Yamaha PZ50W Owner's Manual
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Yamaha PZ50W Owner's Manual

Yamaha PZ50W Owner's Manual

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SNOWMOBILE
OWNER'S MANUAL
PZ50W
LIT-12628-02-58
8GC-28199-10

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  • Page 1 SNOWMOBILE OWNER’S MANUAL PZ50W LIT-12628-02-58 8GC-28199-10...
  • Page 3 Record the frame number, engine number (Primary ID), and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer. 1 The frame number is the seventeen-digit number stamped on the frame of the snowmobile. (See fig.
  • Page 4 ESU00011 I NTRODUCTION Congratulations on your purchase of a Yamaha snowmo- bile. This model is the result of Yamaha’s vast experience in the production of fine sporting and touring snowmo- biles. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 5 PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE SNOWMO- BILE. NOTE: Yamaha continually seeks advancements in product design and quality. Therefore, while this manual con- tains the most current product information available at the time of printing, there may be minor discrepan- cies between your snowmobile and this manual.

  • Page 6: Table Of Contents

    ESU00003 CONTENTS YAMAHA MOTOR CORPORATION, Drive guard ........5-11 U.S.A. SNOWMOBILE LIMITED Storage compartment ....5-12 WARRANTY ........1-1 PRE-OPERATION CHECKS....6-1 YAMAHA EXTENDED SERVICE Fuel ..........6-1 (Y.E.S.) ..........1-4 Engine oil.........6-2 Engine oil level ........6-3 Coolant ..........6-4 LOCATION OF THE IMPORTANT Throttle lever ........6-5 LABELS..........2-1...
  • Page 7 Driving ..........7-8 Engine ...........11-1 Stopping the engine......7-8 Chassis..........11-1 Transporting ........7-9 Electric...........11-2 PERIODIC MAINTENANCE ....8-1 WIRING DIAGRAM ......12-1 Periodic maintenance chart for the emission control system ....8-1 General maintenance and lubrication chart .......8-2 Tool kit ..........8-5 Removing and installing the covers ..........8-5 Checking the spark plugs ....8-8 Adjusting the engine idling speed..........8-10...

  • Page 8: Yamaha Motor Corporation, U.s.a. Snowmobile Limited Warranty

    WARRANTY PERIOD: WARRANTY TRANSFER: To transfer any remain- 1. All Yamaha snowmobiles shall be warranted for a ing warranty from the original purchaser to any subse- term of one (1) year from the date of purchase, plus quent purchaser, it is imperative that the machine be a special early-season extension (if applicable).
  • Page 9 Post Office Box 6555 specified in the Owner’s Manual? Cypress, California 90630 A. No. The warranty on a new Yamaha cannot be “voided” or “canceled.” However, if a particular failure is caused by operation or maintenance other than as shown in the Owner’s Manual, that failure may not be...

  • Page 10: Change Of Address

    If the dealer is not able to do so, he is expected to contact Yamaha Motor If you should move after you have purchased your new Corporation, U.S.A., for clarification or assistance.

  • Page 11: Yamaha Extended Service (Y.e.s.)

    ESU04280 YAMAHA EXTENDED SERVICE (Y.E.S.) CW-06E...

  • Page 12: Location Of The Important Labels

    ESU00070 L OCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operat- ing this snowmobile. NOTE: Maintain or replace safety and instruction labels, as nec- essary. 8EK-77761-E0...

  • Page 13: Safety Information

    1. Read the Owner’s Manual and all labels before oper- ating this snowmobile. Become familiar with all of the operating controls and their function. Consult a Yamaha dealer about any control or function you do not understand. 2. This snowmobile was not manufactured for use on public streets, roads, or highways.
  • Page 14 7. Do not allow anyone to stand behind the snowmobile when starting, inspecting, or adjusting the snowmo- bile. A broken track, track fittings, or debris thrown by the track could be dangerous to the operator or bystanders. 8. Handle fuel with care; it is HIGHLY FLAMMABLE. Never add fuel when the engine is running or hot.
  • Page 15 Fuel may leak out from the fuel breather hose. 2. Modifications made to the snowmobile not approved by Yamaha, or the removal of original equipment may render your snowmobile unsafe for use that may cause severe personal injury. Modifications may also make the snowmobile illegal to use.

  • Page 16: Description

    ESU00012 D ESCRIPTION 1 Top cover 2 Left side cover 3 Steering handlebar 4 Seat 5 Frame 6 Storage compartment 7 Slide rail suspension 8 Drive track 9 Skis 0 Right side cover A Right upper cover B Headlights C Air filter case cover D Front cover...
  • Page 17 E Tail/brake light F Snow flap G Brake lever H Parking brake lever I Grip/Thumb warmer adjustment switch J Headlight beam switch K Speedometer unit L Engine stop switch M Throttle lever N Main switch O “RESET” button P “SELECT” button Q Fuel level warning indicator R Oil level warning indicator S Coolant temperature warning indicator...

  • Page 18: Control Functions

    ESU00013 C ONTROL FUNCTIONS ESU05210 Main switch The main switch controls the following items. 1 “OFF” The ignition circuit is switched off. The key can be removed only in this position. 2 “ON” The ignition circuit is switched on. 3 “START” The starting circuit is switched on.

  • Page 19: Engine Overheating Prevention System

    ESU00361 Engine overheating prevention system This model is equipped with an engine overheating pre- vention system to prevent overheating when the engine is idling. When the engine has been idling for at least 3 minutes and the coolant temperature has risen above 100 °C (212 °F), the engine automatically shuts off to prevent overheating.
  • Page 20 CA-19E Mode Idling/ Running Trouble starting Item Throttle switch Throttle position Closed Open Open sensor T.O.R.S. Engine will operate È Idling/starting É Running Ê Trouble 1 Throttle position sensor (throttle valve position) 2 Throttle switch 3 Throttle cable a On b Off c Open d Closed...

  • Page 21: Speedometer Unit

    ESU05400 Speedometer unit The speedometer unit is equipped with the following: a digital speedometer (which shows the riding speed) an odometer (which shows the total distance trav- eled) a tripmeter (which shows the distance traveled since it was last set to zero) an engine speed meter (which shows the engine speed;...

  • Page 22: High Beam Indicator Light

    ESU00363 High beam indicator light The high beam indicator light 1 comes on when the high beams of the headlights are switched on. (See page 5-10 for headlight beam switch operation.) ESU05390 Fuel meter and grip/thumb warmer level indicator The fuel meter and grip/thumb warmer level indicator 1 have eight segments which show the amount of fuel remaining in the fuel tank, or show the grip warmer, or the thumb warmer level.

  • Page 23: Fuel Level Warning Indicator

    The fuel level warning indicator 1, warning light 2, and all segments of the fuel meter 3 warn the rider of the above problems by flashing continuously. When this occurs, have a Yamaha dealer inspect the snowmobile as soon as possible. ESU03770...

  • Page 24: Knock Control System "Kcs" Indicator Light

    If the knock control system “KCS” indicator light is flashing, have a Yamaha dealer inspect the snowmobile as soon as possible. NOTE: To help prevent knocking, use premium unleaded gaso- line only.

  • Page 25: Self-Diagnostic System

    If the self-diagnosis warning indicator, warning light, and an error code flash after the engine has been restarted, note the error code, and then have a Yamaha dealer inspect the snowmobile as soon as possible. ESU00031 Engine stop switch The engine stop switch 1 is used to stop the engine in an emergency.

  • Page 26: Brake Lever

    ESU00320 Brake lever The snowmobile is stopped by braking the entire drive system. Squeeze the brake lever towards the handlebar grip to stop the snowmobile. 1 Brake lever 2 Brake lever end 3 Handlebar end NOTE: When the brake lever is operated, the brake light will illu- minate.

  • Page 27: Headlight Beam Switch

    ESU00039 Headlight beam switch Push the headlight beam switch to change the headlight beam to high or low. 1 Headlight beam switch 2 Push 3 High beam 4 Low beam ESU05200 Grip/thumb warmer adjustment switch The grip/thumb warmer adjustment switch 1 controls the electrically heated handlebar grips and throttle lever.

  • Page 28: Covers

    ESU05220 Covers Securely fasten the covers before operating the snowmo- bile. (See pages 8-5–8-8 for removal and installation pro- cedures.) 1 Air filter case cover 2 Front cover 3 Right side cover 4 Right upper cover 5 Top cover 6 Right lower cover 7 Left side cover WARNING Do not drive the snowmobile with the covers...

  • Page 29: Storage Compartment

    ESU00680 Storage compartment Open the storage compartment to store the service tools, spare parts, or other small items. 5-12...

  • Page 30: Pre-Operation Checks

    Fuel tank capacity: 30.1 L (6.6 Imp gal, 8.0 US gal) NOTE: Your Yamaha engine has been designed to use pre- mium unleaded gasoline with a pump octane number [(R+M)/2] of 91 or higher, or a research octane num- ber of 95 or higher.

  • Page 31: Engine Oil

    5% of ethanol can be used, although richer jetting may be required to prevent engine dam- age. Consult a Yamaha dealer. Gasohol contain- ing methanol is not recommended. Make sure that snow or ice does not enter the fuel tank when refueling.

  • Page 32: Engine Oil Level

    ESU05250 Engine oil level The engine oil level should be checked before each use. CAUTION : Do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the air filter case and the engine could be damaged.

  • Page 33: Coolant

    CAUTION : When adding the engine oil, be careful not to fill above the “H” level mark on the oil level gauge/dipstick. Make sure that no foreign material enters the engine oil tank. 7. Insert the oil level gauge/dipstick into the oil filler hole, and then tighten it securely.

  • Page 34: Throttle Lever

    The T.O.R.S. will operate and the engine should run between 2,800 and 3,000 r/min. 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 consult a Yamaha dealer.

  • Page 35: Brake

    Do not operate the snowmobile if you find any problems in the brake system. You could lose braking ability, which could lead to an accident. Ask a Yamaha dealer to inspect and repair the brake system. CAUTION : Make sure that the brake lever end does not project out over the handlebar end.

  • Page 36: Brake Fluid Leakage

    Apply the brake for a few minutes. Check to see if any brake fluid leaks out from the brake hose joints or the master cylinder. WARNING If brake fluid leakage is found, ask a Yamaha dealer for immediate repairs. CAUTION : Brake fluid may deteriorate painted surfaces or plas- tic parts.

  • Page 37: Drive Track

    ESU00097 Drive track Check the drive track for deflection, wear, or damage. Adjust or replace if necessary. (See pages 8-22–8-24 for more details.) WARNING Do not operate the snowmobile if you find damage to the drive track, or if it has been maladjusted. Drive track damage or failure could result in loss of brak- ing ability and snowmobile control, which could cause an accident.

  • Page 38: Skis And Ski Runners

    Check the handlebar for excessive free play: 1. Push the handlebar up and down and back and forth. 2. Turn the handlebar slightly to the right and left. If excessive free play is noticed, consult a Yamaha dealer. ESU01050 Lights Check the lights.

  • Page 39: Air Filter

    ESU05260 Air filter Always check that there is no snow under the air filter element. 1. Remove the front cover and the air filter case cover. (See pages 8-5–8-8 for removal procedures.) 2. Unhook the air filter element frame fasteners. 3.

  • Page 40: Operation

    ESU00112 O PERATION ESU04640 Starting the engine WARNING Be sure to check the “SAFETY INFORMATION” section carefully before starting the engine. Make sure that the parking brake is applied. NOTE: Make sure that the engine stop switch is in the on posi- tion.

  • Page 41: Break-In

    CAUTION : After 800 km (500 mi) of operation, the engine oil must be changed and the oil filter cartridge replaced. If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the snowmobile.

  • Page 42: Riding Your Snowmobile

    totally familiar with the snowmobile’s han- ESU01272 Riding your snowmobile dling and performance characteristics. Getting to know your snowmobile Set the parking brake and follow the A snowmobile is a rider active vehicle, and instructions on page 7-1 to start the your riding position and your balance are engine.

  • Page 43: Turning

    Turning Riding uphill For most snow surfaces, “body English” is You should practice first on gentle slopes. the key to turning. Try more difficult climbs only after you have As you approach a curve, slow down and developed your skill. As you approach a begin to turn the handlebar in the desired hill, accelerate before you start the climb, direction.

  • Page 44: Riding Downhill

    Riding downhill downhill leg on the seat and the foot of your uphill leg on the running board. This position will make it easier for you to shift your body weight as needed. Snow and ice are slippery, so be prepared for the possibility that your snowmobile could begin to slip sideways on the slope.

  • Page 45: Hard-Packed Snow

    Hard-packed snow WARNING It can be more difficult to negotiate on Drive track damage or failure could hard-packed snow as both the skis and result in loss of braking ability and drive track do not have as much traction as snowmobile control, which could cause when the snowmobile is operated on fresh an accident.

  • Page 46: Maximizing Drive Track Life

    Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible dam- age, consult your stud manufacturer for installation and stud pattern recommendations. Yamaha does not recommend track studding.

  • Page 47: Driving

    ESU01300 Driving WARNING Be sure to read the “SAFETY INFORMATION” and “Riding your snowmobile” sections carefully before operating the snowmobile. NOTE: Make sure that the engine is warmed up enough before riding. 1. Release the parking brake by moving the parking brake lever to the right.

  • Page 48: Transporting

    ESU04651 Transporting When transporting your snowmobile on a trailer or in a truck, observe the following recommendations to help protect it from damage: If transporting the snowmobile in an open trailer or truck, put a tight fitting cover on the snowmobile. A cover specifically designed for your snowmobile is best.

  • Page 49: Periodic Maintenance

    (if applicable). WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. PROPER PERIODIC MAINTENANCE OF YOUR SNOWMOBILE IS IMPORTANT IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL.

  • Page 50: General Maintenance And Lubrication Chart

    ∗ Fuel injection Adjust synchronization. Check for leakage. ∗ Exhaust system Tighten or replace gasket if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer. ESU04980 General maintenance and lubrication chart CD-32E Every Initial Pre-...
  • Page 51 Replace if necessary. Lubricate with specified grease. ∗ Steering column Lubricate with specified bearing grease. ∗ Ski and front Lubricate with specified suspension grease. ∗ It is recommended that these items be serviced by a Yamaha dealer.
  • Page 52 Tool kit and recom- Check for proper placement. 6-10 mended equipment ∗ It is recommended that these items be serviced by a Yamaha dealer. NOTE: Brake system: After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regularly check the brake fluid level and add fluid if necessary.

  • Page 53: Tool Kit

    NOTE: If you do not have a torque wrench available during a service operation requiring one, take your snowmobile to a Yamaha dealer to check the torque settings and adjust them if necessary. ESU05300 Removing and installing the covers...
  • Page 54 To install the air filter case cover and front cover 1. Insert the projections on the end of the air filter case cover into the slots in the air filter case, place it in the original position, and then tighten the quick fasteners. 2.
  • Page 55 Top cover To remove the top cover Pull up on the rear of the top cover. 1 Top cover To install the top cover Insert the projections on the front of the top cover into the slots in the left and right upper covers, and then fit the projections on the rear of the top cover into the grom- mets.

  • Page 56: Checking The Spark Plugs

    You should periodically remove and inspect the spark plug because heat and deposits will cause a spark plug to slowly break down and erode. Consult a Yamaha dealer before chang- ing to a different type of spark plug. Specified spark plug:...
  • Page 57 Spark plug reach a: 19.0 mm (0.75 in) Before installing any spark plug, measure the electrode gap with a wire thickness gauge and adjust to specifica- tion. Spark plug gap b: 0.6–0.7 mm (0.024–0.028 in) When installing the spark plug, always clean the gasket surface.

  • Page 58: Adjusting The Engine Idling Speed

    ESU05370 Adjusting the engine idling speed CAUTION : Be sure to have a Yamaha dealer make this adjust- ment. 1. Start the engine and warm it up. 2. Select the engine speed meter mode. (See page 5-4 for details.) 3. Remove the rubber cap 1.

  • Page 59: Adjusting The High-Altitude Settings

    If you plan to operate your snowmobile at an altitude different from the area where you bought it, be sure to consult a Yamaha dealer. The dealer can tell you if there are any changes necessary for the altitude where you plan to ride.

  • Page 60: Changing The Engine Oil

    ESU05340 Changing the engine oil It is recommended to have a Yamaha dealer change the engine oil. WARNING Engine oil is extremely hot immediately after the engine is turned off. Coming into contact with or get- ting any engine oil on your clothes could result in burns.
  • Page 61 8. Install the engine oil drain bolts, and then tighten them to the specified torques. Tightening torques: Crankcase engine oil drain bolt: 30 Nm (3.0 m·kgf, 22 ft·lb) Oil tank engine oil drain bolt: 16 Nm (1.6 m·kgf, 11 ft·lb) 9.

  • Page 62: Cooling System

    If oil is leaking or the oil level warning indicator comes on when the engine is running, immediately turn the engine off and have a Yamaha dealer check the snowmobile. Continuing to operate the engine under such conditions could cause severe engine damage.
  • Page 63 3. Start the engine, allow it to idle for several minutes, and then turn it off. 4. Check for any coolant leakage. NOTE: If you find any leaks, consult a Yamaha dealer. 5. Install the right upper cover and the top cover. 8-15...

  • Page 64: Replacing The V-Belt

    ESU05280 Replacing the V-belt WARNING Have a Yamaha dealer replace the V-belt and adjust the gap between the secondary fixed sheave and the secondary sliding sheave. Serious injury can occur from the sudden release of spring tension during sheave disassembly.

  • Page 65: Checking The Drive Chain Housing Oil Level And The Drive Chain Tension

    7. Rotate the secondary sliding sheave clockwise 4 and push 5 it so that it separates from the secondary fixed sheave. 8. Install the V-belt 6 between the secondary sliding and secondary fixed sheaves. 9. Install the drive guard. 10. Install the left side cover. WARNING Never run the engine with the V-belt or drive guard removed.

  • Page 66: Checking The Brake Pads

    5. Install the right side cover. ESU00174 Checking the brake pads Check the brake pads for wear. If the brake pads reach the wear limit, ask a Yamaha dealer to replace them. 1 Brake pad wear indicator Wear limit a: 1.5 mm (0.06 in)

  • Page 67: Checking The Parking Brake Pads

    Checking the parking brake pads Check the parking brake pads for wear by measuring the thickness of the pads. If the parking brake pads reach the wear limit, ask a Yamaha dealer to replace them. Wear limit a: 1.2 mm (0.05 in) Adjustment As the parking brake pads wear, adjustment may be nec- essary to ensure proper brake performance.

  • Page 68: Changing The Brake Fluid

    Water will significantly lower the boiling point of the fluid and may result in vapor lock. If the brake fluid level goes down, consult a Yamaha dealer. CAUTION : Brake fluid may deteriorate painted surfaces or plas- tic parts.
  • Page 69 The spring preload for the shock absorber and the spring can be adjusted separately by turning the respective spring preload adjuster. WARNING Be sure to have a Yamaha dealer make this adjust- ment. CD-13E Spring adjuster position Preload...

  • Page 70: Adjusting The Drive Track

    ESU03532 Adjusting the drive track WARNING A broken track, track fittings or debris thrown by the drive track could be dangerous to an operator or bystanders. Observe the following precautions: Do not allow anyone to stand behind the snow- mobile when the engine is running. When the rear of the snowmobile is raised to allow the drive track to spin, a suitable stand must be used to support the rear of the snowmo-...
  • Page 71 Adjusting the drive track WARNING Be sure to have a Yamaha dealer make this adjustment. Support the snowmobile securely on a suitable stand before working underneath the snowmo- bile. Operate the engine in a well-ventilated area. 1. Lift the rear of the snowmobile onto a suitable stand to raise the drive track off the ground.

  • Page 72: Aligning The Skis

    2. Check the following for ski alignment: a.Skis are facing forward. b.Ski toe-out (1 – 2) is within specification. Ski toe-out (1 – 2): 0–15 mm (0–0.59 in) 3. If the alignment is not correct, consult a Yamaha dealer. 8-24...

  • Page 73: Lubrication

    Apply a dab of grease onto the cable end only. Do not grease the throttle cable because it could become frozen, which could cause loss of control. 2 Rear suspension WARNING Be sure to have a Yamaha dealer lubricate the front and rear suspensions. 8-25...

  • Page 74: Replacing A Headlight Bulb

    ESU05320 Replacing a headlight bulb 1. Remove the top cover. (See pages 8-5–8-8 for removal procedures.) 2. Disconnect the headlight coupler. 3. Remove the bulb holder cover. 4. Unhook the bulb holder by pushing it in, then down- ward. 1 Headlight coupler 2 Bulb holder cover 3 Bulb holder 5.

  • Page 75: Adjusting The Headlight Beams

    To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the snowmobile is equipped with electrical accessories.

  • Page 76: Replacing A Fuse

    5 “IGN” (Ignition) fuse: 20 A 6 Spare fuses (20 A, 7.5 A) 4. Connect the negative battery lead. 5. Install the right side cover. NOTE: If the fuse immediately blows again, ask a Yamaha dealer to inspect the snowmobile. 8-28...

  • Page 77: Troubleshooting

    Worn or damaged piston and cylinder No fuel in tank ... Supply fuel..Ask a Yamaha dealer to inspect. Clogged fuel line ... Clean fuel line. Clogged injector ... Ask a Yamaha B. Starting the engine with a dis- dealer to inspect.
  • Page 78 10. Disconnect the red (+) jumper cable 2. Air in cooling system ... Bleed the cool- from the positive (+) terminal of the ing system or ask a Yamaha dealer to booster battery. inspect. 11. Disconnect the red (+) jumper cable 3.
  • Page 79 3. Tight, loose, or broken drive chain ..Replace. Ask a Yamaha dealer to inspect. 4. Worn or damaged idler wheels or shafts ... Ask a Yamaha dealer to H. V-belt twists inspect. 1. Improper V-belt ... Replace with the 5.

  • Page 80: Storage

    Make sure that the battery terminals content in the fuel increases the chance for are tight. water to enter the engine. Use Yamaha Stor-Rite Engine Fogging Oil, or an equiva- lent fogging oil, to protect both the com- bustion chamber and crankshaft from corrosion.
  • Page 81 To charge a sealed-type (MF) battery, and tuned by a Yamaha dealer. The dealer a special (constant-voltage) battery has the experience and training to help you charger is required. Using a conven-...

  • Page 82: Specifications

    ESU00228 S PECIFICATIONS 1 1 - ESU00229 Dimensions CS-01E PZ50 Overall length 2,820 mm (111.0 in) Overall width 1,215 mm ( 47.8 in) Overall height 1,190 mm ( 46.9 in) Dry weight 215 kg ( 474 lb) Ski stance 1,080 mm ( 42.5 in) ESU00230 Engine CS-02E...
  • Page 83 PZ50 Transmission: Type Automatic centrifugal engagement, infinite- ly variable 3.8:1–0.95:1 Sheave distance Approx. 268.5 mm (10.57 in) Sheave offset Approx. 16 mm (0.63 in) ∗1 Engagement speed Approx. 3,900 r/min ∗1 ∗2 Shift speed Approx. 11,300 r/min Drive chain Silent chain enclosed in oil bath Reduction ratio 41/18 (2.28) Fuel tank:...
  • Page 84 (10A) (20A) (7.5A) (20A) 12-1...
  • Page 85 12-2...
  • Page 86 –MEMO–...
  • Page 88 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2006.05 - 0.6×1 CR...

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