensor detected. Diagnostic code No. 01 (throttle position sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of throttle position sensor. Check for looseness or pinching. Check that it is installed in the specified position. Refer to “THROTTLE BODY”. 2 Defective throttle position sensor. Execute the diagnostic mode (code No. 01). Replace if defective.
FUEL INJECTION SYSTEM Fault code No. 25 Symptom FI Cylinder-#2 intake air pressure sensor: open or short circuit detected. Diagnostic code No. 04 (cylinder-#2 intake air pressure sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder-#2 intake air pressure sensor coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out. Check the locking condition of the couplers.
FUEL INJECTION SYSTEM Fault code No. 26 Symptom FI Cylinder-#2 intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. 04 (cylinder-#2 intake air pressure sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Cylinder-#2 intake air pressure sensor hose is detached, clogged, kinked, or pinched. Cylinder-#2 intake air pressure sensor malfunction at intermediate electrical potential.
FUEL INJECTION SYSTEM Fault code No. 33 Symptom FI Open circuit detected in the primary lead of the cylinder-#1 ignition coil. Diagnostic code No. 30 (cylinder-#1 ignition coil) Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder-#1 ignition coil coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out. Check the locking condition of the couplers.
FUEL INJECTION SYSTEM Fault code No. 42 Symptom FI No normal signals are received from the speed sensor. Diagnostic code No. 07 (speed sensor) Order Item/components and probable cause Check or maintenance job 1 Connections Speed sensor coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out. Check the locking condition of the couplers. If there is a malfunction, repair it and connect the coupler securely. 2 Open or short circuit in wire harness.
FUEL INJECTION SYSTEM Fault code No. 43 Symptom FI ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. 09 (fuel system voltage) Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections Fuel injection system relay coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out. Check the locking condition of the couplers.
FUEL INJECTION SYSTEM Fault code No. 44 Symptom FI Error is detected while reading or writing on EEPROM (CO adjustment value). Diagnostic No. 60 (EEPROM improper cylinder indication) Order 1 Item/components and probable cause Check or maintenance job Reinstatement method Malfunction in ECU. Execute the diagnostic mode (code No. 60). 1. Check the faulty cylinder. (If both cylinders are defective, the display alternates every 2 seconds.) 2. Readjust the CO of the displayed cylinder.
FUEL INJECTION SYSTEM Fault code No. 65 Symptom FI Knock sensor: open or short circuit detected. Diagnostic code No. – – Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of knock sensor Check for looseness or pinching. 2 Connections Knock sensor coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out. Check the locking condition of the couplers.
FUEL INJECTION SYSTEM Fault code No. 85 Symptom FI Oil pressure switch: open circuit detected. Diagnostic code No. – – Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections Oil pressure switch coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out. Check the locking condition of the couplers. If there is a malfunction, repair it and connect the coupler securely. Starting the engine and operating it at idle.
FUEL INJECTION SYSTEM FI Er-1 Symptom No signals are received from the ECU. Er-2 Symptom No signals are received from the ECU within the specified duration. Er-3 Symptom Data from the ECU cannot be received correctly. Er-4 Symptom Non-registered data has been received from the meter. Fault code No. Diagnostic code No.
FUEL INJECTION SYSTEM FI OIL PRESSURE SWITCH 1. Disconnect: • Oil pressure switch coupler 1 2. Connect: • Pocket tester (between the engine ground and oil pressure switch terminal) 1 3. Check: • Oil pressure switch continuity No continuity → Replace the oil pressure switch. INTAKE AIR TEMPERATURE SENSOR 1. Remove the intake air temperature sensor. CAUTION: 3 1 Handle the intake air temperature sensor with special care. Never subject it to shock or allow it to be dropped.
THROTTLE BODY FI THROTTLE BODY 10 6 10 8 5 11 7 3 4 2 9 1 Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Throttle body removal Air filter case assembly Throttle position sensor coupler Fuel hose Fuel return hose Idle adjusting screw Throttle cable Plastic band Throttle body heater inlet hose Throttle body assembly Throttle body heater outlet hose Injector coupler Throttle body joint Q’ty 1 2 1 1 1 1 1 1 1 2 2 Remarks Remove the parts in the order listed below.
FI THROTTLE BODY INJECTORS 8 11 4 1 New 7 11 5 New 6 New E 9 E 10 12 E New 3 2 Order 1 2 3 4 5 6 7 8 9 10 11 12 Job name/Part name Injector removal Negative pressure hose Idle adjusting screw Throttle position sensor Pressure regulator hose Pressure regulator Fuel strainer seat Fuel strainer Fuel rail Injector Throttle body heater hose Air screw Throttle body assembly Q’ty Remarks Remove the parts in the order listed below.
THROTTLE BODY FI INSPECTION 1. Inspect: • Injectors Damage → Replace. 2. Inspect: • Throttle body Cracks/damage → Replace the throttle body. 3. Check: • Fuel passages Obstructions → Clean. NOTE: • Use a petroleum based solvent for cleaning. • Blow out all passage with compressed air. 4. Check: • Throttle body joints Cracks/damage → Replace. PRESSURE REGULATOR OPERATION 1. Remove: • Right side panel Refer to “COWLINGS” in CHAPTER 3. 2.
THROTTLE BODY FI • Use the mity vac set to adjust the fuel pressure in relation to the vacuum pressure as described below. NOTE: The vacuum pressure should not exceed 100 kPa (760 mmHg). Increase the vacuum pressure → Fuel pressure is decreased Decrease the vacuum pressure → Fuel pressure is increased Faulty → Replace the pressure regulator. INSPECTION AND ADJUSTMENT NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1.
THROTTLE BODY FI 2. Adjust: • Throttle position sensor angle 2 1 Adjusting steps: • Connect the throttle position sensor coupler to the wire harness. • Connect the digital circuit tester to the throttle position sensor. L B/L Y Positive tester probe → yellow terminal 1 Negative tester probe → black/blue terminal 2 Digital circuit tester: 90890-03174 • Measure the throttle position sensor voltage. • Adjust the throttle position sensor angle so the measured voltage is within the specified range.
FI 7-34
SWITCH INSPECTION ELEC – + ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112, YU-03112-C NOTE: • Set the pocket tester to “0” before starting a test. • When testing the switch for continuity the pocket tester should be set to the “× 1 Ω” range. • When checking the switch turn it on and off a few times.
B R W W (BLACK) 8-2 WWW W 2 W B 3 R W WW WWW 1 (7.
IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM 1 4 5 0 B C J K L M R y Crankshaft position sensor Main switch Main fuse Battery Engine stop switch Throttle switch ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Throttle position sensor Ignition fuse 8-3 ELEC – +
IGNITION SYSTEM ELEC – + TROUBLESHOOTING NO SPARK OR WEAK SPARK. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the spark plug gap. Refer to “SPARK PLUGS” in CHAPTER 2. OK Repair or replace the spark plug.
IGNITION SYSTEM ELEC – + T.O.R.S. OPERATES. Is self-diagnosis code 15, 16, or 42 displayed? NO Check the affected item(s). YES Has throttle body icing occurred or is foreign material stuck in the throttle body? NO Perform throttle body maintenance. YES Is the throttle switch malfunctioning? NO Repair or replace the throttle switch. YES Is the throttle cable free play out of specification? NO Adjust the throttle cable free play. Refer to “THROTTLE CABLE FREE PLAY ADJUSTMENT” in CHAPTER 2.
IGNITION SYSTEM ELEC – + IGNITION SPARK GAP È 1. Remove: • Ignition coil 2. Measure: • Ignition spark gap Out of specification → Replace the ignition coil. Measurement steps: • Disconnect the ignition coil 1 from the spark plug. • Connect the dynamic spark tester 2 or ignition checker 3. É Dynamic spark tester: YM-34487 Ignition checker: 90890-06754 • Measure the ignition spark gap a. • Crank the engine by turning the main switch to start and gradually increase the spark gap until a misfire occurs.
IGNITION SYSTEM ELEC – CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor coupler 2. Connect: • Pocket tester (to the crankshaft position sensor coupler) 3. Measure: • Crankshaft position sensor resistance Out of specification → Replace.
IGNITION SYSTEM ELEC – + THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the throttle bodies or throttle cable malfunctions during operation, the T.O.R.S. will operate when the throttle lever is released. The T.O.R.S. is designed to interrupt the fuel injection and keep the engine speed between 2,800 and 3,000 r/min if the throttle valves fail to return to the idle position when the throttle lever is released. WARNING È • If the T.O.R.S.
IGNITION SYSTEM ELEC – + ENGINE STOP SWITCH 1. Disconnect: • Engine stop switch coupler 2. Connect: • Pocket tester 3. Check: • Engine stop switch continuity Faulty → Replace the right handlebar switch. Ω×1 – + Br Br/W Switch position Continuity RUN (pulled out) Yes OFF (pushed in) No THROTTLE SWITCH 1. Disconnect: • Throttle switch couplers 2. Connect: • Pocket tester 3. Check: • Throttle switch continuity Faulty → Replace the right handlebar switch.
IGNITION SYSTEM ELEC – + MAIN SWITCH 1. Disconnect: • Main switch coupler 2. Connect: • Pocket tester 3. Check: • Main switch continuity Faulty → Replace.
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ELECTRICAL STARTING SYSTEM ELEC – + TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. NO 1. Connect: • Starter relay terminals (battery side and starter motor side) Check the battery and connectors. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK NO Charge and/or replace the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. 1 Jumper lead 2. Check: • Starter motor operation Repair or replace the starter motor.
ELECTRICAL STARTING SYSTEM ELEC – + * FAULTY Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the engine stop switch and main switch. Refer to “IGNITION SYSTEM”. OK Replace the right handlebar switch and/or main switch. FAULTY Check the electrical starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. OK Properly connect or repair the electrical starting system’s wiring. Correct the connection.
ELECTRICAL STARTING SYSTEM ELEC – + STARTER MOTOR È: 12 Nm (1.2 m • kg, 8.7 ft • lb) C New 3 5 New 4 67 1 8 3 A 2 9 New B 0 3 2 1 : 1 ESSO beacon 325 grease or Aeroshell grease #7A È Order 1 2 3 1 2 3 4 5 6 7 8 9 0 Job name/Part name Starter motor removal Engine assembly Q’ty Negative battery lead Starter motor lead Starter motor assembly 1 1 1 Remarks Remove the parts in the order listed below. Refer to “ENGINE ASSEMBLY” in CHAPTER 5. Disconnect. Disconnect.
ELECTRICAL STARTING SYSTEM ELEC – + s È: 12 Nm (1.2 m • kg, 8.7 ft • lb) C New 3 5 New 4 67 1 8 3 A 2 9 New B 0 3 2 1 : 1 ESSO beacon 325 grease or Aeroshell grease #7A È Order A B C Job name/Part name Brush holder Armature assembly Starter motor yoke Q’ty 1 1 1 Remarks For assembly, reverse the disassembly procedure.
ELECTRICAL STARTING SYSTEM ELEC – + Inspection 1. Inspect: • Commutator (outer surface) Dirty → Clean with #600 grit sandpaper 1. Hold the armature in a vise 2 and copper or aluminium plate 3. CAUTION: Lightly grip the armature with a vise. 2. Measure: • Commutator diameter a Measure the diameter a of the commutator at points where the brush comes in contact. Out of specification → Replace the starter motor. Commutator diameter wear limit: 23.5 mm (0.93 in) 3.
ELECTRICAL STARTING SYSTEM ELEC – + 5. Measure: • Brush length a Out of specification → Replace the starter motor. Brush length wear limit: 3.65 mm (0.14 in) 6. Measure: • Brush spring pressure Fatigue/out of specification → Replace as a set. Brush spring pressure: 5.28 ~ 7.92 N (538 ~ 808 g, 19.01 ~ 28.51 oz) 7. Check: • Bearing • Oil seal • Bushing Damage/wear part(s). → Replace the defective Assembly Reverse the “Disassembly” procedure. Note the following points. 1.
ELECTRICAL STARTING SYSTEM 3 b 2 a ELEC – + 3. Install: • O-rings New • Rear bracket 1 • Starter motor yoke 2 • Front bracket 3 1 NOTE: Align the match mark a on the rear bracket with the match mark b on the front bracket.
CHARGING SYSTEM CIRCUIT DIAGRAM È B A 2 3 5 0 È C E D R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O R/L B B R/L G/W B/L Ch B/L G/W Ch L/R G B O/B WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS FUEL PUMP SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS F Br/R Sb W/L W/R L/B W/L Sb Br/R L/B W/R Y G B G Y B WIRE HARNESS GEAR MOTOR SUB-WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS G L/R O/B B A.C.
CHARGING SYSTEM ELEC – + TROUBLESHOOTING BATTERY IS NOT CHARGED. 1. Connect: • Pocket tester (to the battery terminals) 2. Measure: • Battery voltage OUT OF SPECIFICATION Battery voltage: more than 12 V at 20 °C (68 °F) • Check the battery. • Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK 3. Start the engine and accelerate to 5,000 r/min. NOTE: Place the machine onto a suitable stand to raise the track off of the ground. 4.
CHARGING SYSTEM ELEC – + BATTERY Inspection 1. Inspect: • Battery condition Refer to “BATTERY INSPECTION” in CHAPTER 2. Battery Storage The battery should be stored if the machine is not going to be used for a long period. 1. Remove: • Battery WARNING When removing the battery, disconnect the negative lead first. Battery storage and maintenance tips: • Recharge the battery periodically. • Store the battery in a cool, dry place. • Recharge the battery before reinstalling.
LIGHTING SYSTEM CIRCUIT DIAGRAM È B A È C E D R/G R/W F R/W R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O R/L B WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS Br/R Sb W/L W/R L/B W/L Sb Br/R L/B W/R Y G B G Y B WIRE HARNESS GEAR MOTOR SUB-WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS G L/R O/B B B R/L G/W B/L Ch B/L G/W Ch L/R G B O/B FUEL PUMP SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS R/W O O A O B/L Gy Gy B 1 Gy B/L (BLACK) WWW 2 (GLAY) WWW
LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 2 3 4 5 6 0 B J h l r s t u y { | A.C.
LIGHTING SYSTEM ELEC – + TROUBLESHOOTING HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT AND/OR METER LIGHT DO NOT COME ON. Check the headlight bulb(s). OK Replace the bulb(s). NO CONTINUITY Check the main fuse, ignition fuse, and headlight fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse, ignition fuse, and/or headlight fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2.
LIGHTING SYSTEM ELEC – + TAIL LIGHT DOES NOT COME ON. Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse, ignition fuse, and/or signal fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
LIGHTING SYSTEM ELEC – + BULB(S) NOTE: Do not check any of the lights that use LEDs. 1. Remove: • Headlight bulb 2. Connect: • Pocket tester (to the bulb terminals) WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the bulb until it cools down. 3. Check: • Bulb(s) Terminal Continuity 1–3 Yes 2–3 Yes HEADLIGHT BEAM SWITCH 1. Disconnect: • Headlight beam switch coupler 2. Connect: • Pocket tester (to the headlight beam switch coupler) 3.
LIGHTING SYSTEM ELEC – + HEADLIGHT RELAY 1. Remove: • Headlight relay (with the black coupler) 1 L/W Inspection steps: • Connect the pocket tester (Ω × 1) to the headlight relay terminals as shown. Y Lg G B 2 Positive tester probe → Blue/White 1 Negative tester probe → Green 2 • If headlight relay does not have continuity between the blue/white and green terminals, replace it. • Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay terminals as shown.
SIGNAL SYSTEM CIRCUIT DIAGRAM È B A È C E D R/G R/W F R/W R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O WIRE HARNESS SUB-WIRE HARNESS 1 Br/R Sb W/L W/R L/B W/L Sb Br/R L/B W/R Y G B G Y B WIRE HARNESS GEAR MOTOR SUB-WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS G L/R O/B B B R/L G/W B/L Ch B/L G/W Ch L/R G B O/B FUEL PUMP SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS R/L B R/W SUB-WIRE HARNESS 3 O O A O B/L Gy Gy B 1 Gy B/L (BLACK) WWW 2 (GLAY)
SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 2 3 4 5 6 0 B D H I J S W X g h i j l m n o p q y { *1 A.C.
SIGNAL SYSTEM ELEC – + TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse, ignition fuse, and/or signal fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
SIGNAL SYSTEM ELEC – + LOW COOLANT TEMPERATURE INDICATOR LIGHT, COOLANT TEMPERATURE WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”.
SIGNAL SYSTEM ELEC – + FUEL METER AND/OR FUEL LEVEL WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
SIGNAL SYSTEM ELEC – + OIL LEVEL WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
SIGNAL SYSTEM ELEC – + KNOCK CONTROL SYSTEM INDICATOR LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
SIGNAL SYSTEM ELEC – + DRIVE POSITION INDICATOR LIGHT AND/OR REVERSE POSITION INDICATOR LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
SIGNAL SYSTEM ELEC – + SPEEDOMETER DOES NOT OPERATE. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
SIGNAL SYSTEM ELEC – + BACK BUZZER DOES NOT SOUND. (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse, ignition fuse, and/or signal fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”.
SIGNAL SYSTEM ELEC – + BRAKE LIGHT SWITCH 1. Disconnect: • Brake light switch coupler 2. Connect: • Pocket tester (to the brake light switch coupler) 3. Check: • Brake light switch continuity Faulty → Replace. G L/R Switch position Continuity Brake lever operates Yes Brake lever does not operate No DRIVE POSITION SWITCH AND REVERSE POSITION SWITCH (PZ50GT/PZ50FX/ PZ50M/PZ50VT/PZ50MP) 1. Remove: • Drive position switch and reverse position switch 2.
SIGNAL SYSTEM ELEC – + COOLANT TEMPERATURE SENSOR 1. Remove the coolant temperature sensor. CAUTION: Handle the coolant temperature sensor with special care. Never subject it to shock or allow it to be dropped. If it is dropped, it must be replaced. 2. Connect: • Pocket tester 1 (to the coolant temperature sensor) NOTE: Set the tester selector to the “Ω × 1k” position. 3. Immerse the coolant temperature sensor 2 in coolant 3 and check the coolant temperature sensor operation.
SIGNAL SYSTEM ELEC – + OIL LEVEL SWITCH 1. Remove: • Oil level switch 2. Connect: • Pocket tester (to the oil level switch coupler) 3. Check: • Oil level switch continuity Faulty → Replace. Ch R/B É È Switch position È Good condition Bad condition Down position É Up position : Continuity : No continuity FUEL SENDER a 1. Remove: • Fuel sender (from the fuel tank) 2. Connect: • Pocket tester (to the fuel sender coupler) 3.
SIGNAL SYSTEM ELEC – + SPEED SENSOR 1. Inspect: • Speed sensor Inspection steps: • Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. Positive tester probe → White/Yellow Negative tester probe → Black/Blue Positive battery terminal → Blue Negative battery terminal → Black/Blue • Elevate the track and slowly rotate it. • Measure the voltage (DC 5 V) of white/yellow and black/blue. With each full rotation of the track the voltage reading should cycle from 0.
GRIP WARMER SYSTEM CIRCUIT DIAGRAM È B A È C E D R/G R/W F R/W R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O R/L B B R/L G/W B/L Ch B/L G/W Ch L/R G B O/B WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS FUEL PUMP SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS Br/R Sb W/L W/R L/B W/L Sb Br/R L/B W/R Y G B G Y B WIRE HARNESS GEAR MOTOR SUB-WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS G L/R O/B B R/W O O A O B/L Gy Gy B 1 Gy B/L (BLACK) WWW 2 (GLAY) W
GRIP WARMER SYSTEM GRIP WARMER SYSTEM CIRCUIT DIAGRAM 2 3 4 5 6 0 B E F J Z c e f l y { A.C.
GRIP WARMER SYSTEM ELEC – + TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
GRIP WARMER SYSTEM ELEC – + PASSENGER GRIP WARMER DOES NOT OPERATE. (PZ50VT) Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse, ignition fuse, and/or signal fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”. OK Replace the stator coil assembly.
GRIP WARMER SYSTEM ELEC – + GRIP AND THUMB WARMER 1. Disconnect: • Grip warmer coupler • Thumb warmer coupler 2. Connect: • Pocket tester (to the grip warmer coupler and/or thumb warmer coupler) 3. Measure: • Grip warmer resistance 1 • Thumb warmer resistance 2 Out of specification → Replace. 1 2 B B B W Ω×1 + – Grip warmer resistance: PZ50/PZ50GT/PZ50M/PZ50VT/ PZ50MP: 1.53 ~ 1.87 Ω at 20 °C (68 °F) (Black – Black) PZ50FX: 6.12 ~ 7.48 Ω at 20 °C (68 °F) (Black – Black) Thumb warmer resistance: 37.
GRIP WARMER SYSTEM ELEC – + PASSENGER GRIP WARMER (PZ50VT) 1. Disconnect: • Passenger grip warmer coupler 2. Connect: • Pocket tester (to the passenger grip warmer coupler) 3. Measure: • Passenger grip warmer resistance Out of specification → Replace. Ω×1 – + G B Y Passenger grip warmer resistance (high): 8.82 ~ 10.78 Ω (Green – Black) Passenger grip warmer resistance (low): 14.67 ~17.93 Ω (Yellow – Black) PASSENGER GRIP WARMER SWITCH (PZ50VT) 1.
GRIP WARMER SYSTEM ELEC – + PASSENGER GRIP WARMER RELAY (PZ50VT/PZ50MP) 3 4 1. Remove: • Passenger grip warmer relay L/R O/B L/R 2 Inspection steps: • Connect the pocket tester (Ω × 1) and battery (12 V) to the passenger grip warmer relay terminals as shown.
ELEC 8-49 – +
COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) CIRCUIT DIAGRAM È B A È C E D R/G R/W F R/W R/L G/B R/B R/W Gy/R O R/L B WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS Br/R Sb W/L W/R L/B W/L Sb Br/R L/B W/R Y G B G Y B WIRE HARNESS GEAR MOTOR SUB-WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS G L/R O/B B G/W B/L Ch B/L G/W Ch L/R G B O/B WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS B R/L R/W SUB-WIRE HARNESS 3 O O A O B/L Gy Gy B 1 Gy B/L (BLACK) WWW 2 (GLAY) WWW (BLACK) R
COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) COOLING SYSTEM (PZ50M/PZ50VT/ PZ50MP) CIRCUIT DIAGRAM 2 3 4 5 6 0 A J X v w y z A.C.
COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) ELEC – + TROUBLESHOOTING THE RADIATOR FAN MOTOR DOES NOT MOVE Check the main fuse, ignition fuse, and radiator fan motor fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse, ignition fuse, and/or radiator fan motor fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil. Refer to “CHARGING SYSTEM”.
COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) ELEC – + RADIATOR FAN MOTOR 1. Disconnect: • Radiator fan motor coupler 2. Connect: • Battery 3. Inspect: • Radiator fan motor Positive battery terminal → Blue 1 Negative battery terminal → Black 2 Does not move → Replace the radiator fan motor. RADIATOR FAN MOTOR RELAY 1. Remove: • Radiator fan motor relay Inspection steps: • Connect the pocket tester (Ω × 1) and battery (12 V) to the radiator fan motor relay terminals as shown.
DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) CIRCUIT DIAGRAM È B A È C E D R/G R/W F R/W R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O R/L B WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS Br/R Sb W/L W/R L/B W/L Sb Br/R L/B W/R Y G B G Y B WIRE HARNESS GEAR MOTOR SUB-WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS G L/R O/B B B R/L G/W B/L Ch B/L G/W Ch L/R G B O/B FUEL PUMP SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS R/W O O A O Gy
DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/ PZ50M/PZ50VT/ PZ50MP) CIRCUIT DIAGRAM 2 3 4 5 6 0 H I J [ \ ] ` y ~ A.C.
DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) ELEC – + TROUBLESHOOTING CANNOT SHIFT TO DRIVE OR REVERSE. Check the main fuse, ignition fuse, and gear motor fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. OK Replace the main fuse, ignition fuse, and/or gear motor fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OK Replace and/or charge the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Check the stator coil.
DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) ELEC – + GEAR MOTOR 1. Remove: • Gear motor Refer to “SECONDARY SHAFT AND REVERSE GEAR CASE” in CHAPTER 4. NOTE: Since the pinion gear is in the drive position when the gear motor is removed, be sure to perform the reverse position inspection first. Reverse position inspection steps È: • Connect the battery (12 V) to the gear motor terminals as shown.
DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) ELEC – + GEAR MOTOR RELAY 1 1. Remove: • Gear motor relay 1 (with the black coupler) 1 R/G Inspection steps: • Connect the pocket tester (Ω × 1) to the gear motor relay 1 terminals as shown. Y/R R/G Br/R Br/B 2 Positive tester probe → Red/Green 1 Negative tester probe → Brown/Red 2 • If gear motor relay 1 does not have continuity between the red/green and brown/red terminals, replace it.
DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) – + • Connect the pocket tester (Ω × 1) and battery (12 V) to the gear motor relay 2 terminals as shown. 5 6 Sb Positive battery terminal → Red/Green 3 Negative battery terminal → Sky blue/White 4 Positive tester probe → Sky blue 5 Negative tester probe → Red/Green 6 R/G R/G 4 ELEC B Sb/W 3 • If gear motor relay 2 does not have continuity between the sky blue and red/green terminals, replace it. GEAR MOTOR RELAY 3 1.
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number: Dimensions: Overall length Overall width Overall height Weight: Dry weight Minimum turning radius: Clockwise Counterclockwise PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 8GC1 (PZ50 “USA/Canada”) 8GC2 (PZ50 “Europe”) 8GK1 (PZ50GT “USA/Canada”) 8GK2 (PZ50GT “Europe”) 8GN1 (PZ50FX “USA/Canada”) 8GN2 (PZ50FX “Europe”) 8GP1 (PZ50M “USA/Canada”) 8GP2 (PZ50M “Europe”) 8GJ1 (PZ50VT “USA/Canada”) 8GJ2 (PZ50VT “Europe”) 8GR
GENERAL SPECIFICATIONS Model Engine: Engine type Cylinder type Displacement Bore × stroke Compression ratio Maximum hose power r/min Maximum torque r/min Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Starting system Lubrication system: Engine oil: Type Oil capacity Periodic oil change With oil filter replacement Total amount Oil tank capacity Oil filter: Oil filter type Drive chain oil: Type Capacity Coolant: Filler cap opening pressure Capacity Fuel: Type Tank capaci
GENERAL SPECIFICATIONS Model Transmission: Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio Reverse system Reverse gear ratio Chassis: Frame type Caster Ski stance (center to center) Suspension: Front suspension type Rear suspension type Track: Track type Track width Length on ground Track deflection mm/100 N (10 kg, 22 lb) Brake: Brake type Operation method Electrical: Ignition system Generator system SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50
GENERAL SPECIFICATIONS Model Headlight bulb type: Bulb wattage × Quantity: Headlight Tail/brake light Meter light Warning light High beam indicator light Low coolant temperature indicator light Knock control system indicator light Drive position indicator light Reverse position indicator light SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Halogen bulb 12 V, 60/55 W × 2 LED LED LED LED LED LED LED (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) LED (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) 9-4
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model Cylinder head: Volume (with spark plug) Cylinder: Material Bore size Camshaft: Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance Camshaft dimensions Intake “A” “B” A Exhaust “A” B “B” Camshaft runout Timing chain: Model/Number of links Tensioning system PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 13.
MAINTENANCE SPECIFICATIONS Model Valves, valve seats, valve guides: Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A Intake A Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout limit Valve seat width Intake Exhaust
MAINTENANCE SPECIFICATIONS Model Valve spring: Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt Intake Exhaust Winding direction (top view) Intake Exhaust Valve lifter: Valve lifter outside diameter Intake Exhaust Valve lifter hole inside diameter Intake Exhaust Piston: Piston size (D) Measuring point (H) D Piston to-cylinder clearance Piston pin bore off set Off-se
MAINTENANCE SPECIFICATIONS Model SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Piston ring: Sectional sketch Top ring B Ring type T Dimensions (B × T) 2nd ring B T Top ring (same or no) Ring type Dimensions (B × T) B Oil ring T Dimensions (B × T) End gap (installed) Top ring 2nd ring Oil ring Side clearance (installed) Top ring 2nd ring Oil ring Plating/coating Top ring 2nd ring Connecting rod: Small end diameter Big end diameter Crankshaft-pin-to-big-end-bearing clearance Bearing color code Crank pin: Cra
MAINTENANCE SPECIFICATIONS Model Throttle body: Type × Quantity Manufacturer I.D. mark Throttle valve (Th.
MAINTENANCE SPECIFICATIONS SPEC POWER TRAIN Model Transmission: Type Range of ratio Engagement speed r/min Shift r/min Sheave distance Sheave offset Secondary sheave free play (clearance) V-belt height (standard) V-belt: Part number/Manufacturer Circumference Width “A” Wear limit “B” Primary sheave spring: Part number Color code Outside diameter Wire diameter Preload Spring rate Number of coils PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP V-belt automatic 3.80 ~ 0.
MAINTENANCE SPECIFICATIONS Model Free length Set length Primary sheave weight arm: Part number (with bush) Weight (without bush and rivets) Additional weight type Rivet: Outer Part number Material Size Quantity Hole quantity Center Part number Material Size Quantity Hole quantity Inner Part number Material Size Quantity Hole quantity SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 72.1 mm (2.84 in) (PZ50/PZ50GT/PZ50FX) 74.1 mm (2.92 in) (PZ50M) 73.4 mm (2.89 in) (PZ50VT “USA/Canada”) 72.9 mm (2.
MAINTENANCE SPECIFICATIONS Model Secondary sheave spring: Part number Color code Outside diameter Wire diameter Hole position Sheave side-spring seat side (twist angle) Spring rate Compression Torsion Number of coils Free length Torque cam angle Drive chain: Type Number of links Secondary reduction ratio Maximum 14 link drive chain section length SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 90508-55007 (PZ50/PZ50GT/PZ50FX/PZ50M) 90508-58007 (PZ50VT/PZ50MP) Red (PZ50/PZ50GT/PZ50FX/PZ50M) Blue (
MAINTENANCE SPECIFICATIONS Model Track: Part number Width Length Pitch Number of links Thickness “A” Height “B” Track deflection at 100 N (10 kg, 22 lb) Slide rail suspension (rear suspension): Front travel Rear travel Suspension spring rate Front Rear SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 8GK-47110-00 (PZ50/PZ50FX) 8GN-47110-00 (PZ50GT) 8GP-47110-00 (PZ50M) 8ET-47110-10 (PZ50VT) 8GR-47110-00 (PZ50MP) 355.6 mm (14.0 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 381.0 mm (15.0 in) (PZ50VT) 406.4 mm (16.
MAINTENANCE SPECIFICATIONS Model Suspension wire diameter Front Rear Shock absorber: Damping force Front Extension Compression SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 8.8 mm (0.346 in) (PZ50/PZ50FX) 7.8 mm (0.307 in) (PZ50GT “USA/Canada”) 7.5 mm (0.295 in) (PZ50GT “Europe”/PZ50M/PZ50VT “Europe”) 8.2 mm (0.322 in) (PZ50VT “USA/Canada”/PZ50MP) 11.2 mm (0.441 in) (PZ50/PZ50FX/PZ50VT “Europe”/ PZ50MP) 10.9 mm (0.429 in) (PZ50GT) 10.3 mm (0.406 in) (PZ50M) 11.5 mm (0.453 in) (PZ50VT “USA/Canada”) 830.
MAINTENANCE SPECIFICATIONS Model Rear Extension Compression Slide runner: Thickness Wear limit Track sprocket wheel: Material Number of teeth Rear guide wheel: Material Outside diameter Brake: Recommended brake fluid Pad thickness Pad wear limit Pad to disc clearance Parking brake cable distance Disc outside diameter Disc thickness Disc minimum thickness SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 3,170.0 N/0.3 m/s (323.2 kg/0.3 m/s, 712.6 lb/0.3 m/s) (PZ50) 1,450.0 N/0.3 m/s (147.9 kg/0.3 m/s, 326.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Frame: Frame material Seat height Luggage box location Steering: Lock-to-lock angle Monocoque (Aluminum and Steel) 719 mm (28.31 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 724 mm (28.
MAINTENANCE SPECIFICATIONS Model Wire diameter Shock absorber: Damping force Extension Compression SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 8.8 mm (0.346 in) (PZ50) 7.8 mm (0.307 in) (PZ50GT/PZ50VT “Europe”) 8.5 mm (0.335 in) (PZ50FX) 8.2 mm (0.323 in) (PZ50M) 9.8 mm (0.386 in) (PZ50VT “USA/Canada”) 8.0 mm (0.315 in) (PZ50MP) 2,260 N/0.3 m/s (230.4 kg/0.3 m/s, 508.0 lb/0.3 m/s) (PZ50) 690 N/0.3 m/s (70.4 kg/0.3 m/s, 155.1 lb/0.3 m/s) (PZ50GT) 1,120 N/0.3 m/s (114.2 kg/0.3 m/s, 251.8 lb/0.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Model Voltage Ignition system: Ignition timing (B.T.D.C.) Advanced type Ignition coil: Model/Manufacturer Ignition spark gap Primary coil resistance Secondary coil resistance Charging system: Type Nominal output DC-T.C.I.
MAINTENANCE SPECIFICATIONS Model T.P.S.
MAINTENANCE SPECIFICATIONS Model Speed sensor: Model/Manufacture Cylinder identification sensor: Model/Manufacture Crankshaft position sensor: Model/Manufacture Resistance Intake air pressure sensor: Model/Manufacture Intake air temperature sensor: Model/Manufacture Resistance Knock sensor: Model/Manufacture Resistance SPEC PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 8FP/NIPPON SEIKI 8GC/NIPPON SEIKI 8GC/MITSUBISHI 189 ~ 231 Ω at 20 °C (68 °F) (Gray – Black) 5PS/DENSO 8FP/MITSUBISHI 290 ~ 390 kΩ at 80 °C (176
TIGHTENING TORQUE SPEC TIGHTENING TORQUE ENGINE Parts to be tightened Tightening torque Spark plug Cylinder head bolt (M10 × 1.
TIGHTENING TORQUE Parts to be tightened Bearing retainer Right balancer weight Connecting rod and cap A.C. magneto rotor A.C. magneto rotor cover bolt (M6 × 1.0) × 7 A.C. magneto rotor cover bolt (M6 × 1.0) × 6 Starter clutch Stator coil Pickup coil A.C.
TIGHTENING TORQUE SPEC POWER TRAIN Parts to be tightened Primary sheave Spider and sliding sheave Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Bushing stopper bolt (secondary sheave) Drive chain cover and frame Drive chain oil drain bolt Drive chain adjusting locknut Driven sprocket Bearing holder (secondary shaft) Set bolt (secondary shaft) Frame and secondary shaft assembly Gear motor and secondary shaft assembly Right reverse gear case and left reverse gear
TIGHTENING TORQUE Parts to be tightened Front pivot arm and connecting arm Front pivot arm and sliding frame Front suspension bracket and connecting arm Sliding frame and wheel bracket SPEC Tightening torque Nm 72 60 72 72 60 60 6 49 49 Remarks m · kg ft · lb 7.2 52 (PZ50VT/PZ50MP) 6.0 43 7.2 52 7.2 52 Apply LOCTITE® (PZ50M) 6.0 43 6.0 43 0.6 4.3 4.9 35 (PZ50/PZ50GT/PZ50FX/PZ50M) 4.
TIGHTENING TORQUE SPEC CHASSIS Parts to be tightened Front bumper Wind shield bracket Mirror Headlight bracket Side panel Lower cover Seat rail assembly bolt Seat rail assembly nut Seat Rider seat Rear cover Side cover Passenger grip warmer and frame Passenger grip warmer and rear carrier Rear side cover Rear side lower cover Passenger seat bracket Passenger seat Rear cover Sub frame panel Rear carrier Tail/brake light assembly Handlebar holder Multi-function meter bracket Steering joint and steering join
TIGHTENING TORQUE Parts to be tightened Shock absorber (upper) Shock absorber (lower) Upper arm ball joint and upper arm Upper arm and frame Upper arm ball joint and steering knuckle Lower arm and frame Lower arm and steering knuckle Stabilizer and stabilizer joint Stabilizer joint and lower arm Stabilizer bracket Stabilizer holder Tightening torque Nm 45 45 60 45 45 65 65 45 34 7 34 9-26 SPEC Remarks m · kg ft · lb 4.5 33 4.5 33 6.0 43 4.5 32 4.5 32 6.5 47 6.5 47 4.5 32 (PZ50/PZ50FX/PZ50M) 3.
GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.
GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS 9-28 SPEC
SPEC CABLE ROUTING 1 2 3 [ Z 4 Y X W V U T 5 S R Q 6 7 8 9 0 A B C P O D N M L E K F J G I H 9-29
CABLE ROUTING CABLE ROUTING PZ50/PZ50M/PZ50FX/PZ50GT 1 To the coolant temperature sensor 2 To the knock sensor 3 Route the fuel hose over the wire harness and fuel tank breather hose. 4 Wire harness 5 Bundle the slack in the wire harness and fasten it with the plastic band. 6 Right handlebar switch lead couplers 7 Route the sub-wire harness over the wire harness and fuel tank breather hose. 8 Fasten the sub-wire harness and fuel tank breather hose to the steering gate with the plastic band.
SPEC CABLE ROUTING 1 2 3 [ Z 4 Y X W V U T 5 S R Q 6 7 8 9 0 A B C P O D N M L E K F J G I H 9-31
CABLE ROUTING M Parking brake cable N Brake hose O Route the fuel tank breather hose along the steering gate. P Speed sensor coupler Q Auxiliary DC jack (PZ50GT/ PZ50FX/PZ50M) R Install the frame ground lead terminal and the Rectifier/regulator using the same nut. S Sub-wire harness coupler T Left handlebar switch lead couplers U Rectifier/regulator V Connect the wire harness coupler to the Rectifier/regulator coupler shown in the illustration. W A.C.
SPEC CABLE ROUTING ] ^ 1 2 3 \ 4 [ 5 Z Y X W V 6 7 8 9 0 A U T S R B C D E F Q P O N G M L K 9-33 J I H
CABLE ROUTING PZ50VT/PZ50MP 1 To the coolant temperature sensor 2 To the knock sensor 3 Pass the plastic band through the hole in the frame front cross member, and then fasten the wire harness with the band. Position the buckle of the plastic band on top of the leads, with the end facing to the left.
SPEC CABLE ROUTING ] ^ 1 2 3 \ 4 [ 5 Z Y X W V 6 7 8 9 0 A U T S R B C D E F Q P O N G M L K 9-35 J I H
CABLE ROUTING O Install the fuel tank breather hose to the fuel tank with the hose clamp. Be sure to connect the hose end that does not have a paint mark to the fuel tank. P Parking brake cable Q Brake hose R Auxiliary DC jack S Route the fuel tank breather hose along the steering gate. T Speed sensor coupler U Left handlebar switch lead couplers V Install the frame ground lead terminal and the Rectifier/regulator using the same nut.
CABLE ROUTING M 1 N SPEC 2 3 L 4 K J 5 A 6 I H G F E D C A Z O XY W B 0 9 8 7 P V Q U R T A S 9-37
CABLE ROUTING 1 Injector coupler 2 Cylinder head breather hose 3 Reverse position switch coupler (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 4 Drive position switch coupler (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 5 Fasten the sub-wire harness to the coolant reservoir with the plastic band, making sure to route the harness to the front of the gear motor. Install the plastic band with its buckle positioned towards the front of the machine and its end facing to the right.
CABLE ROUTING M 1 N SPEC 2 3 L 4 K J 5 A 6 I H G F E D C A Z O XY W B 0 9 8 7 P V Q U R T A S 9-39
CABLE ROUTING G H I J K L M N O P Q R S T U V W X Y Z Cylinder #2 ignition coil lead Speed sensor lead coupler To the speed sensor Frame ground lead Connect the sub-wire harness coupler to the wire harness coupler. To the handlebar switch Throttle position sensor coupler Oil pressure switch coupler Wire harness Cylinder identification sensor lead To the cylinder identification sensor To the handlebar switch To the sub-wire harness Location where the sub-wire harness branches off from the wire harness.
SPEC CABLE ROUTING 9A 0 AB C D 8 7 6 5 4 3 E F G 2 H 1 I J B M K L 9 9 0 A Q 3 E 3 N R P A 2 1 S B 9-41 6 0 A B C 8 O
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K To the oil pressure switch Throttle position sensor coupler Fuel hose Fasten the corrugated tube and sub-wire harness to the frame front cross member with the plastic band. (PZ50/PZ50GT/ PZ50FX/ PZ50M) Brake light switch (PZ50/ PZ50GT/PZ50FX/PZ50M) Sub-wire harness coupler Fasten the corrugated tube to the headlight stay. Fasten the fuel hose with the hose clamp. Face the ends of the hose clamp outward, angled 45° downward.
SPEC CABLE ROUTING 9A 0 AB C D 8 7 6 5 4 3 E F G 2 H 1 I J B M K L 9 9 0 A Q 3 E 3 N R P A 2 1 S B 9-43 6 0 A B C 8 O
CABLE ROUTING L Cylinder identification sensor M Ignition coil N Fasten the sub-wire harness to the frame front cross member with the plastic band. (PZ50VT/ PZ50MP) O Fasten the fuel tank breather hose, auxiliary DC jack lead, and speed sensor with the plastic band. (PZ50VT/PZ50MP) P To the left handlebar switch Q Frame rear cross member R To the speed sensor S Align the paint mark on the fuel tank breather hose with the top of the grommet.
CABLE ROUTING 5 3 4 2 1 6 7 8 9 a SPEC 0 A \ ^ ] B \ C [ D Z E Y X F G H O I W J V K M L N P O R Q U T S PZ50 O b g c h f d Q e R PZ50VT/PZ50MP i j h g k n l m N i PZ50GT/PZ50FX/PZ50M T j i h k g l m 9-45
CABLE ROUTING 1 2 3 4 5 6 7 8 9 0 A B C D E F G H To the main switch To the main switch To the fuel pump Route the wire harness over the frame rear cross member. To the multi-function meter unit Brake hose Coolant reservoir breather hose Wire harness Fasten the wire harness at the white tape to the frame rear cross member with the plastic band. Face the end of the plastic band downward.
CABLE ROUTING 5 3 4 2 1 6 7 8 9 a SPEC 0 A \ ^ ] B \ C [ D Z E Y X F G H O I W J V K M L N P O R Q U T S PZ50 O b g c h f d Q e R PZ50VT/PZ50MP i j h g k n l m N i PZ50GT/PZ50FX/PZ50M T j i h k g l m 9-47
CABLE ROUTING I Oil tank inlet hose J Oil tank outlet hose K Place the end of the coolant reservoir breather hose to the inside of the frame rear cross member. L Fasten the starter motor lead and negative battery lead to the radiator joint pipe with the plastic band. M Fasten the wire harness, starter motor lead, and negative battery lead to the oil tank with the plastic band. Face the end of the plastic band upward.
CABLE ROUTING 5 3 4 2 1 6 7 8 9 a SPEC 0 A \ ^ ] B \ C [ D Z E Y X F G H O I W J V K M L N P O R Q U T S PZ50 O b g c h f d Q e R PZ50VT/PZ50MP i j h g k n l m N i PZ50GT/PZ50FX/PZ50M T j i h k g l m 9-49
CABLE ROUTING [ Fasten the tail/brake light lead and brake hose to the frame rear cross member with the plastic band. Install the plastic band with its buckle positioned towards the front of the machine and its end facing to the right. \ 40 ~ 50 mm (1.6 ~ 2.0 in) ] Parking brake cable _ Gear motor lead coupler (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) a Fasten the wire harness, brake hose, and parking brake cable with the plastic band.
SPEC CABLE ROUTING 3 6 7 8 9 4 5 0 f 2 1 A A B B C BA D b c e d E F G H a I J ^ C Z [ \ ] Y K L M N O P Q R X W V S T U I c 1 6 c 5 b 5 6 c b C i C 1 h g B-B C 9-51 A-A
CABLE ROUTING PZ50/PZ50GT/PZ50FX/PZ50M 1 Corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) 2 Right grip warmer lead 3 Right handlebar switch 4 Route the throttle cable over the handlebar. 5 Multi-function meter unit lead 6 Parking brake cable 7 Route the brake hose over the top rod of the windshield bracket. (Except for PZ50) 8 Route the parking brake cable between the top and bottom rods of the windshield bracket.
SPEC CABLE ROUTING 3 6 7 8 9 4 5 0 f 2 1 A A B B C BA D b c e d E F G H a I J ^ C Z [ \ ] Y K L M N O P Q R X W V S T U I c 1 6 c 5 b 5 6 c b C i C 1 h g B-B C 9-53 A-A
CABLE ROUTING P Route the A.C. magneto lead behind the idling adjusting screw remote adjustment cable. Q Fasten the idling adjusting screw and oil pressure switch lead at the white tape with the plastic band. Install the plastic band with its buckle positioned towards the rear of the machine and its end facing to the right. R Route the oil pressure switch lead under the idling adjusting screw. Make sure that there is no slack in the oil pressure switch lead.
SPEC CABLE ROUTING 3 6 7 8 9 4 5 0 f 2 1 A A B B C BA D b c e d E F G H a I J ^ C Z [ \ ] Y K L M N O P Q R X W V S T U I c 1 6 c 5 b 5 6 c b C i C 1 h g B-B C 9-55 A-A
CABLE ROUTING f Fasten the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead), corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead), parking brake cable, throttle cable, speedometer unit lead, and brake hose with the plastic band. g Install the plastic band with its buckle positioned behind the leads, cables, and hose and its end facing to the right.
SPEC CABLE ROUTING 4 5 3 6 7 8 9 e 2 1 a b c B A0 A A e C d D B B E F G _ H ] Y C \ [ Z I J K L M N O P Q X W V U R S T H b 1 6 b 5 a 5 6 b a B g B 1 f B-B C 9-57 A-A
CABLE ROUTING PZ50VT/PZ50MP 1 Corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) 2 Right grip warmer lead 3 Right handlebar switch 4 Route the throttle cable over the handlebar. 5 Multi-function meter unit lead 6 Parking brake cable 7 Route the brake hose in front of the handlebar. 8 Route the left handlebar switch leads behind the handlebar.
SPEC CABLE ROUTING 4 5 3 6 7 8 9 e 2 1 a b c B A0 A A e C d D B B E F G _ H ] Y C \ [ Z I J K L M N O P Q X W V U R S T H b 1 6 b 5 a 5 6 b a B g B 1 f B-B C 9-59 A-A
CABLE ROUTING P Fasten the idling adjusting screw and oil pressure switch lead with the plastic band. Install the plastic band with its buckle positioned towards the rear of the machine and its end facing to the right. Q Route the oil pressure switch lead under the idling adjusting screw, making sure that the lead is not taut.
SPEC CABLE ROUTING 4 5 3 6 7 8 9 e 2 1 a b c B A0 A A e C d D B B E F G _ H ] Y C \ [ Z I J K L M N O P Q X W V U R S T H b 1 6 b 5 a 5 6 b a B g B 1 f B-B C 9-61 A-A
CABLE ROUTING e Fasten the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead), corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead), parking brake cable, throttle cable, speedometer unit lead, and brake hose with the plastic band. f Install the plastic band with its buckle positioned behind the leads, cables, and hose and its end facing to the right.
CABLE ROUTING SPEC 6 5 1 4 3 2 9-63
CABLE ROUTING PZ50VT/PZ50MP 1 2 3 4 Headlight unit Headlight lead coupler Headlight lead Fasten the headlight lead at the white tape to the shroud frame with the plastic band, making sure to position the band near the bracket. 5 Fasten the headlight lead to the shroud frame with the plastic band, making sure to route the lead along the bend in the frame. 6 Route the headlight lead to the inside of the shroud frame.
CABLE ROUTING PZ50/PZ50GT/PZ50FX/PZ50M SPEC PZ50VT/PZ50MP 1 6 5 2 7 8 3 9 4 4 9-65
CABLE ROUTING 1 Tail/brake light lead 2 Fasten the tail/brake light lead with the plastic band. Face the end of the plastic band downward. 3 Fasten the tail/brake light lead at the white tape with the plastic band. Face the end of the plastic band downward. 4 Tail/brake light 5 Passenger grip warmer switch coupler 6 Connect the passenger grip warmer coupler, and then place it in the rear lower cover. 7 Passenger grip warmer switch 8 Fasten the tail/brake light lead to the rear carrier with the plastic band.
WIRING DIAGRAM PZ50 2007 8GC-0F001-00 B A C R/G R/W R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O G/W B/L Ch B/L G/W Ch WIRE HARNESS SUB-WIRE HARNESS 2 B R/L R/L B R/W R/W R/W O O A O Gy B B/L Gy (BLACK) 1 Gy B/L WWW 2 (GLAY) WWW B (BLACK) W W/L R R/W Br Br/W OFF ON START Br R Y Br/W B/Y W/Y Y/W P/W Gy G/W L/W P Y/L L/W R/Y B Br 5 (40A) R R/G R/G L/W R/W (10A) R R R Br R R W R 6 A 7 R R B R B 0 R B B B L/W RUN STOP L/W C B/Y G/B A G/B Br Br/W R/W Br
WIRING DIAGRAM PZ50 2007 8GC-0F001-00 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] _ a b c d e f g h i j k l Crankshaft position sensor A.C.
WIRING DIAGRAM PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 2007 8GK-0F001-00/8GN-0F001-00/8GJ-0F001-00 È B A È C E D R/G R/W F R/W R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O B/L G/W Ch G/W B/L Ch B R/L R/L B Br/R Sb W/L W/R L/B G L/R O/B B L/R G B O/B Y G B W/L Sb Br/R L/B W/R G Y B FUEL PUMP SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 3 WIRE HARNESS GEAR MOTOR SUB-WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS WIRE HARNESS O O A O B/L Gy Gy
WIRING DIAGRAM PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 2007 8GK-0F001-00/8GN-0F001-00/8GJ-0F001-00 1 Crankshaft position warmer relay COLOR CODE 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] _ a b c sensor A.C.
Cover_SMB.fm Page 1 Thursday, July 27, 2006 9:56 AM SERVICE MANUAL PZ50W PZ50GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN U.S.A. 2006.
