Yamaha PHAZER PZ50X Supplementary Service Manual
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Yamaha PHAZER PZ50X Supplementary Service Manual

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SUPPLEMENTARY SERVICE MANUAL
2008
PZ50X
PZ50GTX
PZ50RTX
PZ50MTX
PZ50VTX
PZ50MPX
LIT-12618-02-67
8GC-28197-11

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Summary of Contents for Yamaha PHAZER PZ50X

  • Page 1 SUPPLEMENTARY SERVICE MANUAL 2008 PZ50X PZ50GTX PZ50RTX PZ50MTX PZ50VTX PZ50MPX LIT-12618-02-67 8GC-28197-11...
  • Page 2 PZ50X, PZ50GTX, PZ50RTX, PZ50MTX, PZ50VTX, PZ50MPX SUPPLEMENTARY SERVICE MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. 1st Edition, November 2007 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N.LIT-12618-02-67...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4 ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment POWR 3 Chassis CHAS 4 Power train 5 Engine 6 Cooling system 7 Fuel injection system...
  • Page 5 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL ELEC SPECIFICATIONS SPEC...
  • Page 6 PERIODIC INSPECTION AND CHASSIS ............. 52 ELECTRICAL ..........54 ADJUSTMENT TIGHTENING TORQUE........57 ENGINE ............57 TUNING ..............1 POWER TRAIN..........59 FRONT SUSPENSION ........1 CHASSIS ............. 61 AIR PRESSURE ADJUSTMENT (PZ50RT) ...3 REAR SUSPENSION ........5 GENERAL TORQUE SPECIFICATIONS ..63 CHASSIS DEFINITION OF UNITS ........
  • Page 7 INSP FRONT SUSPENSION PERIODIC INSPECTION AND È ADJUSTMENT TUNING FRONT SUSPENSION Spring preload 1. Adjust: • Spring preload Adjustment steps: • Loosen the locknut 1. É • Turn the spring seat 2 in or out. PZ50GT Standard Spring seat Shorter ← →...
  • Page 8 INSP FRONT SUSPENSION CAUTION: Be sure that the left and right spring preload are the same. WARNING These shock absorber contain highly pressur- ized 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.
  • Page 9 FRONT SUSPENSION/ INSP AIR PRESSURE ADJUSTMENT (PZ50RT) Compression damping force adjustment (PZ50GT) The compression damping force can be adjusted by turning the adjuster 1. 12 clicks out 7 clicks out 2 clicks out Adjuster position Minimum Standard Maximum Turns out b* ← →...
  • Page 10 INSP AIR PRESSURE ADJUSTMENT (PZ50RT) Adjustment steps: WARNING Support the snowmobile securely on a suitable stand before adjusting the shock absorbers. CAUTION: Make sure that there is no load on the shock absorbers and that they are fully extended before making any air pressure adjustments. 1.
  • Page 11 AIR PRESSURE ADJUSTMENT (PZ50RT)/ INSP REAR SUSPENSION 6. Remove the hose connector from the air valve. NOTE: When removing the connector, the sound of air escaping may be heard, but this is from the pump hose, not the shock absorber. Air pressure range: 345 kPa (3.4 kgf/cm², 50 psi) to 1,034 kPa (10.3 kgf/cm², 150 psi)
  • Page 12 INSP REAR SUSPENSION Adjustment steps: È • Remove the stopper band bolts 1, nuts and washers. • Adjust the length of the stopper bands 2 by No.1 inserting the bolts in different holes. No.2 No.3 Standard setting: No.4 No. 1 hole (PZ50/PZ50VT “Europe”/PZ50MP) No.5 No.
  • Page 13 INSP REAR SUSPENSION Spring preload È 1. Adjust: • Spring preload Adjustment step: Front side • Loosen the locknut 1. • Turn the spring seat 2 in or out. PZ50GT “Europe”/PZ50RT “USA/Canada”/ PZ50MT “Europe” Standard Spring seat Shorter ← → Longer distance Harder ←...
  • Page 14 INSP REAR SUSPENSION • Turn the adjusting ring 3 to the proper position. É PZ50/PZ50GT “USA/Canada”/PZ50MT “USA/ Canada”/PZ50VT “USA/Canada” Spring adjuster position Softer ← → Harder Preload Standard WARNING This shock absorber contains highly pressur- ized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly.
  • Page 15 INSP REAR SUSPENSION Rear suspension damping force adjustment The damping force can be adjusted by turning the adjuster 1. PZ50RT 20 clicks out 11 clicks out 1 click out Adjuster position Minimum Standard Maximum Turns out b* ← → Turns in a Damping Soft ←...
  • Page 16 CHAS COWLINGS CHASSIS COWLINGS PZ50/PZ50GT/PZ50RT/PZ50MT È: PZ50RT kg, 5.8 ft 8 Nm (0.8 m • • È È È È Order Job name/Part name Q’ty Remarks Cowling removal Remove the parts in the order listed below. Windshield PZ50GT Front panel Air filter case cover Headlight cover Left side panel...
  • Page 17 CHAS COWLINGS È: PZ50RT kg, 5.8 ft 8 Nm (0.8 m • • È È È È Q’ty Remarks Order Job name/Part name Cylinder-#1 intake air pressure sensor cou- Disconnect. pler Intake air temperature sensor coupler Disconnect. Cylinder head breather hose Disconnect.
  • Page 18 CHAS STEERING STEERING PZ50/PZ50GT/PZ50RT/PZ50MT È: Ê kg, 5.1 ft 7 Nm (0.7 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: kg, 11 ft 15 Nm (1.5 m • • Ë: 16 Nm (1.6 m kg, 11 ft •...
  • Page 19 CHAS STEERING È: Ê kg, 5.1 ft 7 Nm (0.7 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: 15 Nm (1.5 m kg, 11 ft • • Ë: kg, 11 ft 16 Nm (1.6 m •...
  • Page 20 CHAS STEERING 1. Install: For PZ50RT • Wind deflector bracket holder 1 • Wind deflector bracket 2 NOTE: Align the end of the wind deflector bracket with the punch mark a on the handlebar.
  • Page 21 CHAS FRONT SUSPENSION FRONT SUSPENSION PZ50/PZ50RT/PZ50MT È: 28 Nm (2.8 m kg, 20 ft Ê: kg, 32 ft • • 45 Nm (4.5 m Ê • • É: kg, 24 ft 34 Nm (3.4 m Ë: kg, 65 ft • •...
  • Page 22 CHAS FRONT SUSPENSION È: kg, 20 ft 28 Nm (2.8 m Ê: kg, 32 ft • • 45 Nm (4.5 m Ê • • É: kg, 24 ft Ë: 34 Nm (3.4 m • • 90 Nm (9.0 m kg, 65 ft •...
  • Page 23 CHAS FRONT SUSPENSION PZ50GT/PZ50VT/PZ50MP È: kg, 5.1 ft Ë 7 Nm (0.7 m Ê: kg, 24 ft • • 34 Nm (3.4 m • • É: Ë: 28 Nm (2.8 m kg, 20 ft kg, 32 ft • • 45 Nm (4.5 m •...
  • Page 24 CHAS FRONT SUSPENSION È: kg, 5.1 ft Ë 7 Nm (0.7 m Ê: kg, 24 ft • • 34 Nm (3.4 m • • É: Ë: kg, 20 ft 28 Nm (2.8 m kg, 32 ft • • 45 Nm (4.5 m •...
  • Page 25 CHAS FRONT SUSPENSION INSTALLATION È 1. Install: • Stabilizer 1 • Bushing 2 • Stabilizer holder 3 CAUTION: Always install the stabilizers, bushings, and stabilizer holders in the same positions on both sides of the snowmobile, otherwise poor han- dling and loss of stability may result. (PZ50GT/ PZ50VT/PZ50MP) É...
  • Page 26 POWR SLIDE RAIL SUSPENSION POWER TRAIN SLIDE RAIL SUSPENSION PZ50/PZ50GT/PZ50RT/PZ50MT È: kg, 2.9 ft 4 Nm (0.4 m • • É: kg, 35 ft 49 Nm (4.9 m • • Ê: kg, 43 ft 60 Nm (6.0 m • • Ë: kg, 80 ft 110 Nm (11.0 m...
  • Page 27 POWR SLIDE RAIL SUSPENSION È È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 43 ft 60 Nm (6.0 m • • Ê: kg, 52 ft 72 Nm (7.2 m • • É Ê É È Ê É...
  • Page 28 POWR SLIDE RAIL SUSPENSION È: kg, 25 ft 35 Nm (3.5 m • • É: kg, 35 ft 49 Nm (4.9 m • • Ë Ê: kg, 43 ft 60 Nm (6.0 m • • Ë: kg, 52 ft 72 Nm (7.2 m •...
  • Page 29 POWR SLIDE RAIL SUSPENSION È: kg, 43 ft 60 Nm (6.0 m • • É: 75 Nm (7.5 m kg, 54 ft • • PZ50MT È É È PZ50MT PZ50MT Q’ty Remarks Order Job name/Part name Rear axle Guide wheel Guide wheel Collar Tension adjuster...
  • Page 30 POWR SLIDE RAIL SUSPENSION PZ50VT/PZ50MP È: kg, 2.9 ft 4 Nm (0.4 m • • É É kg, 4.3 ft 6 Nm (0.6 m Ë • • Ê kg, 35 ft 49 Nm (4.9 m • • Ë kg, 43 ft 60 Nm (6.0 m •...
  • Page 31 POWR SLIDE RAIL SUSPENSION È: 4 Nm (0.4 m kg, 2.9 ft • • É É kg, 4.3 ft 6 Nm (0.6 m Ë • • Ê kg, 35 ft 49 Nm (4.9 m • • Ë kg, 43 ft 60 Nm (6.0 m •...
  • Page 32 POWR SLIDE RAIL SUSPENSION È: Ê: Ì: kg, 4.3 ft kg, 18 ft kg, 43 ft 6 Nm (0.6 m 25 Nm (2.5 m 60 Nm (6.0 m • • • • • • É: Ë: Í: kg, 6.5 ft 9 Nm (0.9 m 72 Nm (7.2 m kg, 52 ft...
  • Page 33 POWR SLIDE RAIL SUSPENSION È: Ê: Ì: kg, 4.3 ft kg, 18 ft kg, 43 ft 6 Nm (0.6 m 25 Nm (2.5 m 60 Nm (6.0 m • • • • • • É: Ë: Í: kg, 6.5 ft 9 Nm (0.9 m 72 Nm (7.2 m kg, 52 ft...
  • Page 34 POWR SLIDE RAIL SUSPENSION È: kg, 54 ft 75 Nm (7.5 m • • È Q’ty Remarks Order Job name/Part name Rear axle Guide wheel Collar Collar Guide wheel Collar Tension adjuster Sliding frame For assembly, reverse the disassembly pro- cedure.
  • Page 35 SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK PZ50/PZ50GT/PZ50RT/PZ50MT È: kg, 5.1 ft 7 Nm (0.7 m • • É: 8 Nm (0.8 m kg, 5.8 ft • • È Ê: kg, 7.2 ft 10 Nm (1.0 m • •...
  • Page 36 SEAT AND FUEL TANK È: kg, 5.1 ft 7 Nm (0.7 m • • É: kg, 5.8 ft 8 Nm (0.8 m • • È Ê: kg, 7.2 ft 10 Nm (1.0 m • • È Ê É Ê É Q’ty Remarks Order...
  • Page 37 BALANCER BALANCER È Ê Ë È: 10 Nm (1.0 m kg, 7.2 ft • • É: kg, 8.7 ft 12 Nm (1.2 m • • Ê: kg, 36 ft 50 Nm (5.0 m • • É Ë: kg, 54 ft 75 Nm (7.5 m •...
  • Page 38 BALANCER È Ê Ë È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 8.7 ft 12 Nm (1.2 m • • Ê: kg, 36 ft 50 Nm (5.0 m • • É Ë: 75 Nm (7.5 m kg, 54 ft •...
  • Page 39 BALANCER REMOVAL 1. Straighten the lock washer tabs. 2. Loosen: • Balancer shaft drive gear bolt 1 • Balancer shaft driven gear nut 2 CAUTION: The balancer shaft drive gear bolt and balancer shaft driven gear nut has left-handed threads. To loosen the bolt and nut, turn it clockwise.
  • Page 40 BALANCER CAUTION: The balancer shaft driven gear nut and balancer shaft drive gear bolt has left-handed threads. Turn the retainer counterclockwise to tighten it. NOTE: Place an aluminum plate 1 or 2 between the teeth of the balancer shaft drive gear 3 and balancer shaft driven gear 4.
  • Page 41 THROTTLE BODY FUEL INJECTION SYSTEM THROTTLE BODY INJECTORS Order Job name/Part name Q’ty Remarks Injector removal Remove the parts in the order listed below. Negative pressure hose Idle adjusting screw Throttle position sensor Pressure regulator hose Pressure regulator Fuel strainer seat Fuel strainer Fuel rail Injector...
  • Page 43 SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Model code number: 8GC3 (PZ50) 8GK3 (PZ50GT “USA/Canada”) 8GK4 (PZ50GT “Europe”) 8GN3 (PZ50RT “USA/Canada”) 8GN4 (PZ50RT “Europe”) 8GP3 (PZ50MT “USA/Canada”) 8GP4 (PZ50MT “Europe”) 8GJ3 (PZ50VT “USA/Canada”) 8GJ4 (PZ50VT “Europe”) 8GR3 (PZ50MP “Canada”) 8GR4 (PZ50MP “Europe”) Dimensions: Overall length...
  • Page 44 SPEC GENERAL SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Engine: Engine type Liquid-cooled, 4-stroke, DOHC Cylinder type Backward-inclined parallel 2-cylinder Displacement 499 cm (30.45 cu.in) Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 12.4 : 1 Maximum horse power r/min 58.8 kw (80.0 PS)/11,250 r/min Maximum torque r/min 51.0 Nm (5.2 kgf)/9,000 r/min...
  • Page 45 SPEC GENERAL SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Transmission: Primary reduction system V-Belt Primary reduction ratio 3.80 ~ 0.95 : 1 Clutch type Automatic centrifugal engagement Secondary reduction system Chain Secondary reduction ratio 2.28 (41/18) (PZ50/PZ50RT) 2.05 (41/20) (PZ50GT) 2.41 (41/17) (PZ50MT “USA/Canada”) 2.16 (41/19) (PZ50MT “Europe”) 2.37 (45/19) (PZ50VT “USA/Canada”) 2.50 (45/18) (PZ50VT “Europe”/PZ50MP)
  • Page 46 SPEC GENERAL SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Headlight bulb type: Halogen bulb Bulb wattage × Quantity: 12 V, 60/55 W × 2 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 LED (PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP) Reverse position indicator light...
  • Page 47 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Cylinder head: Volume (with spark plug) 13.82 ~ 14.62 cm (0.84 ~ 0.89 cu.in) <Warpage limit> 0.10 mm (0.0039 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating Bore size 77.000 ~ 77.010 mm (3.0315 ~ 3.0319 in) <Taper limit>...
  • Page 48 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Valves, valve seats, valve guides: Valve clearance (cold) Intake 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Exhaust 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Valve dimensions Valve head diameter A Intake 23.4 ~ 23.6 mm (0.9213 ~ 0.9291 in) Exhaust 24.9 ~ 25.1 mm (0.9803 ~ 0.9882 in) Valve face width B...
  • Page 49 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Valve spring: Free length Intake 36.51 mm (1.44 in) <Limit> 34.68 mm (1.37 in) Exhaust 37.92 mm (1.49 in) <Limit> 36.02 mm (1.42 in) Installed length (valve closed) Intake 30.13 mm (1.19 in) Exhaust 30.50 mm (1.20 in) Compressed spring force (installed) Intake 120.7 ~ 138.9 N (12.3 ~ 14.2 kg, 27.1 ~ 31.2 lb)
  • Page 50 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Piston ring: Sectional sketch Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.75 mm (0.035 × 0.108 in) 2nd ring Top ring (same or no) Ring type Taper Dimensions (B × T) 0.80 ×...
  • Page 51 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Throttle body: Type × Quantity TSK43 × 1 Manufacturer KEIHIN I.D. mark 8GC3 10 Throttle valve (Th.V) N503-89A00 (θ = 8°) Throttle cable free play 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) Engine idle speed 1,700 ~ 1,900 r/min Fuel pump: Type...
  • Page 52 SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Transmission: Type V-belt automatic Range of ratio 3.80 ~ 0.95 : 1 Engagement speed r/min 3,700 ~ 4,100 r/min (PZ50/PZ50GT/PZ50RT) 4,100 ~ 4,500 r/min (PZ50MT “USA/Canada”) 3,900 ~ 4,300 r/min (PZ50MT “Europe”) 3,300 ~ 3,700 r/min (PZ50VT “USA/Canada”) 2,900 ~ 3,300 r/min (PZ50VT “Europe”/PZ50MP) Shift r/min 10,800 ~ 11,800 r/min...
  • Page 53 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Free length 72.1 mm (2.84 in) (PZ50/PZ50GT/PZ50RT) 74.1 mm (2.92 in) (PZ50MT) 73.4 mm (2.89 in) (PZ50VT “USA/Canada”) 72.9 mm (2.87 in) (PZ50VT “Europe”/PZ50MP) Set length 65.4 mm (2.57 in) Primary sheave weight arm: Part number (with bush) 8GC-17605-00 (PZ50/PZ50GT/PZ50RT/PZ50VT/PZ50MP) 8DN-17605-30 (PZ50MT) Weight (without bush and rivets)
  • Page 54 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Secondary sheave spring: Part number 90508-55007 (PZ50/PZ50GT/PZ50RT/PZ50MT) 90508-58007 (PZ50VT/PZ50MP) Color code Red (PZ50/PZ50GT/PZ50RT/PZ50MT) Blue (PZ50VT/PZ50MP) Outside diameter 66.0 mm (2.598 in) Wire diameter 5.5 mm (0.217 in) (PZ50/PZ50GT/PZ50RT/PZ50MT) 5.8 mm (0.228 in) (PZ50VT/PZ50MP) Hole position Sheave side-spring seat side (twist angle) A-1 (45°) (PZ50/PZ50GT/PZ50RT) B-1 (55°) (PZ50MT)
  • Page 55 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Track: Part number 8GK-47110-00 (PZ50/PZ50RT) 8GN-47110-00 (PZ50GT) 8GP-47110-00 (PZ50MT) 8ET-47110-10 (PZ50VT) 8GR-47110-00 (PZ50MP) Width 355.6 mm (14.0 in) (PZ50/PZ50GT/PZ50RT/PZ50MT) 381.0 mm (15.0 in) (PZ50VT) 406.4 mm (16.0 in) (PZ50MP) Length 3,072.4 mm (120.96 in) (PZ50/PZ50GT/PZ50RT) 3,648.5 mm (143.64 in) (PZ50MT/PZ50VT/PZ50MP) Pitch 64.0 mm (2.52 in)
  • Page 56 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Suspension wire diameter Front 8.8 mm (0.346 in) (PZ50/PZ50GT “Europe”/PZ50RT “Europe”) 9.0 mm (0.354 in) (PZ50GT “USA/Canada”) 8.2 mm (0.323 in) (PZ50RT “USA/Canada”/PZ50VT “Europe”/PZ50MP) 7.5 mm (0.295 in) (PZ50MT “USA/Canada”) 8.0 mm (0.315 in) (PZ50MT “Europe”) 8.5 mm (0.335 in) (PZ50VT “USA/Canada”) Rear 11.2 mm (0.441 in) (PZ50/PZ50RT/PZ50MP)
  • Page 57 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Rear Extension 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, 326.0 lb/0.3 m/s) (PZ50GT) 2,690.0 N/0.3 m/s (247.3 kg/0.3 m/s, 604.7 lb/0.3 m/s) (PZ50RT “USA/Canada”) 2,470.0 N/0.3 m/s (251.9 kg/0.3 m/s, 555.3 lb/0.3 m/s) (PZ50RT “Europe”) 1,430.0 N/0.3 m/s (145.8 kg/0.3 m/s, 321.5 lb/0.3 m/s) (PZ50MT)
  • Page 58 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Frame: Frame material Monocoque (Aluminum and Steel) Seat height 719 mm (28.31 in) (PZ50/PZ50GT/PZ50RT/PZ50MT) 724 mm (28.50 in) (PZ50VT/PZ50MP) Luggage box location Not available Steering: Lock-to-lock angle (left) 32.4° (R ski) 37.6° (L ski) (right) 37.6°...
  • Page 59 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Wire diameter 8.5 mm (0.335 in) (PZ50) 8.0 mm (0.315 in) (PZ50GT) 8.2 mm (0.323 in) (PZ50MT/PZ50VT “USA/Canada”) 8.8 mm (0.346 in) (PZ50VT “Europe”/PZ50MP) Shock absorber: Damping force Extension 2,260 N/0.3 m/s (230.4 kg/0.3 m/s, 508.0 lb/0.3 m/s) (PZ50) 1,045 N/0.3 m/s (106.6 kg/0.3 m/s, 234.9 lb/0.3 m/s) (PZ50GT)
  • Page 60 Ten hour rate amperage 1.2 A Electric starter system: Type Constant mesh type Starter motor: Model/Manufacturer 8GC/YAMAHA Output 0.90 kW Armature coil resistance 0.009 ~ 0.011 Ω at 20 °C (68 °F) Continuity check Insulation check More than 100 kΩ at 20 °C (68 °F)
  • Page 61 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP T.P.S. (throttle position sensor): Model/Manufacturer 8GC3/KEIHIN Resistance 4 ~ 6 kΩ at 20 °C (68 °F) (Blue – Black) Oil level switch: Model/Manufacturer 8FA/ASTI Fuel sender: Model/Manufacturer 8GC/NIPPON SEIKI 10 ~ 12 Ω at 20 °C (68 °F) Sender resistance Full 179 ~ 185 Ω...
  • Page 62 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Speed sensor: Model/Manufacture 8EK/NIPPON SEIKI Cylinder identification sensor: Model/Manufacture 8GC/NIPPON SEIKI Crankshaft position sensor: Model/Manufacture 8GC/MITSUBISHI 189 ~ 231 Ω at 20 °C (68 °F) (Gray – Black) Resistance Intake air pressure sensor: Model/Manufacture 5PS/DENSO Intake air temperature sensor: Model/Manufacture 8FP/MITSUBISHI...
  • Page 63 SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m · kg ft · lb Spark plug Cylinder head bolt (M10 × 1.25) See NOTE.*1 Cylinder head bolt Camshaft cap and cylinder head Apply the engine oil. Cylinder head cover Cylinder identification sensor Ignition coil...
  • Page 64 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Balancer shaft driven gear ® Bearing retainer Apply LOCTITE Connecting rod and cap See NOTE.*3 A.C. magneto rotor 13.0 Apply the engine oil. A.C. magneto rotor cover bolt (M6 × 1.0) × 7 A.C.
  • Page 65 SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Remarks m · kg ft · lb Primary sheave See NOTE. Apply engine oil. Spider and sliding sheave 20.0 Left-hand thread. ® Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Bushing stopper bolt (secondary sheave)
  • Page 66 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Front pivot arm and connecting arm (PZ50VT/PZ50MP) Front pivot arm and sliding frame Front suspension bracket and connecting arm ® Sliding frame and wheel bracket Apply LOCTITE (PZ50MT) Suspension wheel...
  • Page 67 SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Remarks m · kg ft · lb Front bumper Wind shield bracket (PZ50GT/PZ50RT/PZ50MT) Mirror (PZ50VT/PZ50MP) Headlight bracket (PZ50/PZ50GT/PZ50RT/PZ50MT) Side panel (PZ50/PZ50GT/PZ50RT/PZ50MT) Lower cover Seat rail assembly bolt (PZ50/PZ50GT/PZ50RT/PZ50MT) Seat rail assembly nut (PZ50/PZ50GT/PZ50RT/PZ50MT) Seat/fuel tank side cover bolt (rear side) (PZ50/PZ50GT/PZ50RT/PZ50MT)
  • Page 68 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Ski runner Ski and ski handle (M8 × 55) Ski and ski handle (M8 × 100) Shock absorber (upper) Shock absorber (lower) ® Upper arm ball joint and upper arm Apply LOCTITE Upper arm and frame Upper arm ball joint and steering knuckle...
  • Page 69 GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasteners m · kg ft · lb with standard I.S.O. pitch threads. Torque specifi- 10 mm 6 mm cations for special components or assemblies are 12 mm 8 mm included in the applicable sections of this book.
  • Page 70 SPEC CABLE ROUTING...
  • Page 71 SPEC CABLE ROUTING CABLE ROUTING PZ50/PZ50GT/PZ50RT/PZ50MT 1 To the coolant temperature sen- 2 To the knock sensor 3 Route the fuel hose over the wire harness and fuel tank breather hose. 4 Wire harness 5 Radiator fan motor lead coupler 6 Bundle the slack in the wire har- ness and fasten it with the plastic band.
  • Page 72 SPEC CABLE ROUTING...
  • Page 73 SPEC CABLE ROUTING N Parking brake cable O Brake hose P Route the fuel tank breather hose along the frame rear cross member. Q Speed sensor coupler R Auxiliary DC jack (PZ50GT/ PZ50RT/PZ50MT) (optional) S Install the frame ground lead ter- minal and the Rectifier/regulator using the same nut.
  • Page 74 SPEC CABLE ROUTING...
  • Page 75 SPEC CABLE ROUTING PZ50GT/PZ50MT NOTE: The following items are for routing the grip warmer sub-wire harness. 1 Wire harness 2 Slide the rubber cover over the couplers. 3 Fasten the wire harness, grip warmer sub-wire harness, and fuel tank breather hose to the frame rear cross member with the plastic band.
  • Page 76 SPEC CABLE ROUTING...
  • Page 77 SPEC CABLE ROUTING PZ50VT/PZ50MP 1 To the coolant temperature sen- 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. Posi- tion the buckle of the plastic band on top of the leads, with the end facing to the left.
  • Page 78 SPEC CABLE ROUTING...
  • Page 79 SPEC CABLE ROUTING O Parking brake cable P 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. Q Brake hose R Auxiliary DC jack S Route the fuel tank breather...
  • Page 80 SPEC CABLE ROUTING...
  • Page 81 SPEC CABLE ROUTING 1 Injector coupler 2 Cylinder head breather hose 3 Reverse position switch coupler (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) 4 Drive position switch coupler (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) 5 Fasten the reverse position switch lead to the coolant reser- voir tank with the plastic band. Install the plastic band with its buckle positioned on top of the coolant reservoir tank and its end...
  • Page 82 SPEC CABLE ROUTING...
  • Page 83 SPEC CABLE ROUTING G Cylinder #2 ignition coil lead H Auxiliary DC jack lead I Frame ground lead J To the speed sensor K Connect the sub-wire harness coupler to the wire harness cou- pler. L To the handlebar switch M Speed sensor lead coupler N Throttle position sensor coupler O Oil pressure switch coupler...
  • Page 84 SPEC CABLE ROUTING...
  • Page 85 SPEC CABLE ROUTING 1 To the oil pressure switch 2 Throttle position sensor coupler 3 Fuel hose 4 Fasten the corrugated tube and wire harness to the frame front cross member with the plastic band. (PZ50/PZ50GT/PZ50RT/ PZ50MT) 5 Sub-wire harness coupler 6 Fasten the corrugated tube to the headlight stay with the plastic band.
  • Page 86 SPEC CABLE ROUTING...
  • Page 87 SPEC CABLE ROUTING K Cylinder identification sensor L Ignition coil M Fasten the wire harness to the frame front cross member with the plastic band. (PZ50VT/ PZ50MP) N Fasten the fuel tank breather hose, auxiliary DC jack lead, and speed sensor with the plastic band.
  • Page 88 SPEC CABLE ROUTING PZ50 PZ50VT/PZ50MP PZ50GT/PZ50RT/PZ50MT...
  • Page 89 SPEC CABLE ROUTING 1 To the main switch 2 To the main switch 3 To the fuel sender 4 Route the wire harness over the frame rear cross member. 5 To the multi-function meter unit 6 Brake hose 7 Coolant reservoir breather hose 8 Wire harness 9 Fasten the wire harness at the white tape to the frame rear...
  • Page 90 SPEC CABLE ROUTING PZ50 PZ50VT/PZ50MP PZ50GT/PZ50RT/PZ50MT...
  • Page 91 SPEC CABLE ROUTING I Oil tank inlet hose J Oil tank outlet hose K Place the end of the coolant res- ervoir breather hose to the inside of the frame front cross member. L Fasten the starter motor lead and negative battery lead to the radi- ator joint pipe with the plastic band.
  • Page 92 SPEC CABLE ROUTING PZ50 PZ50VT/PZ50MP PZ50GT/PZ50RT/PZ50MT...
  • Page 93 SPEC CABLE ROUTING Y 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 rear of the machine and its end facing to the right. Z 40 ~ 50 mm (1.6 ~ 2.0 in) [ Parking brake cable \ Gear motor lead coupler...
  • Page 94 SPEC CABLE ROUTING 5 6 b...
  • Page 95 SPEC CABLE ROUTING PZ50/PZ50GT/PZ50RT/PZ50MT 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 top rod of the windshield...
  • Page 96 SPEC CABLE ROUTING 5 6 b...
  • Page 97 SPEC CABLE ROUTING P Route the A.C. magneto lead behind the idling adjusting screw. 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.
  • Page 98 SPEC CABLE ROUTING 5 6 b...
  • Page 99 SPEC 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 adjust- ment switch lead, brake light switch lead, and headlight beam switch lead), parking brake cable, throttle cable, speedome- ter unit lead, and brake hose with...
  • Page 100 SPEC CABLE ROUTING 5 6 a...
  • Page 101 SPEC 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.
  • Page 102 SPEC CABLE ROUTING 5 6 a...
  • Page 103 SPEC CABLE ROUTING P Fasten the idling adjusting screw and oil pressure switch lead with the plastic band. Install the plas- tic band with its buckle posi- tioned towards the rear of the machine and its end facing to the right.
  • Page 104 SPEC CABLE ROUTING 5 6 a...
  • Page 105 SPEC 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 adjust- ment switch lead, brake light switch lead, and headlight beam switch lead), parking brake cable, throttle cable, speedome- ter unit lead, and brake hose with...
  • Page 106 SPEC CABLE ROUTING...
  • Page 107 SPEC CABLE ROUTING PZ50VT/PZ50MP 1 Headlight unit 2 Headlight lead coupler 3 Headlight lead 4 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...
  • Page 108 SPEC CABLE ROUTING PZ50/PZ50GT/PZ50RT/PZ50MT PZ50VT/PZ50MP...
  • Page 109 SPEC 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 down- ward. 3 Fasten the tail/brake light lead with the plastic band. Install the plastic band with its buckle posi- tioned to the inside of the tail/ brake light lead and its end fac- ing downward.
  • Page 110 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN U.S.A. 2007.11 CR...
  • Page 111 WIRING DIAGRAM PZ50 2008 8GC-0F001-20 1 Crankshaft position d Low coolant temper- COLOR CODE sensor ature indicator light B ....Black 2 A.C. magneto e Knock control sys- Br.....Brown 3 Rectifier/regulator tem indicator light Ch....Chocolate 4 Main switch f High beam indicator G....Green 5 Main fuse light...
  • Page 112 WIRING DIAGRAM PZ50 2008 8GC-0F001-20 R/G R/W B/L G/W SUB-WIRE SUB-WIRE WIRE HARNESS WIRE HARNESS HARNESS 1 HARNESS 2 O R/W R/L L/R (BLACK) Gy/R R/W Gy/R Y/R Gy (BLACK) G/B Gy/R Br/L R/L R/B B/L Gy (BLACK) (GRAY) (BLACK) Br/W B/Y W/Y Y/W (GRAY)
  • Page 113 WIRING DIAGRAM PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 2008 8GK-0F001-20/8GN-0F001-20/8GJ-0F001-20 1 Crankshaft position c Engine ground COLOR CODE d Passenger grip sensor B ....Black 2 A.C. magneto warmer relay Br.....Brown 3 Rectifier/regulator e Frame ground Ch....Chocolate 4 Main switch f Passenger grip G....Green 5 Main fuse warmer switch Gy....Gray 6 Load control relay...
  • Page 114 WIRING DIAGRAM PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 2008 8GK-0F001-20/8GN-0F001-20/8GJ-0F001-20 È È R/G R/W B/L G/W G L/R Br/R Sb W/L Br/R B O/B GEAR MOTOR HEADLIGHT O R/W SUB-WIRE SUB-WIRE SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS R/L L/R WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 2 HARNESS 1...

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Phazer pz50gtxPhazer pz50rtxPhazer pz50mtxVenture pz50vtxVenture pz50mpx8gc3 ... Show all

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