SERVICE MANUAL

PZ50W PZ50GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW

LIT-12618-02-58

8GC-28197-10

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 mechanics 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. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

HOW TO USE THIS MANUAL

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!

WARNING
Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile.

CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile.

NOTE:
A NOTE provides key information that can make procedures easier or clearer.

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g., Bearings Pitting/damage Replace.

EXPLODED DIAGRAM
PZ50W, PZ50GTW, PZ50FXW, PZ50MW, PZ50VTW, PZ50MPW SERVICE MANUAL 2006 by Yamaha Motor Corporation, U.S.A. 1st Edition, July 2006 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-12618-02-58 Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.

GEN INFO
3

INSP ADJ
4

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapters number and content.
1 2 3 4 5 6 7 8 9 General information Periodic inspection and adjustment Chassis Power train Engine Cooling system Fuel injection system Electrical Specifications

CHAS
5

POWR TR
6

ENG
7

COOL
8

FI
9

ELEC

SPEC
0 A B
T.

Illustrated symbols 0 to F are used to identify the specifications which appear.

0 A B C D E F Filling fluid Lubricant Tightening Wear limit, clearance Engine speed Special tool , V, A
R.

G
LT

5
K

Illustrated symbols G to O in the exploded diagram indicate grade of lubricant and location of lubrication point.
G H I J K L M N O Apply locking agent (LOCTITE) Apply Yamabond No.5 Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply low-temperature lithium-soap base grease Apply molybdenum disulfide grease Use new one

E
L
B

G
M
LS

M
N
M

New

INDEX
GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SPECIFICATIONS
GEN INFO

1 2 3 4 5 6 7
+

INSP ADJ

CHAS

POWR TR

ENG

COOL

FI

ELEC

8 9

SPEC

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............................................................ 1-3 BEARINGS AND OIL SEALS ..................... 1-3 CIRCLIPS ................................................... 1-3 LOCTITE ................................................... 1-3 SPECIAL TOOLS ............................................. 1-4 FOR TUNE UP............................................ 1-4 FOR ENGINE SERVICE............................. 1-4 FOR POWER TRAIN SERVICE ................. 1-7 FOR FUEL INJECTION SERVICE ............. 1-8 FOR ELECTRICAL SERVICE .................... 1-8

CYLINDER HEAD BREATHER HOSE INSPECTION ............................................ 2-23 THROTTLE BODY JOINTS INSPECTION ............................................ 2-23 CHECKING THE AIR FILTER ELEMENT ................................................. 2-24 EXHAUST SYSTEM INSPECTION .......... 2-25 POWER TRAIN............................................... 2-26 SHEAVE OFFSET ADJUSTMENT ........... 2-26 DRIVE V-BELT.......................................... 2-28 ENGAGEMENT SPEED CHECK.............. 2-29 PARKING BRAKE ADJUSTMENT............ 2-29 BRAKE FLUID LEVEL INSPECTION ....... 2-30 BRAKE PAD INSPECTION....................... 2-31 BRAKE HOSE INSPECTION.................... 2-32 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .................................................. 2-32 DRIVE CHAIN ........................................... 2-33 TRACK TENSION ADJUSTMENT............ 2-35 SLIDE RUNNER INSPECTION ................ 2-37 MAXIMIZING DRIVE TRACK LIFE ........... 2-37 CHASSIS ........................................................ 2-39 SKI/SKI RUNNER ..................................... 2-39 STEERING SYSTEM ................................ 2-39 LUBRICATION .......................................... 2-41 ELECTRICAL ................................................. 2-42 HEADLIGHT BEAM ADJUSTMENT ......... 2-42 BATTERY INSPECTION........................... 2-42 FUSE INSPECTION.................................. 2-48 TUNING .......................................................... 2-50 CLUTCH.................................................... 2-50 GEAR SELECTION................................... 2-55 FRONT SUSPENSION ............................. 2-61 REAR SUSPENSION................................ 2-63

CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION............................................... 2-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM.............. 2-1 GENERAL MAINTENANCE AND LUBRICATION CHART.................................... 2-2 ENGINE ............................................................ 2-4 SPARK PLUGS........................................... 2-4 FUEL LINE INSPECTION........................... 2-4 COOLING SYSTEM.................................... 2-5 VALVE CLEARANCE ADJUSTMENT ........ 2-7 THROTTLE BODY SYNCHRONIZATION ............................... 2-13 ENGINE IDLE SPEED ADJUSTMENT..... 2-14 THROTTLE CABLE FREE PLAY ADJUSTMENT.......................................... 2-15 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK .................................... 2-16 COMPRESSION PRESSURE MEASUREMENT ...................................... 2-17 ENGINE OIL LEVEL INSPECTION .......... 2-19 ENGINE OIL REPLACEMENT ................. 2-20

CHAPTER 3. CHASSIS
COWLINGS ...................................................... 3-1 PZ50/PZ50GT/PZ50FX/PZ50M .................. 3-1 PZ50VT/PZ50MP ........................................ 3-3 STEERING ........................................................ 3-4 PZ50W/PZ50GT/PZ50FX/PZ50M............... 3-4 PZ50VT/PZ50MP ........................................ 3-6 REMOVAL................................................. 3-10 INSPECTION ............................................ 3-10 INSTALLATION......................................... 3-11 SKI .................................................................. 3-14 PZ50/PZ50GT/PZ50FX/PZ50VT USA/ Canada .................................................... 3-14

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 ........................................ 3-23

BRAKE CALIPER ASSEMBLY ................. 4-37 BRAKE CALIPER INSTALLATION ........... 4-37 INSPECTION ............................................ 4-39 BRAKE MASTER CYLINDER ASSEMBLY............................................... 4-39 INSTALLATION......................................... 4-39 SLIDE RAIL SUSPENSION............................ 4-40 PZ50/PZ50GT/PZ50FX/PZ50M ................ 4-40 PZ50VT/PZ50MP ...................................... 4-45 REMOVAL................................................. 4-51 INSPECTION ............................................ 4-51 ASSEMBLY............................................... 4-51 INSTALLATION......................................... 4-55 FRONT AXLE AND TRACK ........................... 4-56 INSPECTION ............................................ 4-57 INSTALLATION......................................... 4-57

CHAPTER 4. POWER TRAIN

PRIMARY SHEAVE AND DRIVE V-BELT ....... 4-1 REMOVAL .................................................. 4-3 DISASSEMBLY........................................... 4-3 INSPECTION .............................................. 4-4 ASSEMBLY................................................. 4-6 INSTALLATION .......................................... 4-9 SECONDARY SHEAVE ................................. 4-10 DISASSEMBLY......................................... 4-12 INSPECTION ............................................ 4-12 ASSEMBLY............................................... 4-13 INSTALLATION ........................................ 4-14 DRIVE CHAIN................................................. 4-15 REMOVAL ................................................ 4-16 INSPECTION ............................................ 4-16 INSTALLATION ........................................ 4-18 SECONDARY SHAFT .................................... 4-19 PZ50 ......................................................... 4-19 REMOVAL ................................................ 4-20 INSPECTION ............................................ 4-20 INSTALLATION ........................................ 4-20 SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION ............................ 4-22 SECONDARY SHAFT AND REVERSE GEAR CASE................................................... 4-23 PZ50GT/PZ50FX/PZ50M/PZ50VT/ PZ50MP .................................................... 4-23 REMOVAL ................................................ 4-27 INSPECTION ............................................ 4-28 ASSEMBLY............................................... 4-28 INSTALLATION ........................................ 4-29 SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION ............................ 4-30 BRAKE ........................................................... 4-31 BRAKE PAD REPLACEMENT ................. 4-33 BRAKE CALIPER DISASSEMBLY ........... 4-36 BRAKE CALIPER INSPECTION AND REPAIR ............................................ 4-36

CHAPTER 5. ENGINE
SEAT AND FUEL TANK................................... 5-1 PZ50/PZ50GT/PZ50FX/PZ50M .................. 5-1 BACKREST AND PASSENGER SEAT ........... 5-3 PZ50VT/PZ50MP ........................................ 5-3 RIDER SEAT AND FUEL TANK ...................... 5-5 PZ50VT/PZ50MP ........................................ 5-5 REMOVAL................................................... 5-7 INSTALLATION........................................... 5-8 EXHAUST PIPE AND MUFFLER ..................... 5-9 PZ50/PZ50GT/PZ50FX/PZ50M .................. 5-9 PZ50VT/PZ50MP ...................................... 5-10 INSTALLATION......................................... 5-11 OIL TANK ....................................................... 5-12 ENGINE ASSEMBLY ..................................... 5-13 HOSE AND LEADS................................... 5-13 ENGINE ASSEMBLY ................................ 5-15 REMOVAL................................................. 5-16 INSTALLATION......................................... 5-16 CAMSHAFTS.................................................. 5-18 CYLINDER HEAD COVER ....................... 5-18 CAMSHAFTS ............................................ 5-19 REMOVAL................................................. 5-20 INSPECTION ............................................ 5-21 INSTALLATION......................................... 5-25

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. MAGNETO ROTOR AND STARTER CLUTCH ......................................................... 5-41 REMOVAL ................................................ 5-42 INSPECTION ............................................ 5-43 INSTALLATION ........................................ 5-44 OIL PAN AND OIL PUMP .............................. 5-46 REMOVAL ................................................ 5-49 INSPECTION ............................................ 5-49 INSTALLATION ........................................ 5-50 BALANCER .................................................... 5-52 REMOVAL ................................................ 5-54 INSPECTION ............................................ 5-55 INSTALLATION ........................................ 5-55 CRANKCASE ................................................. 5-58 CRANKCASE............................................ 5-58 CONNECTING RODS AND PISTONS ..... 5-59 CRANKSHAFT.......................................... 5-60 REMOVAL ................................................ 5-61 INSPECTION ............................................ 5-63 INSTALLATION ........................................ 5-73

CHAPTER 7. FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM ............................. 7-1 WIRING DIAGRAM ..................................... 7-2 ECU SELF-DIAGNOSTIC FUNCTION ....... 7-4 SELF-DIAGNOSTIC FUNCTION TABLE.... 7-4 TROUBLESHOOTING CHART................... 7-6 DIAGNOSTIC MODE .................................. 7-7 TROUBLESHOOTING DETAILS .............. 7-14 OIL PRESSURE SWITCH ........................ 7-28 INTAKE AIR TEMPERATURE SENSOR ................................................... 7-28 THROTTLE BODY.......................................... 7-29 INJECTORS.............................................. 7-30 INSPECTION ............................................ 7-31 PRESSURE REGULATOR OPERATION ............................................. 7-31 INSPECTION AND ADJUSTMENT .......... 7-32

CHAPTER 8. ELECTRICAL
SWITCH INSPECTION ..................................... 8-1 SWITCH INSPECTION ............................... 8-1 INSPECTING A SWITCH SHOWN IN THE MANUAL ............................................. 8-1 IGNITION SYSTEM .......................................... 8-2 CIRCUIT DIAGRAM.................................... 8-2 TROUBLESHOOTING ................................ 8-4 IGNITION SPARK GAP .............................. 8-6 IGNITION COIL........................................... 8-6 CRANKSHAFT POSITION SENSOR ......... 8-7 THROTTLE OVERRIDE SYSTEM (T.O.R.S.).................................................... 8-8 ENGINE STOP SWITCH ............................ 8-9 THROTTLE SWITCH .................................. 8-9 MAIN SWITCH .......................................... 8-10 ELECTRICAL STARTING SYSTEM .............. 8-11 CIRCUIT DIAGRAM.................................. 8-11 TROUBLESHOOTING .............................. 8-12 STARTER MOTOR ................................... 8-14 CHARGING SYSTEM ..................................... 8-19 CIRCUIT DIAGRAM.................................. 8-19 TROUBLESHOOTING .............................. 8-20 BATTERY.................................................. 8-21 A.C. MAGNETO ........................................ 8-21

CHAPTER 6. COOLING SYSTEM

RADIATOR AND HEAT EXCHANGER............ 6-1 INSPECTION .............................................. 6-3 INSTALLATION .......................................... 6-4 THERMOSTAT ................................................. 6-5 INSPECTION .............................................. 6-6 INSTALLATION .......................................... 6-6 WATER PUMP.................................................. 6-8 DISASSEMBLY......................................... 6-10 INSPECTION ............................................ 6-10 ASSEMBLY............................................... 6-11 INSTALLATION ........................................ 6-12

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.................................. 8-28 TROUBLESHOOTING.............................. 8-30 BRAKE LIGHT SWITCH ........................... 8-38 DRIVE POSITION SWITCH AND REVERSE POSITION SWITCH (PZ50GT/PZ50FX/PZ50M/PZ50VT/ PZ50MP)................................................... 8-38 DC BACK BUZZER (PZ50GT/PZ50FX/ PZ50M/PZ50VT/PZ50MP) ........................ 8-38 COOLANT TEMPERATURE SENSOR .... 8-39 OIL LEVEL SWITCH................................. 8-40 FUEL SENDER......................................... 8-40 SPEED SENSOR...................................... 8-41 KNOCK SENSOR ..................................... 8-41 GRIP WARMER SYSTEM .............................. 8-42 CIRCUIT DIAGRAM.................................. 8-42 TROUBLESHOOTING.............................. 8-44 GRIP AND THUMB WARMER ................. 8-46 GRIP/THUMB WARMER ADJUSTMENT SWITCH.................................................... 8-46 PASSENGER GRIP WARMER (PZ50VT) .................................................. 8-47 PASSENGER GRIP WARMER SWITCH (PZ50VT) .................................................. 8-47 PASSENGER GRIP WARMER RELAY (PZ50VT/PZ50MP) ................................... 8-48 COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) ............................. 8-50 CIRCUIT DIAGRAM.................................. 8-50 TROUBLESHOOTING.............................. 8-52 RADIATOR FAN MOTOR......................... 8-53 RADIATOR FAN MOTOR RELAY ............ 8-53 DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/ PZ50MP) ......................................................... 8-54 CIRCUIT DIAGRAM.................................. 8-54 TROUBLESHOOTING.............................. 8-56 GEAR MOTOR ......................................... 8-57 GEAR MOTOR RELAY 1.......................... 8-58 GEAR MOTOR RELAY 2.......................... 8-58 GEAR MOTOR RELAY 3.......................... 8-59

CHAPTER 9. SPECIFICATIONS
GENERAL SPECIFICATIONS.......................... 9-1 MAINTENANCE SPECIFICATIONS................. 9-5 ENGINE ...................................................... 9-5 POWER TRAIN......................................... 9-10 CHASSIS .................................................. 9-16 ELECTRICAL ............................................ 9-18 TIGHTENING TORQUE.................................. 9-21 ENGINE .................................................... 9-21 POWER TRAIN......................................... 9-23 CHASSIS .................................................. 9-25 GENERAL TORQUE SPECIFICATIONS ....... 9-27 DEFINITION OF UNITS .................................. 9-27 CABLE ROUTING .......................................... 9-29

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.

1-1

IMPORTANT INFORMATION IMPORTANT INFORMATION

GEN INFO

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. This includes gears, cylinders, pistons, and other parts that have been mated through normal wear. Mated parts must be reused or replaced as an assembly.

4. During disassembly of the machine, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help ensure that all parts are reinstalled correctly.

5. Keep all parts away from any source of fire.

6. Be sure to keep to the tightening torque specifications. When tightening bolts, nuts, and screws, start with those that have larger diameters, and proceed from the inside to the outside in a crisscross pattern.

ALL REPLACEMENT PARTS

We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments.

1-2

IMPORTANT INFORMATION
GASKETS, OIL SEALS, AND O-RINGS

GEN INFO

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. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

BEARINGS AND OIL SEALS

Install the bearings 1 and oil seals 2 with their manufacturers marks or numbers facing outwards. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil the bearings liberally when installing.

CAUTION:
Do not use compressed air to spin the bearings dry. This causes damage to the surface of the bearings.

CIRCLIPS
All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing a circlip 1, make sure that the sharp edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view.
4 Shaft

LOCTITE
After installing fasteners that have LOCTITE applied, wait 24 hours before using the machine. This will give the LOCTITE time to dry properly.

1-3

SPECIAL TOOLS SPECIAL TOOLS

GEN INFO

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-.

FOR TUNE UP
Dial gauge P/N: YU-03097 90890-03097 This gauge is used for run out measurement. Angle gauge Use goods on the market. This tool is used to tightening the torque.

Steering linkage alignment plate P/N: YS-01515 90890-01515 Locks steering relay arm and pivot arm shaft in place while adjusting the steering linkage for front-end alignment.

FOR ENGINE SERVICE

Piston pin puller P/N: YU-01304 90890-01304 This tool is used to remove the piston pin. Rotor holding puller P/N: YU-33270-B 90890-01362 Flywheel puller attachment P/N: YM-33282 90890-04089 These tools are used to remove the magneto rotor.

1-4

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.

Valve spring compressor P/N: YM-04019 90890-04019 Valve spring compressor attachment P/N: YM-04108 90890-04108 P/N: YM-04114 90890-04114 These tools are used to remove or install the valve assemblies.

1-5

SPECIAL TOOLS
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.

GEN INFO

Rotor holding tool P/N: YU-01235 90890-01235 This tool is used to hold the camshaft sprocket.

Valve guide remover (4) P/N: YM-04111 90890-04111 This tool is used to remove or install the valve guides.

Valve guide installer (4) P/N: YM-04112 90890-04112 This tool is used to install the valve guides.

Valve guide reamer (4) P/N: YM-04113 90890-04113 This tool is used to rebore the new valve guides.

Valve lapper P/N: 90890-04101 This tool is needed to remove and install the valve lifters.

Piston ring compressor P/N: YM-08037 90890-05158 This tool is used to compress the piston rings when installing the piston into the cylinder.

1-6

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.)

FOR POWER TRAIN SERVICE

Sheave holder P/N: YS-01880-A 90890-01701 This tool is used to hold the primary sheave and A.C. magneto rotor. Primary sheave puller (18 mm) P/N: YS-01881-A 1, YS-01881-1 2 90890-01898 This tool is used for removing the primary sheave.

Clutch spider separator P/N: YS-28890-C 90890-01711 This tool is used when disassembling and assembling the primary sheave.

Clutch separator adapter P/N: YS-34480 90890-01740 This tool is used when disassembling and assembling the primary sheave.

YXR clutch bushing jig kit P/N: YS-39752 This tool is used for removal and installation of primary clutch weight and roller bushings.

1-7

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.

Pressure gauge P/N: YU-03153 90890-03153 This tool is used to measure fuel pressure.

Vacuum gauge P/N: YU-08030 90890-03094 This guide is used to synchronize the throttle bodies.

FOR ELECTRICAL SERVICE

Pocket tester P/N: YU-03112-C 90890-03112 This instrument is necessary for checking the electrical components. Engine tachometer P/N: YU-08036-C 90793-80009 This tool is used to check engine speed.

1-8

SPECIAL TOOLS

GEN INFO

Digital circuit tester P/N: YU-A1927 90890-03174 This instrument is necessary for checking the electrical componenets.

1-9

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. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

Pre-operation check (Daily) Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 4,000 km (2,500 mi) (200 hr)

Item

Remarks

Spark plugs Valve clearance Crankcase breather system Fuel filter Fuel line Idle speed Fuel injection Exhaust system

Check condition. Adjust gap and clean. Replace if necessary. Check clearance. Adjust clearance when engine is cold. Check breather hose for cracks or damage. Replace if necessary. Check condition. Replace if necessary. Check fuel hose for cracks or damage. Replace if necessary. Check and adjust engine idle speed. Adjust synchronization. Check for leakage. Tighten or replace gasket if necessary. Every 40,000 km (25,000 mi)

It is recommended that these items be serviced by a Yamaha dealer.

2-1

GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART
Pre-operation check (Daily)

INSP ADJ
Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 4,000 km (2,500 mi) (200 hr)

Item

Remarks

Engine oil Engine oil filter cartridge Fuel Engine coolant Throttle lever (handlebar side) Throttle override system (T.O.R.S.) Engine stop switch Drive guard V-belt Drive track and idler wheels Slide runners

Check oil level. Replace. Replace. Check fuel level. Check coolant level. Air bleed the cooling system if necessary. Check operation. Repair if necessary. Check operation. Repair if necessary. Check operation. Repair if necessary. Check for cracks, bends or damage. Replace if necessary. Check for wear and damage. Replace if necessary. Check deflection, and for wear and damage. Adjust/replace if necessary. Check for wear and damage. Replace if necessary. Check operation and fluid leakage. Adjust free play and/or replace pads if necessary. Replace brake fluid. See NOTE on page 2-3. Every 1,600 km (1,000 mi) Every 20,000 km (12,000 mi)

Brake and parking brake

Disc brake installation Drive chain oil Drive chain Skis and ski runners Steering system Strap (PZ50M) Lights Battery

Check for slight free play. Lubricate shaft with specified grease as required. Check oil level. Replace. Check deflection. Adjust if necessary. Check for wear and damage. Replace if necessary. Check operation. Adjust toe-out if necessary. Check for damage. Replace if necessary. Check operation. Replace bulbs if necessary. Check condition. Charge if necessary. Check engagement and shift speed. Adjust if necessary.

Initial at 500 km (300 mi) and every 800 km (500 mi) thereafter.

Whenever operating elevation is changed.

Primary and secondary clutches

Inspect sheaves for wear/damage. Inspect weights/rollers and bushings for wear-for primary. Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary. Lubricate with specified grease. Lubricate with specified grease. Lubricate with specified grease.

Steering column bearing Ski and front suspension

It is recommended that these items be serviced by a Yamaha dealer.

2-2

GENERAL MAINTENANCE AND LUBRICATION CHART

Pre-operation check (Daily)

INSP ADJ
Initial 1 month or 800 km (500 mi) (40 hr) Every Seasonally or 4,000 km (2,500 mi) (200 hr)

Item

Remarks

Suspension component

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 Fittings and fasteners Tool kit and recommended equipment Make sure that the shroud and covers are securely fastened. Check tightness. Repair if necessary. Check for proper placement.

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. Replace the oil seals of the master cylinder and caliper cylinder every two years. Replace the brake hose every four years, or if cracked or damaged.

2-3

SPARK PLUGS/FUEL LINE INSPECTION ENGINE

SPARK PLUGS

INSP ADJ

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. Use a wire thickness gauge. Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) If necessary, clean the spark plugs with a spark plug cleaner. Standard spark plug: NGK R CR9EKB (NGK) Before installing a spark plug, clean the gasket surface and spark plug surface. 5. Install: Spark plugs Spark plug: 13 Nm (1.3 m kg, 9.4 ft lb)

NOTE:
Finger-tighten a the spark plug before torquing b it to specification.

FUEL LINE INSPECTION

1. Remove: Headlight assembly (PZ50/PZ50GT/PZ50FX/ PZ50M) Refer to COWLINGS in CHAPTER 3. 2. Inspect: Fuel hose 1 Fuel return hose Cracks/damage Replace.

T.

R.

2-4

COOLING SYSTEM
COOLING SYSTEM
Coolant replacement

INSP ADJ

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

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. When the engine has cooled, place a thick rag or a towel over the coolant filler cap. Slowly turn the cap counterclockwise until it stop. This allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise to remove it.

4. Place an open container under the radiator outlet hose 1. 5. Disconnect: Radiator outlet hose 1 1 6. Drain the coolant.

NOTE:
Lift up the tail of the machine to drain the coolant.

WARNING
Coolant is poisonous. It is harmful or fatal if swallowed. If coolant is swallowed, induce vomiting immediately and get immediate medical attention. If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. If coolant splashes on your skin or clothes, quickly wash it away with soap and water.

2-5

COOLING SYSTEM
7. Connect: Radiator outlet hose 1 8. Fill: Cooling system

INSP ADJ

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. Do not use water containing impurities or oil. 9. Bleed the air from the cooling system.

2 1

10. Inspect: Cooling system Decrease of pressure (leaks) Repair as required. Inspection steps: Attach the cooling system tester 1 and adapter 2 to the coolant filler 3.

Cooling system tester: 90890-01325, YU-24460-01 Adapter: 90890-01352, YU-33984 Apply 100 kPa (1.0 kg/cm2, 14 psi). Measure the pressure with the gauge.

2-6

COOLING SYSTEM/VALVE CLEARANCE ADJUSTMENT

1

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). The heat exchanger will be warm to the touch.

WARNING
To avoid severe injury or death: Make sure the machine is securely supported with a suitable stand. Do not exceed 3,500 r/min. Drive line damage and excessive V-belt wear could occur, or the machine could unexpectedly move forward if the clutch engages. Operate the engine only in a well-ventilated area.

Remove the coolant filler cap and bleed the cooling system again, as described above. No air bubbles OK. Pour coolant into the coolant reservoir 2 until the coolant level reaches the COLD LEVEL mark b.

VALVE CLEARANCE ADJUSTMENT NOTE:

Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at the top dead center (TDC) on the compression stroke. 1. Drain: Engine oil Refer to ENGINE OIL REPLACEMENT. 2. 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) Oil tank Refer to A.C. MAGNETO ROTOR AND STARTER CLUTCH in CHAPTER 5.
2-7

VALVE CLEARANCE ADJUSTMENT

INSP ADJ

1 2

3. Remove: Cylinder head cover Refer to CAMSHAFTS in CHAPTER 5. Timing mark accessing screw 1 Crankshaft end accessing screw 2 4. Measure: Valve clearance Out of specification Adjust. Valve clearance (cold): Intake valve: 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Exhaust valve: 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Checking steps: 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 mark b on the A.C. magneto cover.

NOTE:
TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. Measure the valve clearance with a thickness gauge 1.

NOTE:
If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 #2

Turn the crankshaft 180 counterclockwise and check the valve clearance of piston #2.
Front

2-8

VALVE CLEARANCE ADJUSTMENT

5. Remove: Intake camshaft Exhaust camshaft

INSP ADJ

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. Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. Select the proper valve pad from the following table. Valve pad thickness range Nos. 120 ~ 240 1.20 ~ 2.40 mm (0.047 ~ 0.094 in) Available valve pads 25 thicknesses in 0.05 mm (0.0020 in) increments

NOTE:
The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original. Round off the original valve pad number according to the following table. Last digit 0 or 2 5 8 Rounded value 0 5 10

2-9

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.

2-10

VALVE CLEARANCE ADJUSTMENT

VALVE PAD SELECTION TABLE INTAKE
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 ~ 1.40
Measured clearance

INSP ADJ

INSTALLED PAD NUMBER

120 125 130 135 120 120 125 120 125 130 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 125 130 135 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 130 135 140 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 150 135 140 145 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 155 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 160 145 150 155 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 165 150 155 160 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 170 155 160 165 175 180 185 190 195 200 205 210 215 220 225 230 235 240 175 180 185 160 165 170 165 170 175 170 175 180 Specification 180 185 190 185 190 195 190 195 200 195 200 205 200 205 210 205 210 215 210 215 220 215 220 225 220 225 230 225 230 235 230 235 240 235 240 240 190 175 180 185 195 200 205 210 215 220 225 230 235 240 195 180 185 190 200 205 210 215 220 225 230 235 240 200 185 190 195 205 210 215 220 225 230 235 240 205 190 195 200 210 215 220 225 230 235 240 210 195 200 205 215 220 225 230 235 240 215 200 205 210 220 225 230 235 240 220 205 210 215 225 210 215 220 230 215 220 225 235 220 225 230 240 225 230 235

exa

225 230 235 240 230 235 240 235 240 240

EXAMPLE: VALVE CLEARANCE: 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Installed is 175 Measured clearance is 0.27 mm (0.0106 in) Replace 175 pad with 185 pad

EXHAUST
0.00 ~ 0.02 0.03 ~ 0.07 0.08 ~ 0.12 0.13 ~ 0.17 0.18 ~ 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 ~ 1.40 1.41 ~ 1.45
Measured clearance

INSTALLED PAD NUMBER

120 125 130 135 140 145 120 120 125 120 125 130 120 125 130 135 120 125 130 135 140 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 150 125 130 135 140 145 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 155 130 135 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 160 135 140 145 150 155 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 165 140 145 150 155 160 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 170 145 150 155 160 165 175 180 185 190 195 200 205 210 215 220 225 230 235 240 175 180 185 150 155 160 155 160 165 160 165 170 165 170 175 170 175 180 Specification 180 185 190 185 190 195 190 195 200 195 200 205 200 205 210 205 210 215 210 215 220 215 220 225 220 225 230 225 230 235 230 235 240 235 240 240 190 165 170 175 180 185 195 200 205 210 215 220 225 230 235 240 195 170 175 180 185 190 200 205 210 215 220 225 230 235 240 200 175 180 185 190 195 205 210 215 220 225 230 235 240 205 180 185 190 195 200 210 215 220 225 230 235 240 210 185 190 195 200 205 215 220 225 230 235 240 215 190 195 200 205 210 220 225 230 235 240 220 195 200 205 210 215 225 200 205 210 215 220 230 205 210 215 220 225 235 210 215 220 225 230 240 215 220 225 230 235

exa

225 230 235 240 230 235 240 235 240 240

EXAMPLE: VALVE CLEARANCE: 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Installed is 175 Measured clearance is 0.35 mm (0.0138 in) Replace 175 pad with 185 pad

2-11

VALVE CLEARANCE ADJUSTMENT

INSP ADJ

Install the new valve pad 1 and the valve lifter 2.

NOTE:

2 1

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. Install the exhaust and intake camshafts, timing chain and camshaft caps. Camshaft cap bolt: 9 Nm (0.9 m kg, 6.5 ft lb)

NOTE:
Refer to CAMSHAFTS in CHAPTER 5. Lubricate the camshaft caps, camshaft lobes, camshaft journals and camshaft cap bolts. Align the camshaft marks with the camshaft cap marks. Rotate the crankshaft counterclockwise several turns to seat the parts. Measure the valve clearance again. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 7. Install: Crankshaft end accessing screw Timing mark accessing screw 8. Install: Cylinder head cover Refer to CAMSHAFTS in CHAPTER 5. 9. Install: All removed parts

NOTE:
For installation, reverse the removal procedure. Note the following points.

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2-12

THROTTLE BODY SYNCHRONIZATION

NOTE:

INSP ADJ

THROTTLE BODY SYNCHRONIZATION

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

3. Install: Vacuum gauge 1

Vacuum gauge: 90890-03094, YU-44456 4. Install: Air filter case Refer to COWLINGS in CHAPTER 3. 5. Start the engine and let it warm up for several minutes. 6. Inspect: Engine idle speed Out of specification Adjust. Refer to ENGINE IDLE SPEED ADJUSTMENT. Engine idle speed: 1,700 ~ 1,900 r/min 7. Adjust: Throttle body synchronization

2-13

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. Vacuum pressure at engine idling speed: 20.27 ~ 22.93 kPa (0.20 ~ 0.23 kg/cm2, 2.88 ~ 3.26 psi)

NOTE:
The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (0.01 kg/cm2, 0.19 psi). 8. Measure: Engine idle speed Out of specification Adjust. Make sure that the vacuum pressure is within specification. 9. Stop the engine and remove the measuring equipment. 10. Adjust: Throttle cable free play Refer to THROTTLE CABLE FREE PLAY ADJUSTMENT.

ENGINE IDLE SPEED ADJUSTMENT NOTE:

Prior to adjusting the engine idling speed, the throttle body synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Measure: Engine idle speed Out of specification Adjust. Engine idle speed: 1,700 ~ 1,900 r/min

2-14

ENGINE IDLE SPEED ADJUSTMENT/ THROTTLE CABLE FREE PLAY ADJUSTMENT

3. Adjust: Engine idle speed

INSP ADJ

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.

NOTE:
After adjusting the engine idle speed, the throttle cable free play should be adjusted.

THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE:

Before adjusting the throttle cable free play, the engine idle speed should be adjusted. Adjust the throttle cable free play while the cable is in the cable guide.

1. Measure: Throttle cable free play a Out of specification Adjust. Throttle cable free play: 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) 2. Adjust: Throttle cable free play

2 1

Throttle body side adjustment steps: Remove the air filter case. Refer to COWLINGS in CHAPTER 3. Loosen the locknut 1. Turn the adjusting nut 2 in or out until the specified free play is obtained. Turning in Free play is increased. Turning out Free play is decreased.

2-15

THROTTLE CABLE FREE PLAY ADJUSTMENT/ THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK
Tighten the locknut.

INSP ADJ

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)

2 1

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. Turning in Free play is increased. Turning out Free play is decreased.

NOTE:
After adjusting the free play, turn the handlebar to right and left, and make sure that the engine idling does not run faster.

THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK

WARNING
When checking T.O.R.S.: Be sure the parking brake is applied. Be sure the throttle lever moves smoothly. Do not run the engine up to the clutch engagement speed. Otherwise, the machine could start moving forward unexpectedly, which could cause an accident. 1. Start the engine. 2. Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb (above) and forefinger (below) between the throttle lever pivot 1 and stop switch housing 2. While holding as described above, press the throttle lever 3 gradually. The T.O.R.S. will operate and the engine should run between 2,800 and 3,000 r/min.
2-16

THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK/ COMPRESSION PRESSURE MEASUREMENT

WARNING

INSP ADJ

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. Start the engine, warm it up for several minutes, and then turn it off. 3. 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) 4. Remove: Spark plug

CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders.

5. Install: Compression gauge 1

Compression gauge: 90890-03081, YU-33223

2-17

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 Higher than without oil Diagnosis Piston ring(-s) wear or damage Repair. Piston, valves, cylinder head gasket or piston possibly defective Repair. Compression pressure (at sea level)

Same as without oil

Compression pressure (at sea level): Standard: 1,450 kPa (14.5 kg/cm2, 206 psi) at 400 r/min Minimum: 1,260 kPa (12.6 kg/cm2, 179 psi) at 400 r/min Maximum: 1,620 kPa (16.2 kg/cm2, 230 psi) at 400 r/min Measurement steps: Turn the main switch to START. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

WARNING
To prevent sparking, ground all ignition coil leads before cranking the engine.

NOTE:
The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm2, 14.2 psi). 7. Install: Spark plug Spark plug: 13 Nm (1.3 m kg, 9.4 ft lb)

T.

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2-18

ENGINE OIL LEVEL INSPECTION

1. Inspect: Engine oil level

INSP ADJ

ENGINE OIL LEVEL INSPECTION

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. Disconnect the oil level switch coupler 1.

CAUTION:
Disconnect the oil level switch coupler before removing the oil level gauge. Otherwise the lead can twist and become severed. Remove the oil level gauge/dipstick 2, wipe it clean, insert it back into the filler hole (without screwing it in), and then remove it again to check the oil level. The engine oil level should be between the maximum level mark H a and minimum level mark L b. Below the minimum level mark Add the recommended engine oil to the proper level.

CAUTION:
When adding the engine oil, be careful not to fill above the maximum level mark and minimum level mark on the oil level gauge. Recommended oil: Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard: API SE, SF, SG or higher SAE 0W-30

CAUTION:
Do not allow foreign materials to enter the crankcase.

NOTE:
Before checking the engine oil level, wait a few minutes until the oil has settled.

2-19

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. In addition, do not use oils labeled ENERGY CONSERVING II or higher.

ENGINE OIL REPLACEMENT

1. Place the snowmobile on a level surface and apply the parking brake. 2. Start the engine, warm up for several minutes, and then turn it off. 3. Place a containers under the engine oil pan and oil tank.

4. Remove: Bottom panel 1 5. Remove: Left side panel Right side cover Right lower cover Refer to COWLINGS in CHAPTER 3. 6. Disconnect: Oil level gauge coupler Refer to ENGINE OIL LEVEL INSPECTION. 7. Remove: Oil level gauge/dipstick Refer to ENGINE OIL LEVEL INSPECTION.

2-20

ENGINE OIL REPLACEMENT

8. Remove: Cylinder head cap 1

INSP ADJ

9. Remove: Oil pan engine oil drain bolt 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 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. Oil filter wrench: 90890-01469, YM-01469

2-21

ENGINE OIL REPLACEMENT

INSP ADJ

Apply a thin coat of engine oil onto the O-ring 4 of the new oil filter cartridge.

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. Oil filter cartridge: 17 Nm (1.7 m kg, 12 ft lb)

Tighten the oil cooler bolts to specification. Oil cooler bolt: 10 Nm (1.0 m kg, 7.2 ft lb) LOCTITE

13. Install: Drain bolts (along with the new gaskets) Oil tank engine oil drain bolt: 16 Nm (1.6 m kg, 11 ft lb) Oil pan engine oil drain bolt: 30 Nm (3.0 m kg, 22 ft lb)

14. Fill: Engine oil (with the specified amount of the recommended engine oil) Add 1.5 L (1.3 Imp qt, 1.6 US qt) of the recommended engine oil to the oil tank, and then install and tighten the oil level gauge/dipstick and the cylinder head cap. Quantity: Total amount: 3.00 L (2.64 Imp qt, 3.17 US qt) Periodic oil change: 2.45 L (2.16 Imp qt, 2.59 US qt) With oil filter replacement: 2.63 L (2.31 Imp qt, 2.78 US qt) 15. Inspect: Engine and oil tank (for engine oil leaks) 16. Inspect: Engine oil level Refer to ENGINE OIL LEVEL INSPECTION.

T.

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T.

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T.

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2-22

ENGINE OIL REPLACEMENT/CYLINDER HEAD BREATHER HOSE INSPECTION/THROTTLE BODY JOINTS INSPECTION
17. Inspect: Engine oil pressure

INSP ADJ

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. (PZ50VT/PZ50MP) Start the engine and keep it idling until engine oil starts to seep from the oil check bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. Check the engine oil passages, the oil filter and the oil pump for damage or leakage. Start the engine after solving the problem(-s) and check the engine oil pressure again. Tighten the oil check bolt to specification. Oil check bolt: 10 Nm (1.0 m kg, 7.2 ft lb)

CYLINDER HEAD BREATHER HOSE INSPECTION

1. Inspect: Cylinder head breather hose 1 Cracks/damage Replace. Loosen connection Connect properly.

CAUTION:
Make sure that the cylinder head breather hose is routed correctly.

THROTTLE BODY JOINTS INSPECTION

1. Remove: Air filter case Refer to COWLINGS in CHAPTER 3. 2. Inspect: Throttle body joints 1 Cracks/damage Replace. Refer to THROTTLE BODY in CHAPTER 7.

T.

R.

2-23

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. Install: Air filter element Air filter case cover

2-24

EXHAUST SYSTEM INSPECTION

B

INSP ADJ

EXHAUST SYSTEM INSPECTION

9 1 7

3 1 A 5 A 0 2 6 5 6 4 C

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. Inspect: Tightening torque Exhaust pipe joint bolt 9: 25 Nm (2.5 m kg, 18 ft lb) Exhaust pipe/muffler bolt 0: 33 Nm (3.3 m kg, 24 ft lb) Muffler damper holder bolt A: 10 Nm (1.0 m kg, 7.2 ft lb) Exhaust pipe band bolt B: 18 Nm (1.8 m kg, 13 ft lb) Muffler end cover bolt C: 10 Nm (1.0 m kg, 7.2 ft lb) LOCTITE

4. Install: 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)

T.

R.

2-25

SHEAVE OFFSET ADJUSTMENT POWER TRAIN

INSP ADJ

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. Adjust: Sheave offset

2 1 3

Adjustment steps: Apply the brake to lock the secondary sheave. Remove the secondary sheave bolt 1, washer 2, shim(s) (left), and secondary sheave 3. Install the appropriate shim(s) (right) 4 from the following table so that the sheave offset is within specification. Shim size Part number 90201-252F1 90201-25527 Thickness 0.5 mm (0.02 in) 1.0 mm (0.04 in)

2-26

SHEAVE OFFSET ADJUSTMENT

Install the secondary sheave bolt and washer.

INSP ADJ
sheave, secondary

Secondary sheave bolt: 60 Nm (6.0 m kg, 43 ft lb)

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 (0.04 ~ 0.08 in)

T.

R.

3 2 1

6. Adjust: Secondary sheave free play (clearance) Adjustment steps: Apply the brake to lock the secondary sheave. Remove the secondary sheave bolt 1 and washer 2. Install the appropriate shim(s) (left) 3 from the following table so that the secondary sheave free play is within specification. Shim size Part number 90201-252F1 90201-25527 Thickness 0.5 mm (0.02 in) 1.0 mm (0.04 in)

2-27

DRIVE V-BELT
DRIVE V-BELT

INSP ADJ

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. Oil or grease on the V-belt Check the primary and secondary sheaves.

2. Inspect: Primary sheave Secondary sheave Oil or grease on the primary and secondary sheaves Use a rag soaked in lacquer thinner or solvent to remove the oil or grease. Check the primary and secondary sheaves.

3. Measure: Drive V-belt circumference a Out of specification Replace. V-belt circumference: 1,132 ~ 1,138 mm (44.6 ~ 44.8 in)

2-28

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. Engagement speed: PZ50/PZ50GT/PZ50FX: 3,700 ~ 4,100 r/min PZ50M USA/Canada: 4,100 ~ 4,500 r/min PZ50M Europe: 3,900 ~ 4,300 r/min PZ50VT USA/Canada: 3,300 ~ 3,700 r/min PZ50VT Europe/PZ50MP: 2,900 ~ 3,300 r/min

PARKING BRAKE ADJUSTMENT

1. Remove: Right side cover Refer to COWLINGS in CHAPTER 3. 2. Measure: Parking brake cable distance Out of specification Adjust. Parking brake cable distance: 43.5 ~ 46.5 mm (1.713 ~ 1.831 in)

2-29

PARKING BRAKE ADJUSTMENT/ BRAKE FLUID LEVEL INSPECTION

3. Adjust: Parking brake cable

INSP ADJ

2
a 1
Adjustment steps: Loosen the locknut 1. Turn the adjuster 2 in or out until the specified distance a is obtained. 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. Adjust: Brake pad clearance Adjustment steps: Loosen the locknut 1. Turn the adjuster 2 in or out until the specified clearance between the brake pad 3 and brake disc 4 is obtained. Tighten the locknut.

2 1
BRAKE FLUID LEVEL INSPECTION
1. Place the machine on a level surface. 2. Check: Fluid level Fluid level is under the lower level line a Fill to the proper level. Recommended brake fluid: DOT 4

2-30

BRAKE FLUID LEVEL INSPECTION/ BRAKE PAD INSPECTION

NOTE:

INSP ADJ

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. Mixing fluids may result in a harmful chemical reaction leading to poor brake performance. When refilling, be careful that water does not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the fluid and may cause vapor lock.

BRAKE PAD INSPECTION

1. Remove: Right side cover Refer to COWLINGS in CHAPTER 3. 2. Apply the brake lever. 3. Inspect: Brake pad wear a Wear indicator 1 nearly contacts the brake disc Replace as a set. Wear limit: 4.7 mm (0.19 in)

2-31

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. If the brake system is not properly bled a loss of braking performance may occur. 1. Remove: Right side cover Refer to COWLINGS in CHAPTER 3. 2. Bleed: Brake system Air bleeding steps: a. Fill the brake master cylinder reservoir with the proper brake fluid. b. Install the diaphragm. Be careful not to spill any fluid or allow the brake master cylinder reservoir to overflow. c. Connect clear plastic hose 1 tightly to the brake caliper bleed screw 2. d. Place the other end of the hose in a container. e. Slowly apply the brake lever several times. f. Pull the lever in, then hold the lever in position. g. Loosen the bleed screw and allow the brake lever to travel towards its limit. h. Tighten the bleed screw when the brake lever limit has been reached, then release the lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the fluid.

2 1

2-32

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ DRIVE CHAIN

j. Tighten the bleed screw.

INSP ADJ

Bleed screw: 6 Nm (0.6 m kg, 4.3 ft lb)

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
Oil level inspection

WARNING
The engine and muffler will be very hot after the engine has run. Avoid touching a hot engine and muffler while they are still hot with any part of your body or clothing during inspection or repair. 1. Remove: Right side cover Refer to COWLINGS in CHAPTER 3. 2. Place the machine on a level surface. 3. Check: Oil level Checking steps: Remove the dipstick 1 and wipe it off with a clean rag. The put the dipstick in the hole.

T.

R.

CAUTION:
There is a magnet attached to the end of the dipstick. It is used to remove any metal particles that may accumulate in the drive chain housing. Be sure to: Pull the dipstick out slowly and gently so the metal particles do not fall off the magnet back into the drive chain housing. Wipe off the magnet before reinserting the dipstick into the drive chain housing.
2-33

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.

b 1

NOTE:
Align the notch a of the dipstick handle with the projection b of the drive chain housing.

Oil replacement Oil replacement steps: Place the oil pan under the drain hole. Remove the right lower cover. Refer to COWLINGS in CHAPTER 3. Remove the oil drain bolt (along with the gasket) 1 and drain the oil.

CAUTION:
1
Be sure to remove any oil from the heat protector. Install the new gasket and oil drain bolt 1. Oil drain bolt: 16 Nm (1.6 m kg, 11 ft lb) Recommended oil: Gear oil GL-3 75W or 80W Oil capacity: 0.25 L (0.22 Imp qt, 0.26 US qt)
2-34

T.

R.

DRIVE CHAIN/TRACK TENSION ADJUSTMENT

Chain slack adjustment 1. Adjust: Drive chain slack

INSP ADJ

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. Drive chain adjusting locknut: 25 Nm (2.5 m kg, 18 ft lb)

TRACK TENSION ADJUSTMENT

WARNING
A broken track or track fittings, and debris thrown by the track could be dangerous to an operator or bystanders. Observe the following precautions. Do not allow anyone to stand behind the machine when the engine is running. When the rear of the machine is raised to allow the track to spin, a suitable stand must be used to support the rear of the machine. Never allow anyone to hold the rear of the machine off the ground to allow the track to spin. Never allow anyone near a rotating track. Inspect the condition of the track frequently. Replace the track if it is damaged to a level where the fabric reinforcement material is visible. 1. Lift the rear of the machine onto a suitable stand to raise the track off the ground. 2. Measure: Track deflection a Using a spring scale 1, pull down on the center of the track with 100 N (10 kg, 22 lb) of force. Out of specification Adjust. Track deflection: 30 ~ 35 mm (1.18 ~ 1.38 in)
2-35

T.

R.

TRACK TENSION ADJUSTMENT

3. Adjust: Track deflection

INSP ADJ

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. Track alignment 3 Left adjuster 4 Right adjuster
5 6 7 a Slide runner Track Track metal Gap Forward

Shifted to right Turn out Turn in

Shifted to left Turn in Turn out

e. Adjust the track deflection until the specified amount is obtained. Track deflection 3 Left adjuster 4 Right adjuster More than specified Turn in Turn in Less than specified Turn out Turn out

CAUTION:
The adjusters should be turned an equal amount. f. Recheck the alignment and deflection. If necessary, repeat steps (c) to (e) until the specified amount is obtained. g. Tighten the rear axle nut. Rear axle nut: 75 Nm (7.5 m kg, 54 ft lb)

T.

R.

2-36

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. (See pages 2-35 ~ 2-36 for adjustment procedures.) A loose track can slip (ratchet), derail or catch on suspension parts causing severe damage. Do not overtighten the drive track, otherwise it may increase the friction between the track and the slide runners, resulting in the rapid wear of both components. Also, this may put an excessive load on the suspension components, resulting in component failure. Marginal snow The drive track and the slide runners are lubricated and cooled by snow and water. To prevent the drive track and slide runners from overheating, avoid sustained high-speed usage in areas such as icy trails, frozen lakes and rivers that have minimal snow coverage. An overheated track will be weakened internally, which may cause failure or damage.

2-37

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. Drilling stud holes into the drive track will cut the internal fibers, which weakens the track. Avoid spinning the drive track. Studs may catch on an object and pull out of the track, leaving tears and damage around the already weakened area. To minimize possible damage, consult your stud manufacturer for installation and stud pattern recommendations. Yamaha does not recommend track studding.

2-38

SKI/SKI RUNNER/STEERING SYSTEM CHASSIS

SKI/SKI RUNNER

INSP ADJ

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 (0.95 in)

CAUTION:
To avoid scratching, wearing and damaging the plastic skis, be careful when loading and unloading the snowmobile and avoid riding in areas with little or no snow and on surfaces with sharp edges such as concrete, curbs, etc.

STEERING SYSTEM
Free play check 1. Check: Steering system free play Move the handlebar up and down and back and forth. Turn the handlebar slightly to the right and left. Excessive free play Check that the handlebar, tie rod ends and relay rod ends are installed securely in position. If free play still exists, check the steering bearing, front suspension links and ski mounting area for wear. Replace if necessary.

2-39

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
Adjustment steps: Remove the air filter case assembly. Refer to COWLINGS in CHAPTER 3. Loosen the locknuts (tie-rods) 1. Turn the tie rods 2 in or out until the specified toe-out is obtained. Tighten the locknuts (tie-rods) 1. Tie-rod end locknut: 25 Nm (2.5 m kg, 18 ft lb) LOCTITE

1
LT

1
LT

CAUTION:
After tightening the inside and outside ball joint locknuts 1, make sure the tie rods 2 can be rotated freely through the ball joint travel. If not, loosen the locknuts 1 and reposition the ball joint so that the tie rods 2 can be rotated freely. Tighten the locknuts to specification.

T.

R.

2-40

LUBRICATION
LUBRICATION

INSP ADJ

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. Recommended lubricant: ESSO Beacon 325 Grease or Aeroshell Grease #7A
1 2 PZ50/PZ50GT/PZ50FX/PZ50M PZ50VT/PZ50MP Nipple Nipple (both sides)

1
2-41

HEADLIGHT BEAM ADJUSTMENT/BATTERY INSPECTION ELECTRICAL

INSP ADJ

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. Switch on the headlights high beam and check the height of the projected beam on the wall. The projection should be at the position marked in step 3 or 1/2 lower (set range S). D S 3.0 m (10 ft) 26 mm (1.0 in)
H: Height

7.6 m (25 ft) 66 mm (2.6 in)

S: Set range

D: Distance

6. Adjust: Headlight beam Adjustment steps: Turn the headlight beam adjuster 1 in or out to adjust the headlight beams.
Headlight beam movement: a Down and to the left b Up and to the right c Down and to the right d Up and to the left

BATTERY INSPECTION

WARNING
Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.

2-42

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. Charging time, charging amperage and charging voltage for a MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.

NOTE:
Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: Right side cover Refer to COWLINGS in CHAPTER 3.

2 1

2. Disconnect: Battery leads (from the battery terminals)

CAUTION:
First, disconnect the negative battery lead 1, then the positive battery lead 2. 3. Remove: Battery
2-43

BATTERY INSPECTION
4. Inspect: Battery charge

INSP ADJ

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. Check the charge of the battery, as shown in the charts and the following example. Example Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20 ~ 30%

2-44

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. If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. When charging a battery, be sure to remove it from the snowmobile. (If charging has to be done with the battery mounted on the snowmobile, disconnect the negative lead from the battery terminal.) To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! As shown in the following illustration, the open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

2-45

BATTERY INSPECTION
Charging method using a variable voltage charger
Charger AMP meter

INSP ADJ

Measure the open-circuit voltage prior to charging.

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. If too high, the battery will be overcharged.)

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.

NO

By turning the charging voltage adjust dial, set the charging voltage at 20 ~ 24 V.

Adjust the voltage so that the current is at the standard charging level.

YES

Monitor the amperage for 3 ~ 5 minutes to check if the standard charging current is reached. NO

Set the time according to the charging time suitable for the open-circuit voltage. Refer to BATTERY INSPECTION.

If the current does not exceed the standard charging current after 5 minutes, replace the battery.

If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current.

Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.

2-46

BATTERY INSPECTION
Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging.

INSP ADJ

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.

NO

Charge the battery until the batterys charging voltage is 15 V.

NOTE: Set the charging time at 20 hours (maximum).

This type of battery charger cannot charge the MF battery. A variable voltage charger is recommended.

Charger

Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.

APM meter Volt meter

2-47

BATTERY INSPECTION/FUSE INSPECTION

1
6. Install: Battery 7. Connect: Battery leads (to the battery terminals)

INSP ADJ

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.

CAUTION:
To avoid a short circuit, always set the main switch to OFF when checking or replacing a fuse. 1. Remove: Right side cover Refer to COWLINGS in CHAPTER 3. 2. Inspect: Continuity Inspection steps: Connect the pocket tester to the fuse and check the continuity.

NOTE:
Set the pocket tester selector to 1. Pocket tester: 90890-03112, YU-03112-C If the pocket tester indicates , replace the fuse.

2-48

FUSE INSPECTION
3. Replace: Blown fuse

INSP ADJ

9 1
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. Item 1 Main fuse 2 Fuel injection system fuse 3 Headlight fuse 4 Signal fuse 5 Auxiliary DC jack fuse*1 6 Ignition fuse Amperage 40 A 10 A 20 A 7.5 A 3A 20 A 15 A 4A 20 A 15 A*1 10 A 7.5 A 4 A*1 3 A*1 Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1

9 7 6 5 4 3

9 7 6 5 4 3 9

7 Radiator fan motor fuse*1

8 Gear motor fuse*1 9 Reserve fuse

*1:

PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP

WARNING
Never use a fuse with an amperage other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting, ignition, grip warmer, signal and meter systems to malfunction and could possibly cause a fire.

2-49

CLUTCH TUNING
CLUTCH
High altitude Specifications
Elevation Engine idle speed Engagement r/min Shift r/min Secondary reduction ratio (number of links) Primary sheave spring Color Free length Preload Spring rate Wire diameter Outside diameter Weight (ID)

INSP ADJ
P Pink

L Blue R Red Model: PZ50/PZ50FX

~ 800 m (~ 2,500 ft) 1,800 100 r/min Approx. 3,900 r/min Approx. 11,300 r/min 18/41 (80 L) 600 ~ 1,400 m (2,000 ~ 4,500 ft) Steel 10.3 (OUT) Steel 10.3 (CENTER) Steel 10.3 (IN) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) Steel 10.3 (OUT) Steel 10.3 (CENTER) Aluminum 10.3 (IN) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 17/41 (80 L) Steel 10.3 (OUT) Aluminum 10.3 (CENTER) Aluminum 10.3 (IN)

2,400 ~ 3,000 m (8,000 ~ 10,000 ft) Approx. 4,000 r/min Aluminum 10.3 (OUT) Aluminum 10.3 (CENTER) None (IN)

90501-606G9 P-L-P 72.1 mm (2.84 in) 196 N (20 kg, 44 lb) 29.4 N/mm (3.0 kg/mm, 168 lb/in) 6.0 mm (0.236 in) 60.0 mm (2.36 in) 8GC-17605-00 (8GC00) Steel 13.3 (OUT) Steel 10.3 (CENTER) Steel 10.3 (IN) VESPEL TP-8549 15.6 mm (0.614 in) VESPEL TP-8549 None 90508-55007 R 85 mm (3.35 in) 45 (A-1) 931 kgmm/rad 5.5 mm (0.217 in) 66.0 mm (2.60 in) 39 1.0 mm (0.039 in) 2

Weight rivet

Weight bushing Roller outer dia. Roller bushing Pri. clutch shim Secondary sheave spring Color Free length Preload rate Wire diameter Outside diameter Sec. torque cam angle Sec. clutch shim

2-50

CLUTCH
L Blue R Red Specifications
Elevation Engine idle speed Engagement r/min Shift r/min Secondary reduction ratio (number of links) Primary sheave spring Color Free length Preload Spring rate Wire diameter Outside diameter Weight (ID)

INSP ADJ
P Pink

Model: PZ50GT
~ 800 m (~ 2,500 ft) 1,800 100 r/min Approx. 3,900 r/min Approx. 11,300 r/min 20/41 (80 L) 600 ~ 1,400 m (2,000 ~ 4,500 ft) Steel 10.3 (OUT) Steel 10.3 (CENTER) Steel 10.3 (IN) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 19/41 (80 L) Steel 10.3 (OUT) Steel 10.3 (CENTER) Aluminum 10.3 (IN) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 18/41 (80 L) Steel 10.3 (OUT) Aluminum 10.3 (CENTER) Aluminum 10.3 (IN) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) Approx. 4,000 r/min Aluminum 10.3 (OUT) Aluminum 10.3 (CENTER) None (IN)

90501-606G9 P-L-P 72.1 mm (2.84 in) 196 N (20 kg, 44 lb) 29.4 N/mm (3.0 kg/mm, 168 lb/in) 6.0 mm (0.236 in) 60.0 mm (2.36 in) 8GC-17605-00 (8GC00) Steel 13.3 (OUT) Steel 10.3 (CENTER) Steel 10.3 (IN) VESPEL TP-8549 15.6 mm (0.614 in) VESPEL TP-8549 None 90508-55007 R 85 mm (3.35 in) 45 (A-1) 931 kgmm/rad 5.5 mm (0.217 in) 66.0 mm (2.60 in) 39 1.0 mm (0.039 in) 2

Weight rivet

Weight bushing Roller outer dia. Roller bushing Pri. clutch shim Secondary sheave spring Color Free length Preload rate Wire diameter Outside diameter Sec. torque cam angle Sec. clutch shim

2-51

CLUTCH
G Green Y Yellow Specifications
Elevation Engine idle speed Engagement r/min Shift r/min Secondary reduction ratio (number of links) Primary sheave spring Color Free length Preload Spring rate Wire diameter Outside diameter Weight (ID) Weight rivet Weight bushing Roller outer dia. Roller bushing Pri. clutch shim Secondary sheave spring Color Free length Preload rate Wire diameter Outside diameter Sec. torque cam angle Sec. clutch shim

INSP ADJ
R Red

Model: PZ50M
~ 800 m (~ 2,500 ft) 1,800 100 r/min Approx. 4,100 r/min Approx. 11,300 r/min 19/41 (80 L) 600 ~ 1,400 m (2,000 ~ 4,500 ft) Steel 13.3 (OUT) Steel 13.9 (IN) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 18/41 (80 L) Steel 13.3 (OUT) Steel 13.3 (IN) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) Approx. 4,300 r/min 17/41 (80 L) Steel 10.3 (OUT) Steel 10.3 (IN) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) Steel 10.3 (OUT) None (IN)

90501-605G7 G-Y-G 74.1 mm (2.92 in) 245 N (25 kg, 55 lb) 27.0 N/mm (2.75 kg/mm, 154 lb/in) 6.0 mm (0.236 in) 60.0 mm (2.36 in) 8DN-17605-30 (8DN10) Steel 13.9 (OUT) Steel 13.9 (IN) VESPEL TP-8549 15.0 mm (0.591 in) VESPEL TP-8549 None 90508-55007 R 85 mm (3.35 in) 55 (B-1) 931 kgmm/rad 5.5 mm (0.217 mm) 66.0 mm (2.60 in) 37 1.0 mm (0.039 in) 2

2-52

CLUTCH
L Blue Specifications
Elevation Engine idle speed Engagement r/min Shift r/min Secondary reduction ratio (number of links) Primary sheave spring Color Free length Preload Spring rate Wire diameter Outside diameter Weight (ID)

INSP ADJ
Y Yellow

Model: PZ50VT USA/Canada

~ 800 m (~ 2,500 ft) 1,800 100 r/min Approx. 3,500 r/min Approx. 11,300 r/min 19/45 (82 L) 600 ~ 1,400 m (2,000 ~ 4,500 ft) Steel 17.2 (OUT) Steel 13.9 (CENTER) Steel 13.9 (IN) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) 18/45 (82 L) Steel 13.9 (OUT) Steel 13.9 (CENTER) Steel 13.3 (IN) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 17/45 (82 L) Steel 13.3 (OUT) Steel 13.3 (CENTER) Steel 10.3 (IN) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) Approx. 3,700 r/min Steel 10.3 (OUT) Steel 10.3 (CENTER) Aluminum 10.3 (IN)

90501-556G7 Y-L-Y 73.4 mm (2.89 in) 196 N (20 kg, 44 lb) 24.5 N/mm (2.5 kg/mm, 140 lb/in) 5.5 mm (0.217 in) 60.0 mm (2.36 in) 8GC-17605-00 (8GC00) Steel 17.2 (OUT) Steel 17.2 (CENTER) Steel 13.9 (IN) VESPEL TP-8549 14.5 mm (0.571 in) VESPEL TP-8549 None 90508-58007 L 85 mm (3.35 in) 50 (A-1) 1,030 kgmm/rad 5.8 mm (0.228 in) 66.0 mm (2.60 in) 37 1.0 mm (0.039 in) 2

Weight rivet Weight bushing Roller outer dia. Roller bushing Pri. clutch shim Secondary sheave spring Color Free length Preload rate Wire diameter Outside diameter Sec. torque cam angle Sec. clutch shim

2-53

CLUTCH
Go Gold Specifications
Elevation Engine idle speed Engagement r/min Shift r/min Secondary reduction ratio (number of links) Primary sheave spring Color Free length Preload Spring rate Wire diameter Outside diameter Weight (ID)

INSP ADJ
L Blue

Model: PZ50VT Europe/PZ50MP

~ 800 m (~ 2,500 ft) 1,800 100 r/min Approx. 3,100 r/min Approx. 11,300 r/min 18/45 (82 L) 600 ~ 1,400 m (2,000 ~ 4,500 ft) Steel 17.2 (OUT) Steel 13.9 (CENTER) Steel 13.9 (IN) 1,200 ~ 2,000 m (4,000 ~ 6,500 ft) Steel 13.9 (OUT) Steel 13.9 (CENTER) Steel 13.3 (IN) 1,800 ~ 2,600 m (6,000 ~ 8,500 ft) 17/45 (82 L) Steel 13.3 (OUT) Steel 13.3 (CENTER) Steel 10.3 (IN) 2,400 ~ 3,000 m (8,000 ~ 10,000 ft) Approx. 3,200 r/min Steel 10.3 (OUT) Steel 10.3 (CENTER) Aluminum 10.3 (IN)

90501-526G4 L-Go-L 72.9 mm (2.87 in) 147 N (15 kg, 33 lb) 19.6 N/mm (2.0 kg/mm, 112 lb/in) 5.2 mm (0.205 in) 60.0 mm (2.36 in) 8GC-17605-00 (8GC00) Steel 17.2 (OUT) Steel 17.2 (CENTER) Steel 17.2 (IN) VESPEL TP-8549 14.5 mm (0.571 in) VESPEL TP-8549 None 90508-58007 L 85 mm (3.35 in) 50 (A-1) 1,030 kgmm/rad 5.8 mm (0.228 in) 66.0 mm (2.60 in) 37 1.0 mm (0.039 in) 2

Weight rivet Weight bushing Roller outer dia. Roller bushing Pri. clutch shim Secondary sheave spring Color Free length Preload rate Wire diameter Outside diameter Sec. torque cam angle Sec. clutch shim

2-54

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. Normally, when a machine reaches shifting speed, the vehicle speed increases but the engine speed remains nearly constant. Under unfavorable conditions (wet snow, icy snow, hills, or rough terrain), however, engine speed may decrease after the shifting speed has been reached.
Engine speed Good condition Clutch shifting speed Clutch engagement speed Starting position Distance travelled 800 m (2,500 ft)

GEAR SELECTION
The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions. If there are many rough surfaces or unfavorable snow conditions, the drive/driven gear ratio should be increased. If the surfaces are fairly smooth or better snow conditions exist, decrease the ratio. Gear ratio chart The drive and driven gears and the chains shown in the gear ratio chart are available as options. The figures containing a decimal point represent the drive/driven gear ratios, while the bottom numbers designate the number of links in the chain.

2-55

GEAR SELECTION
1 Chain and sprocket part number Parts name Teeth & links 17 teeth 18 teeth Drive sprocket 19 teeth 20 teeth 40 teeth Driven sprocket 41 teeth 45 teeth 46 teeth Chain 2 Gear ratio Drive gear Driven gear 40 teeth 41 teeth 45 teeth 46 teeth 3 Secondary sheave spring
Part No. 90508-50571 90508-50746 90508-55012 90508-55007 90508-58007 90508-60015 Spring rate N mm/rad (kg mm/rad) 7071 (721) 7071 (721) 8125 (829) 9131 (931) 10098 (1030) 11603 (1183) Preload N/mm (kg/mm, lb/in) 8.7 (0.89, 49.84) 8.7 (0.89, 49.84) 9.0 (0.92, 51.52) 10.6 (1.08, 60.48) 11.3 (1.16, 64.96) 13.1 (1.34, 75.04) Color Pink White Brown Red Blue Yellow Free length Wire gauge No. of coils mm (in) mm (in) 5.0 (0.197) 5.0 (0.197) 5.5 (0.217) 5.5 (0.217) 5.8 (0.228) 6.0 (0.236) 4.74 4.74 5.99 5.33 5.99 5.99 85 (3.35) 93.5 (3.68) 85 (3.35) 85 (3.35) 85 (3.35) 85 (3.35)

INSP ADJ
Standard

Parts no. 8GC-17682-70 8GC-17682-80 8GC-17682-90 8GC-17682-00 8GC-47587-00 8GC-47587-10 8GC-47587-50 8GC-47587-60 94591-63080 94591-63082

PZ50M USA/Canada PZ50/PZ50FX/ PZ50VT Europe/PZ50MP PZ50M Europe/ PZ50VT USA/Canada PZ50GT PZ50/PZ50GT/PZ50FX/PZ50M PZ50VT/PZ50MP PZ50/PZ50GT/PZ50FX/PZ50M PZ50VT/PZ50MP

80 links 82 links

17 teeth

18 teeth

19 teeth 2.11 80 links

20 teeth 2.00 80 links 2.05 80 links 2.25 82 links

2.41 80 links 2.65 82 links 2.71 82 links

2.28 80 links 2.50 82 links 2.56 82 links

2.16 80 links 2.37 82 links 2.42 82 links

Outside diameter mm (in) 65 (2.559) 65 (2.559) 66 (2.598) 66 (2.598) 66 (2.598) 66 (2.598)

Standard

PZ50/PZ50GT/ PZ50FX/PZ50M PZ50VT/PZ50MP

2-56

GEAR SELECTION
4 Secondary spring twist angle 90508-55007 (Red) Seat Sheave C A B 1 35 45 55 2 65 75 85 3 95 105 115

INSP ADJ

4 5 15 25

90508-55012 (Brown)/90508-58007 (Blue)/90508-60015 (Yellow) Seat Sheave C A B 5 Torque cam (secondary spring seat)
2
1
89N01

1 40 50 60

2 70 80 90

3 100 110 120

4 10 20 30

Identification mark

Effects Quicker upshifting during acceleration

Part no. 89N-17684-01 88R-17684-03

Cam angle 42 39 37

Identification mark 89N-01 88R-03 8AT-01

Quicker backshifting under load

8AT-17684-01

2-57

Standard

PZ50/PZ50GT/ PZ50FX PZ50M/PZ50VT/ PZ50MP

GEAR SELECTION
6 Primary spring

INSP ADJ

Spring identification color code

Spring rate color Preload color

Parts No. 90501-481J1 90501-487G8 90501-507G2 90501-507G7 90501-521J6 90501-524G4 90501-524G5 90501-525J8 90501-526G4 90501-526J9 90501-527G1 90501-550J8 90501-553G0 90501-553G6 90501-555J9 90501-556G5 90501-556G6 90501-556G7 90501-557G5 90501-557G6 90501-581J7 90501-582J1 90501-585J3 90501-586J0 90501-602J0 90501-604G0 90501-605G7 90501-605J5 90501-606G9 90501-607G0 90501-607G3 90501-607G4

Spring rate N/mm (kg/mm) 9.8 (1.0) 14.7 (1.5) 14.7 (1.5) 17.2 (1.75) 14.7 (1.5) 17.2 (1.75) 14.7 (1.5) 19.6 (2.0) 19.6 (2.0) 17.2 (1.75) 17.2 (1.75) 22.1 (2.25) 19.6 (2.0) 22.1 (2.25) 22.1 (2.25) 22.1 (2.25) 19.6 (2.0) 24.5 (2.5) 24.5 (2.5) 22.1 (2.25) 24.5 (2.5) 24.5 (2.5) 27.0 (2.75) 24.5 (2.5) 29.4 (3.0) 29.4 (3.0) 26.9 (2.74) 31.9 (3.25) 29.4 (3.0) 27.0 (2.75) 29.4 (3.0) 27.0 (2.75)

Preload N/mm (kg) 196 (20) 147 (15) 196 (20) 147 (15) 294 (30) 245 (25) 245 (25) 294 (30) 147 (15) 294 (30) 196 (20) 294 (30) 245 (25) 245 (25) 343 (35) 196 (20) 196 (20) 196 (20) 147 (15) 147 (15) 245 (25) 294 (30) 294 (30) 343 (35) 294 (30) 235 (24) 235 (24) 294 (30) 196 (20) 196 (20) 147 (15) 147 (15)

Color Silver-Blue-Silver Gold Gold-Blue-Gold Red-Gold-Red Gold-Pink-Gold Red-Yellow-Red Gold-Yellow-Gold Blue-Pink-Blue Blue-Gold-Blue Red-Pink-Red Red-Blue-Red White-Pink-White Blue-Yellow-Blue White-Yellow-White White-Silver-White White-Blue-White Blue Yellow-Blue-Yellow Yellow-Gold-Yellow White-Gold-White Yellow Yellow-Pink-Yellow Green-Pink-Green Yellow-Silver-Yellow Pink Pink-Yellow-Pink Green-Yellow-Green Orange-Pink-Orange Pink-Blue-Pink Green-Blue-Green Pink-Gold-Pink Green-Gold-Green

Wire gauge mm (in) 4.8 (0.189) 4.8 (0.189) 5.0 (0.197) 5.0 (0.197) 5.2 (0.205) 5.2 (0.205) 5.2 (0.205) 5.2 (0.205) 5.2 (0.205) 5.2 (0.205) 5.2 (0.205) 5.5 (0.217) 5.5 (0.217) 5.5 (0.217) 5.5 (0.217) 5.5 (0.217) 5.5 (0.217) 5.5 (0.217) 5.5 (0.217) 5.5 (0.217) 5.8 (0.228) 5.8 (0.228) 5.8 (0.228) 5.8 (0.228) 6.0 (0.236) 6.0 (0.236) 6.0 (0.236) 6.0 (0.236) 6.0 (0.236) 6.0 (0.236) 6.0 (0.236) 6.0 (0.236)

Outside diameter mm (in) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 58.4 (2.299) 60 (2.362) 58.4 (2.299) 60 (2.362) 60 (2.362) 59.3 (2.335) 59.3 (2.335) 59.0 (2.323) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 59.6 (2.346) 59.6 (2.346) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362) 60 (2.362)

No. of coils 5.16 4.19 4.61 4.24 5.09 4.64 5.08 4.43 4.32 4.77 4.65 4.62 5.10 4.61 4.66 4.62 4.95 4.36 4.36 4.62 4.96 4.96 4.64 4.91 4.74 4.80 5.00 4.53 4.86 5.12 4.86 5.12

Free length mm (in) 85.4 (3.362) 75.4 (2.969) 78.7 (3.098) 74.0 (2.913) 85.4 (3.362) 79.7 (3.138) 82.1 (3.232) 80.4 (3.165) 72.9 (2.870) 82.5 (3.248) 76.8 (3.024) 78.7 (3.098) 78.0 (3.071) 76.5 (3.012) 81.0 (3.189) 74.3 (2.925) 75.4 (2.969) 73.4 (2.890) 71.4 (2.811) 72.1 (2.839) 75.4 (2.969) 77.4 (3.047) 76.3 (3.004) 79.4 (3.126) 75.4 (2.969) 73.3 (2.886) 74.1 (2.917) 74.6 (2.937) 72.1 (2.839) 72.7 (2.862) 70.4 (2.772) 70.9 (2.791)

Standard

PZ50VT Europe/ PZ50MP

PZ50VT USA/Canada

PZ50M

PZ50/PZ50GT/ PZ50FX

2-58

GEAR SELECTION
7 Clutch weight Parts No. Weight g (oz) without bush and rivets Shape & ID mark

INSP ADJ
Standard

8BU 10

8BU-17605-20

45.41 (1.603)

8DN 10

8DN-17605-30

39.76 (1.404)

PZ50M

8ES 00

8ES-17605-00

54.63 (1.928)

8FA 00

8FA-17605-10

63.81 (2.251)

8FN 00

8FN-17605-00

75.28 (2.657)

8 FP 00

8FP-17605-00

67.81 (2.394)

8 FS 00

8FS-17605-00

65.52 (2.313)

8G C 00

8GC-17605-00

47.28 (1.669)

PZ50/PZ50GT/ PZ50FX/PZ50VT/ PZ50MP

2-59

GEAR SELECTION
8 Weight rivets
Parts No. Material Length mm (in) 17.2 (0.677) Weight g (oz) 4.5 (0.159) Standard

INSP ADJ
Effects Increased force

90261-06033

Steel

IN: PZ50VT Europe/PZ50MP CENTER, OUT: PZ50VT/ PZ50MP IN: PZ50M Europe/PZ50VT USA/Canada OUT: PZ50M Europe OUT: PZ50/PZ50GT/PZ50FX IN, CENTER: PZ50/PZ50GT/ PZ50FX OUT: PZ50M USA/Canada

90261-06034 90261-06019 90261-06015 90261-06028 None

Steel Steel Steel Aluminum

13.9 (0.547) 13.3 (0.524) 10.3 (0.406) 10.3 (0.406)

3.6 (0.127) 3.1 (0.109) 2.44 (0.086) 0.85 (0.030)

IN: PZ50M USA/Canada

Decreased force

9 Rollers
I.D. 9 mm (0.354 in) Roller with bushing part number 8FG-17624-00 Outside diameter mm (in) 14.5 (0.57) Bushing type (P/N) VESPEL TP-8549 Identification mark (Width) Grooved & Machined Standard Effects

Increased force

PZ50VT/PZ50MP

90386-09001 8FG-17624-10 15.0 (0.59) VESPEL TP-8549

(14.6 mm) Grooved

PZ50M

90386-09001 8FG-17624-20 15.6 (0.61) VESPEL TP-8549

(14.6 mm) No Mark

PZ50/PZ50GT/ PZ50FX

90386-09001 8FG-17624-30 16.0 (0.63) VESPEL TP-8549

(14.6 mm) Grooved & Grooved

90386-09001 8FG-17624-40 16.5 (0.65) VESPEL TP-8549

(14.6 mm) Machined

90386-09001

(14.6 mm)

Decreased force

2-60

FRONT SUSPENSION

INSP ADJ

FRONT SUSPENSION
Spring preload 1. Adjust: Spring preload Adjustment steps: Loosen the locknut 1. Turn the spring seat 2 in or out. PZ50GT/PZ50MP

Spring seat distance Preload Length a

Standard Shorter Harder Min. 205 mm (8.07 in) 215 mm (8.46 in) Longer Softer Max. 215 mm (8.46 in)

2 1 a

PZ50VT Europe Spring seat distance Preload Length a Standard Shorter Harder Min. 190 mm (7.48 in) 200 mm (7.87 in) Longer Softer Max. 200 mm (7.87 in)

PZ50FX Spring seat distance Preload Length a Standard Shorter Harder Longer Softer

Max. Min. 231.6 mm 241.6 mm 241.6 mm (9.51 in) (9.12 in) (9.51 in)

Turn the adjusting ring 3 to the proper position. PZ50/PZ50M/PZ50VT USA/Canada Spring adjuster position Preload Standard 1 2 3 4 5

Softer 1

Harder

PZ50GT/PZ50MP/PZ50VT Europe PZ50FX PZ50/PZ50M/PZ50VT USA/Canada

2-61

FRONT SUSPENSION
CAUTION:

INSP ADJ

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.
20 clicks out 12 clicks out 3 clicks out

b 1 a

Adjuster position Rebound damping force

Minimum

Standard

Maximum

Turns out b* 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. The shock absorber can be damaged and rebound damping force adjustments cannot be made. Do not turn the adjuster in direction b more than 20 clicks. Even if the adjuster is continually turned after 20 clicks, there will be no change in the rebound damping force. Be sure to stop the adjuster at a position where there is a click.

2-62

FRONT SUSPENSION/REAR SUSPENSION

b 1 a

INSP ADJ

Compression damping force adjustment (PZ50FX) The compression damping force can be adjusted by turning the adjuster 1.
12 clicks out 7 clicks out 2 clicks out

Adjuster position Compression damping force

Minimum

Standard

Maximum

Turns out b* 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. The shock absorber can be damaged and compression damping force adjustments cannot be made. Do not turn the adjuster in direction b more than 12 clicks. Even if the adjuster is continually turned after 12 clicks, there will be no change in the compression damping force. Be sure to stop the adjuster at a position where there is a click.

REAR SUSPENSION
Stopper band 1. Adjust: Stopper band length

CAUTION:
Make sure the left and right rear suspension stopper bands are adjusted evenly. (PZ50VT, PZ50MP)

NOTE:
This adjustment affects the handling characteristics of the machine.

2-63

REAR SUSPENSION

INSP ADJ

1
No.1 No.2 No.3 No.4 No.5

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. Standard setting: No. 1 hole (PZ50/PZ50MP) No. 2 holes (PZ50FX) No. 3 holes (PZ50GT/PZ50M) No. 4 holes (PZ50VT) Tighten the stopper band nuts.

1 2

1 No.1 No.2 No.3 No.4

T.

Stopper band nut: 4 Nm (0.4 m kg, 2.9 ft lb)

PZ50/PZ50GT/PZ50FX/PZ50M PZ50VT/PZ50MP

Choosing other settings:

CAUTION:
The standard settings work well under most general riding conditions. The suspension can be adjusted to work better in one condition, but only at the expense of another. Keep this in mind when you adjust the suspension. : No. 5 hole : No. 4 hole (shortest) More weight on skis: Heavy steering/ oversteer More maneuverability Favors: hardpack snow, ice, smooth trails, tight turns

PZ50/PZ50GT/PZ50FX/PZ50M PZ50VT/PZ50MP

R.

No. 1 hole (longest) Less weight on skis: Light steering/ understeer Better acceleration and speed Favors: deep snow, straight line acceleration, top speed

2-64

REAR SUSPENSION
Spring preload 1. Adjust: Spring preload

INSP ADJ

Adjustment step: Front side Loosen the locknut 1. Turn the spring seat 2 in or out. PZ50GT Europe Spring seat distance Preload Length a Standard Shorter Harder Min. 175 mm (6.89 in) 185 mm (7.28 in) Longer Softer Max. 185 mm (7.28 in)

PZ50FX Spring seat distance Preload Length a Standard Shorter Harder Min. 180 mm (7.09 in) 190 mm (7.48 in) Longer Softer Max. 190 mm (7.48 in)

PZ50VT Europe Spring seat distance Preload Length a Standard Shorter Harder Min. 182 mm (7.17 in) 192 mm (7.56 in) Longer Softer Max. 192 mm (7.56 in)

PZ50MP Spring seat distance Preload Length a Standard Shorter Harder Min. 194 mm (7.64 in) 204 mm (8.03 in) Longer Softer Max. 205 mm (8.07 in)

PZ50GT Europe/PZ50FX/PZ50VT Europe/ PZ50MP

2-65

REAR SUSPENSION

INSP ADJ

Turn the adjusting ring 3 to the proper position. PZ50/PZ50GT USA/Canada/PZ50M Spring adjuster position Preload Standard PZ50VT USA/Canada Spring adjuster position Preload Standard 1 2 3 4 5 1 2 3 4 5

Softer 1

Harder

Softer 3

Harder

WARNING
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode.
PZ50/PZ50GT USA/Canada/PZ50M PZ50VT USA/Canada

Rear side Turn the adjuster 1 to proper position. Spring adjuster position Spring rate Standard S Soft M Medium M H Hard

WARNING
Always adjust both spring preload (left and right) to the same setting. Uneven adjustment can cause poor handling and loss of stability.

2-66

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 1 click out

Adjuster position Damping force

Minimum

Standard

Maximum

Turns out b* 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. The shock absorber can be damaged and damping force adjustments cannot be made. Do not turn the adjuster in direction b more than 20 clicks. Even if the adjuster is continually turned after 20 clicks, there will be no change in the damping force. Be sure to stop the adjuster at a position where there is a click.

2-67

REAR SUSPENSION

INSP ADJ

Control rod (PZ50VT/PZ50MP) 1. Adjust: Control rod stroke a

CAUTION:
a
Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: Loosen the locknut 1. Turn the adjusting nut 2 in or out to adjust the control rod stroke. Adjusting position Effect 1 Increase weight transfer 2 2 3 Decrease weight transfer

1 2 3 2 1
Standard

WARNING
Never adjust the control rods beyond the maximum range indicated on the rods with red paint 3. While holding the adjusting bolt securely, tighten the locknut 1.

3
T.

Locknut: 25 Nm (2.5 m kg, 18 ft lb)

R.

2-68

REAR SUSPENSION

INSP ADJ

2-up adjusting block (PZ50VT/PZ50MP) 1. Position: 2-up adjusting blocks Solo (rider only) Position Spring force A Soft 2-up (rider and passenger) B 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.

NOTE:
Make sure that the lock lever has returned to its original position and that the 2-up adjusting block is locked in place. Do not ride the snowmobile with the lock lever pulled out.

CAUTION:
Make sure that the 2-up adjusting blocks are in the same position on both sides of the machine.

2-69

COWLINGS

CHAS

CHASSIS
COWLINGS
PZ50/PZ50GT/PZ50FX/PZ50M

: 8 Nm (0.8 m kg, 5.8 ft lb) 12

PZ50FX

2 3 18

6 11 16 15 13 17 19 14

8 9

10
Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Cowling removal Windshield Front panel Air filter case cover Headlight cover Left side panel Right side panel Left side cover Right side cover Left lower cover Right lower cover Headlight coupler Headlight assembly Cylinder-#2 intake air pressure sensor coupler Qty 1 1 1 1 1 1 1 1 1 1 2 1 1

Remarks Remove the parts in the order listed below. PZ50GT

Disconnect.

3-1

COWLINGS
: 8 Nm (0.8 m kg, 5.8 ft lb) 12 4

CHAS

PZ50FX

2 3 18

6 11 16 15 13 17 19 14

8 9

10
Order 14 15 16 17 18 19 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 Qty 1 1 1 1 1 2 Remarks Disconnect. Disconnect. Disconnect. Disconnect.

For installation, reverse the removal procedure.

3-2

COWLINGS
PZ50VT/PZ50MP

CHAS

: 8 Nm (0.8 m kg, 5.8 ft lb)

5 11 12 1 13

10

14 4

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Remarks Remove the parts in the order listed below.

Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Job name/Part name Cowling removal Air filter case cover Left side panel Right side panel Left side cover Right side cover Left lower cover Right lower cover Cylinder-#2 intake air pressure sensor coupler 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

Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure.

3-3

STEERING STEERING
PZ50/PZ50GT/PZ50FX/PZ50M

CHAS

: 10 Nm (1.0 m kg, 7.2 ft lb) : 15 Nm (1.5 m kg, 11 ft lb) : 16 Nm (1.6 m kg, 11 ft lb) : 20 Nm (2.0 m kg, 14 ft lb) 3

20 15

16 14

17

2 1 21

18

22 9 8 7 10 6 19

6 11 10 12 13

Order

1 2 3 4 5 6 7 8 9 10 11 12 13

Job name/Part name Handlebar removal Windshield/left side panel/right side panel Windshield bracket Multi-function meter coupler Multi-function meter Multi-function meter bracket Steering pad Plastic band Thumb warmer lead coupler Engine stop switch coupler Throttle switch coupler Grip warmer lead connector Grip thumb warmer adjustment switch lead coupler Brake light switch coupler Headlight beam switch coupler

Qty

1 1 1 1 1 2 1 1 2 2 1 1 1

Remarks Remove the parts in the order listed below. Refer to COWLINGS. PZ50GT/PZ50FX/PZ50M

PZ50GT/PZ50FX/PZ50M Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.

3-4

STEERING
: 10 Nm (1.0 m kg, 7.2 ft lb) : 15 Nm (1.5 m kg, 11 ft lb) : 16 Nm (1.6 m kg, 11 ft lb) : 20 Nm (2.0 m kg, 14 ft lb) 3

CHAS

20 15

16 14

17

2 1 21

18

22 9 8 7 10 6 19

6 11 10 12 13

Order 14 15 16 17 18 19 20 21 22

Job name/Part name Right handlebar switch cover Throttle cable holder Throttle cable Left handlebar switch Brake master cylinder holder Master cylinder assembly Handlebar holder Handlebar Steering joint

Qty 1 1 1 1 1 1 2 1 1

Remarks

NOTE:
After installing all parts, refer to CABLE ROUTING in CHAPTER 9, to check the cable and lead routings. For installation, reverse the removal procedure.

3-5

STEERING
PZ50VT/PZ50MP

CHAS
16

: 10 Nm (1.0 m kg, 7.2 ft lb) : 15 Nm (1.5 m kg, 11 ft lb) : 16 Nm (1.6 m kg, 11 ft lb) : 20 Nm (2.0 m kg, 14 ft lb) :
21 Nm (2.1 m kg, 15 ft lb)

19 14

(4) 15 13

17 20 3 23 21 18 22 (4)

8 7 6 9

5 10 9 11 12
Qty Remarks Remove the parts in the order listed below. Refer to COWLINGS.

Order

1 2 3 4 5 6 7 8 9 10 11 12 13

Job name/Part name Handlebar removal Windshield/left side panel/right side panel Multi-function meter coupler Multi-function meter Multi-function meter bracket Steering pad Plastic band Thumb warmer lead coupler Engine stop switch coupler Throttle switch coupler Grip warmer lead connector Grip thumb warmer adjustment switch lead coupler Brake light switch coupler Headlight beam switch coupler Right handlebar switch cover

1 1 1 1 3 1 1 2 2 1 1 1 1

PZ50GT/PZ50FX/PZ50M Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.

3-6

STEERING
: 10 Nm (1.0 m kg, 7.2 ft lb) : 15 Nm (1.5 m kg, 11 ft lb) : 16 Nm (1.6 m kg, 11 ft lb) : 20 Nm (2.0 m kg, 14 ft lb) : 21 Nm (2.1 m kg, 15 ft lb) 2 3 23 20 21 14 19 (4) 15 13 17 4

CHAS
16

18 22 (4)

8 7 6 9

5 10 9 11 12
Qty 1 1 1 1 1 2 1 1 1 1 Remarks

Order 14 15 16 17 18 19 20 21 22 23

Job name/Part name Throttle cable holder Throttle cable Left handlebar switch Brake master cylinder holder Master cylinder assembly Handlebar holder Handlebar Steering joint Steering joint bracket cover Steering joint bracket

NOTE:
After installing all parts, refer to CABLE ROUTING in CHAPTER 9, to check the cable and lead routings.

For installation, reverse the removal procedure.

3-7

STEERING
: 21 Nm (2.1 m kg, 15 ft lb) : 23 Nm (2.3 m kg, 17 ft lb) : 25 Nm (2.5 m kg, 18 ft lb) : 28 Nm (2.8 m kg, 20 ft lb) : 30 Nm (3.0 m kg, 22 ft lb) 19 21 7

CHAS

New 2 3

4 10 9 10 5

New
22 23 16
LT

26

8
LT LT

11

15 1

New
17 25 27 20 20 24

New
22

13 14

New

21 12 23
LT

LT

: 35 Nm (3.5 m kg, 25 ft lb) : 38 Nm (3.8 m kg, 27 ft lb) : 90 Nm (9.0 m kg, 65 ft lb)

New
18
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order

Job name/Part name Steering column and tie rod removal Air filter case Fuel tank

Qty

Remarks Remove the parts in the order listed below. Refer to COWLINGS. 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)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Relay rod Lock washer Cable holder Plate Bearing holder Lock washer Bearing holder Bearing Steering column Bearing Circlip Steering arm Steering control arm bracket Spacer
3-8

1 1 1 1 1 1 1 1 1 1 1 1 1 1

PZ50VT/PZ50MT

STEERING
: 21 Nm (2.1 m kg, 15 ft lb) : 23 Nm (2.3 m kg, 17 ft lb) : 25 Nm (2.5 m kg, 18 ft lb) : 28 Nm (2.8 m kg, 20 ft lb) : 30 Nm (3.0 m kg, 22 ft lb) 19 21 7

CHAS

New 2 3

4 10 9 10 5

New
22 23 16
LT

26

8
LT LT

11

15 1

New
17 25 27 20 20 24

New
22

13 14

New

21 12 23
LT

LT

: 35 Nm (3.5 m kg, 25 ft lb) : 38 Nm (3.8 m kg, 27 ft lb) : 90 Nm (9.0 m kg, 65 ft lb)

New
18
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order 15 16 17 18 19 20 21 22 23 24 25 26 27

Job name/Part name Steering control arm Steering shaft Pivot arm cover Tie rod end bolt Pivot arm bracket 1 Bushing Dust boots holder Dust boots Tie rod Idler arm Relay arm Pivot arm shaft Pivot arm bracket 2

Qty 1 1 1 2 1 4 2 2 2 1 1 1 1

Remarks

For installation, reverse the removal procedure.

3-9

STEERING
REMOVAL

CHAS

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.

WARNING
Do not attempt to straighten bent rods. This may dangerously weaken the rods. 4. Check: Rod end movement Rod end free play exists Replace the rod end. Rod end turns roughly Replace the rod end. 5. Inspect: Right relay arm Left relay arm Idler arm Cracks/damage Replace. Bearings Wear/damage Replace.

3-10

STEERING
INSTALLATION

CHAS

a b

1. Install: Tie rod 1 Locknuts 2 Joints 3 Tie rod part number Set length a 504.7 mm (19.87 in) Tie rod length b 433.2 mm (17.06 in)

8GC-23830-00 (PZ50/PZ50GT/ PZ50FX/ PZ50VT/ PZ50MP) 8GP-23830-00 (PZ50M)

464.9 mm (18.30 in)

393.4 mm (15.49 in)

2. Check: Tie rod angle c

c
Tie rod angle: 85

CAUTION:
After tightening the inside and outside ball joint locknut 2, make sure the tie rod 1 can be rotated freely through the ball joint travel. If not, loosen the locknut 2 and re-position the ball joint so that the tie rod 1 can be rotated freely. Tighten the locknut to specification.
Left side Right side

3. Install: Tie rods 1

NOTE:
Make sure that the indentation a on the tie rod faces out.

a 1

CAUTION:
Always use new cotter pins. Tie rod end locknut: 25 Nm (2.5 m kg, 18 ft lb) LOCTITE Tie rod-idler arm nut: 25 Nm (2.5 m kg, 18 ft lb) Tie rod-steering knuckle nut: 28 Nm (2.8 m kg, 20 ft lb)

T.

R.

3-11

STEERING
4. Install: Steering arm 1

CHAS

NOTE:
Align the punch mark a on the steering arm 1 with the punch mark b on the pivot arm shaft 2.

b a

a b

5. Install: Steering shaft 1 Locknuts 2 Joints 3 Steering shaft part number Set length a 311.3 mm (12.26 in) Shaft length b 244.3 mm (9.62 in)

8GC-23820-00

CAUTION:
Always use new cotter pin. Steering shaft and steering control arm nut: 21 Nm (2.1 m kg, 15 ft lb) Steering shaft and steering arm nut: 35 Nm (3.5 m kg, 25 ft lb)

1
T.

6. Bend the lock washer tab along a flat side of the bolt.

R.

3-12

STEERING
1
7. Adjust: Skis

CHAS

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. Adjust each angle of right and left skis by turning the tie rod respectively. Turning the steering shaft in direction a Turning the steering shaft in direction b Turning the handlebar in direction c Turning the handlebar in direction d

Tighten the locknuts (steering shaft) 2. Steering shaft locknut: 25 Nm (2.5 m kg, 18 ft lb) LOCTITE

8. Install: Handlebar 1 Handlebar holders 2

CAUTION:
First, tighten the bolts on the front side of the handlebar holder, and then on the rear side.

T.

R.

1 b 2
NOTE:
The handlebar holders should be installed with the punch marks a facing forward. Align the match mark b on the handlebar with the upper surface of the steering joint. Handlebar holder bolt: 15 Nm (1.5 m kg, 11 ft lb)

T.

R.

3-13

SKI SKI
PZ50/PZ50GT/PZ50FX/PZ50VT USA/Canada

CHAS

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

Qty 1 1 1 1 1 2 1 1 1

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

3-14

SKI
PZ50VT Europe/PZ50MP

CHAS

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

Qty 1 1 1 1 1 2 1 1 1 1

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

3-15

SKI
PZ50M

CHAS

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

Qty 1 1 1 2 1 2 1 1 1

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

3-16

SKI
INSPECTION

CHAS

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.

3-17

FRONT SUSPENSION FRONT SUSPENSION

PZ50/PZ50FX/PZ50M

CHAS

: 28 Nm (2.8 m kg, 20 ft lb) : 34 Nm (3.4 m kg, 24 ft lb)

2 3

: 45 Nm (4.5 m kg, 32 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 65 Nm (6.5 m kg, 47 ft lb)

10 9 7 8 14 14 14 13
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

1 8 2

PZ50FX

3 6 5 15 11
Qty

New

12

Order

1 2 3 4 5 6 7 8 9 10

Job name/Part name Front suspension removal Air filter case cover Pivot arm cover Ski Shock absorber Collar Bushing Tie rod Steering knuckle Upper arm ball joint Upper arm Bushing Stabilizer holder Bushing

Remarks Remove the parts in the order listed below. Refer to COWLINGS. Refer to STEERING. Refer to SKI. PZ50/PZ50M PZ50/PZ50M Disconnect.

1 2 4 1 1 1 1 2 1 1

3-18

FRONT SUSPENSION
: 28 Nm (2.8 m kg, 20 ft lb) :
34 Nm (3.4 m kg, 24 ft lb)

CHAS

2 3

: 45 Nm (4.5 m kg, 32 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 65 Nm (6.5 m kg, 47 ft lb)

10 9 7 8 14 14 14 13
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

1 8 2

PZ50FX

3 6 5 15 11
Qty 1 1 1 4 1 Remarks

New

12

Order 11 12 13 14 15

Job name/Part name Stabilizer joint Stabilizer Lower arm Bushing Lower arm ball joint

For installation, reverse the removal procedure.

3-19

FRONT SUSPENSION
PZ50GT/PZ50VT/PZ50MP

CHAS

: 7 Nm (0.7 m kg, 5.1 ft lb) : 28 Nm (2.8 m kg, 20 ft lb)

2 3

: 34 Nm (3.4 m kg, 24 ft lb) 45 Nm (4.5 m kg, 32 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 65 Nm (6.5 m kg, 47 ft lb)

10 9 8 2

8 PZ50VT USA/Canada 14 14 14 13 11 11 12 15 6

New

5
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order

1 2 3 4 5 6 7 8 9 10

Job name/Part name Front suspension removal Air filter case cover Pivot arm cover Ski Shock absorber Collar Bushing Tie rod Steering knuckle Upper arm ball joint Upper arm Bushing Stabilizer holder Bushing

Qty

Remarks Remove the parts in the order listed below. Refer to COWLINGS. Refer to STEERING. Refer to SKI.

1 2 4 1 1 1 1 2 1 1

Disconnect.

3-20

FRONT SUSPENSION
: 7 Nm (0.7 m kg, 5.1 ft lb) : 28 Nm (2.8 m kg, 20 ft lb) 2 3

CHAS

: 34 Nm (3.4 m kg, 24 ft lb) 45 Nm (4.5 m kg, 32 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 65 Nm (6.5 m kg, 47 ft lb)

10 9 8 2

8 PZ50VT USA/Canada 14 14 14 13 11 11 12 15 6

New

5
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order 11 12 13 14 15

Job name/Part name Stabilizer bracket Stabilizer Lower arm Bushing Lower arm ball joint

Qty 2 1 1 4 1

Remarks

For installation, reverse the removal procedure.

3-21

FRONT SUSPENSION
HANDLING NOTES

CHAS

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. This may cause the unit to explode due to excessive gas pressure. Do not deform or damage the gas chamber in any way. Gas chamber damage will result in poor damping performance.

INSPECTION
1. Inspect: Shock absorber Oil (gas) leaks/bends/damage Replace. Bushings Wear/scratches/damage Replace. 2. Inspect: Steering knuckle Cracks/bends/damage Replace. 3. Inspect: Upper arms Lower arms Cracks/bends/damage Replace. Bushings Wear/scratches/damage Replace. Upper ball joints Lower ball joints Damage/pitting Replace. 4. Inspect: Stabilizer Cracks/bends/damage Replace. Bushings Wear/scratches/damage Replace.

3-22

FRONT SUSPENSION

CHAS

INSTALLATION

2 3 a

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 handling and loss of stability may result. (PZ50GT/ PZ50VT/PZ50MP)

2 3 a

1
NOTE:

Install the stabilizer holder in the direction shown in the illustration. (PZ50/PZ50FX/PZ50M) The stabilizer force can be adjusted by changing the installation positions of the stabilizer, bushing, and stabilizer holder. (PZ50GT/PZ50VT/ PZ50MP)
a b c d e PZ50/PZ50FX/PZ50M PZ50GT/PZ50VT/PZ50MP Forward Very hard Hard Medium Soft

Stabilizer, bushing, and stabilizer holder standard installation positions:

d (PZ50GT) b (PZ50VT/PZ50MP)

2. Install: Shock absorber 1 (PZ50GT/PZ50VT Europe/PZ50MP)

NOTE:

Install the shock absorber with the charging valve a facing inward.

3-23

FRONT SUSPENSION
Ski alignment

CHAS

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. Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) a b = Toe-out Refer to STEERING SYSTEM in CHAPTER 2.

3-24

PRIMARY SHEAVE AND DRIVE V-BELT

POWR TR
s

POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT
: 1st
2nd 120 Nm (12.0 m kg, 85 ft lb) 60 Nm (6.0 m kg, 43 ft lb)

2
E

Order

1 2

Job name/Part name Primary sheave removal Left side cover V-belt Primary sheave assembly

Qty

Remarks Remove the parts in the order listed below. Refer to COWLINGS in CHAPTER 3.

1 1 For installation, reverse the removal procedure.

4-1

PRIMARY SHEAVE AND DRIVE V-BELT

POWR TR

Order 1 2 3 4 5 6 7 8 9 0 A B C D

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

Qty 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.

4-2

PRIMARY SHEAVE AND DRIVE V-BELT

REMOVAL

POWR TR

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. Attach the lower piece of the clutch spider separator 6 onto a rigid table using suitable mounting bolts. Then, install the clutch separator adapter 7 onto the separator. Clutch spider separator: 90890-01711, YS-28890-C Clutch separator adapter: 90890-01740, YS-34480

4-3

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. Since a high torque is required to loosen the spider, make sure that the spider, fixed sheave and special tool are well secured. Loosen the spider carefully to prevent cracks and damage to the sheaves and spider. Remove the fixed sheave, fixed sheave stopper, and sliding sheave from the spider.

INSPECTION
1. Inspect: Spider Sliding sheave Fixed sheave Primary sheave cap Cracks/damage Replace.

4-4

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. Inspect: Primary sheave cap bush 1 Sliding sheave bush 2 Cracks/damage Replace. Clutch bushing press: YS-42424

5. Inspect: Weight 1 Roller 2 Bushing 3 Slider 4 Rivet 5 Collar Wear/scratches/damage Replace. Slider inside clearance A1 + A2 : Min. 0 mm (0 in) Max. 0.3 mm (0.0118 in)

4-5

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.

6. Measure: Bushing inside diameter Out of specification Replace as a set. Bushing inside diameter: Roller : New: 9.077 mm (0.357 in) Wear limit: 9.3 mm (0.366 in) Weight : New: 8.077 mm (0.318 in) Wear limit: 8.3 mm (0.327 in)

NOTE:
When replacing the weight and roller bushings, use the YXR clutch bushing jig kit. YXR clutch bushing jig kit: YS-39752
Removing Installing

ASSEMBLY
1. Install: Sliding sheave (onto the spider)

NOTE:
Be sure the sliding sheave match mark (X) is aligned with the spider match mark (X).

4-6

PRIMARY SHEAVE AND DRIVE V-BELT

2. Install: Fixed sheave (onto the spider)

POWR TR

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. Tighten: Spider Tightening steps: Finger-tighten the spider until it is stopped by the fixed sheave stopper. Hold the fixed sheave with the clutch spider separator 1. Clutch spider separator: 90890-01711, YS-28890-C

NOTE:
Securely fit the projections on the clutch separator adapter 2 into the fixed sheave holes.

4-7

PRIMARY SHEAVE AND DRIVE V-BELT

POWR TR

Tighten the spider to specification using the bar wrench 3. Spider: 200 Nm (20.0 m kg, 145 ft lb)

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. Tighten the spider carefully to prevent cracks and damage to the sheaves and spider.

2 1

5. Install: Weight Bolts 1 Nuts 2 Nut: 6 Nm (0.6 m kg, 4.3 ft lb)

NOTE:
To maintain the primary sheave balance, the bolts 1 must be installed with their threaded portions pointing in a counterclockwise direction, as illustrated.

6. Install: Primary sheave spring 1 Primary sheave cap 2

NOTE:
Be sure the sheave cap match mark (X) is aligned with the spider match mark (X). Primary sheave cap bolt: 14 Nm (1.4 m kg, 10 ft lb)

T.

R.
T.

R.
T.

R.

4-8

PRIMARY SHEAVE AND DRIVE V-BELT

INSTALLATION

POWR TR

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

3 1

Tightening steps: Hold the primary sheave 2 using the primary sheave holder 3 and tighten the primary sheave bolt to specification. Sheave holder: 90890-01701, YS-01880-A Primary sheave bolt: 1st: 120 Nm (12.0 m kg, 85 ft lb)

Loosen the primary sheave bolt completely. Retighten the primary sheave bolt to specification. Primary sheave bolt: 2nd: 60 Nm (6.0 m kg, 43 ft lb)

4. Adjust: V-belt position Refer to DRIVE V-BELT in CHAPTER 2. Sheave offset Secondary sheave free play (clearance) Refer to SHEAVE OFFSET ADJUSTMENT in CHAPTER 2.

T.

R.
T.

R.

4-9

SECONDARY SHEAVE SECONDARY SHEAVE

POWR TR

Order

Job name/Part name Secondary sheave removal

Qty

Remarks Remove the parts in the order listed below.

NOTE:
Apply the brake to lock the secondary sheave. V-belt 1 2 3 4 5 Washer Shim (left) Secondary sheave assembly Shim (right) Washer 1 1 1 For installation, reverse the removal procedure. Refer to PRIMARY SHEAVE AND DRIVE VBELT. Refer to SHEAVE OFFSET ADJUSTMENT in CHAPTER 2. Refer to SHEAVE OFFSET ADJUSTMENT in CHAPTER 2.

4-10

SECONDARY SHEAVE
: 7 Nm (0.7 m kg, 5.1 ft lb) New

POWR TR

1 2 3 4 7 8

: 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

Qty 1 1 1 1 1 2 1 1

Remarks Remove the parts in the order listed below.

For assembly, reverse the disassembly procedure.

4-11

SECONDARY SHEAVE
DISASSEMBLY

POWR TR

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. Inspect: Bushing 1 Sliding sheave (V-belt contact surface) 2 Scratches/wear/damage Replace. Sliding bushing 3 Unsymmetrical wear/damage Replace.

3. Inspect: Secondary sheave spring 1 Cracks/damage Replace. 4. Measure: Secondary sheave spring (standard) free length a Below specification Replace the secondary sheave spring. Secondary sheave spring (standard) free length: 85 mm (3.35 in)
4-12

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 2

CAUTION:
Always use a new circlip. Turn in the screw for the sheave compressor so that the spring seat splines engage with the fixed sheave splines. Hold the spring seat 1 and turn the sliding sheave 2 counterclockwise to the specified twist angle a. Twist angle: 45 (PZ50/PZ50GT/PZ50FX) 55 (PZ50M) 50 (PZ50VT/PZ50MP) Push down on the spring seat until the bolts come through the holes. While pushing down on the spring seat, install the washer and circlip.

4-13

SECONDARY SHEAVE
INSTALLATION
1. Lubricate: Splines (fixed sheave)

POWR TR

Recommended grease: ESSO beacon 325 grease or Aeroshell grease #7A 2. Tighten: Secondary sheave bolt Secondary sheave bolt: 60 Nm (6.0 m kg, 43 ft lb)

3. Adjust: Sheave offset Secondary sheave free play (clearance) Refer to SHEAVE OFFSET ADJUSTMENT in CHAPTER 2.

T.

R.

4-14

DRIVE CHAIN DRIVE CHAIN

: 16 Nm (1.6 m kg, 11 ft lb) : 24 Nm (2.4 m kg, 17 ft lb) : 25 Nm (2.5 m kg, 18 ft lb) : 48 Nm (4.8 m kg, 35 ft lb) 10 9 12 6 New 3 (7)
LT

POWR TR

New 7 13

11 8

4 New New

New

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order

1 2 3 4 5 6 7 8 9 10 11 12 13

Job name/Part name Drive chain housing removal Brake caliper/parking brake Shim Shim Brake disc Drain bolt Chain tension adjusting bolt Drive chain cover Rubber seal Chain tensioner assembly Spacer Drive sprocket Driven sprocket Drive chain Spacer

Qty

1 1 1 1 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed below. Refer to BRAKE. t = 0.5 t = 1.0 Drain. Loosen.

For installation, reverse the removal procedure.

4-15

DRIVE CHAIN
REMOVAL
1. Remove: Driven sprocket 1

POWR TR

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.

NOTE:
Use a socket 1 that is the same size as the outside diameter of the bearing race.

CAUTION:
Do not strike the inner race 2 or ball bearings 3. Contact only the outer race 4. Install a new circlip (drive chain cover).

CAUTION:
Always use new circlips.

2. Inspect: Drive sprocket Driven sprocket Chain tensioner Pitting/wear/damage Replace.

4-16

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. Inspect: Drive chain Stiffness Clean and lubricate or replace.

5. Measure: Brake disc thickness a Measure the brake disc thickness 1 ~ 3 mm (0.04 ~ 0.12 in) from the edge of the brake disc. Out of specification Replace.

Minimum thickness: 3.5 mm (0.14 in)

PZ50/PZ50GT/PZ50FX PZ50M/PZ50VT/PZ50MP

4-17

DRIVE CHAIN
INSTALLATION

POWR TR

1. During installation, pay attention to the following.

Make sure that the bearing seals face towards the drive chain as shown.

C1

C3

Properly install the rubber seal onto the drive chain housing, making sure that there are no gaps.

C1 C2 C3

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 ~ 0.028 in) : ESSO beacon 325 grease or Aeroshell grease #7A

For the secondary shaft and drive chain installation, refer to SECONDARY SHAFT.

C2

2. Fill: Drive chain housing oil Refer to DRIVE CHAIN in CHAPTER 2. 3. Adjust: Drive chain slack Refer to DRIVE CHAIN in CHAPTER 2.

4-18

SECONDARY SHAFT SECONDARY SHAFT

PZ50

POWR TR

: 24 Nm (2.4 m kg, 17 ft lb)

New 3 4

2 1

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

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

Qty

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.

4-19

SECONDARY SHAFT
REMOVAL

POWR TR

1. Remove: Drive chain parts Refer to DRIVE CHAIN. Secondary sheave assembly Refer to SECONDARY SHEAVE.

2. Remove: Bearing housing Secondary shaft 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. Inspect: Bearing 1 Pitting/damage Replace.

NOTE:
When reassembling the bearing, press the bearing onto the secondary shaft as shown.

124.9 ~125.1 mm (4.92 ~ 4.93 in)

INSTALLATION
1. Install: Secondary shaft 2. Install Drive chain parts Refer to DRIVE CHAIN.

4-20

SECONDARY SHAFT
3. Tighten: Bearing holder bolts 1

POWR TR

Bearing holder bolt: 24 Nm (2.4 m kg, 17 ft lb)

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.

T.

R.

4-21

SECONDARY SHAFT

POWR TR

SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION

1. Install: Secondary shaft Drive chain parts

3 a 4 5
Installation steps: Install the secondary shaft. Install the drive chain parts. Install the drive chain, drive sprocket and driven sprocket. Tighten the bolt 1. Driven sprocket bolt: 48 Nm (4.8 m kg, 35 ft lb) LOCTITE

Install the drive chain cover 2.

Properly install the rubber seal onto the drive chain housing, making sure that these are no gaps.

T.

R.

Tighten the bolts 3. Drive chain cover bolt: 24 Nm (2.4 m kg, 17 ft lb)

NOTE:
Tighten the drive chain cover bolts in proper tightening sequence as shown. Install the brake disc. Adjust the brake disc clearance. 2. Measure: Brake disc clearance a Out of the specification Adjust. Brake disc clearance: 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) 3. Adjust: Brake disc clearance Adjustment steps: Remove the circlip 4. Adjust the brake disc clearance by adding or removing shim(s) 5.

T.

R.

3 4 6 5

1 7
Part number 90201-203F0 90201-20021

Shim size Thickness 0.5 mm (0.02 in) 1.0 mm (0.04 in)

Install the new circlip.

4-22

SECONDARY SHAFT AND REVERSE GEAR CASE SECONDARY SHAFT AND REVERSE GEAR CASE
PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP

POWR TR

: 9 Nm (0.9 m kg, 6.5 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) : 17 Nm (1.7 m kg, 12 ft lb) : 24 Nm (2.4 m kg, 17 ft lb)

New 10 11

New (3) 8 New 7 4

(4)

LT

New 6

1 2 1
LT

9
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order

Job name/Part name Secondary shaft and reverse gear case removal Secondary sheave assembly Drive chain Fuel tank

Qty

Remarks Remove the parts in the order listed below. Refer to SECONDARY SHEAVE. Refer to DRIVE CHAIN. Refer to SEAT AND FUEL TANK in CHAPTER 5. (PZ50GT/PZ50FX/PZ50M) Refer to RIDER SEAT AND FUEL TANK in CHAPTER 5. (PZ50VT/PZ50MP) Refer to RADIATOR AND HEAT EXCHANGER in CHAPTER 6. Refer to EXHAUST PIPE AND MUFFLER in CHAPTER 5.

Coolant reservoir/radiator outlet pipe 2 Exhaust pipe joint lower cover 1 2 3 4 5 Bearing holder Bearing Circlip Gear motor coupler Reverse position switch connector 2 1 1 1 1

Disconnect. Disconnect.

4-23

SECONDARY SHAFT AND REVERSE GEAR CASE

: 9 Nm (0.9 m kg, 6.5 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) : 17 Nm (1.7 m kg, 12 ft lb) : 24 Nm (2.4 m kg, 17 ft lb) New 10 11 3

POWR TR

New (3) 8 New 7 4

(4)

LT

New 6

1 2 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

Qty 1 1 1 1 1 1

Remarks Disconnect.

For installation, reverse the removal procedure.

4-24

SECONDARY SHAFT AND REVERSE GEAR CASE

: 6 Nm (0.6 m kg, 4.3 ft lb) : 17 Nm (1.7 m kg, 12 ft lb) I 0 C New A M B G D K New 5 2 F E 6

POWR TR

New D

New

3 J 5 H 9 L
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

4 New

Order

1 2 3 4 5 6 7 8 9 0 A B C D E

Job name/Part name Secondary shaft and reverse gear case disassembly Drive position switch Reverse position switch Right reverse gear case Gasket Dowel pin Middle shaft Counter axle Chain Reverse driven gear Shift fork Dog gear Shift fork guide bar Circlip Washer Reverse drive gear

Qty

Remarks Remove the parts in the order listed below.

1 1 1 1 2 1 1 1 1 1 1 1 1 2 1

4-25

SECONDARY SHAFT AND REVERSE GEAR CASE

: 6 Nm (0.6 m kg, 4.3 ft lb) : 17 Nm (1.7 m kg, 12 ft lb) I 0 C New A M B G D K New 5 2 F E 6

POWR TR

New D

New

3 J 5 H 9 L
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

4 New

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

Qty 1 1 1 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

4-26

SECONDARY SHAFT AND REVERSE GEAR CASE

REMOVAL

POWR TR

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.

2 3 1

3. Remove: Exhaust pipe/muffler assembly 1 Exhaust pipe joint upper cover Exhaust pipe joints 2 Exhaust pipe joint lower cover 3

NOTE:
Slide the exhaust pipe/muffler assembly rearward as shown in the illustration.

4. Remove: Secondary shaft assembly 1 Removal steps: Slide the secondary shaft assembly to the left until the right end of the assembly is past the frame. Lift up the right end of the secondary shaft assembly, and then pull it outward to remove.

1
4-27

SECONDARY SHAFT AND REVERSE GEAR CASE

INSPECTION

POWR TR

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. Inspect: Reverse driven gear Reverse drive gear Counter axle Middle shaft Dog gear Pitting/wear/damage Replace. Chain Wear/damage Replace. Shift Clean or replace.

ASSEMBLY

1. Install: Oil seal 1

NOTE:
Press the oil seal onto the left reverse gear case as shown.
0.5 ~ 1.5 mm (0.02 ~ 0.06 in)

2. Install: Dog gear 1

NOTE:

Install the dog gear with its side toward the middle shaft.
30 mm (1.18 in) 33 mm (1.30 in)

4-28

SECONDARY SHAFT AND REVERSE GEAR CASE

1
INSTALLATION

POWR TR

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. Secondary shaft assembly bolt: 10 Nm (1.0 m kg, 7.2 ft lb)

Tighten the bearing holder bolts 2. Bearing holder bolt: 24 Nm (2.4 m kg, 17 ft lb)

Tighten the set bolts 3. Set bolt (secondary shaft): 9 Nm (0.9 m kg, 6.5 ft lb) LOCTITE

T.

R.
T.

R.
T.

R.

2. Install: Shift arm Gear motor Installation steps: Check that the gear motor is in the drive position. Refer to GEAR MOTOR in CHAPTER 8. Install the shift arm 1 onto the gear motor, making sure that the center of the projection a on the shift arm is within the range shown in the illustration. Slide the shift fork 2 toward the middle shaft, making sure to fit the projection a on the shift arm into the slot b in the shift fork. After installing the shift arm and gear motor, turn the secondary shaft by hand and check that the middle shaft turns in the same direction.

a b

4-29

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.

4-30

BRAKE BRAKE
: 23 Nm (2.3 m kg, 17 ft lb) 10 11 12 13

POWR TR

6 7 8 9

14 5 3 4 (3) 1 2

Order

Job name/Part name Battery bracket removal Battery Starter relay Main fuse Fuse box ECU (engine control unit) DC back buzzer Gear motor relay 1 Gear motor relay 2 Gear motor relay 3 Passenger grip warmer relay Headlight relay Load control relay Fuel injection system relay Radiator fan motor relay Battery bracket

Qty

Remarks Remove the parts in the order listed below. Refer to BATTERY INSPECTION in CHAPTER 2.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 1 1 1 1 1 1 1 1 1 1 1 1 1

PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP PZ50VT/PZ50MP

PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP For installation, reverse the removal procedure.

4-31

BRAKE
: 6 Nm (0.6 m kg, 4.3 ft lb) : 18 Nm (1.8 m kg, 13 ft lb) : 48 Nm (4.8 m kg, 35 ft lb)

POWR TR

1 4 1

Order 1 2 3 4

Job name/Part name Brake pad removal Retaining pin Brake pad Pad spring Brake caliper assembly

Qty 2 2 1 1

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

4-32

BRAKE
CAUTION:

POWR TR

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. Do not disconnect any hydraulic connection, otherwise the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT NOTE:

It is not necessary to disassemble the brake caliper and brake hose in order to replace the brake pads.

1. Remove: Brake pads

NOTE:
Do not depress the brake lever when the caliper or disc is off the machine otherwise the brake pads will be forced shut. Install a new brake pad spring when the brake pads are replaced. Replace the pads as a set if either one is found to be worn to the wear limit a. Wear limit: 4.7 mm (0.19 in)

4-33

BRAKE
2. Install: Brake pads Pad spring

POWR TR

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. Bleed screw: 6 Nm (0.6 m kg, 4.3 ft lb)

Install the brake pads and pad spring. 3. Check: Brake fluid level Refer to BRAKE FLUID LEVEL INSPECTION in CHAPTER 2. 4. Check: Brake lever operation A soft or spongy feeling Bleed brake system. Refer to AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) in CHAPTER 2.

T.

R.

4-34

BRAKE

POWR TR

New New
6 2

8 5 8 7 4 : 6 Nm (0.6 m kg, 4.3 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb)

: 1 Silicone grease

3 10 9 11

: 16 Nm (1.6 m kg, 12 ft lb) : 30 Nm (3.0 m kg, 22 ft lb) : 48 Nm (4.8 m kg, 35 ft lb)

Order

1 2 3 4 5 6 7 8 9 10 11

Job name/Part name Brake caliper and parking brake removal Brake fluid Brake hose Retaining pin Brake pad Pad spring Brake caliper bracket Brake caliper Brake caliper piston Brake caliper piston seal Parking brake cable Spring Parking brake assembly

Qty

Remarks Remove the parts in the order listed below. Drain.

1 2 2 1 1 1 2 4 1 1 1 For installation, reverse the removal procedure.

4-35

BRAKE
NOTE:

POWR TR

BRAKE CALIPER DISASSEMBLY

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.

WARNING
Never try to pry out the pistons.

BRAKE CALIPER INSPECTION AND REPAIR

Recommended brake component replacement schedule Brake pads Piston seals Brake hose Brake fluid As required Every two years Every four years Only when brakes are disassembled.

WARNING
All internal brake components should be cleaned only with new brake fluid. Do not use solvents as they will cause seals to swell and distort.

4-36

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. Internal parts should be lubricated with brake fluid when installed. Recommended brake fluid: DOT 4 Replace the piston seals whenever a caliper is disassembled.

BRAKE CALIPER INSTALLATION

1. Install: Brake hose 1

CAUTION:
When installing the brake hose 1 onto the brake caliper 2, make sure that the brake pipe touches the projection a on the brake caliper.

2
Union bolt (brake hose): 30 Nm (3.0 m kg, 22 ft lb)

T.

R.

4-37

BRAKE

POWR TR

Order

1 2 3 4 5 6 7

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

Qty

Remarks Remove the parts in the order listed below. Drain. Refer to STEERING in CHAPTER 3.

1 1 1 1 1 1 1

Disconnect.

1 2 3 4

Brake master cylinder disassembly Reservoir cap set Diaphragm Master cylinder kit Master cylinder body

For installation, reverse the removal procedure. Remove the parts in the order listed below. 1 1 1 1 For assembly, reverse the disassembly procedure.

4-38

BRAKE
INSPECTION

POWR TR

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. Recommended brake fluid: DOT 4 Replace the piston seals and dust seals whenever a caliper is disassembled.

INSTALLATION
1. Install: Brake hose

CAUTION:
When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a as shown.

a
T.

Union bolt (brake hose): 30 Nm (3.0 m kg, 22 ft lb)

R.

4-39

SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION

PZ50/PZ50GT/PZ50FX/PZ50M

POWR TR

: 72 Nm (7.2 m kg, 52 ft lb) : 110 Nm (11.0 m kg, 80 ft lb)

LT

LT

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order

Job name/Part name Slide rail suspension removal Rear axle nut Tension adjuster Slide rail suspension

Qty

Remarks Remove the parts in the order listed below. Loosen. Loosen. For installation, reverse the removal procedure.

4-40

SLIDE RAIL SUSPENSION

POWR TR

: 4 Nm (0.4 m kg, 2.9 ft lb) 8 9 5 3 2 4 6 5 3 1 C

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

: 49 Nm (4.9 m kg, 35 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 110 Nm (11.0 m kg, 80 ft lb) 0 A 7 0 8

Order 1 2 3 4 5 6 7 8 9 0 A B C

Job name/Part name Slide rail suspension disassembly Stopper band Front shock absorber Bushing Collar Bushing Collar Front pivot arm Bushing Shaft Collar Shaft Collar Shaft

Qty 1 1 2 1 2 1 1 2 1 2 1 1 1

Remarks Remove the parts in the order listed below.

4-41

SLIDE RAIL SUSPENSION

H K D New E F J I M

POWR TR

: 6 Nm (0.6 m kg, 4.3 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb)

L G
LT

I J H

G P O

N N O P F
LT

E New D

PZ50M
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order D E F

Job name/Part name Suspension wheel Circlip Spring end guide

Qty 2 2 2

Remarks

NOTE:
Apply grease to the inner surface of each spring end guide.

G H I J K L M N O P

Spring end guide bracket Wheel bracket Suspension wheel Bushing Shaft Front suspension bracket Collar Suspension wheel Collar Wheel bracket

2 2 2 2 1 1 1 2 2 2

4-42

SLIDE RAIL SUSPENSION

: 35 Nm (3.5 m kg, 25 ft lb) : 49 Nm (4.9 m kg, 35 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) [ Z X ^ S Y S [ W New a ]

POWR TR

LT

LT

V U

LT

T
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

LT

Order Q R S T U V W X Y Z [ \ ] _ a

Job name/Part name Connecting arm Rear shock absorber Collar Rear pivot arm joint Torsion spring Rear pivot arm protector Circlip Adjuster Rear pivot arm Shaft Guide wheel Rear pivot arm bracket Shaft Collar Stopper

Qty 1 1 2 2 2 2 2 2 1 1 2 1 1 4 4

Remarks

4-43

SLIDE RAIL SUSPENSION

POWR TR

: 60 Nm (6.0 m kg, 43 ft lb) : 75 Nm (7.5 m kg, 54 ft lb) b

PZ50M

c i j

e h l d g

f f

l c e

k PZ50M j i PZ50M

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

Qty 1 2 1 2 2 1 1 2 2 1 2

Remarks

For assembly, reverse the disassembly procedure.

4-44

SLIDE RAIL SUSPENSION

PZ50VT/PZ50MP

POWR TR

: 72 Nm (7.2 m kg, 52 ft lb)

LT

LT

Order

Job name/Part name Slide rail suspension removal Rear axle nut Tension adjuster Slide rail suspension

Qty

Remarks Remove the parts in the order listed below. Loosen. Loosen. For installation, reverse the removal procedure.

4-45

SLIDE RAIL SUSPENSION

6 New 7 I H J I J 6 I 3 1 4 2
3
K

POWR TR

A B

: 4 Nm (0.4 m kg, 2.9 ft lb) : 6 Nm (0.6 m kg, 4.3 ft lb) : 49 Nm (4.9 m kg, 35 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) 0 F C G E

8 59

M N

D
B

N M K New L

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order 1 2 3 4 5 6 7 8 9 0 A B C

Job name/Part name Slide rail suspension disassembly Stopper band Shaft Collar Collar Front pivot arm Bushing Shaft Collar Shaft Collar Wheel bracket Suspension wheel Shaft

Qty 2 1 2 1 1 2 1 2 1 1 2 2 1

Remarks Remove the parts in the order listed below.

4-46

SLIDE RAIL SUSPENSION

6 New 7 I H J I J 6 I 3 1 4 2
3
K

POWR TR

A B

: 4 Nm (0.4 m kg, 2.9 ft lb) : 6 Nm (0.6 m kg, 4.3 ft lb) : 49 Nm (4.9 m kg, 35 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) 0 F C G E

8 59

M N

D
B

N M K New L

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order D E F G H I J K L M

Job name/Part name Bushing Connecting arm Collar Front suspension bracket Front shock absorber Bushing Collar Suspension wheel Circlip Spring end guide

Qty 2 1 1 1 1 4 2 2 2 2

Remarks

NOTE:
Apply grease to the inner surface of each spring end guide.

Spring end guide bracket

4-47

SLIDE RAIL SUSPENSION

: 6 Nm (0.6 m kg, 4.3 ft lb) : 9 Nm (0.9 m kg, 6.5 ft lb) : 25 Nm (2.5 m kg, 18 ft lb) : 49 Nm (4.9 m kg, 35 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) g o U V U V X P O R Q R O P S W T X T V U c U l k New d e f i i

POWR TR

h New n m pq

i i

p q

] Z [ Y \

a ^

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order O P Q R S T U V W X Y Z [ \ ] _ a b

Job name/Part name Suspension wheel Wheel bracket Shaft Bushing Rear suspension bracket Pull rod Collar Bushing Rear shock absorber Collar Lock lever guide plate Lock lever Collar 2-up adjusting block 2-up adjusting block plate Collar Guide wheel Torsion spring

Qty 2 2 1 2 1 2 4 4 1 2 2 2 2 2 2 2 2 2

Remarks

4-48

SLIDE RAIL SUSPENSION

: 6 Nm (0.6 m kg, 4.3 ft lb) : 9 Nm (0.9 m kg, 6.5 ft lb) : 25 Nm (2.5 m kg, 18 ft lb) : 49 Nm (4.9 m kg, 35 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) g o U V U V X P O R Q R O P S W T X T V U c U l k New d e f i i

POWR TR

h New n m pq

i i

p q

] Z [ Y \

a ^

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order c d e f g h i j k l m n o p q

Job name/Part name Rear pivot arm protector Bushing Shaft Rear pivot arm Collar Shaft Bushing Collar Circlip Adjuster Control rod stopper Circlip Control rod Locknut Adjuster nut

Qty 2 2 1 1 2 1 4 1 2 2 1 2 2 2 2

Remarks

4-49

SLIDE RAIL SUSPENSION

POWR TR

: 75 Nm (7.5 m kg, 54 ft lb) r

t w y v u

x y x t s

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

Qty 1 2 2 1 1 1 2 2

Remarks

For assembly, reverse the disassembly procedure.

4-50

SLIDE RAIL SUSPENSION

REMOVAL

POWR TR

1. Unhook the torsion spring 1 (PZ50/PZ50GT/PZ50FX/PZ50M)

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. Shock absorber Oil leaks/damage Replace. Bushings Wear/cracks/damage Replace. Front pivot arm Rear pivot arm Rear pivot arm bracket (PZ50/PZ50GT/PZ50FX/PZ50M) Suspension wheel bracket Front suspension bracket Rear suspension bracket Connecting arm Connecting arm Rear pivot arm joint Sliding frame Cracks/damage Replace. Slide runner Wear/damage Replace.

ASSEMBLY

1. Apply: ESSO beacon 325 grease or Aeroshell grease #7A (PZ50VT/PZ50MP)

NOTE:
Apply grease to the bushings 1 and the shaft 2 in the area a shown in the illustration.

2 a

b 5 ~ 15 mm (0.20 ~ 0.59 in)

4-51

SLIDE RAIL SUSPENSION

1

POWR TR

2. Install: Control rods 1 (PZ50VT/PZ50MP)

NOTE:
Install the control rods with the water drain holes a facing downward.

3. Install: Rear pivot arm joint 1 (PZ50/PZ50GT/PZ50FX/PZ50M)

b a 1

NOTE:
Align the punch mark a in the rear pivot arm joint with the punch mark b in the rear pivot arm.

4. Install: Rear shock absorber 1 (PZ50GT/PZ50FX/PZ50M)

NOTE:
For PZ50GT/PZ50M: Install the rear shock absorber with the charging valve a facing upward. If the shock absorber is not equipped with a charging valve, install it with the label facing downward. For PZ50FX Install the rear shock absorber with its gas cylinder b facing downward.
PZ50GT/PZ50M PZ50FX

5. Install: Front shock absorber 1 (PZ50GT/PZ50FX)

NOTE:

Install the front shock absorber with the charging valve a facing upward. If the shock absorber is not equipped with a charging valve, install it with the label facing downward.

4-52

SLIDE RAIL SUSPENSION

1 a

POWR TR

6. Install: 2-up adjusting block 1 (PZ50VT/PZ50MP)

NOTE:
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.

4-53

SLIDE RAIL SUSPENSION

7. Install: Stopper band 1

POWR TR

NOTE:
Install the stopper band with a toward the front pivot arm and b toward the shaft.
PZ50 PZ50GT/PZ50M PZ50FX PZ50VT PZ50MP

T.

Stopper band nut: 4 Nm (0.4 m kg, 2.9 ft lb)

R.

4-54

SLIDE RAIL SUSPENSION

INSTALLATION

POWR TR

1. Adjust: Track tension Refer to TRACK TENSION ADJUSTMENT in CHAPTER 2.

Control rod part numbers (PZ50VT/PZ50MP)

a b c

Control rod 1 PZ50VT/PZ50MP

Length a mm (in) 242.3 (9.54)

Length b mm (in) 188.7 (7.43)

Length c mm (in) 2.5P 2 = 5 (0.098P 2 = 0.197)

Control rod 1 part numbers

Control rod stopper part numbers

Washer part numbers Washer thickness mm (in) Upper 90202-25001 2.0 (0.079) 90201-24015 2.0 (0.079) Qty 1 1 Lower 90202-25002 4.0 (0.157) Qty

8ET-4745A-00 (PZ50VT/PZ50MP)

8ES-4745D-00

Standard position Metal washer(s) Plastic washer(s)

4-55

FRONT AXLE AND TRACK FRONT AXLE AND TRACK

1 2 5
LT

POWR TR

: 9 Nm (0.9 m kg, 6.5 ft lb) : 24 Nm (2.4 m kg, 17 ft lb) : 40 Nm (4.0 m kg, 29 ft lb)

LT

6 4

LT

LT

New 7 10 New 9
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

8 (3) 11

12 New
Qty

Order

1 2 3 4 5 6 7 8 9 10 11 12

Job name/Part name Front axle and track removal Drive chain Slide rail suspension Secondary sheave Speed sensor Bearing holder Gear unit Set bolt Bearing Bearing holder Front axle assembly Track Bearing housing Spacer Circlip Bearing

Remarks Remove the parts in the order listed below. Refer to DRIVE CHAIN. Refer to SLIDE RAIL SUSPENSION. Refer to SECONDARY SHEAVE.

1 1 1 2 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.

4-56

FRONT AXLE AND TRACK

INSPECTION

POWR TR

1. Inspect: Track 1 Slide metal 2 Wear/cracks/damage Replace.

2. Inspect: Sprocket wheels 1 Wear/break/damage Replace. Front axle 2 Bends/scratches (excessive)/damage Replace. 3. Inspect: Bearing Pitting/damage Replace.

INSTALLATION

1. Install: Oil seal 1

NOTE:
Press the oil seal onto the bearing housing as shown.
2.5 ~ 3.5 mm (0.10 ~ 0.14 in)

4-57

FRONT AXLE AND TRACK

2 (1. 7 mm 06 in)

POWR TR

2. Install: Sprocket wheels Guide wheels

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.
PZ50/PZ50GT/PZ50FX PZ50M PZ50VT/PZ50MP

123.7 mm (4.87 in) 155.2 mm (6.11 in)

60 mm (2.36 in) 123 mm (4.84 in)

122.4 mm (4.82 in)

4 mm (0.16 in) 4 mm (0.16 in)

122.2 mm (4.81 in) 155.2 mm (6.11 in)

63 mm (2.48 in) 123 mm (4.84 in)

120.9 mm (4.76 in)

2 (1. 7 mm 06 in)
150.7 mm (5.93 in) 182.2 mm (7.17 in) 60 mm (2.36 in) 123 mm (4.84 in) 149.4 mm (5.88 in)

2 (1. 7 mm 06 in)

3. Place the track in the chassis.

NOTE:

For track with a direction of rotation mark a: Install the track with the mark pointing in the direction of track rotation.
PZ50/PZ50GT/PZ50FX/PZ50VT/PZ50MP PZ50M

4-58

SEAT AND FUEL TANK

ENG

ENGINE
SEAT AND FUEL TANK
PZ50/PZ50GT/PZ50FX/PZ50M

10

(6) 9 15 8

: 7 Nm (0.7 m kg, 5.1 ft lb) 12 : 10 Nm (1.0 m kg, 7.2 ft lb)

11 6

1 (4) 2

13

11

3 3 3 16 4

14

Order 1 2 3 4 5 6 7 8 9 10

Job name/Part name Seat and fuel tank removal Seat Rear cover Plastic band Tail/brake light coupler Tail/brake light assembly Main switch coupler Fuel tank cover Fuel pump coupler Fuel hose connector holder Fuel hose

Qty 1 1 4 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed below.

Disconnect. Disconnect. Disconnect. Disconnect.

5-1

SEAT AND FUEL TANK

7 10 (6) 9 15 8 13 11 1

ENG

: 7 Nm (0.7 m kg, 5.1 ft lb) 12 : 10 Nm (1.0 m kg, 7.2 ft lb)

11 6

(4)

3 3 3 16 4

14

5
Order 11 12 13 14 15 16 Job name/Part name Plastic band Fuel tank assembly Fuel sender coupler Fuel hose Fuel pump Fuel tank lower plate Qty 6 1 1 2 1 1 Remarks Disconnect. Disconnect.

For installation, reverse the removal procedure.

5-2

BACKREST AND PASSENGER SEAT BACKREST AND PASSENGER SEAT

PZ50VT/PZ50MP

ENG

: 7 Nm (0.7 m kg, 5.1 ft lb) : 8 Nm (0.8 m kg, 5.8 ft lb) :

10 Nm (1.0 m kg, 7.2 ft lb)

: 23 Nm (2.3 m kg, 17 ft lb) 14 11 4

15 8 15 13 9 1 10 12

(4)

7 6 13 2 (4) 5

Order 1 2 3 4 5 6 7 8 9 10

Job name/Part name Backrest and passenger seat removal Rear cover Passenger seat bracket Backrest Passenger seat Left side rear cover Right side rear cover Left side rear lower cover Right side rear lower cover Passenger grip warmer switch coupler Plastic band

Qty 1 1 1 1 1 1 1 1 1 3

Remarks Remove the parts in the order listed below.

Disconnect.

5-3

BACKREST AND PASSENGER SEAT

: 7 Nm (0.7 m kg, 5.1 ft lb) : 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) 15 8 15 13 9 1 10 12 : 23 Nm (2.3 m kg, 17 ft lb) 14 11

ENG

(4)

7 6 13 2 (4) 5

Order 11 12 13 14 15

Job name/Part name Tail/brake light assembly Tail/brake light switch coupler Passenger grip warmer coupler Rear carrier Passenger grip warmer

Qty 1 1 2 1 2

Remarks Disconnect. Disconnect.

For installation, reverse the removal procedure.

5-4

RIDER SEAT AND FUEL TANK RIDER SEAT AND FUEL TANK
PZ50VT/PZ50MP

ENG

: 7 Nm (0.7 m kg, 5.1 ft lb) :

8 Nm (0.8 m kg, 5.8 ft lb)

: 11 Nm (1.1 m kg, 8.0 ft lb) 6 4 5 10 12 9 (6)

: 10 Nm (1.0 m kg, 7.2 ft lb) 3 2

14 7

1 10

11 10 3

13

Order

Job name/Part name Rider seat and fuel tank removal Passenger seat Sub-wire harness 3 coupler Rider seat Side cover Main switch coupler Auxiliary DC jack coupler Fuel tank cover Fuel pump coupler Fuel hose connector holder Fuel hose Plastic band

Qty

1 2 3 4 5 6 7 8 9 10

1 1 2 1 1 1 1 1 1 6

Remarks Remove the parts in the order listed below. Refer to BACKREST AND PASSENGER SEAT. Disconnect.

Disconnect. Disconnect. Disconnect. Disconnect.

5-5

RIDER SEAT AND FUEL TANK

: 7 Nm (0.7 m kg, 5.1 ft lb) : 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) 3 2 4 5 10 : 11 Nm (1.1 m kg, 8.0 ft lb) 6 9

ENG
(6) 8

14 7

12 1 10 11 10 3

13

Order 11 12 13 14

Job name/Part name Fuel tank assembly Fuel sender coupler Fuel return hose Fuel pump

Qty 1 1 2 1

Remarks Disconnect. Disconnect. For installation, reverse the removal procedure.

5-6

RIDER SEAT AND FUEL TANK

REMOVAL

ENG

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.

NOTE:
When removing the fuel hose from the fuel pump, remove the fuel hose connector holder first, and next, insert a slotted head screwdriver etc. in the slot part a of the fuel hose connector cover 1, then slide the screwdriver in the direction of the arrow, and remove the fuel hose. To remove the fuel hose from the throttle body, slide the fuel hose connector cover 2 on the end of the hose in direction of the arrow shown, press the two buttons 3 on the sides of the connector, and then remove the hose. Before removing the hose, place a few rags in the area under where it will be removed. 3. Remove: Fuel tank

NOTE:
Do not set the fuel tank down on the installation surface of the fuel pump. Be sure to lean the fuel tank against a wall or like. 4. Remove: Fuel pump bracket Fuel pump Fuel pump gasket

CAUTION:
Do not drop the fuel pump or give it a strong shock. Do not touch the base section of the fuel sender.

5-7

RIDER SEAT AND FUEL TANK

INSTALLATION
1. Install: Fuel pump gasket New Fuel pump Fuel pump bracket

ENG

Fuel pump nut: 7 Nm (0.7 m kg, 5.1 ft lb)

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. Install the fuel pump in the direction shown in the illustration.

2. Install: Fuel hose Fuel hose holder Fuel pump coupler

CAUTION:
When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, otherwise the fuel hose will not be properly installed.

NOTE:
Install the fuel hose connector cover 1 securely onto the fuel tank until a distinct click is heard, and then make sure that it does not come loose.

T.

R.

5-8

EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER

PZ50/PZ50GT/PZ50FX/PZ50M

ENG

: 6 Nm (0.6 m kg, 4.3 ft lb) : 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) : 18 Nm (1.8 m kg, 13 ft lb) : 23 Nm (2.3 m kg, 17 ft lb)

6 7 1 10 9 2 2 7 3 3 5

LT

: 25 Nm (2.5 m kg, 18 ft lb) 11 : 33 Nm (3.3 m kg, 24 ft lb) New 8 : 47 Nm (4.7 m kg, 34 ft lb)

Order

Job name/Part name Exhaust pipe and muffler removal Fuel tank Radiator outlet pipe 2 Exhaust pipe joint upper cover Exhaust pipe band Muffler damper holder Seat rail assembly Exhaust pipe/muffler assembly Muffler end cover Muffler damper Gasket Exhaust pipe joint Gasket Exhaust pipe joint lower cover

Qty

Remarks Remove the parts in the order listed below. Refer to SEAT AND FUEL TANK. Refer to RADIATOR AND HEAT EXCHANGER in CHAPTER 6.

1 2 3 4 5 6 7 8 9 10 11

1 2 2 1 1 1 1 2 2 1 1 For installation, reverse the removal procedure.

5-9

EXHAUST PIPE AND MUFFLER

PZ50VT/PZ50MP

ENG

: 6 Nm (0.6 m kg, 4.3 ft lb) : 7 Nm (0.7 m kg, 5.1 ft lb) : 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) : 18 Nm (1.8 m kg, 13 ft lb)

: 25 Nm (2.5 m kg, 18 ft lb) : 33 Nm (3.3 m kg, 24 ft lb)

6 4 2 9 8 3 3 6 4 10 7 New 5

Order

Job name/Part name Exhaust pipe and muffler removal Fuel tank Radiator outlet pipe 2 Slide rail suspension

Qty

Remarks Remove the parts in the order listed below. Refer to RIDER SEAT AND FUEL TANK. Refer to RADIATOR AND HEAT EXCHANGER in CHAPTER 6. Refer to SLIDE RAIL SUSPENSION in CHAPTER 4.

1 2 3 4 5 6 7 8 9 10

Sub frame panel Exhaust pipe joint upper cover Exhaust pipe band Muffler damper holder Exhaust pipe/muffler assembly Muffler damper Gasket Exhaust pipe joint Gasket Exhaust pipe joint lower cover

1 1 2 2 1 1 2 2 1 1 For installation, reverse the removal procedure.

5-10

EXHAUST PIPE AND MUFFLER

INSTALLATION

ENG

1. Install: Muffler damper holder (temporarily) 2. Install: Exhaust pipe/muffler assembly

NOTE:
Position the exhaust pipe bolt 1 at the rear of the hole a in the seat rail assembly, and then finger tighten it.
Forward

3. Install: Exhaust pipe band 1 Exhaust pipe band bolt: 18 Nm (1.8 m kg, 13 ft lb)

4. Tighten: Exhaust pipe bolt Exhaust pipe bolt: 33 Nm (3.3 m kg, 24 ft lb)

5. Tighten: Muffler damper holder bolts Muffler damper holder bolt: 10 Nm (1.0 m kg, 7.2 ft lb)

T.

R.
T.

R.
T.

R.

5-11

OIL TANK OIL TANK

: 10 Nm (1.0 m kg, 7.2 ft lb) : 16 Nm (1.6 m kg, 11 ft lb)

ENG

1 2 6

5
LS

New
Order

Qty 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. Disconnect. Disconnect.

Job name/Part name Oil tank removal Right side panel Engine oil

1 2 3 4 5 6

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

For installation, reverse the removal procedure.

5-12

ENGINE ASSEMBLY ENGINE ASSEMBLY

HOSE AND LEADS

ENG

: 7 Nm (0.7 m kg, 5.1 ft lb)

1 4 6 1 2

5 7

Order

Job name/Part name Hose and leads removal Coolant Engine oil

Qty

Throttle body Primary sheave Brake disc Radiator/coolant reservoir/thermostat Handlebar/steering shaft Oil tank inlet hose/oil tank outlet hose Fuel tank

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. Refer to THROTTLE BODY in CHAPTER 7. Refer to PRIMARY SHEAVE AND DRIVE VBELT in CHAPTER 4. Refer to DRIVE CHAIN in CHAPTER 4. Refer to RADIATOR AND HEAT EXCHANGER in CHAPTER 6. Refer to STEERING in CHAPTER 3. Refer to OIL TANK. Refer to SEAT AND FUEL TANK.

5-13

ENGINE ASSEMBLY
: 7 Nm (0.7 m kg, 5.1 ft lb)

ENG

1 4 6 1 2

5 7

Order

Job name/Part name Exhaust pipe/muffler assembly Water pump Battery 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

Qty

1 2 3 4 5 6 7 8 9

2 1 1 1 1 1 1 3 1

Remarks Refer to EXHAUST PIPE AND MUFFLER. Refer to WATER PUMP in CHAPTER 6. Refer to BATTERY INSPECTION in CHAPTER 2. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure.

5-14

ENGINE ASSEMBLY
ENGINE ASSEMBLY

ENG

: 7 Nm (0.7 m kg, 5.1 ft lb) : 23 Nm (2.3 m kg, 17 ft lb) : 25 Nm (2.5 m kg, 18 ft lb) : 30 Nm (3.0 m kg, 22 ft lb) : 40 Nm (4.0 m kg, 29 ft lb)

5 2 4

11 9 2 6 2 7 10 10

Order 1 2 3 4 5 6 7 8 9 10 11

Job name/Part name Engine assembly removal Frame rear cross member Nut Washer Washer Front engine right mounting bolt/washer Engine mounting bracket Front engine left mounting bolt Rear engine mounting bolt Rear engine mounting bolt spacer Front engine mounting bolt spacer Engine assembly

Qty 1 3 1 1 1/1 1 1 1 1 2 1

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

5-15

ENGINE ASSEMBLY
REMOVAL

ENG

1. Remove: Rear engine mounting nut Front engine mounting nuts Washers

NOTE:
Do not remove the engine mounting bolts.

2. Remove: Engine assembly 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. Engine mount spacer wrench: 90890-01516, YS-01516 Remove the engine mounting bolts and engine mounting bracket. Remove the rear engine mounting bolt spacer, and then remove the engine assembly.

INSTALLATION NOTE:
After installing all parts, refer to CABLE ROUTING in CHAPTER 9, to check the cable, lead and hose routing. 1. Install: Engine assembly

NOTE:
Use the pivot shaft wrench to tighten the engine mounting bolt spacers.

5-16

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 (0.39 in) diameter rod that is approximately 130 mm (5.12 in) long. Install the engine mount spacer wrench 1. Engine mount spacer wrench: 90890-01516, YS-01516 Tighten the rear engine mounting bolt spacer. Rear engine mounting bolt spacer: 7 Nm (0.7 m kg, 5.1 ft lb)

T.

R.

Tighten the rear engine mounting nut. Rear engine mounting nut: 40 Nm (4.0 m kg, 29 ft lb)

Tighten the front engine mounting bolt spacers 2 (right and left) until they come to contact with the engine damper 3.

NOTE:
Do not apply torque to the front engine mounting bolt spacers. Remove the rod from the engine mounting bracket, and then install the front engine right mounting bolt. Install the washers and nuts and then, tighten the front engine mounting nuts (right and left). Front engine mounting nut: 40 Nm (4.0 m kg, 29 ft lb)

T.

R.
T.

R.

5-17

CAMSHAFTS CAMSHAFTS
CYLINDER HEAD COVER

ENG

: 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) :

12 Nm (1.2 m kg, 8.7 ft lb)

2 1 New 3 4
LS

: 13 Nm (1.3 m kg, 9.4 ft lb)

5 New

Order

Job name/Part name Cylinder head cover removal Fuel tank

Qty

Remarks Remove the parts in the order listed below. Refer to SEAT AND FUEL TANK. (PZ50/ PZ50GT/PZ50FX/PZ50M) Refer to RIDER SEAT AND FUEL TANK. (PZ50VT/PZ50MP)

1 2 3 4 5 6

Cylinder identification sensor Ignition coil Spark plug Cylinder head cover Cylinder head cover gasket Timing chain guide (top side)

1 3 3 1 1 1 For installation, reverse the removal procedure.

5-18

CAMSHAFTS
CAMSHAFTS

ENG

: 9 Nm (0.9 m kg, 6.5 ft lb) 6

E

: 12 Nm (1.2 m kg, 8.7 ft lb) : 24 Nm (2.4 m kg, 17 ft lb)

E

5 7

7 1
M

New

8
M

10
M

2 New

3
LT

LT

4 New

Order

1 2 3 4 5 6 7 8 9 10

Job name/Part name Camshaft removal Engine Timing accessing screw Crankshaft end accessing screw Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft assembly Intake camshaft sprocket

Qty

Remarks Remove the parts in the order listed below. Refer to ENGINE ASSEMBLY.

1 1 1 1 3 3 4 1 1 1

NOTE:
During removal, the dowel pins may still be connected to the camshaft caps.

For installation, reverse the removal procedure.

5-19

CAMSHAFTS
b
REMOVAL

ENG

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.

3. Remove: Timing chain tensioner 1 Gasket

4. Remove: Camshaft caps Dowel pins

CAUTION:
To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.

5. Remove: Intake camshaft 1 (with camshaft sprocket) Exhaust camshaft 2

NOTE:
To prevent the timing chain from falling into the crankcase, fasten it with a wire 3.

5-20

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: <Limit>: a 30.350 mm (1.1949 in) b 22.510 mm (0.8862 in) Exhaust: <Limit>: a 30.600 mm (1.2047 in) b 22.493 mm (0.8856 in)

3. Measure: Camshaft runout Out of specification Replace. Camshaft runout: 0.03 mm (0.0012 in)

5-21

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.

NOTE:
Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge. Camshaft cap bolt: 9 Nm (0.9 m kg, 6.5 ft lb) Remove the camshaft caps and then measure the width of the Plastigauge 1.

5. Measure: Camshaft journal diameter a Out of specification Replace the camshaft. Within specification Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter: 21.959 ~ 21.972 mm (0.8645 ~ 0.8650 in)

6. Inspect: Camshaft sprocket More than 1/4 tooth a wear Replace the camshaft sprockets and the timing chain as a set.
a b 1 2 1/4 tooth Correct Timing chain roller Camshaft sprocket

5-22

CAMSHAFTS
1 2 1
7. Inspect: Decompression system

ENG

Inspection steps: Check that the decompressor lever pins 1 projects from the camshaft. Check that the decompressor cams 2 moves smoothly. 8. Inspect: Timing chain guide (top side) Damage/wear Replace the timing chain guide.

9. Remove: Timing chain tensioner rod 1 Timing chain tensioner spring seat 2 Timing chain tensioner spring 3 Timing chain tensioner housing 5

NOTE:
Squeeze the timing chain tensioner clip 4, and then remove the timing chain tensioner springs and timing chain tensioner rod. 10. Inspect: Timing chain tensioner housing Timing chain tensioner rod Timing chain tensioner spring seat Timing chain tensioner spring Damage/wear Replace the as a set. 11. Assemble: Timing chain tensioner spring Timing chain tensioner spring seat Timing chain tensioner rod

NOTE:
Prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain tensioner housing.

5-23

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.

NOTE:
Hook the timing chain tensioner rod pin 5 to the center of the clip 4. After the installation, check that the clip 4 can come off by its own weight by pushing the timing chain tensioner rod 3 at the position of installation.

12. Inspect: All parts Damage/wear Replace the defective part(s).

5-24

CAMSHAFTS
INSTALLATION

ENG

1. Install: Intake camshaft sprocket 1 (with the special tool 2) Rotor holding tool: 90890-01235, YU-01235 Camshaft sprocket bolts Camshaft sprocket bolt: 24 Nm (2.4 m kg, 17 ft lb)

T.

R.

a c c b

a
NOTE:

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

2. Install: Exhaust camshaft 1 Intake camshaft 2 (with the camshaft sprocket) Installation steps: 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. Install the timing chain onto both camshaft sprockets, and then install the camshafts.

NOTE:
When installing the timing chain, start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side. Make sure the marks d and e on the timing chain sprockets are parallel with the edge of the cylinder head. c: Exhaust side d: Intake side e: Cylinder #1 - cam

e d

d c

e c

5-25

CAMSHAFTS
a
3. Install: Dowel pins Intake camshaft cap Exhaust camshaft cap

ENG

NOTE:

Install the camshaft caps with the arrow mark a pointing towards the right side of the engine. 4. Install: Camshaft cap bolts Camshaft cap bolt: 9 Nm (0.9 m kg, 6.5 ft lb)

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. The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.

b
L

5. Install: Timing chain tensioner gasket 1 New Timing chain tensioner 2 Timing chain tensioner bolt: 12 Nm (1.2 m kg, 8.7 ft lb)

NOTE:
Be sure to install the timing chain tensioner gasket so that its section with the L mark a is protruding from the lower left side of the timing chain tensioner. The arrow mark b on the timing chain tensioner should face up. 6. Turn: Crankshaft (several turns counterclockwise)

T.

R.
T.

R.

5-26

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.

d c

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. Timing chain sprocket marks c and d Make sure the marks c and d on the timing chain sprockets are parallel with the edge of the cylinder head. Out of alignment Adjust. Refer to the installation steps above. 10. Measure: Valve clearance Out of specification Adjust. Refer to VALVE CLEARANCE ADJUSTMENT in CHAPTER 2.

11. Install Cylinder head cover gasket New Cylinder head cover Cylinder head cover bolt: 12 Nm (1.2 m kg, 8.7 ft lb)

NOTE:
Apply bond TB1541 1 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket. Apply Yamaha bond No. 1215 2 onto the mating surfaces of the cylinder head cover gasket and cylinder head. Tighten the cylinder head cover bolts stages and in a crisscross pattern.

T.

R.

5-27

CYLINDER HEAD CYLINDER HEAD

(6)
E

ENG

New 2

New 3

4 4

: 10 Nm (1.0 m kg, 7.2 ft lb) : 12 Nm (1.2 m kg, 8.7 ft lb) : 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

Qty

Remarks Remove the parts in the order listed below. Refer to ENGINE ASSEMBLY. Refer to CAMSHAFTS.

1 1 1 2 For installation, reverse the removal procedure.

5-28

CYLINDER HEAD
REMOVAL
1. Remove: Cylinder head bolts

ENG

5 1 3

NOTE:
Loosen each bolt 1/2 of a turn at a time. After all of the bolt are fully loosened, remove them.

4 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. Inspect: Cylinder head Damage/scratches Replace. Cylinder head water jacket Mineral deposits/rust Eliminate. 4. Measure: Cylinder head warpage Out of specification Resurface the cylinder head. Maximum cylinder head warpage: 0.10 mm (0.0039 in) Measurement steps: Place a straightedge 1 and a thickness gauge 2 across the cylinder head. Measure the warpage. If the limit is exceeded, resurface the cylinder head as follows. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.

NOTE:
To ensure an even surface, rotate the cylinder head several times.

5-29

CYLINDER HEAD
2 New 1
INSTALLATION
1. Install: Dowel pins 1 Gasket 2 New

ENG

1
2. Install: Cylinder head

NOTE:
Pass the timing chain through the timing chain cavity.

3. Tighten: Cylinder head bolts (M10)

NOTE:
The tightening procedure of the cylinder head bolts is angle controlled, therefore tighten the bolts using the following procedure.

Tightening steps: Lubricate the cylinder head bolts and washers with engine oil. Install the washers and cylinder head bolts. Tighten the cylinder head bolts in the proper tightening sequence as shown. Cylinder head bolt (M10): 1st: 25 Nm (2.5 m kg, 18 ft lb)

Loosen and retighten the cylinder head bolts in the proper tightening sequence as shown. Cylinder head bolt (M10): 2nd: 25 Nm (2.5 m kg, 18 ft lb)

T.

R.
T.

R.

5-30

CYLINDER HEAD

ENG

Tighten the cylinder head bolts further to reach the specified angle 180 in the proper tightening sequence as shown. 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. Tighten the bolt until it is at the specified angle.

NOTE:
When using a hexagonal bolt, note that the angle from one corner to another is 60.

4. Tighten: Cylinder head bolts (M6) 1 Cylinder head bolt: 12 Nm (1.2 m kg, 8.7 ft lb)

T.

R.

T.

R.

5-31

VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS

1 2 3 4 5 New 8 1 3
M

ENG

9
M

2 3 4 5 8
M

New

9 10 10 7
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

Qty

Remarks Remove the parts in the order listed below. Refer to CYLINDER HEAD.

10 10 20 10 10 4 6 10 10 10 For installation, reverse the removal procedure.

5-32

VALVES AND VALVE SPRINGS

REMOVAL

ENG

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. Inspect: Valve (for leakage) Leakage at the valve seat Check the valve face, valve seat, and valve seat width. Inspection steps: Pour a clean solvent a into the intake and exhaust ports. Check that the valves properly seal.

NOTE:
There should be no leakage at the valve seat 1.

3. Remove: Valve cotters 1

NOTE:
Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor: 90890-04019, YM-04019 Valve spring compressor attachment: Intake valve: 90890-04114, YM-04114 Exhaust valve: 90890-04108, YM-04108
5-33

3 1

VALVES AND VALVE SPRINGS

4. Remove: Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5

ENG

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 (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.0031 in) Exhaust: 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) <Limit>: 0.10 mm (0.0039 in)

2. Replace: Valve guide

NOTE:
To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 C (212 F) in an oven. Replacement steps: Remove the valve guide with the valve guide remover 1. Install the new valve guide with the valve guide installer 2 and valve guide remover 1.

5-34

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 (4): 90890-04111, YM-04111 Valve guide installer (4): 90890-04112, YM-04112 Valve guide reamer (4): 90890-04113, YM-04113 3. Eliminate: Carbon deposits (from the valve face and valve seat) 4. Inspect: Valve face Pitting/wear Grind the valve face. Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve. 5. Measure: Valve margin thickness a Out of specification Replace the valve. Valve margin thickness: Intake: 0.5 ~ 0.9 mm (0.0197 ~ 0.0354 in) Exhaust: 0.5 ~ 0.9 mm (0.0197 ~ 0.0354 in)

6. Measure: Valve stem runout Out of specification Replace the valve.

NOTE:
When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the oil seal. Valve stem runout: 0.01 mm (0.0004 in) 7. Eliminate: Carbon deposits (from the valve face and valve seat) 8. Inspect: Valve seat Pitting/wear Replace the cylinder head.

5-35

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) <Limit>: 1.6 mm (0.0630 in) Exhaust: 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) <Limit>: 1.9 mm (0.0748 in) Measurement steps: Apply Mechanics 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. Measure the valve seat width.

NOTE:
Where the valve seat and valve face contacted one another, the blueing will have been removed.

10. Lap: Valve face Valve seat

NOTE:
After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: Apply a coarse lapping compound a to the valve face.

CAUTION:
Do not let the lapping compound enter the gap between the valve stem and the valve guide. Apply molybdenum disulfide oil onto the valve stem.

5-36

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. Apply Mechanics blueing dye (Dykem) b 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. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat.

11. Measure: Valve spring free length a Out of specification Replace the valve spring. 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)

5-37

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 (0.06 in) Exhaust: 2.5/1.7 mm (0.07 in)

14. Inspect: Valve lifter Damage/scratches Replace the valve lifters and cylinder head.

INSTALLATION
1. Deburr: Valve stem end (with an oil stone)

5-38

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. Install: Valve cotters 1

NOTE:

3 1

Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor: 90890-04019, YM-04019 Valve spring compressor attachment: Intake valve: 90890-04114, YM-04114 Exhaust valve: 90890-04108, YM-04108

5-39

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. Each valve lifter and valve pad must be reinstalled in its original position.

5-40

A.C. MAGNETO ROTOR AND STARTER CLUTCH A.C. MAGNETO ROTOR AND STARTER CLUTCH

ENG
i

: 7 Nm (0.7 m kg, 5.1 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb)

: 12 Nm (1.2 m kg, 8.7 ft lb) : 130 Nm (13.0 m kg, 94 ft lb)

LT

10

4 3 5 (5) (3) 1
LT LT LT

(7)

LT

2 New 12 11 9
E LT E

8 7

6
E

Order

1 2 3 4 5 6 7 8 9 10 11 12

Job name/Part name A.C. magneto rotor and starter clutch removal Engine assembly A.C. magneto cover Gasket Dowel pin Pickup coil Stator coil A.C. magneto rotor Idle gear shaft Starter clutch idle gear Starter clutch Woodruff key Starter clutch gear Washer

Qty

Remarks Remove the parts in the order listed below. Refer to ENGINE ASSEMBLY.

1 1 2 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.

5-41

A.C. MAGNETO ROTOR AND STARTER CLUTCH

REMOVAL
1. Remove: A.C. magneto rotor bolt Washer

ENG

NOTE:

2 1

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. Sheave holder: 90890-01701, YS-01880-A

2. Remove: A.C. magneto rotor 1 (with the rotor holding puller 2 and flywheel puller attachment) Woodruff key

CAUTION:
2 1
To protect the end of the crankshaft, place an appropriate sized socket between the rotor holding puller sets center bolt and the crankshaft.

NOTE:
Make sure the rotor holding puller is centered over the A.C. magneto rotor. Rotor holding puller: 90890-01362, YU-33270-B Flywheel puller attachment: 90890-04089, YM-33282

5-42

A.C. MAGNETO ROTOR AND STARTER CLUTCH

3. Remove: Starter clutch

ENG

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.

1 a

3. Inspect: Starter clutch idle gear Starter clutch gear 1 Burrs/chips/roughness/wear Replace the defective part(s). Starter clutch gears contacting surfaces a Damage/pitting/wear Replace the starter clutch gear.

5-43

A.C. MAGNETO ROTOR AND STARTER CLUTCH

4. Inspect: Starter clutch operation

ENG

Installation steps: Install the starter clutch gear onto the starter clutch and hold the starter clutch. When turning the starter clutch gear clockwise , 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 , it should turn freely, otherwise the starter clutch is faulty and must be replaced.

INSTALLATION
1. Install: Starter clutch

NOTE:
While holding the magneto rotor with the sheave holder, tighten the starter clutch bolt. Do not allow the sheave holder to touch the projection on the magneto rotor. Sheave holder: 90890-01701, YS-01880-A 2. Tighten: Starter clutch bolts 1 Starter clutch bolt: 12 Nm (1.2 m kg, 8.7 ft lb) LOCTITE

3. Install: Woodruff key A.C. magneto rotor Washer A.C. magneto rotor bolt

NOTE:
Clean the tapered portion of the crankshaft and the magneto rotor hub. When installing the magneto rotor, make sure the woodruff key is properly seated in the key-way of the crankshaft.

T.

R.

5-44

A.C. MAGNETO ROTOR AND STARTER CLUTCH

ENG

4. Tighten: A.C. magneto rotor bolt 1 A.C. magneto rotor bolt: 130 Nm (13.0 m kg, 94 ft lb)

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. Sheave holder: 90890-01701, YS-01880-A

T.

R.

3 2
5. Apply: Sealant (onto the A.C. magneto lead grommet) Yamaha bond No. 1215: 90890-85505 (Three Bond No.1215)

6. Tighten: A.C. magneto cover bolt A.C. magneto 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 A.C. magneto cover.

T.

R.

5-45

OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP
1

ENG
New

(13)

2
E

4 12 13 New 3 11 7
LT LT

New 6 New 7 New

10 : 10 Nm (1.0 m kg, 7.2 ft lb)

E

9
LT

: 12 Nm (1.2 m kg, 8.7 ft lb) 8 : 15 Nm (1.5 m kg, 11 ft lb) : 17 Nm (1.7 m kg, 12 ft lb) : 30 Nm (3.0 m kg, 22 ft lb)

: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order

Job name/Part name Oil pan and oil pump removal Engine Starter clutch gear Oil tank inlet hose Oil tank outlet hose Oil pressure switch Oil filter cartridge Oil pan Gasket Dowel pin Oil pump drive chain guide Oil pump driven sprocket shaft Oil pump driven sprocket

Qty

Remarks Remove the parts in the order listed below. Refer to ENGINE ASSEMBLY. Refer to A.C. MAGNETO ROTOR AND STARTER CLUTCH.

1 2 3 4 5 6 7 8 9 10

1 1 1 1 1 1 2 1 1 1

5-46

OIL PAN AND OIL PUMP

ENG
New (13)

2
E

4 12 13 New 3 11 7
LT LT

New 6 New 7 New

10 : 10 Nm (1.0 m kg, 7.2 ft lb)

E

9
LT

: 12 Nm (1.2 m kg, 8.7 ft lb) 8 : 15 Nm (1.5 m kg, 11 ft lb) : 17 Nm (1.7 m kg, 12 ft lb) : 30 Nm (3.0 m kg, 22 ft lb)

: 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

Qty 1 1 2

Remarks

For installation, reverse the removal procedure.

5-47

OIL PAN AND OIL PUMP

: 5 Nm (0.5 m kg, 3.6 ft lb) E New

ENG

6 4

1 New (5) D
E

C (5) New A B 3 2 0 8

Order 1 2 3 4 5 6 7 8 9 0 A B C D E

Job name/Part name Oil pump disassembly Oil pump housing cover 1 Spring Relief valve Oil pump inner rotor 1 Pin Oil pump outer rotor 1 Oil pump housing cover 2 Oil pump inner rotor 2 Oil pump outer rotor 2 Oil pump shaft Check ball seat Check ball Spring Spacer Oil pump housing

Qty 1 1 1 1 2 1 1 2 2 1 1 1 1 1 1

Remarks Remove the parts in the order listed below.

For assembly, reverse the disassembly procedure.

5-48

OIL PAN AND OIL PUMP

REMOVAL
1. Remove: Oil pan

ENG

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. Measure: Inner-rotor-to-outer-rotor-tip clearance a (between inner rotor 1 and outer rotor 2) Outer-rotor-to-oil-pump-housing clearance b (between outer rotor 2 and pump housing 3) Out of specifications Replace oil pump assembly. Inner-rotor-to-outer-rotor-tip clearance: Less than 0.12 mm (0.005 in) Outer-rotor-to-oil-pump-housing clearance: Oil pump outer rotor: 0.09 ~ 0.15 mm (0.004 ~ 0.006 in)

3. Inspect: Oil pump operation Rough movement Repeat steps (1) and (2) or replace the defective part(s).

5-49

OIL PAN AND OIL PUMP

ENG

1 2 3

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).

8. Inspect: Oil strainer 1 Damage Replace. Obstruction Wash and blow out with compressed air. Contaminants Clean with engine oil.

INSTALLATION
1. Lubricate: Inner rotor Outer rotor Oil pump shaft (with the recommended lubricant) Recommended lubricant: Engine oil 2. Inspect: Oil pump operation Unsmooth operation Replace.

5-50

OIL PAN AND OIL PUMP

b

ENG

3. Install: Oil pump driven sprocket shaft 1

NOTE:

Align the slit a on the oil pump driven sprocket shaft with the projection b on the oil pump shaft. 4. Install: Dowel pins Gasket New Oil pan Oil pan bolts Oil pan bolt: 10 Nm (1.0 m kg, 7.2 ft lb)

NOTE:
Tighten the oil pan bolts in stages and in a crisscross pattern.

T.

R.

5-51

BALANCER BALANCER
New 4 5 8 15

ENG

LT

18 19 10 9 New 11 16 7 6 New 4 13 12 2 1 3 New : 10 Nm (1.0 m kg, 7.2 ft lb) : 12 Nm (1.2 m kg, 8.7 ft lb) : 50 Nm (5.0 m kg, 36 ft lb) : 75 Nm (7.5 m kg, 54 ft lb) (4) New (10)
Qty
LT

14

17

(2)

Order

Job name/Part name Balancer shaft removal Engine Cylinder head A.C. magneto rotor/starter clutch gear Primary sheave drive shaft cover Gasket Primary sheave drive shaft assembly Lock washer Right balancer weight Balancer shaft driven gear Left balancer weight Balancer shaft Lock washer Balancer shaft drive gear

Remarks Remove the parts in the order listed below. Refer to ENGINE ASSEMBLY. Refer to CYLINDER HEAD. Refer to A.C. MAGNETO ROTOR AND STARTER CLUTCH.

1 2 3 4 5 6 7 8 9 10

1 1 1 2 1 1 1 1 1 1

5-52

BALANCER
New 4 5 8 15

ENG

LT

18 19 10 9 New 11 16 7 6 New 4 13 12 2 1 3 New : 10 Nm (1.0 m kg, 7.2 ft lb) : 12 Nm (1.2 m kg, 8.7 ft lb) : 50 Nm (5.0 m kg, 36 ft lb) : 75 Nm (7.5 m kg, 54 ft lb) (4) New (10)
Qty 1 1 1 1 1 1 1 1 1 Remarks
LT

14

17

(2)

Order 11 12 13 14 15 16 17 18 19

Job name/Part name Circlip Bearing Circlip Bearing Bearing retainer Bearing Bearing Circlip Bearing

For installation, reverse the removal procedure.

5-53

BALANCER
REMOVAL

ENG

1. Straighten the lock washer tab. 2. Loosen: Right balancer weight nut 1

CAUTION:
1
The right balancer weight nut has left-handed threads. To loosen the nut, turn it clockwise.

NOTE:
Place an aluminum plate 2 between the teeth of the balancer shaft drive gear 3 and balancer shaft driven gear 4.

2 3
3. Straighten the lock washer tabs. 4. Loosen: Balancer shaft drive gear bolt 1 Balancer shaft driven gear nut 2

4 6

2 3

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.

NOTE:
Place an aluminum plate 3 or 4 between the teeth of the balancer shaft drive gear 5 and balancer shaft driven gear 6.

5-54

BALANCER
INSPECTION

ENG

2 1

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. 5. Inspect: Primary sheave drive shaft assembly Damage Replace.

INSTALLATION
1. Install: Balancer shaft drive gear Lock washer Balancer shaft drive gear bolt

NOTE:
Align the shallow groove a in the balancer shaft drive gear with the low spline b of the crankshaft.

b
2. Install: Left balancer weight 1

NOTE:

Align the punch mark a on the left balancer weight with the shorter spline b on the balancer shaft end.

5-55

BALANCER
a c d 1

ENG

3. Install: Balancer shaft driven gear 1 Lock washers Balancer shaft driven gear nut Right balancer weight nut Balancer shaft drive gear bolt

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. Tighten: Balancer shaft driven gear nut Right balancer weight nut Balancer shaft drive gear bolt

1
T.

Right balancer weight nut: 50 Nm (5.0 m kg, 36 ft lb) Balancer shaft driven gear nut: 50 Nm (5.0 m kg, 36 ft lb) Balancer shaft drive gear bolt: 75 Nm (7.5 m kg, 54 ft lb)

CAUTION:
The right balancer weight nut, 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.

R.

5-56

BALANCER

ENG

5. Tighten: Primary sheave drive shaft cover bolt 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.

T.

R.

5-57

CRANKCASE CRANKCASE
CRANKCASE

ENG

: 12 Nm (1.2 m kg, 8.7 ft lb) :

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

(6)

(2)
E

(5)

3 (2)
LT

2
E E

(3)

4
LT

Order

Job name/Part name Crankcase removal Engine Cylinder head A.C. magneto rotor/starter clutch gear Oil pump Balancer shaft Starter motor

Qty

Remarks Remove the parts in the order listed below. Refer to ENGINE ASSEMBLY. Refer to CYLINDER HEAD. Refer to A.C. MAGNETO ROTOR AND STARTER CLUTCH. Refer to OIL PAN AND OIL PUMP. Refer to BALANCER. Refer to STARTER MOTOR in CHAPTER 8.

1 2 3 4

Timing chain guide (intake side) Timing chain Lower crankcase Dowel pin

1 1 1 2 For installation, reverse the removal procedure.

5-58

CRANKCASE
CONNECTING RODS AND PISTONS

ENG

: 1st 20 Nm (2.0 m kg, 14 ft lb)

2nd Specified angle 120 ~ 130

1
M E

2 2

6
E

New 3 4 5

9 3 New 8 7
E 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

Qty 2 4 4 2 2 2 2 2 2

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

5-59

CRANKCASE
CRANKSHAFT

ENG

2 2
E

1
E E

Order 1 2 3

Job name/Part name Crankshaft removal Crankshaft Crankshaft journal bearing Upper crankcase

Qty 1 6 1

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

5-60

CRANKCASE

ENG

REMOVAL
1. Remove: Crankcase bolts

NOTE:
19 18 17

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.
Cylinder head side Oil pan side

10 8 7 9 11

3 4

1 2

5 6

12 13

15 14

2. Remove: Lower crankcase

CAUTION:
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure that the crankcase halves separate evenly. 3. Remove: Dowel pins Crankshaft journal bearing

NOTE:
Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place.

4. Remove: Connecting rod cap 1 Big end bearing

NOTE:
Identify the position of each big end bearing so that it can be reinstalled in its original place.

5-61

CRANKCASE
4 3 2 1
5. Remove: Piston pin clips 1 Piston pin 2 Piston 3 Connecting rod 4

ENG

CAUTION:
Do not use a hammer to drive the piston pin out.

NOTE:
For reference during installation, put identification marks on the piston crown. Before removing the piston pin, deburr the piston pin clips groove and the pistons 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. Piston pin puller: 90890-01304, YU-01304

6. Remove: Top ring 2nd ring Oil ring

NOTE:
When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. 7. Remove: Crankshaft Crankshaft journal bearing

NOTE:
Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.

5-62

CRANKCASE
INSPECTION

ENG

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. 77.000 ~ 77.010 mm (3.0315 ~ 3.0319 in) 0.050 mm (0.0020 in) 0.050 mm (0.0020 in)

Cylinder bore C Taper limit T Out of round R

C = maximum of D1 ~ D6 T = maximum of D1 or D2 maximum of D5 or D6 R = maximum of D1, D3 or D5 maximum of D2, D4 or D6 If out of specification, replace the cylinder, and the piston and piston rings as a set. 2nd step: Measure piston skirt diameter P with the micrometer.
a 11.0 mm (0.43 in) from the bottom edge of the piston.

Piston size (standard) (P): 76.955 ~ 76.970 mm (3.0297 ~ 3.0303 in) If out of specification, replace the piston and piston rings as a set.

5-63

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) <Limit>: 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.

NOTE:
Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance. Piston rings side clearance: Top ring: 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 2nd ring: 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in)

4. Install: Piston ring (into the cylinder)

NOTE:
Level the piston ring in the cylinder with the piston crown.
a 5.0 mm (0.20 in)

5-64

CRANKCASE

ENG

5. Measure: Piston ring end gap Out of specification Replace the piston rings as a set.

NOTE:
The oil ring expander spacers end gap cannot be measured. If the oil ring rails 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. Inspect: Piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 7. Measure: Piston pin outside diameter Out of specification Replace the piston pin. Piston pin outside diameter: 16.991 ~ 17.000 mm (0.6689 ~ 0.6693 in)

8. Measure: Piston pin bore inside diameter Out of specification Replace the piston. Piston pin bore inside diameter: 17.002 ~ 17.013 mm (0.6694 ~ 0.6698 in)

5-65

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) <Limit>: 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: 0.03 mm (0.0012 in)

11. Inspect: Crankshaft journal surfaces Crankshaft pin surfaces Bearing surfaces Scratches/wear Replace the crankshaft.

5-66

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. To obtain the correct crankshaft-journalto-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. Place the upper crankcase upside down on a bench.

Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase.

NOTE:
Align the projections a of the crankshaft journal upper bearings with the notches b in the crankcase.

Put a piece of Plastigauge 2 on each crankshaft journal.

NOTE:
Do not put the Plastigauge over the oil hole in the crankshaft journal.

5-67

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. Crankcase bolt: Bolt 1: 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 Bolt 2 ~ 6: 12 Nm (1.2 m kg, 8.7 ft lb)

T.

R.

53 1 5 1 5

6 1
1

64 1
1

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

Cylinder head side Oil pan side

3 6

6 6 4

NOTE:
Lubricate the crankcase bolt threads with engine oil. Remove the lower crankcase and the crankshaft journal lower bearings. Measure the compressed Plastigauge width c on each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings.

5-68

CRANKCASE

ENG

13. Select: Crankshaft journal bearings (J1 ~ J3)

NOTE:
The numbers stamped into the crankshaft web and the numbers 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. Selection of bearings: For example, if the crankcase J1 and crankshaft web J1 numbers are 4 and 2 respectively, then the bearing size for J1 is: Bearing size for J1: J1 (crankcase) J1 (crankshaft web) 1 = 4 2 1 = 1 (blue) CRANKSHAFT JOURNAL BEARING COLOR CODE 0 1 2 3 4 white blue black brown green

J1

J2

J3

J3 J2 J1
212 22
BAC

J3 J2 J1

14. Measure: Crankshaft-pin-to-big-end-bearing clearance Out of specification Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance: 0.034 ~ 0.058 mm (0.0013 ~ 0.0023 in)

5-69

CRANKCASE
Measurement steps:

ENG

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.

NOTE:
Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap. Put a piece of Plastigauge 1 on the crankshaft pin. Assemble the connecting rod halves.

NOTE:

Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Apply molybdenum disulfide grease onto the bolts, threads, and nut seats. Make sure that the Y mark c on the connecting rod faces towards the right side of the crankshaft. Make sure that the characters d on both the connecting rod and connecting rod cap are aligned.

d
5 F

5F
d
5-70

CRANKCASE

ENG

Tighten the connecting rod bolts. 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. Tighten the connecting rod bolt further to reach the specified angle (120 ~ 130).

WARNING
When the bolt is 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. Tighten the bolt until it is at the specified angles. Remove the connecting rod and big end bearings. Measure the compressed Plastigauge width f on the crankshaft pin. If the clearance is out of specification, select replacement big end bearings.

T.

R.

5-71

CRANKCASE

ENG

15. Select: Big end bearings (P1 ~ P2)

NOTE:
The numbers 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. Selection of bearings: For example, if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 respectively, then the bearing size for P1 is: Bearing size for P1: P 1 (connecting rod) P1 (crankshaft web) 1 = 5 2 1 = 2 (black) BIG END BEARING COLOR CODE 0 1 2 3 white blue black brown

P1 P2

P2 P1
212 22
BAC

5F
1

16. Inspect: Crankcase: Cracks/damage Replace.

NOTE:
Thoroughly wash the crankcase halves in a mild solvent. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Oil delivery passages Obstruction Blow out with compressed air. 17. Inspect: Bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement Replace. 18. Inspect: Timing chain Damage/stiffness Replace the chain and sprocket as a set. 19. Inspect: Timing chain guide (intake side) Damage/wear Replace the timing chain guide.

5-72

CRANKCASE
INSTALLATION

ENG

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. Install: Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5

NOTE:
Be sure to install the piston rings so that the manufacturers marks or numbers a face up. 4. Install: Piston 1 (onto the respective connecting rod 2) Piston pin 3 Piston pin clip New 4

a 2
Y

3 4

NOTE:
Apply engine oil onto the piston pin. Make sure that the Y mark a on the connecting rod faces left when the punch mark b on the piston is pointing up. Refer to the illustration. Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #3).

5-73

CRANKCASE
be 90 c
5. Offset: Piston ring end gaps
a b c d e Top ring 2nd ring Upper oil ring rail Oil ring expander Lower oil ring rail Exhaust side

ENG

90

ad 45

6. Lubricate: Piston Piston rings Cylinder Recommended lubricant: Engine oil 7. Lubricate: Bolt threads Nut seats (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide grease 8. Lubricate: Crankshaft pins Big end bearings Connecting rod inner surface (with the recommended lubricant) Recommended lubricant: Engine oil

5-74

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. Make sure that the Y marks a on the connecting rods face towards the A.C. magneto. Make sure that the characters b on both the connecting rod and connecting rod cap are aligned. Piston ring compressor: 90890-05158, YM-08037 10. Align: Bolt heads (with the connecting rod caps)

5-75

CRANKCASE
11. Tighten: Connecting rod bolts

ENG

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. Tighten the connecting rod bolt further to reach the specified angle (120 ~ 130).

WARNING
When the bolt is 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. Tighten the bolt until it is at the specified angles. 12. Lubricate: Crankshaft journal bearings (with the recommended lubricant) Recommended lubricant: Engine oil

T.

R.

5-76

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. Install: Crankshaft journal bearings 1 (into the lower crankcase)

NOTE:
Align the projections a on the crankshaft journal lower bearings with the notches b in the crankcase. Install each crankshaft journal lower bearing in its original place. 16. Install: Lower crankcase (onto the upper crankcase)

5-77

CRANKCASE
17. Install: Crankcase bolts

ENG

NOTE:
Lubricate the bolt threads with engine oil. Tighten the bolts in the order of the embossed numbers on the crankcase.

2
Crankcase bolt: Bolt 1: 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 Bolt 2 ~ 6: 12 Nm (1.2 m kg, 8.7 ft lb)
T.

R.

53 1 5 1 5

6 1
1

64 1
1

3 6

6 6 4

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

Cylinder head side Oil pan side

NOTE:
Lubricate the crankcase bolt threads with engine oil.

5-78

RADIATOR AND HEAT EXCHANGER

COOL

COOLING SYSTEM
RADIATOR AND HEAT EXCHANGER
: 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) 23 2 7 4 6 (3) 3 5 16 20 11 14 18 3
LS

(2)

1 24 22 21 19 25

15

26

New

8 17 (3) 12 : 27 Nm (2.7 m kg, 19 ft lb)

LT

13 10 24

9 New

(4)

Order

Job name/Part name Radiator and heat exchanger removal Coolant

Qty

Engine assembly 1 2 3 4 5 6 7 8 9 10 Coolant reservoir Radiator fan motor coupler Plastic band Radiator inlet hose Radiator outlet hose 1 Radiator assembly Radiator fan motor Oil cooler outlet hose Oil cooler inlet hose Oil cooler
6-1

Remarks Remove the parts in the order listed below. Drain. Refer to COOLING SYSTEM in CHAPTER 2. Refer to ENGINE ASSEMBLY in CHAPTER 5. Disconnect. PZ50M/PZ50VT/PZ50MP

1 1 3 1 1 1 1 1 1 1

PZ50M/PZ50VT/PZ50MP

RADIATOR AND HEAT EXCHANGER

: 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) 23 2 7 4 6 (3) 3 5 16 20 11 14 18 3
LS

COOL

(2)

1 24 22 21 19 25

15

26

New

8 17 (3) 12 : 27 Nm (2.7 m kg, 19 ft lb)

LT

13 10 24

9 New

(4)

Order 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Job name/Part name Water pump outlet hose Sub-wire harness Knock sensor Water jacket joint Throttle body outlet hose Water pump inlet hose Water pump assembly Engine outlet hose Coolant reservoir inlet hose Coolant temperature connector Thermostat assembly Coolant reservoir inlet hose Radiator outlet pipe 1 Radiator outlet hose 2 Radiator outlet pipe 2 Radiator outlet hose 3 Heat exchanger

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Remarks

Disconnect.

For installation, reverse the removal procedure.

6-2

RADIATOR AND HEAT EXCHANGER

INSPECTION

COOL

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. Measure: Filler cap opening pressure Cap opens with a pressure below the specified pressure Replace. Filler cap opening pressure: 93.3 ~ 122.7 kPa (0.93 ~ 1.23 kg/cm2, 13.2 ~ 17.5 psi) Measurement steps: Attach the cooling system tester 1 to the coolant filler cap 2. Cooling system tester: 90890-01325, YU-24460-01 Adapter: 90890-01352, YU-33984 Apply the specified pressure for 10 seconds and make sure there is no pressure drop.

6-3

RADIATOR AND HEAT EXCHANGER

INSTALLATION
1. Install: Heat exchanger Use the rivet gun. 2. Install: O-ring Oil cooler 1

COOL

1
T.

Oil cooler bolt: 10 Nm (1.0 m kg, 7.2 ft lb) LOCTITE

NOTE:
Install the oil cooler with the manufacturers mark a facing down.

R.

6-4

THERMOSTAT THERMOSTAT
: 10 Nm (1.0 m kg, 7.2 ft lb) : 23 Nm (2.3 m kg, 17 ft lb) 9 4

COOL

A New 2 1 3 5
B

8 6

Order 1 2 3 4 5 6 7 8 9 0 A

Job name/Part name Thermostat disassembly Coolant temperature sensor coupler Coolant temperature sensor Radiator inlet hose Throttle body heater inlet hose Oil cooler outlet hose Water pump inlet hose Coolant reservoir outlet hose Engine outlet hose Thermostat housing cover Thermostat Thermostat housing

Qty 1 1 1 1 1 1 1 1 1 1 1

Remarks Remove the parts in the order listed below. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.

For assembly, reverse the disassembly procedure.

6-5

THERMOSTAT
INSPECTION

COOL

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 thermometers indicated temperature.
1 2 3 4 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. A faulty thermostat could cause serious overheating or overcooling. 2. Inspect: Thermostat housing cover Thermostat housing Cracks/damage Replace.

INSTALLATION
1. Install: Thermostat (into the thermostat housing)

a b

NOTE:
Install the thermostat with its breather hole a aligned with the this place b on the thermostat housing. 2. Install: Thermostat housing cover Thermostat housing cover bolts Thermostat housing cover bolt: 10 Nm (1.0 m kg, 7.2 ft lb)

T.

R.

6-6

THERMOSTAT

COOL

3. Install: Coolant temperature sensor (to the thermostat housing) Coolant temperature sensor: 23 Nm (2.3 m kg, 17 ft lb)

CAUTION:
Use extreme care when handling the coolant temperature sensor. Replace any part that was dropped or subjected to a strong impact.

T.

R.

6-7

WATER PUMP WATER PUMP

: 12 Nm (1.2 m kg, 8.7 ft lb)

COOL

3 1 2 New 5

LS

Order 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 Qty Remarks Remove the parts in the order listed. Refer to OIL TANK in CHAPTER 5. Refer to RADIATOR AND HEAT EXCHANGER. Disconnect. Disconnect. Disconnect.

1 2 3 4 5

1 1 1 1 1

For installation, reverse the removal procedure.

6-8

WATER PUMP

COOL

3 New 7

8 6 New 5 New 4

2 New

Order 1 2 3 4 5 6 7 8

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

Qty 1 1 2 1 1 1 1 1

Remarks Remove the parts in the order listed below.

For assembly, reverse the disassembly procedure.

6-9

WATER PUMP
DISASSEMBLY
1. Remove: Impeller Water pump seal 1

COOL

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.

1 2

3. Remove: Rubber damper holder 1 Rubber damper 2 (from the impeller, with a thin, flat-head screwdriver)

NOTE:
Do not scratch the impeller shaft.

INSPECTION
1. Inspect: Water pump housing cover Water pump housing Impeller Rubber damper Rubber damper holder Water pump seal Oil seal Cracks/damage/wear Replace. 2. Inspect: Bearing Rough movement Replace.

6-10

WATER PUMP
ASSEMBLY

COOL

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.

NOTE:
Install the water pump seal 1 with the mechanical seal installer 4 and 40 and 50 mm bearing driver 5. Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3. Mechanical seal installer: 90890-04145, YM-04145 40 and 50 mm bearing driver: 90890-04058, YM-04058 Yamaha bond No. 1215: 90890-85505 (Three Bond No.1215)
Push down

6-11

WATER PUMP

COOL

4. Install: Rubber damper holder 1 Rubber damper 2

NOTE:

1 2

Before installing the rubber damper, apply tap water or coolant onto its outer surface.

5. Measure: Impeller shaft tilt Out of specification Repeat steps (4) and (5).

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. Install: Water pump

NOTE:

Align the projection a on the impeller shaft assembly with the slot in the driven gear shaft b.

6-12

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 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 D Oil pressure switch E Coolant temperature sensor F Crankshaft position sensor G Injector #2 H Cylinder-#2 intake air pressure sensor I Intake air temperature sensor J Grip/thumb warmer adjustment switch K Warning light

45

67

58

9 0 A I H G F E B

C D

7-1

WIRING DIAGRAM

D R/W L/R G B O/B G Y B A R/W R/W WIRE HARNESS WIRE HARNESS O (BLACK) B A R/L R/L R/L R/B B B B R/L G/B (GLAY) L Y B/L B A O R/W Gy/R R/W R/B A R/B R/B (BLACK) Gy/R Gy/R A Gy/R G/B A G/B G/B
W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

E F R/G R/W

N
L/R

R/B G/B R/L O Gy/R R/W G L/R O/B B W/L Sb Br/R L/B W/R R/W O R/W R/L L/R R/L R/L R/L R/L Y G B

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

Br/R Sb W/L W/R L/B

R/G R/L

WIRE HARNESS O

SUB-WIRE HARNESS 1 WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

WIRE HARNESS

SUB-WIRE HARNESS 2

GEAR MOTOR SUB-WIRE HARNESS

K L O P M L
(GLAY) R/L

R/L B

B/L Gy (BLACK)

Gy B

Gy B/L

(BLACK)

WWW

2
L/W R/Y B Br (BLACK)

R/Y L/W

(GLAY)

WWW

W WW

OFF ON START

R R/W Br Br/W

R S
L W/B B/L (BLACK) B/L W/B L W B (BLACK) L P O/R B/W L W/Y B/L

3
Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B O/B Y/R B/R Y/R Y/G Y/G B W Y/G B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G (GRAY) Lg O/B L/R Y/R O Gy/R B B

Br

(BLACK)

L W/Y B/L

L B/L Y (BLACK)

B R/W L/W (BLACK) R R/W (10A) R R/G R/G L/W R/W

R R L/R R/L R/B G/B

(40A)

5
P Br

T
L P/W B/L

R Br

7 D
L/R Br B/W B/Y B/Y

A J
R/W L/W L/W

U
B/L P/W L (BLACK)

R W R R

Br R B B R B RUN STOP CLOSE OPEN B Br Br/W (BLACK) B W/R Y/R Y/R W/L B B B Lg B W/L W/R Ch C Ch Ch B B W/L E B B Ch Lg Br/B Y/R Br/R B/R W/R Lg Y/R B/R B B Ch Ch (BLACK) Y/R W E R/W Br (BLACK) B/L (BLACK) B/R B Lg Lg

Br/L

6 9
B/Y B

8 B E
B/R W/L W/R

L Y W/Y W/B P/W P G/W Br/W W

V
L P B/L B/L P W B (BLACK) (BLACK) L (BLACK)

W Br/L

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

FUEL INJECTION SYSTEM

7-2
C F a [ E E E
B B B

G/W C G/W

G/W

~ } | { z y

X
R/G Y/R R/G Br/R Br/B (BLACK) B/L C B/L B/L

G/W B/L (DARK GREEN)

R/G

O/B

L/W

L/R

Br/R

R/Y

Br/R R/W

B B

O/B

Br/R L

Br/W Br/W B/L R/G R/G B Y/R B

G W/B

R/W

G/Y

O/B B

G/Y L

\
Sb R/G R/G B Sb/W (BLACK)

]
Y/R

Y
B L/B Sb/W B/L

(BLACK)

H I

B B L L (BLACK) (BLACK)

Sb/W Sb Br/R E Br/R Sb E Sb

Sb/W L/B L/B E L/B Ch Br/R Sb L/B

Y/W Ch Y/L Y/L Y/W Y/W Y/L B/L

L L/R

L/W L/R D L/R OFF ON L/R G

LO OFF HI

R/W R/W G/B L/Y R/B Ch B/R Y (BLACK)

k g
G L/R

Z ^
L/B Br/R Sb

u
B/R L/Y G/B Y/L O/B G/R G G D

HI LO

L/W Y Lg G B

m e

O/B

L/W (BLACK)

Lg L/W

Lg

Y Lg

t l
R/B G/B

n j
G B Ch Ch G/B Ch R/B (GRAY) Ch Y/L B B D B B B G/R Ch

G B

o i h
L Y B G L/R B G L/R G

Y/L O/B G/R (BLACK) (BLACK) Y/L G/R G/R Y/L G/R Y/L

L/R L/R Y/L O/B L/R O/B

FI

c f
Y/L Y B G B G/R

L/R

Y/L

YG

YG

f
Y B G

O/B D

O/B

d
B

B F

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 Throttle position sensor Speed sensor Cylinder identification sensor Cylinder-#1 intake air pressure sensor Cylinder-#2 intake air pressure sensor Knock sensor Coolant temperature sensor Intake air temperature sensor Grip/thumb warmer adjustment switch Passenger grip warmer relay Passenger grip warmer switch Passenger grip warmer Multi-function meter Warning light Headlight Headlight relay Headlight beam switch Radiator fan motor Radiator fan motor relay *1 Ignition fuse Radiator fan motor fuse *1 Signal fuse Headlight fuse

FI

*1 PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP PZ50VT/PZ50MP PZ50M/PZ50VT/PZ50MP PZ50VT (STANDARD)/PZ50MP (OPTION) PZ50/PZ50GT/PZ50M/PZ50VT/PZ50MP PZ50FX

7-3

FUEL INJECTION SYSTEM

ECU SELF-DIAGNOSTIC FUNCTION

FI

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. Once a malfunction has been detected, a fault code is stored in the memory of the ECU. To inform the rider that the fuel injection system is not functioning, the warning light and self-diagnosis warning indicator flash when the main switch is being turned to the start position. If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appropriate substitute characteristic operation, and the warning light and self-diagnosis warning indicator flash to alert the rider of the detected malfunction. After the engine has been stopped, the lowest fault code number appears on the odometer/tripmeter LCD. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted.

SELF-DIAGNOSTIC FUNCTION TABLE

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the warning light and self-diagnosis warning indicator come on to alert the rider that a malfunction has occurred and the ECU provides the engine with alternate operating instructions that are appropriate for the type of malfunction. When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions. Self-Diagnostic-Function table
Fault code No. 11 12 13 Item Cylinder identification sensor Crankshaft position sensor Cylinder-#1 intake air pressure sensor (open or short circuit) Cylinder-#1 intake air pressure sensor (hose line) Throttle position sensor (open or short circuit) Throttle position sensor (stuck) Coolant temperature sensor Intake air temperature sensor Cylinder-#2 intake air pressure sensor (open or short circuit) Cylinder-#2 intake air pressure sensor (hose line) Oil pressure dropped Cylinder-#1 ignition coil (faulty ignition) 33 Symptom No normal signals are received from the cylinder identification sensor. No normal signals are received from the crankshaft position sensor. Cylinder-#1 intake air pressure sensor: open or short circuit detected. Cylinder-#1 intake air pressure sensor: hose system malfunction (clogged or detached hose). Throttle position sensor: open or short circuit detected. Stuck throttle position sensor detected. Coolant temperature sensor: open or short circuit detected. Intake air temperature sensor: open or short circuit detected. Cylinder-#2 intake air pressure sensor: open or short circuit detected. Cylinder-#2 intake air pressure sensor: hose system malfunction (clogged or detached hose). Engine stops when an oil pressure drop is detected. Open circuit detected in the primary lead of the cylinder-#1 ignition coil. Able/unable to start Unable Unable Able Able/unable to drive Able Unable Able

14

Able

Able

15 16 21 22 25

Able Able Able Able Able

Able Able Able Able Able

26

Able

Able

30

Unable Able (depending on the number of faulty cylinders)

Unable Able (depending on the number of faulty cylinders)

7-4

FUEL INJECTION SYSTEM

Fault code No. Item Cylinder-#2 ignition coil (faulty ignition) 34 Symptom Open circuit detected in the primary lead of the cylinder-#2 ignition coil.

FI
Able/unable to start Able (depending on the number of faulty cylinders) Able Able/unable to drive Able (depending on the number of faulty cylinders) Able

42

Speed sensor Fuel system voltage (monitoring voltage)

No normal signals are received from the speed sensor. ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Error is detected while reading or writing on EEPROM (CO adjustment value). Power supply to the fuel injection system is not normal. Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.) Knock sensor: open or short circuit detected. Grip warmer: open or short circuit detected. Thumb warmer: short circuit detected. Conditions requiring T.O.R.S. operation are detected. Oil pressure switch: open circuit detected. Drive position switch: short circuit detected. Reverse position switch: short circuit detected.

43 Error in writing the amount of CO adjustment on EEPROM Vehicle system power supply (monitoring voltage) ECU internal malfunction (memory check error) Knock sensor Grip warmer Thumb warmer T.O.R.S. Oil pressure switch Drive position switch 88 Reverse position switch

Able

Able

44 46

Able Able

Able Able

50

Unable

Unable

65 81 83 84 85

Able Able Able Able Able Able

Able Able Able Unable Able Able

Communication error with the meter

Fault code No. Er-1 Er-2 Er-3 Er-4 Item ECU internal malfunction (output signal error) ECU internal malfunction (output signal error) ECU internal malfunction (output signal error) ECU internal malfunction (input signal error) Symptom No signals are received from the ECU. No signals are received from the ECU within the specified duration. Data from the ECU cannot be received correctly. Non-registered data has been received from the meter. Able/unable to start Unable Unable Unable Unable Able/unable to drive Unable Unable Unable Unable

7-5

FUEL INJECTION SYSTEM

TROUBLESHOOTING CHART

FI

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-

cator flash.

The warning light and self-diagnosis warning indicator do not come on.

Check the fault code number displayed on the meter.

Identify the system with the malfunction. (Refer to Self-Diagnostic-Function table.)

Identify the probable cause of the malfunction. (Refer to Fault code table.)

Check the operation of the following sensors and actuators in the diagnostic mode. (Refer to Diagnostic mode table.) 01: Throttle position sen30: Cylinder-#1 ignition sor (throttle angle) coil 03, 04:Intake air pres31: Cylinder-#2 ignition sure coil 07: Vehicle speed pulse 36: Injector #1 09: Fuel system voltage 37: Injector #2 (battery voltage) OK NG

Check and repair the probable cause of the malfunction. Engine malfunction Fault code No. Check and repair. (Refer to TROUBLESHOOTING DETAILS.) Monitor the operation of the sensors and actuators in the diagnostic mode. (Refer to Diagnostic mode table.) No fault code No. Check and repair. (Refer to Self-Diagnostic-Function table.)

Defective sensor or actuator

Check and repair the inner parts of the engine. (Refer to CHAPTER 5.) OK

Check and repair the corresponding sensor or actuator. NG OK

Check the engine condition. Perform the ECU reinstatement action. (Refer to Reinstatement method in TROUBLESHOOTING DETAILS.) Fault code number displayed

Turn the main switch off, turn the main switch back on, and then check if the fault code number is still displayed.

OK

Fault code number not displayed Repairs completed

Erasing the malfunction history:* The malfunction history is stored even if the main switch is turned off. The malfunction history must be erased in the diagnostic mode. (Refer to the Diagnostic mode table (Diagnostic code No. 62).) * Operated when the warning light and self-diagnosis warning indicator flash.

7-6

FUEL INJECTION SYSTEM

DIAGNOSTIC MODE

FI

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.

SELECT RESET

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. Simultaneously press and hold the SELECT and RESET buttons, turn the main switch on, and continue to press the buttons for 8 seconds or more.

NOTE:
All displays on the meter disappear except the odometer/tripmeter displays. dIAG appears on the odometer/tripmeter LCD. 4. Check that dIAG appears, and then simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the diagnostic mode. The diagnostic code number 01 appears on the speedometer LCD. 5. Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET buttons.

01 70

70 01

NOTE:
To decrease the selected diagnostic code number, press the RESET button. Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers. To increase the selected diagnostic code number, press the SELECT button. Press the SELECT button for 1 second or longer to automatically increase the diagnostic code numbers.

7-7

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. Turn the main switch off to cancel the diagnostic mode.

NOTE:
To perform a reliable diagnosis, make sure to turn off the power supply before every check and then start right from the beginning.

7-8

FUEL INJECTION SYSTEM

Fault code table
Fault code No. Symptom No normal signals are received from the cylinder identification sensor. No normal signals are received from the crankshaft position sensor. Probable cause of malfunction Open or short circuit in wire harness. Defective cylinder identification sensor. Malfunction in ECU. Improperly installed cylinder identification sensor. Open or short circuit in wire harness. Defective crankshaft position sensor. Malfunction in A.C. magneto rotor. Malfunction in ECU. Improperly installed crankshaft position sensor.

FI
Diagnostic code No.

11

12

13

Cylinder-#1 intake air pressure sensor: open or short circuit detected. Cylinder-#1 intake air pressure sensor: hose system malfunction (clogged or detached hose). Throttle position sensor: open or short circuit detected.

Open or short circuit in wire harness. Defective cylinder-#1 intake air pressure sensor. Malfunction in ECU. Cylinder-#1 intake air pressure sensor hose is detached, clogged, kinked, or pinched. Malfunction in ECU. Open or short circuit in wire harness. Defective throttle position sensor. Malfunction in ECU. Improperly installed throttle position sensor.

03

14

03

15

01

16

Stuck throttle position sensor detected. Coolant temperature sensor: open or short circuit detected.

Stuck throttle position sensor. Malfunction in ECU. Open or short circuit in sub-wire harness 2. Open or short circuit in wire harness. Defective coolant temperature sensor. Malfunction in ECU.

01

21

06

22

Intake air temperature sensor: open or short circuit detected. Cylinder-#2 intake air pressure sensor: open or short circuit detected. Cylinder-#2 intake air pressure sensor: hose system malfunction (clogged or detached hose). Engine stops when an oil pressure drop is detected. Open circuit detected in the primary lead of the cylinder#1 ignition coil.

Open or short circuit in wire harness. Defective intake air temperature sensor. Malfunction in ECU. Open or short circuit in wire harness. Defective cylinder-#2 intake air pressure sensor. Malfunction in ECU. Cylinder-#2 intake air pressure sensor hose is detached, clogged, kinked, or pinched. Malfunction in ECU. Oil pressure dropped. Open or short circuit in sub-wire harness 1. Open or short circuit in wire harness. Malfunction in cylinder-#1 ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut-off circuit system. Open or short circuit in sub-wire harness 1. Open or short circuit in wire harness. Malfunction in cylinder-#2 ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut-off circuit system.

05

25

04

26

04

30

33

30

34

Open circuit detected in the primary lead of the cylinder#2 ignition coil.

31

42

No normal signals are received from the speed sensor. ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Error is detected while reading or writing on EEPROM (CO adjustment value).

Open or short circuit in wire harness. Defective speed sensor. Malfunction in ECU. Open or short circuit in wire harness. Malfunction in ECU.

07

43

09

44

Malfunction in ECU. (The CO adjustment value is not properly written on or read from the internal memory.)

60

7-9

FUEL INJECTION SYSTEM

Fault code No. 46 Symptom Power supply to the fuel injection system is not normal. Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.) Knock sensor: open or short circuit detected. Probable cause of malfunction Malfunction in the charging system. (Refer to CHARGING SYSTEM in CHAPTER 8.)

FI
Diagnostic code No.

50

Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.)

65

Open or short circuit in wire harness. Defective knock sensor. Malfunction in ECU. Improperly installed knock sensor.

81

Grip warmer: open or short circuit detected. Thumb warmer: short circuit detected. Conditions requiring T.O.R.S. operation are detected.

Open or short circuit in wire harness. Defective grip warmer. Malfunction in ECU. Short circuit in wire harness. Defective thumb warmer. Malfunction in ECU. Open or short circuit in wire harness. Defective throttle position sensor. Defective throttle switch. Defective speed sensor. Malfunction in ECU. Improperly installed throttle position sensor.

26

83

27

84

01 07 24

85

Oil pressure switch: open circuit detected. Drive position switch: short circuit detected.

Open circuit in wire harness. Defective oil pressure switch. Malfunction in ECU. Short circuit in gear motor sub-wire harness. Short circuit in wire harness. Defective drive position switch. Malfunction in ECU. Improperly installed drive position switch. Short circuit in gear motor sub-wire harness. Short circuit in wire harness. Defective reverse position switch. Malfunction in ECU. Improperly installed reverse position switch. Open or short circuit in wire harness. Malfunction in speedometer unit. Malfunction in ECU. Defective wire connection of the ECU coupler.

88

Reverse position switch: short circuit detected.

Er-1

No signals are received from the ECU.

Er-2

No signals are received from the ECU within the specified duration. Data from the ECU cannot be received correctly. Non-registered data has been received from the meter.

Improper connection in wire harness. Malfunction in speedometer unit. Malfunction in ECU. Improper connection in wire harness. Malfunction in speedometer unit. Malfunction in ECU. Improper connection in wire harness. Malfunction in speedometer unit. Malfunction in ECU.

Er-3

Er-4

7-10

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. 01 Pressure difference (atmospheric pressure and cylinder-#1 intake air pressure) Pressure difference (atmospheric pressure and cylinder-#2 intake air pressure) Intake air temperature 05 Coolant temperature 06 Vehicle speed pulse 07 Fuel system voltage (battery voltage) Throttle switch Grip warmer operation Item Throttle angle Description of action Displays the throttle angle. Check with throttle fully closed. Check with throttle fully open. Displays the pressure difference (atmospheric pressure and cylinder-#1 intake air pressure). Generate the pressure difference by cranking the engine with the starter, without actually starting the engine. Displays the pressure difference (atmospheric pressure and cylinder-#2 intake air pressure). Generate the pressure difference by cranking the engine with the starter, without actually starting the engine. Displays the intake air temperature. Check the temperature in the air filter case. Displays the coolant temperature. Check the temperature of the coolant. Displays the cumulative number of vehicle pulses that are generated when the tire is spun. Displays the fuel system voltage (battery voltage). Displays that the switch is on or off. Operates the grip warmer and displays the self-diagnosis warning indicator 1 second after the grip warmer side of the grip/thumb warmer adjustment switch is pushed. The grip warmer operates and the self-diagnosis warning indicator remains on for 120 seconds. This operation is performed each time the grip warmer side of the switch is pushed. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Operates the thumb warmer and displays the self-diagnosis warning indicator 1 second after the grip warmer side of the grip/thumb warmer adjustment switch is pushed. The thumb warmer operates and the self-diagnosis warning indicator remains on for 120 seconds. This operation is performed each time the grip warmer side of the switch is pushed. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Data displayed on meter (reference value) 0 ~ 125 degrees Fully closed position (15 ~ 18) Fully open position (95 ~ 100) Not cranking: atmospheric pressure Cranking: intake air pressure decreases to less than the atmospheric pressure. Not cranking: atmospheric pressure Cranking: intake air pressure decreases to less than the atmospheric pressure. Compare it to the value displayed on the meter. (Minimum displayed value: 30 [C]) Compare it to the value displayed on the meter. (Minimum displayed value: 30 [C]) (0 ~ 999; resets to 0 after 999) OK if the numbers appear on the meter. 0 ~ 18.7 V Normally, approximately 12.0 V Throttle open: on Throttle closed: off

03

04

09 24

26

Thumb warmer operation

27

7-11

FUEL INJECTION SYSTEM

Diagnostic code No. Item Cylinder-#1 ignition coil Description of action 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. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Actuates the cylinder-#2 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. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Actuates injector #1 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. This operation is performed each time the grip warmer side of the switch is pushed. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Actuates injector #2 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. This operation is performed each time the grip warmer side of the switch is pushed. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Actuates the fuel injection system relay five times at 1second intervals and displays the self-diagnosis warning indicator 1 second after the grip warmer side of the grip/ thumb warmer adjustment switch is pushed. (The indicator is off when the relay is on and it is on when the relay is off.) This operation is performed each time the grip warmer side of the switch is pushed. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Actuates the radiator fan motor 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. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning.

FI
Data displayed on meter (reference value)

After pushing the switch, check the spark five times.

30

Cylinder-#2 ignition coil

After pushing the switch, check the spark five times.

31

Injector #1

After pushing the switch, check the operating sound of the injector five times.

36

Injector #2

After pushing the switch, check the operating sound of the injector five times.

37

Fuel injection system relay

After pushing the switch, check the operating sound of the fuel injection system relay five times.

50

Radiator fan motor relay

51

After pushing the switch, check the operating sound of the radiator fan motor relay five times. (At that time, the fan motor rotates.

7-12

FUEL INJECTION SYSTEM

Diagnostic code No. Item Headlight relay Description of action 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. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Actuates the passenger grip warmer 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. However, if the grip warmer side of the switch is pushed again while the operation is being performed, the operation will stop immediately and restart from the beginning. Displays the cylinder number if an error is detected in the EEPROM CO adjustment value for the cylinder as fault code No. 44. If both cylinders are defective, the display alternates every 2 seconds. Displays the code numbers of past malfunctions (i.e., a code number of a malfunction that occurred once and which has been corrected). If more than one code number is detected, the display alternates every 2 seconds to show all the detected code numbers. When all code numbers are shown, the display repeats the same process. Displays the total number of codes that are being detected through self diagnosis and the fault codes in the past history. Erases only the history codes when the grip warmer side of the grip/thumb warmer adjustment switch is pushed. Displays the program control number.

FI
Data displayed on meter (reference value)

52

After pushing the switch, check the operating sound of the headlight relay five times. (At that time, the headlight and taillight come on.)

Passenger grip warmer relay

After pushing the switch, check the operating sound of the passenger grip warmer relay five times.

59

EEPROM fault code display 60

(01 ~ 02) Displays the cylinder number. (00) Displays when there is no malfunction. 11 ~ 85 (00) Displays when there is no malfunction.

Malfunction history code display 61

Malfunction history code erasure 62

00 ~ 24 (00) Displays when there is no malfunction.

70

Control number

00 ~ 255

7-13

FUEL INJECTION SYSTEM

TROUBLESHOOTING DETAILS

FI

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.) Diagnostic code No.: Code number to be used when the diagnostic mode is operated. (Refer to DIAGNOSTIC MODE.)
Fault code No. Diagnostic code No. Order 1 2 Item/components and probable cause Installed condition of cylinder identification sensor. Connections Cylinder identification sensor coupler Wire harness ECU coupler Check or maintenance job Check for looseness or pinching. 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. Repair or replace if there is an open or short circuit. Between cylinder identification sensor coupler and ECU coupler. Blue Blue White/Black White/Black Black/Blue Black/Blue Replace if defective. 1. Connect the pocket tester (DC 20 V) to the cylinder identification sensor coupler terminals as shown. Positive tester probe White/Black 1 Negative tester probe Black/Blue 2 Reinstatement method Starting the engine and operating it at idle. 11 Symptom No normal signals are received from the cylinder identification sensor.

Open or short circuit in wire harness.

Defective cylinder identification sensor.

2. Turn the main switch on. 3. Measure the cylinder identification sensor output voltage. Cylinder identification sensor output voltage: When sensor is on: 4.8 V or more When sensor is off: 0.8 V or less 4. Is the cylinder identification sensor OK?

7-14

FUEL INJECTION SYSTEM

Fault code No. Diagnostic code No. Order 1 2 Item/components and probable cause Installed condition of crankshaft position sensor. Connections Crankshaft position sensor coupler Wire harness ECU coupler Check or maintenance job Check for looseness or pinching. 12 Symptom

FI

No normal signals are received from the crankshaft position sensor.

Reinstatement method Cranking the engine.

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. Repair or replace if there is an open or short circuit. Between crankshaft position sensor coupler and ECU coupler. Gray Gray Black/Blue Black/Blue Replace if defective. Refer to CRANKSHAFT POSITION SENSOR in CHAPTER 8.

Open or short circuit in wire harness.

Defective crankshaft position sensor.

7-15

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 1 Item/components and probable cause Connections Cylinder-#1 intake air pressure sensor coupler Wire harness ECU coupler Open or short circuit in wire harness. Check or maintenance job 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. Repair or replace if there is an open or short circuit. Between cylinder-#1 intake air pressure sensor coupler and ECU coupler. Black/Blue Black/Blue Pink/White Pink/White Blue Blue Execute the diagnostic mode (code No. 03). Replace if defective. 1. Connect the pocket tester (DC 20 V) to the cylinder-#1 intake air pressure sensor coupler terminals as shown. Positive tester probe Pink/White 1 Negative tester probe Black/Blue 2 Reinstatement method Turning the main switch on.

Defective cylinder-#1 intake air pressure sensor.

2. Turn the main switch on. 3. Measure the cylinder-#1 intake air pressure sensor output voltage. Cylinder-#1 intake air pressure sensor output voltage: 2.55 ~ 4.25 V 4. Is the cylinder-#1 intake air pressure sensor OK?

7-16

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 1 Item/components and probable cause Cylinder-#1 intake air pressure sensor hose is detached, clogged, kinked, or pinched. Cylinder-#1 intake air pressure sensor malfunction at intermediate electrical potential. Connections Cylinder-#1 intake air pressure sensor coupler Wire harness ECU coupler Defective cylinder-#1 intake air pressure sensor. Check or maintenance job Repair or replace the sensor hose. Inspect and repair the connection. Reinstatement method Starting the engine and operating it at idle.

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. Execute the diagnostic mode (code No. 03). Replace if defective. Refer to Fault code No. 13.

Fault code No.

15

Symptom

Throttle position sensor: open or short circuit detected.

Diagnostic code No. 01 (throttle position sensor) Order 1 Item/components and probable cause Installed condition of throttle position sensor. Connections Throttle position sensor coupler Wire harness ECU coupler Check or maintenance job Check for looseness or pinching. Check that it is installed in the specified position. Refer to THROTTLE BODY. 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. Repair or replace if there is an open or short circuit. Between throttle position sensor coupler and ECU coupler. Black/Blue Black/Blue Yellow Yellow Blue Blue Check for open circuit and replace the throttle position sensor. Black/Blue Yellow Open circuit item Ground wire open circuit Output wire open circuit Power supply wire open circuit 5 Defective throttle position sensor. 5V 0V 0V Output voltage Reinstatement method Turning the main switch on.

Open or short circuit in wire harness.

Throttle position sensor lead wire open circuit output voltage check.

Execute the diagnostic mode (code No. 01). Replace if defective. Refer to THROTTLE BODY.

7-17

FUEL INJECTION SYSTEM

Fault code No. 16 Symptom Stuck throttle position sensor detected.

FI

Diagnostic code No. 01 (throttle position sensor) Order 1 Item/components and probable cause Installed condition of throttle position sensor. Defective throttle position sensor. Check or maintenance job Check for looseness or pinching. Check that it is installed in the specified position. Refer to THROTTLE BODY. Execute the diagnostic mode (code No. 01). Replace if defective. Refer to THROTTLE BODY. Reinstatement method Starting the engine, operating it at idle, and then racing it.

Fault code No.

21

Symptom

Coolant temperature sensor: open or short circuit detected.

Diagnostic code No. 06 (coolant temperature sensor) Order 1 Item/components and probable cause Connections Coolant temperature sensor coupler Wire harness ECU coupler Sub-wire harness 2 coupler Open or short circuit in wire harness and/or sub-wire harness 2. Check or maintenance job 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. Repair or replace if there is an open or short circuit. Between coolant temperature sensor coupler and ECU coupler. Black/Blue Black/Blue Green/White Green/White Execute the diagnostic mode (code No. 06). Replace if defective. Refer to SIGNAL SYSTEM in CHAPTER 8. Reinstatement method Turning the main switch on.

Defective coolant temperature sensor.

Fault code No.

22

Symptom

Intake air temperature sensor: open or short circuit detected.

Diagnostic code No. 05 (intake air temperature sensor) Order 1 Item/components and probable cause Connections Intake air temperature sensor coupler Wire harness ECU coupler Check or maintenance job 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. Repair or replace if there is an open or short circuit. Between intake air temperature sensor coupler and ECU coupler. Black/Blue Black/Blue Brown/White Brown/White Execute the diagnostic mode (code No. 05). Replace if defective. Refer to INTAKE AIR TEMPERATURE SENSOR. Reinstatement method Turning the main switch on.

Open or short circuit in wire harness.

Defective intake air temperature sensor.

7-18

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 1 Item/components and probable cause Connections Cylinder-#2 intake air pressure sensor coupler Wire harness ECU coupler Open or short circuit in wire harness. Check or maintenance job 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. Repair or replace if there is an open or short circuit. Between cylinder-#2 intake air pressure sensor coupler and ECU coupler. Black/Blue Black/Blue Pink Pink Blue Blue Execute the diagnostic mode (code No. 04). Replace if defective. 1. Connect the pocket tester (DC 20 V) to the cylinder-#2 intake air pressure sensor coupler terminals as shown. Positive tester probe Pink 1 Negative tester probe Black/Blue 2 Reinstatement method Turning the main switch on.

Defective cylinder-#2 intake air pressure sensor.

2. Turn the main switch on. 3. Measure the cylinder-#2 intake air pressure sensor output voltage. Cylinder-#2 intake air pressure sensor output voltage: 2.55 ~ 4.25 V 4. Is the cylinder-#2 intake air pressure sensor OK?

7-19

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 1 Item/components and probable cause Cylinder-#2 intake air pressure sensor hose is detached, clogged, kinked, or pinched. Cylinder-#2 intake air pressure sensor malfunction at intermediate electrical potential. Connections Cylinder-#2 intake air pressure sensor coupler Wire harness ECU coupler Defective cylinder-#2 intake air pressure sensor. Check or maintenance job Repair or replace the sensor hose. Inspect and repair the connection. Reinstatement method Starting the engine and operating it at idle.

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. Execute the diagnostic mode (code No. 04). Replace if defective. Refer to Fault code No. 25.

Fault code No. Diagnostic code No. Order 1

30

Symptom

Engine stops when an oil pressure drop is detected.

Item/components and probable cause Oil pressure dropped.

Check or maintenance job Place the snowmobile on a level surface, and then check the oil pressure after warming up the engine. Refer to ENGINE OIL REPLACEMENT in CHAPTER 2. Disconnect the ECU coupler, and then use the circuit tester to check for continuity between the engine ground and the oil pressure switch coupler (yellow/green). Repair or replace if there is no continuity. Start the engine, warm it up for 1 minute, and then use the circuit tester to check for continuity between the oil pressure switch coupler (yellow/ green) and the switch body. Replace if there is continuity.

Reinstatement method Starting the engine and operating it at idle.

Short circuit in oil pressure switch lead.

Defective oil pressure switch.

7-20

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 1 Item/components and probable cause Connections Cylinder-#1 ignition coil coupler Wire harness ECU coupler Check or maintenance job 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. Repair or replace if there is an open or short circuit. Between cylinder-#1 ignition coil coupler and ECU coupler. Orange Orange Red/White Red/White Execute the diagnostic mode (code No. 30). Test the primary and secondary coils for continuity. Replace if defective. Refer to IGNITION SYSTEM in CHAPTER 8. Open circuit detected in the primary lead of the cylinder-#2 ignition coil. Reinstatement method Starting the engine and operating it at idle.

Open or short circuit in wire harness and/or sub-wire harness 1.

Detective cylinder-#1 ignition coil.

Fault code No.

34

Symptom

Diagnostic code No. 31 (cylinder-#2 ignition coil) Order 1 Item/components and probable cause Connections Cylinder-#2 ignition coil coupler Wire harness ECU coupler Check or maintenance job 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. Repair or replace if there is an open or short circuit. Between cylinder-#2 ignition coil coupler and ECU coupler. Gray/Red Gray/Red Red/White Red/White Execute the diagnostic mode (code No. 31). Test the primary and secondary coils for continuity. Replace if defective. Refer to IGNITION SYSTEM in CHAPTER 8. Reinstatement method Starting the engine and operating it at idle.

Open or short circuit in wire harness and/or sub-wire harness 1.

Defective cylinder-#2 ignition coil.

7-21

FUEL INJECTION SYSTEM

Fault code No. 42 Symptom No normal signals are received from the speed sensor.

FI

Diagnostic code No. 07 (speed sensor) Order 1 Item/components and probable cause Connections Speed sensor coupler Wire harness ECU coupler Check or maintenance job 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. Reinstatement method

Open or short circuit in wire harness.

Starting the engine, and inputting the vehicle speed signals by operating the snowRepair or replace if there is an open or short cirmobile at a low cuit. speed of 20 to Between speed sensor coupler and ECU coupler. 30 km/h. Blue Blue White/Yellow White/Yellow Black/Blue Black/Blue Execute the diagnostic mode (code No. 07). Replace if defective. Refer to SIGNAL SYSTEM in CHAPTER 8. Replace if defective. Refer to FRONT AXLE AND TRACK in CHAPTER 4.

Defective speed sensor.

Gear for detecting vehicle speed has broken.

7-22

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 1 Item/components and probable cause Connections Fuel injection system relay coupler Wire harness ECU coupler Check or maintenance job 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. Repair or replace if there is an open or short circuit. Between fuel injection system relay coupler and ECU coupler. Blue/Red Blue/Red Between fuel injection system relay coupler and engine stop switch coupler. Red/White Red/White Between engine stop switch coupler and main switch coupler. Brown Brown Execute the diagnostic mode (code No. 09). Replace if defective. Reinstatement method Starting the engine and operating it at idle.

Open or short circuit in wire harness.

Malfunction or open circuit in fuel injection system relay.

NOTE:
When the leads are disconnected, the voltage check by the code No. 09 is impossible. 1. Disconnect the fuel injection system relay from the wire harness and remove it. 2. Connect the pocket tester ( 1) and battery (12 V) to the fuel injection system relay terminals as shown. Positive battery terminal Red/White 1 Negative battery terminal Blue/Red 2 Positive tester probe Red/Green 3 Negative tester probe Red/Blue 4

3. Does the fuel injection system relay have continuity between the red/green and red/blue terminals?

7-23

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 Malfunction in ECU. Check or maintenance job 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. Replace ECU if defective. Symptom Power supply to the fuel injection system is not normal. Reinstatement method Turning the main switch on.

Fault code No. Diagnostic code No. Order 1

46

Item/components and probable cause Connections Wire harness ECU coupler

Check or maintenance job Check the coupler for any pins that may have pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Replace or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2. Replace if defective. Refer to CHARGING SYSTEM in CHAPTER 8. Repair or replace if there is an open or short circuit. Between battery and ignition fuse. Red Red Between ignition fuse and main switch coupler. Red/Yellow Red/Yellow Between main switch coupler and load control relay coupler. Brown Brown Between load control relay coupler and ECU coupler. Brown/Blue Brown/Blue

Reinstatement method Starting the engine and operating it at idle.

Faulty battery.

3 4

Malfunction in rectifier/regulator. Open or short circuit in wire harness.

Fault code No. Diagnostic code No. Order 1

50

Symptom

Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.)

Item/components and probable cause Malfunction in ECU.

Check or maintenance job Replace the ECU.

Reinstatement method Turning the main switch on.

7-24

FUEL INJECTION SYSTEM

Fault code No. Diagnostic code No. Order 1 2 Item/components and probable cause Installed condition of knock sensor Connections Knock sensor coupler Wire harness ECU coupler Check or maintenance job Check for looseness or pinching. 65 Symptom Knock sensor: open or short circuit detected.

FI

Reinstatement method Starting the engine and operating it at idle.

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. Repair or replace if there is an open or short circuit. Between knock sensor coupler and ECU coupler. White White Replace if defective. Refer to KNOCK SENSOR in CHAPTER 8. Grip warmer: open or short circuit detected.

Open or short circuit in wire harness.

Defective knock sensor.

Fault code No.

81

Symptom

Diagnostic code No. 26 (grip warmer operation) Order 1 Item/components and probable cause Open or short circuit in wire harness. Check or maintenance job Repair or replace if there is an open or short circuit. Between grip warmer coupler and ECU coupler. Yellow/Red Yellow/Red Reinstatement method Turning the main switch on.

Fault code No.

83

Symptom

Thumb warmer: short circuit detected.

Diagnostic code No. 27 (thumb warmer operation) Order 1 Item/components and probable cause Short circuit in wire harness. Check or maintenance job Repair or replace if there is a short circuit. Between thumb warmer coupler and ECU coupler. Light green Light green Reinstatement method Turning the main switch on.

7-25

FUEL INJECTION SYSTEM

Fault code No. Diagnostic code No. Order 1 Item/components and probable cause Connections Oil pressure switch coupler Wire harness ECU coupler Check or maintenance job 85 Symptom Oil pressure switch: open circuit detected.

FI

Reinstatement method Starting the engine and operating it at idle.

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. Repair or replace if there is an open circuit. Between oil pressure switch coupler and ECU coupler. Yellow/Green Yellow/Green With the engine stopped, check that there is continuity between the oil pressure switch terminals and oil pressure switch body metal components. Drive position switch: short circuit detected. Reverse position switch: short circuit detected.

Open circuit in wire harness.

Defective oil pressure switch.

Fault code No. Diagnostic code No. Order 1 2

88

Symptom

Item/components and probable cause Installed condition of switch Connections Drive position switch connector Reverse position switch connector Wire harness ECU coupler Short circuit in wire harness and/or gear motor sub-wire harness.

Check or maintenance job Check for looseness or pinching. 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. Repair or replace if there is an short circuit. Between drive position switch connector and ECU coupler. White/Blue White/Blue Between reverse position switch connector and ECU coupler. White/Red White/Red Replace if defective. Refer to DRIVE POSITION SWITCH AND REVERSE POSITION SWITCH (PZ50GT/ PZ50FX/PZ50M/PZ50VT/PZ50MP) in CHAPTER 8.

Reinstatement method Starting the engine and operating it at idle.

Defective drive position switch and/or reverse position switch.

7-26

FUEL INJECTION SYSTEM

Er-1 Er-2 Fault code No. Er-3 Er-4 Diagnostic code No. Order 1 Item/components and probable cause Connections Wire harness ECU coupler Check or maintenance job Symptom Symptom Data from the ECU cannot be received correctly. Non-registered data has been received from the meter. Symptom Symptom No signals are received from the ECU.

FI

No signals are received from the ECU within the specified duration.

Reinstatement method Turning the main switch on.

Check the coupler for any pins that may have pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit. Between speedometer unit coupler and ECU coupler. Blue/Yellow Blue/Yellow Black/Red Black/Red Replace the speedometer unit. Replace the ECU.

Open or short circuit in wire harness.

3 4

Malfunction in speedometer unit. Malfunction in ECU.

7-27

FUEL INJECTION SYSTEM

OIL PRESSURE SWITCH

FI

1. Disconnect: Oil pressure switch coupler 1 2. Connect: Pocket tester (between the engine ground and oil pressure switch terminal)

3. Check: Oil pressure switch continuity No continuity Replace the oil pressure switch.

INTAKE AIR TEMPERATURE SENSOR

1. Remove the intake air temperature sensor.

3 1

CAUTION:
Handle the intake air 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 (to the intake temperature sensor)

NOTE:
Set the tester selector to the 100 position. 3. Immerse the intake temperature sensor 1 in water 2 and check the intake temperature sensor operation. Intake temperature sensor resistance: 290 ~ 390 at 80 C (176 F)
3 Temperature gauge

CAUTION:
Never heat the water to a temperature of 120 C (248 F) or more. 4. If the intake air temperature sensor operation is defective, replace it. 5. Install the intake air temperature sensor and connect the intake air temperature sensor coupler.
7-28

THROTTLE BODY THROTTLE BODY

10 6 10

FI

8 5 7 11 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

Qty

1 2 1 1 1 1 1 1 1 2 2

Remarks Remove the parts in the order listed below. Refer to COWLINGS in CHAPTER 3. Disconnect. Disconnect.

Disconnect. Disconnect. For installation, reverse the removal procedure.

7-29

THROTTLE BODY
INJECTORS

FI

8 New 7

11 1 11

5 New 6
E E

New 9 10 12
E

New

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

Qty 1 1 1 1 1 1 1 1 4 1 2 1

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

7-30

THROTTLE BODY
INSPECTION

FI

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. Inspect: Fuel pump and pressure regulator operation Measurement steps: Connect the pressure gauge 1 and fuel pressure adapter 2 onto the fuel injection pipe. Connect the mity vac to the pressure regulator 3.

Pressure gauge: 90890-03153, YU-03153 Fuel pressure adapter: 90890-03176, YM-03176 Mity vac: 90890-06756, YS-42423 Start the engine. Measure the fuel pressure. Fuel pressure: 300 kPa (3.0 kg/cm2, 42.7 psi)

7-31

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. Inspect: Throttle position sensor Checking steps: Disconnect the throttle position sensor coupler. Remove the throttle position sensor from the throttle body. Connect the pocket tester ( 1k) to the throttle position sensor.
L B/L Y

Positive tester probe blue terminal 1 Negative tester probe black/blue terminal 2 Measure the maximum throttle position sensor resistance. Out of specification Replace the throttle position sensor. Maximum throttle position sensor resistance: 4.0 ~ 6.0 k at 20 C (68 F) (blue black/blue)

7-32

THROTTLE BODY

FI

2. Adjust: Throttle position sensor angle

2 1
L B/L Y

Adjusting steps: Connect the throttle position sensor coupler to the wire harness. Connect the digital circuit tester to the throttle position sensor. 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. Throttle position sensor voltage: 0.63 ~ 0.73 V (yellow black/blue) After adjusting the throttle position sensor angle, tighten the throttle position sensor screws.

7-33

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 range. When checking the switch turn it on and off a few times.

b
Br R Br/W R/W OFF

INSPECTING A SWITCH SHOWN IN THE MANUAL

The terminal connections for switches (main switch, handlebar switch, engine stop switch, light switch, etc.) are shown in a chart similar to the one on the left. This chart shows the switch positions a in the column and the switch lead colors b in the top row. For each switch position, indicates the terminals with continuity. The example chart shows that: There is continuity between the Brown and Red leads when the switch is set to ON. There is continuity between the Brown and Red and between Brown/White and Red/White leads when the switch is set to START.

ON START R R/W Br Br/W

8-1

IGNITION SYSTEM

CIRCUIT DIAGRAM

D R/W L/R G B O/B G Y B A R/W R/W WIRE HARNESS WIRE HARNESS O (BLACK) B A R/L R/L R/L R/B B B B R/L G/B (GLAY) L Y B/L B A O R/W Gy/R R/W R/B A R/B R/B (BLACK) Gy/R Gy/R A Gy/R G/B A G/B G/B
W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

E F R/G R/W

N
L/R

R/B G/B R/L O Gy/R R/W G L/R O/B B W/L Sb Br/R L/B W/R R/W O R/W R/L L/R R/L R/L R/L R/L Y G B

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

Br/R Sb W/L W/R L/B

R/G R/L

WIRE HARNESS O

SUB-WIRE HARNESS 1 WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

WIRE HARNESS

SUB-WIRE HARNESS 2

GEAR MOTOR SUB-WIRE HARNESS

K L O P M L
(GLAY) R/L

R/L B

B/L Gy (BLACK)

Gy B

Gy B/L

(BLACK)

WWW

2
L/W R/Y B Br (BLACK)

R/Y L/W

(GLAY)

WWW

W WW

OFF ON START

R R/W Br Br/W

R S
L W/B B/L (BLACK) B/L W/B L W B (BLACK) L P O/R B/W L W/Y B/L

3
Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B O/B Y/R B/R Y/R Y/G Y/G B W Y/G B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G (GRAY) Lg O/B L/R Y/R O Gy/R B B

Br

(BLACK)

L W/Y B/L

L B/L Y (BLACK)

B R/W L/W (BLACK) R R/W (10A) R R/G R/G L/W R/W

R R L/R R/L R/B G/B

(40A)

5
P Br

T
L P/W B/L

R Br

7 D
L/R Br B/W B/Y B/Y

A J
R/W L/W L/W

U
B/L P/W L (BLACK)

R W R R

Br R B B R B RUN STOP CLOSE OPEN B Br Br/W (BLACK) B W/R Y/R Y/R W/L B B B Lg B W/L W/R Ch C Ch Ch B B W/L E B B Ch Lg Br/B Y/R Br/R B/R W/R Lg Y/R B/R B B Ch Ch (BLACK) Y/R W E R/W Br (BLACK) B/L (BLACK) B/R B Lg Lg

Br/L

6 9
B/Y B

8 B E
B/R W/L W/R

L Y W/Y W/B P/W P G/W Br/W W

V
L P B/L B/L P W B (BLACK) (BLACK) L (BLACK)

W Br/L

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

8-2
C F a [ E E E
B B B

G/W C G/W

G/W

~ } | { z y

X
R/G Y/R R/G Br/R Br/B (BLACK) B/L C B/L B/L

G/W B/L (DARK GREEN)

R/G

O/B

L/W

L/R

Br/R

R/Y

Br/R R/W

B B

O/B

Br/R L

Br/W Br/W B/L R/G R/G B Y/R B

G W/B

R/W

G/Y

O/B B

G/Y L

\
Sb R/G R/G B Sb/W (BLACK)

]
Y/R

Y
B L/B Sb/W B/L

(BLACK)

H I

B B L L (BLACK) (BLACK)

Sb/W Sb Br/R E Br/R Sb E Sb

Sb/W L/B L/B E L/B Ch Br/R Sb L/B

Y/W Ch Y/L Y/L Y/W Y/W Y/L B/L

L L/R

L/W L/R D L/R OFF ON L/R G

LO OFF HI

R/W R/W G/B L/Y R/B Ch B/R Y (BLACK)

k g
G L/R

Z ^
L/B Br/R Sb

IGNITION SYSTEM

u
B/R L/Y G/B Y/L O/B G/R G G D

HI LO

L/W Y Lg G B

m e

O/B

L/W (BLACK)

Lg L/W

Lg

Y Lg

t l
R/B G/B

n j
G B Ch Ch G/B Ch R/B (GRAY) Ch Y/L B B D B B B G/R Ch

G B

o i h
L Y B G L/R B G L/R G

Y/L O/B G/R (BLACK) (BLACK) Y/L G/R G/R Y/L G/R Y/L

L/R L/R Y/L O/B L/R O/B

c f
Y/L Y B G B G/R

L/R

Y/L

YG

ELEC

YG

f
Y B G

O/B D

O/B

d
B

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

ELEC

8-3

IGNITION SYSTEM
TROUBLESHOOTING
NO SPARK OR WEAK SPARK.

ELEC

Check the main fuse and ignition fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY Replace the main fuse and/or ignition fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the spark plug gap. Refer to SPARK PLUGS in CHAPTER 2. OK OUT OF SPECIFICATION Repair or replace the spark plug. Refer to SPARK PLUGS in CHAPTER 2.

Check the ignition spark gap. OK OUT OF SPECIFICATION Replace the ignition coil.

Check the ignition coil resistance. OK OUT OF SPECIFICATION Replace the ignition coil.

Check the crankshaft position sensor. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch, throttle switch and main switch. OK FAULTY Replace the right handlebar switch, and/or main switch.

Check the throttle position sensor. Refer to THROTTLE BODY in CHAPTER 7. OK FAULTY Replace the throttle position sensor.

Check the ignition systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the ignition systems wiring.

Correct the connection and/or ECU.

8-4

IGNITION SYSTEM
T.O.R.S. OPERATES.

ELEC

Is self-diagnosis code 15, 16, or 42 displayed? NO YES Check the affected item(s).

Has throttle body icing occurred or is foreign material stuck in the throttle body? NO YES Perform throttle body maintenance.

Is the throttle switch malfunctioning? NO YES Repair or replace the throttle switch.

Is the throttle cable free play out of specification? NO YES Adjust the throttle cable free play. Refer to THROTTLE CABLE FREE PLAY ADJUSTMENT in CHAPTER 2.

Was the engine revved with the V-belt removed? NO YES When the engine is revved with the V-belt removed, the speed sensor is diagnosed as malfunctioning and T.O.R.S. operates.

Is the throttle position sensor, speedometer unit, or speed sensor installed incorrectly? NO YES Install correctly.

Correct the connection and/or replace the speedometer unit and/or ECU.

2 3

7 6 9 5

1 2 3 4 5 6 7 8 9

Crankshaft position sensor Engine speed ECU (engine control unit) Ignition Throttle position sensor Throttle switch Speed Speed sensor Speedometer unit

8-5

IGNITION SYSTEM

ELEC

IGNITION SPARK GAP

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. 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 spark gap: 6.0 mm (0.24 in)
For USA/Canada For Europe

IGNITION COIL
1. Disconnect: Ignition coil coupler 2. Connect: Pocket tester 3. Measure: Primary coil resistance a Secondary coil resistance b Out of specification Replace. Primary coil resistance: 1.19 ~ 1.61 at 20 C (68 F) Secondary coil resistance: 8.5 ~ 11.5 k at 20 C (68 F)

8-6

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. Crankshaft position sensor resistance: 189 ~ 231 at 20 C (68 F) (Gray Black)

8-7

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

2b

If the T.O.R.S. is activated, make sure that the cause of the malfunction has been corrected and that the engine can be operated without a problem before restarting the engine. Be sure to use the specified spark plug and spark plug cap. Otherwise, the T.O.R.S. will not work properly.
Mode Idling/ starting Off Closed Run Running On Open Run Trouble Off Open T.O.R.S. will operate

1 d 3

Item

Throttle switch Throttle position sensor Engine

2a

1 c

2b

1 2 3 a b c d

Idling/starting Running Trouble Throttle position sensor (throttle valve position) Throttle switch Throttle cable On Off Open Closed

NOTE:
When the T.O.R.S. is activated, the warning light 4 and self-diagnosis warning indicator 5 will flash and the two-digit code 84 6 will flash in the clock display. The T.O.R.S. monitors the condition of the throttle position sensor, speedometer assembly, and speed sensor, and will operate if any of the monitored items is disconnected or malfunctioning.

1 c

6 5 4

8-8

IGNITION SYSTEM
ENGINE STOP SWITCH

ELEC

1 +

Br Br/W

1. Disconnect: Engine stop switch coupler 2. Connect: Pocket tester 3. Check: Engine stop switch continuity Faulty Replace the right handlebar switch. Switch position RUN (pulled out) OFF (pushed in) Continuity Yes No

THROTTLE SWITCH
1 +

B/L

B/Y

1. Disconnect: Throttle switch couplers 2. Connect: Pocket tester 3. Check: Throttle switch continuity Faulty Replace the right handlebar switch. Throttle switch position Throttle lever is operated. Throttle lever is not operated. Continuity Yes No

8-9

IGNITION SYSTEM
MAIN SWITCH
1 +

ELEC

R R/W Br Br/W

1. Disconnect: Main switch coupler 2. Connect: Pocket tester 3. Check: Main switch continuity Faulty Replace. Switch position OFF ON START Continuity Color code Br R Br/W R/W

8-10

ELECTRICAL STARTING SYSTEM

CIRCUIT DIAGRAM

C D E F G/W B/L Ch B/L G/W Ch L/R G B O/B G Y B W/L Sb Br/R L/B W/R G L/R O/B B Y G B Br/R Sb W/L W/R L/B

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

WIRE HARNESS WIRE HARNESS

SUB-WIRE HARNESS 1 WIRE HARNESS WIRE HARNESS WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 2 SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

GEAR MOTOR SUB-WIRE HARNESS

Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

4 5 8 9 0 A B y
Gy/R A Gy/R

Main switch Main fuse R/W Starter relay A Starter motor R/W R/W Battery O O Diode A Engine stop switch O R/W Ignition fuse Gy/R

B/L Gy (BLACK) R/Y L/W

W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L

Gy B

Gy B/L

(BLACK)

WWW

2
OFF ON START

(GLAY) R R/W Br Br/W L/W R/Y B Br

WWW

4
Br B

Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L

W WW

(BLACK)

3
R R (40A) R R R/W O/B L/R Y/R B/R Y/R R R Br (10A) R/G R/G L/W R/W O/B

(BLACK)

Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

ELECTRICAL STARTING SYSTEM

8-11

B R/W L/W (BLACK)

O Gy/R B B L/R R/L R/B G/B

5 7 D
L/R Br B/W B/Y B/Y R/W L/W B B L/W P Br

Y/R Lg

J
Y/G Y/G B B

R W R Br/L R R B RUN STOP Br Br/W (BLACK) B B Ch R/W Br (BLACK) CLOSE OPEN B/L (BLACK) Ch (BLACK) Y/R B W Br/L R

Br

6 0 9
B/Y

R R

8 B C

L Y W/Y W/B P/W P G/W Br/W W

Y/G (GRAY)

B/L

B/R B Y/R B Y/R Y/R B

~ } | { z y
B B

E
Lg B B/R B/R B B B W/R

Y/L Y/W B/R W/L W/R Br/B Sb/W B W Lg Y/L R/GR/G

R/G

O/B

L/W

L/R

Br/R

R/Y

F
B B B

E W/R W/L B Lg E W/L W/L W/R Lg Ch

Br/R R/W Br/R L R/W G/Y

[ a E E
B B B Lg Br/B Y/ Br/R

O/B

G W/B

ELEC

O/B B

G/Y L

Ch

Ch Ch R

B B L L (BLACK) (BLACK)

b
B

ELECTRICAL STARTING SYSTEM

TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE.

ELEC

1. Connect: Starter relay terminals (battery side and starter motor side)

NO

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. OK

WARNING
A wire for the jumper lead 1 must have the equivalent capacity as that of the battery lead or more, otherwise it may cause the jumper lead to be burned. This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity.

3. Disconnect: Starter relay coupler 4. Connect: Starter relay coupler terminals

NO

1 Jumper lead

5. Check: Starter motor operation OK

Replace the starter relay.

*
8-12

ELECTRICAL STARTING SYSTEM

ELEC

*
Check the main fuse and ignition fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY

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. Check the electrical starting systems wiring. Refer to CIRCUIT DIAGRAM. OK Correct the connection. FAULTY

Properly connect or repair the electrical starting systems wiring.

8-13

ELECTRICAL STARTING SYSTEM

STARTER MOTOR

ELEC

: 12 Nm (1.2 m kg, 8.7 ft lb) 3 New 8

C New 5 4 67 3 A 9 2 New B 0

3 1

2
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order

Job name/Part name Starter motor removal Engine assembly Negative battery lead Starter motor lead Starter motor assembly

Qty

1 2 3

1 1 1

Remarks Remove the parts in the order listed below. Refer to ENGINE ASSEMBLY in CHAPTER 5. Disconnect. Disconnect. For installation, reverse the removal procedure. Remove the parts in the order listed below.

1 2 3 4 5 6 7 8 9 0

Starter motor disassembly Front bracket O-ring O-ring Lock washer Shim Oil seal Bearing Rear bracket Brush 1 Brush 2
8-14

1 1 2 1 1 1 1 3 1

ELECTRICAL STARTING SYSTEM

: 12 Nm (1.2 m kg, 8.7 ft lb) 3 New 8 3 A 9 5 4 67 C New

ELEC

2 New B 0

3 1

2
: 1 ESSO beacon 325 grease or Aeroshell grease #7A

Order A B C

Job name/Part name Brush holder Armature assembly Starter motor yoke

Qty 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

8-15

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. Measure: Mica undercut (insulation depth) a (between commutator segments) Out of specification Scrape mica 1 to proper limits. Use a hacksaw blade 2 that is ground to fit. Mica undercut: 1.5 mm (0.06 in)

4. Measure: Armature coil resistance (insulation/continuity) Defect(s) Replace the starter motor. Inspecting steps: Connect the pocket tester for the continuity check 1 and the insulation check 2. Measure the armature coil resistances. Armature coil resistance: Continuity check: 0.009 ~ 0.011 at 20 C (68 F) Insulation check: More than 100 k at 20 C (68 F) If the resistance is incorrect, replace the starter motor.

8-16

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. Before installing the front bracket and rear bracket, apply bearing grease to the bearing and bushing of the front bracket and rear bracket.

2. Install: Oil seal New Lock washer 1

NOTE:
Align the projection a on the lock washer 1 with the slot in the front bracket.

1 a
8-17

ELECTRICAL STARTING SYSTEM

3 b 2 a 1
3. Install: O-rings New Rear bracket 1 Starter motor yoke 2 Front bracket 3

ELEC

NOTE:
Align the match mark a on the rear bracket with the match mark b on the front bracket.

8-18

CHARGING SYSTEM

CIRCUIT DIAGRAM

C D E F G/W B/L Ch B/L G/W Ch L/R G B O/B G Y B W/L Sb Br/R L/B W/R G L/R O/B B Y G B Br/R Sb W/L W/R L/B

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

2 3 5 0
R/W O O A O
Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

A.C. magneto Rectifier/regulator Main fuseR/W A Battery R/W

WIRE HARNESS WIRE HARNESS

SUB-WIRE HARNESS 1 WIRE HARNESS WIRE HARNESS WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 2 SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

GEAR MOTOR SUB-WIRE HARNESS

R/W Gy/R Gy/R A Gy/R

B/L Gy (BLACK) R/Y L/W

W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L

Gy B

Gy B/L

(BLACK)

WWW

2
OFF ON START

(GLAY) R R/W Br Br/W L/W R/Y B Br

WWW

4
Br B

Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L

W WW

(BLACK)

3
R R (40A) R R R/W O/B L/R Y/R B/R Y/R R R Br (10A) R/G R/G L/W R/W O/B

(BLACK)

Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

8-19

B R/W L/W (BLACK)

O Gy/R B B L/R R/L R/B G/B

5 7 D
L/R Br B/W B/Y B/Y R/W L/W B B L/W P Br

Y/R Lg

J
Y/G Y/G B B

R W R Br/L R R B RUN STOP Br Br/W (BLACK) B B Ch R/W Br (BLACK) CLOSE OPEN B/L (BLACK) Ch (BLACK) Y/R B W Br/L R

Br

6 0 9
B/Y

R R

8 B C

L Y W/Y W/B P/W P G/W Br/W W

Y/G (GRAY)

B/L

B/R B Y/R B Y/R Y/R B

~ } | { z y
B B

E
Lg B B/R B/R B B B W/R

Y/L Y/W B/R W/L W/R Br/B Sb/W B W Lg Y/L R/GR/G

CHARGING SYSTEM

R/G

O/B

L/W

L/R

Br/R

R/Y

F
B B B

E W/R W/L B Lg E W/L W/L W/R Lg Ch

Br/R R/W Br/R L R/W G/Y

[ a E E
B B B Lg Br/B Y/ Br/R

O/B

G W/B

ELEC

O/B B

G/Y L

Ch

Ch Ch R

B B L L (BLACK) (BLACK)

b
B

CHARGING SYSTEM
TROUBLESHOOTING
BATTERY IS NOT CHARGED.

ELEC

1. Connect: Pocket tester (to the battery terminals) 2. Measure: Battery voltage Battery voltage: more than 12 V at 20 C (68 F)

OUT OF SPECIFICATION

OK 3. Start the engine and accelerate to 5,000 r/min.

Check the battery. Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

NOTE:
Place the machine onto a suitable stand to raise the track off of the ground. 4. Measure: Charging voltage Charging voltage: 14 V/5,000 r/min OUT OF SPECIFICATION

Check the main fuse. Refer to FUSE INSPECTION in CHAPTER 2. Check the stator coil. OK FAULTY Replace the main fuse and/or the stator coil assembly.

CAUTION:
Never disconnect the battery cables while the generator is operating; otherwise, the rectifier/ regulator will be damaged. OK Check the charging systems wiring. Refer to CIRCUIT DIAGRAM. OK Correct the connector. Properly connect or repair the charging systems wiring. FAULTY Replace the rectifier/regulator.

8-20

CHARGING SYSTEM
BATTERY

ELEC

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. Refer to BATTERY INSPECTION in CHAPTER 2.

A.C. MAGNETO
1
+

W W W

1. Disconnect: A.C. magneto coupler 2. Connect: Pocket tester (to A.C. magneto coupler) 3. Measure: Stator coil resistance Out of specification Replace. Stator coil resistance: 0.22 ~ 0.26 at 20 C (68 F) (White White)

8-21

LIGHTING SYSTEM

CIRCUIT DIAGRAM

D R/W L/R G B O/B G Y B A R/W R/W WIRE HARNESS WIRE HARNESS O (BLACK) B A R/L R/L R/L R/B B B B R/L G/B (GLAY) L Y B/L B A O R/W Gy/R R/W R/B A R/B R/B (BLACK) Gy/R Gy/R A Gy/R G/B A G/B G/B
W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

E F R/G R/W

N
L/R

R/B G/B R/L O Gy/R R/W G L/R O/B B W/L Sb Br/R L/B W/R R/W O R/W R/L L/R R/L R/L R/L R/L Y G B

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

Br/R Sb W/L W/R L/B

R/G R/L

WIRE HARNESS O

SUB-WIRE HARNESS 1 WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

WIRE HARNESS

SUB-WIRE HARNESS 2

GEAR MOTOR SUB-WIRE HARNESS

K L O P M L
(GLAY) R/L

R/L B

B/L Gy (BLACK)

Gy B

Gy B/L

(BLACK)

WWW

2
L/W R/Y B Br (BLACK)

R/Y L/W

(GLAY)

WWW

W WW

OFF ON START

R R/W Br Br/W

R S
L W/B B/L (BLACK) B/L W/B L W B (BLACK) L P O/R B/W L W/Y B/L

3
Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B O/B Y/R B/R Y/R Y/G Y/G B W Y/G B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G (GRAY) Lg O/B L/R Y/R O Gy/R B B

Br

(BLACK)

L W/Y B/L

L B/L Y (BLACK)

B R/W L/W (BLACK) R R/W (10A) R R/G R/G L/W R/W

R R L/R R/L R/B G/B

(40A)

5
P Br

T
L P/W B/L

R Br

7 D
L/R Br B/W B/Y B/Y

A J
R/W L/W L/W

U
B/L P/W L (BLACK)

R W R R

Br R B B R B RUN STOP CLOSE OPEN B Br Br/W (BLACK) B W/R Y/R Y/R W/L B B B Lg B W/L W/R Ch C Ch Ch B B W/L E B B Ch Lg Br/B Y/R Br/R B/R W/R Lg Y/R B/R B B Ch Ch (BLACK) Y/R W E R/W Br (BLACK) B/L (BLACK) B/R B Lg Lg

Br/L

6 9
B/Y B

8 B E
B/R W/L W/R

L Y W/Y W/B P/W P G/W Br/W W

V
L P B/L B/L P W B (BLACK) (BLACK) L (BLACK)

W Br/L

0 C

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

8-22
F a [ E E E
B B B

G/W C G/W

G/W

~ } | { z y

X
R/G Y/R R/G Br/R Br/B (BLACK) B/L C B/L B/L

G/W B/L (DARK GREEN)

R/G

O/B

L/W

L/R

Br/R

R/Y

Br/R R/W

B B

O/B

Br/R L

Br/W Br/W B/L R/G R/G B Y/R B

G W/B

R/W

G/Y

O/B B

G/Y L

\
Sb R/G R/G B Sb/W (BLACK)

]
Y/R

Y
B L/B Sb/W B/L

(BLACK)

H I

B B L L (BLACK) (BLACK)

Sb/W Sb Br/R E Br/R Sb E Sb

Sb/W L/B L/B E L/B Ch Br/R Sb L/B

Y/W Ch Y/L Y/L Y/W Y/W Y/L B/L

L L/R

L/W L/R D L/R OFF ON L/R G

LO OFF HI

R/W R/W G/B L/Y R/B Ch B/R Y (BLACK)

k g
G L/R

Z ^
L/B Br/R Sb

LIGHTING SYSTEM

u
B/R L/Y G/B Y/L O/B G/R G G D

HI LO

L/W Y Lg G B

m e

O/B

L/W (BLACK)

Lg L/W

Lg

Y Lg

t l
R/B G/B

n j
G B Ch Ch G/B Ch R/B (GRAY) Ch Y/L B B D B B B G/R Ch

G B

o i h
L Y B G L/R B G L/R G

Y/L O/B G/R (BLACK) (BLACK) Y/L G/R G/R Y/L G/R Y/L

L/R L/R Y/L O/B L/R O/B

c f
Y/L Y B G B G/R

L/R

Y/L

YG

ELEC

YG

f
Y B G

O/B D

O/B

d
B

B F

LIGHTING SYSTEM LIGHTING SYSTEM

CIRCUIT DIAGRAM
2 3 4 5 6 0 B J h l r s t u y { | A.C. magneto Rectifier/regulator Main switch Main fuse Load control relay Battery Engine stop switch ECU (engine control unit) Tail/brake light Multi-function meter High beam indicator light Headlight Headlight relay Headlight beam switch Ignition fuse Signal fuse Headlight fuse

ELEC

PZ50VT/PZ50MP

8-23

LIGHTING SYSTEM
TROUBLESHOOTING

ELEC

HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT AND/OR METER LIGHT DO NOT COME ON.

Check the headlight bulb(s). OK NO CONTINUITY Replace the bulb(s).

Check the main fuse, ignition fuse, and headlight fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY Replace the main fuse, ignition fuse, and/or headlight fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the right handlebar switch and/or main switch.

Check the headlight beam switch. OK FAULTY Replace the left handlebar switch.

Check the headlight relay. OK FAULTY Replace the headlight relay.

Check the load control relay. OK FAULTY Replace the load control relay.

Check the lighting systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the lighting systems wiring.

Correct the connection and/or replace the speedometer unit, rectifier/regulator, and/or ECU.

8-24

LIGHTING SYSTEM
TAIL LIGHT DOES NOT COME ON.

ELEC

Check the main fuse, ignition fuse, and signal fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY Replace the main fuse, ignition fuse, and/or signal fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the right handlebar switch and/or main switch.

Check the load control relay. OK FAULTY Replace the load control relay.

Check the lighting systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the lighting systems wiring.

Correct the connection and/or replace the tail/brake light, rectifier/regulator, and/or ECU.

8-25

LIGHTING SYSTEM
BULB(S) NOTE:

ELEC

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 13 23 Continuity Yes Yes

HEADLIGHT BEAM SWITCH

1. Disconnect: Headlight beam switch coupler 2. Connect: Pocket tester (to the headlight beam switch coupler)

1 +

3. Check: Headlight beam switch continuity Faulty Replace the left handlebar switch. Switch position HI LO Continuity Yes No

8-26

LIGHTING SYSTEM
HEADLIGHT RELAY

ELEC

1
L/W Y Lg G B

1. Remove: Headlight relay (with the black coupler) Inspection steps: Connect the pocket tester ( 1) to the headlight relay terminals as shown. 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 ( 1) and battery (12 V) to the headlight relay terminals as shown.
B

5 6
Lg L/W Y G

Positive battery terminal Light green 3 Negative battery terminal Black 4 Positive tester probe Blue/White 5 Negative tester probe Yellow 6 If headlight relay does not have continuity between the blue/white and yellow terminals, replace it.

LOAD CONTROL RELAY

3 4
Br R W Br/L

1. Remove: Load control relay Inspection steps: Connect the pocket tester ( 1) and battery (12 V) to the load control relay terminals as shown. Positive battery terminal Brown 1 Negative battery terminal Brown/Blue 2 Positive tester probe Red 3 Negative tester probe White 4 If load control relay does not have continuity between the red and white terminals, replace it.

8-27

SIGNAL SYSTEM

CIRCUIT DIAGRAM

D R/W L/R G B O/B G Y B A R/W R/W WIRE HARNESS WIRE HARNESS O (BLACK) B A R/L R/L R/L R/B B B B R/L G/B (GLAY) L Y B/L B A O R/W Gy/R R/W R/B A R/B R/B (BLACK) Gy/R Gy/R A Gy/R G/B A G/B G/B
W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

E F R/G R/W

N
L/R

R/B G/B R/L O Gy/R R/W W/L Sb Br/R L/B W/R R/W O R/W R/L L/R R/L R/L R/L R/L Y G B

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

G L/R O/B B

Br/R Sb W/L W/R L/B

R/G R/L

WIRE HARNESS O

SUB-WIRE HARNESS 1 WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

WIRE HARNESS

SUB-WIRE HARNESS 2

GEAR MOTOR SUB-WIRE HARNESS

K L O P M L
(GLAY) R/L

R/L B

B/L Gy (BLACK)

Gy B

Gy B/L

(BLACK)

WWW

2
L/W R/Y B Br (BLACK)

R/Y L/W

(GLAY)

WWW

W WW

OFF ON START

R R/W Br Br/W

R S
L W/B B/L (BLACK) B/L W/B L W B (BLACK) L P O/R B/W L W/Y B/L

3
Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B O/B Y/R B/R Y/R Y/G Y/G B W Y/G B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G (GRAY) Lg O/B L/R Y/R O Gy/R B B

Br

(BLACK)

L W/Y B/L

L B/L Y (BLACK)

B R/W L/W (BLACK) R R/W (10A) R R/G R/G L/W R/W

R R L/R R/L R/B G/B

(40A)

5
P Br

T
L P/W B/L

R Br

7 D
L/R Br B/W B/Y B/Y

A J
R/W L/W L/W

U
B/L P/W L (BLACK)

R W R R

Br R B B R B RUN STOP CLOSE OPEN B Br Br/W (BLACK) B W/R Y/R Y/R W/L B B B Lg B W/L W/R Ch C Ch Ch B B W/L E B B Ch Lg Br/B Y/R Br/R B/R W/R Lg Y/R B/R B B B B Ch (BLACK) Y/R W R/W Br (BLACK) E Ch B/L (BLACK) B/R B Lg Lg

Br/L

6 9
B/Y B

8 B E
B/R W/L W/R

L Y W/Y W/B P/W P G/W Br/W W

V
L P B/L B/L P W B (BLACK) (BLACK) L (BLACK)

W Br/L

0 C

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

8-28
F a [ E E
B B B

G/W C G/W

G/W

~ } | { z y

X
R/G Y/R R/G Br/R Br/B (BLACK) B/L C B/L B/L

G/W B/L (DARK GREEN)

R/G

O/B

L/W

L/R

Br/R

R/Y

Br/R R/W

E H I

O/B

Br/R L

Br/W Br/W B/L R/G R/G B Y/R B

G W/B

R/W

G/Y

O/B B

G/Y L

\
Sb R/G R/G B Sb/W (BLACK)

]
Y/R

Y
B L/B Sb/W B/L

(BLACK)

B B L L (BLACK) (BLACK)

Sb/W Sb Br/R E Br/R Sb E Sb

Sb/W L/B L/B E L/B Ch Br/R Sb L/B

Y/W Ch Y/L Y/L Y/W Y/W Y/L B/L

L L/R

L/W L/R D L/R OFF ON L/R G

LO OFF HI

R/W R/W G/B L/Y R/B Ch B/R Y (BLACK)

k g
G L/R

Z ^
L/B Br/R Sb

SIGNAL SYSTEM

u
B/R L/Y G/B Y/L O/B G/R G G D

HI LO

L/W Y Lg G B

m e

O/B

L/W (BLACK)

Lg L/W

Lg

Y Lg

t l
R/B G/B

n j
G B Ch Ch G/B Ch R/B (GRAY) Ch Y/L B B D B B B G/R Ch

G B

o i h
L Y B G L/R B G L/R G

Y/L O/B G/R (BLACK) (BLACK) Y/L G/R G/R Y/L G/R Y/L

L/R L/R Y/L O/B L/R O/B

c f
Y/L Y B G B G/R

L/R

Y/L

YG

ELEC

YG

f
Y B G

O/B D

O/B

d
B

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. magneto Rectifier/regulator Main switch Main fuse Load control relay Battery Engine stop switch DC back buzzer*1 Drive position switch*1 Reverse position switch*1 ECU (engine control unit) Speed sensor Knock sensor Coolant temperature sensor Brake light switch Tail/brake light Fuel sender Oil level switch Multi-function meter Warning light Low coolant temperature indicator light Knock control system indicator light Drive position indicator light*1 Reverse position indicator light*1 Ignition fuse Signal fuse PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP

ELEC

PZ50VT/PZ50MP

8-29

SIGNAL SYSTEM
TROUBLESHOOTING
BRAKE LIGHT DOES NOT COME ON.

ELEC

Check the main fuse, ignition fuse, and signal fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY Replace the main fuse, ignition fuse, and/or signal fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the right handlebar switch and/or main switch.

Check the brake light switch. OK FAULTY Replace the brake light switch.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the signal systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the signal systems wiring.

Correct the connection and/or replace the tail/brake light, rectifier/regulator, and/or ECU.

8-30

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 FAULTY Replace the main fuse and/or ignition fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the right handlebar switch and/or main switch.

Check the coolant temperature sensor. OK FAULTY Replace the coolant temperature sensor.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the signal systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the signal systems wiring.

Correct the connection and/or replace the speedometer unit, rectifier/regulator, and/or ECU.

8-31

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 FAULTY Replace the main fuse and/or ignition fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the right handlebar switch and/or main switch.

Check the fuel sender. OK FAULTY Replace the fuel sender.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the signal systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the signal systems wiring.

Correct the connection and/or replace the speedometer unit, rectifier/regulator, and/or ECU.

8-32

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 FAULTY Replace the main fuse and/or ignition fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the right handlebar switch and/or main switch.

Check the oil level switch. OK FAULTY Replace the oil level switch.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the signal systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the signal systems wiring.

Correct the connection and/or replace the speedometer unit, rectifier/regulator, and/or ECU.

8-33

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 FAULTY Replace the main fuse and/or ignition fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the right handlebar switch and/or main switch.

Is self-diagnosis code 65 displayed? NO YES Check the knock sensor.

Check the signal systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the signal systems wiring.

Correct the connection and/or replace the speedometer unit, rectifier/regulator, and/or ECU.

8-34

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 FAULTY Replace the main fuse and/or ignition fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the right handlebar switch and/or main switch.

Check the drive position switch and reverse position switch. OK FAULTY Replace the drive position switch and/or reverse position switch.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the signal systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the signal systems wiring.

Correct the connection and/or replace the speedometer unit, rectifier/regulator, and/or ECU.

8-35

SIGNAL SYSTEM
SPEEDOMETER DOES NOT OPERATE.

ELEC

Check the main fuse and ignition fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY Replace the main fuse and/or ignition fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the left handlebar switch and/or main switch.

Check the speed sensor. OK FAULTY Replace the speed sensor.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the signal systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the signal systems wiring.

Correct the connection and/or replace the speedometer unit, rectifier/regulator, and/or ECU.

8-36

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 FAULTY Replace the main fuse, ignition fuse, and/or signal fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK FAULTY Replace the left handlebar switch and/or main switch.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the DC back buzzer. OK DOES NOT SOUND Replace the DC back buzzer.

Check the signal systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the signal systems wiring.

Correct the connection and/or replace the rectifier/ regulator and/or ECU.

8-37

SIGNAL SYSTEM
BRAKE LIGHT SWITCH

ELEC

G L/R

1. Disconnect: Brake light switch coupler 2. Connect: Pocket tester (to the brake light switch coupler) 3. Check: Brake light switch continuity Faulty Replace. Switch position Brake lever operates Brake lever does not operate Continuity Yes No

DRIVE POSITION SWITCH AND REVERSE POSITION SWITCH (PZ50GT/PZ50FX/ PZ50M/PZ50VT/PZ50MP)

1. Remove: Drive position switch and reverse position switch 2. Connect: Pocket tester (to the drive position switch and reverse position switch) 3. Check: Drive position switch and reverse position switch continuity Faulty Replace.

DC BACK BUZZER (PZ50GT/PZ50FX/ PZ50M/PZ50VT/PZ50MP)

1. Disconnect: DC back buzzer coupler 2. Connect: Battery 3. Check: DC back buzzer Does not sound Replace.

8-38

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 1k position. 3. Immerse the coolant temperature sensor 2 in coolant 3 and check the coolant temperature sensor operation. Coolant temperature sensor resistance: 5.21 ~ 6.37 k at 0 C (32 F) 0.290 ~ 0.354 k at 80 C (176 F)
4 Temperature gauge

CAUTION:
Never heat the coolant to a temperature of 120 C (248 F) or more. 4. If the coolant temperature sensor operation is defective, replace it. 5. Install the coolant temperature sensor and connect the coolant temperature sensor coupler. Coolant temperature sensor: 23 Nm (2.3 m kg, 17 ft lb)

CAUTION:
Do not overtighten the coolant temperature sensor.

T.

R.

8-39

SIGNAL SYSTEM
OIL LEVEL SWITCH
Ch R/B

ELEC

1. Remove: Oil level switch 2. Connect: Pocket tester (to the oil level switch coupler) 3. Check: Oil level switch continuity Faulty Replace. Switch position Down position Good condition Bad condition

Up position : Continuity : No continuity

FUEL SENDER

1 +

G B

1. Remove: Fuel sender (from the fuel tank) 2. Connect: Pocket tester (to the fuel sender coupler) 3. Measure: Fuel sender resistance (full a) Fuel sender resistance (empty b) Out of specification Replace. Fuel sender resistance (full): 10 ~ 12 at 20 C (68 F) Fuel sender resistance (empty): 179 ~ 185 at 20 C (68 F)

8-40

SIGNAL SYSTEM
SPEED SENSOR
1. Inspect: Speed sensor

ELEC

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 0.6 V to 4.8 V to 0.6 V to 4.8 V. Out of specification Replace.

KNOCK SENSOR
B

1. Remove: Knock sensor

100 +

CAUTION:
Handle the knock 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 (to the knock sensor coupler and sensor body) 3. Measure: Knock sensor resistance Out of specification Replace. Knock sensor resistance: 504 ~ 616 k at 20 C (68 F) 4. Install the knock sensor and connect the knock sensor coupler. Knock sensor: 27 Nm (2.7 m kg, 19 ft lb)

CAUTION:
Do not overtighten the knock sensor.

T.

R.

8-41

GRIP WARMER SYSTEM

CIRCUIT DIAGRAM

D R/W L/R G B O/B G Y B A R/W R/W WIRE HARNESS WIRE HARNESS O (BLACK) B A R/L R/L R/L R/B B B B R/L G/B (GLAY) L Y B/L B A O R/W Gy/R R/W R/B A R/B R/B (BLACK) Gy/R Gy/R A Gy/R G/B A G/B G/B
W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

E F R/G R/W

N
L/R

R/B G/B R/L O Gy/R R/W G L/R O/B B W/L Sb Br/R L/B W/R R/W O R/W R/L L/R R/L R/L R/L R/L Y G B

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

Br/R Sb W/L W/R L/B

R/G R/L

WIRE HARNESS O

SUB-WIRE HARNESS 1 WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

WIRE HARNESS

SUB-WIRE HARNESS 2

GEAR MOTOR SUB-WIRE HARNESS

K L O P M L
(GLAY) R/L

R/L B

B/L Gy (BLACK)

Gy B

Gy B/L

(BLACK)

WWW

2
L/W R/Y B Br (BLACK)

R/Y L/W

(GLAY)

WWW

W WW

OFF ON START

R R/W Br Br/W

R S
L W/B B/L (BLACK) B/L W/B L W B (BLACK) L P O/R B/W L W/Y B/L

3
Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B O/B Y/R B/R Y/R Y/G Y/G B W Y/G B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G (GRAY) Lg O/B L/R Y/R O Gy/R B B

Br

(BLACK)

L W/Y B/L

L B/L Y (BLACK)

B R/W L/W (BLACK) R R/W (10A) R R/G R/G L/W R/W

R R L/R R/L R/B G/B

(40A)

5
P Br

T
L P/W B/L

R Br

7 D
L/R Br B/W B/Y B/Y

A J
R/W L/W L/W

U
B/L P/W L (BLACK)

R W R R

Br R B B R B RUN STOP CLOSE OPEN B Br Br/W (BLACK) B W/R Y/R Y/R W/L B B B Lg B W/L W/R Ch C Ch Ch B B W/L E B B Ch Lg Br/B Y/R Br/R B/R W/R Lg Y/R B/R B B B B Ch (BLACK) Y/R W R/W Br (BLACK) E Ch B/L (BLACK) B/R B Lg Lg

Br/L

6 9
B/Y B

8 B E
B/R W/L W/R

L Y W/Y W/B P/W P G/W Br/W W

V
L P B/L B/L P W B (BLACK) (BLACK) L (BLACK)

W Br/L

0 C

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

GRIP WARMER SYSTEM

8-42
F a [ E E
B B B

G/W C G/W

G/W

~ } | { z y

X
R/G Y/R R/G Br/R Br/B (BLACK) B/L C B/L B/L

G/W B/L (DARK GREEN)

R/G

O/B

L/W

L/R

Br/R

R/Y

Br/R R/W

E H I

O/B

Br/R L

Br/W Br/W B/L R/G R/G B Y/R B

G W/B

R/W

G/Y

O/B B

G/Y L

\
Sb R/G R/G B Sb/W (BLACK)

]
Y/R

Y
B L/B Sb/W B/L

(BLACK)

B B L L (BLACK) (BLACK)

Sb/W Sb Br/R E Br/R Sb E Sb

Sb/W L/B L/B E L/B Ch Br/R Sb L/B

Y/W Ch Y/L Y/L Y/W Y/W Y/L B/L

L L/R

L/W L/R D L/R OFF ON L/R G

LO OFF HI

R/W R/W G/B L/Y R/B Ch B/R Y (BLACK)

k g
G L/R

Z ^
L/B Br/R Sb

u
B/R L/Y G/B Y/L O/B G/R G G D

HI LO

L/W Y Lg G B

m e

O/B

L/W (BLACK)

Lg L/W

Lg

Y Lg

t l
R/B G/B

n j
G B Ch Ch G/B Ch R/B (GRAY) Ch Y/L B B D B B B G/R Ch

G B

o i h
L Y B G L/R B G L/R G

Y/L O/B G/R (BLACK) (BLACK) Y/L G/R G/R Y/L G/R Y/L

L/R L/R Y/L O/B L/R O/B

c f
Y/L Y B G B G/R

L/R

Y/L

YG

ELEC

YG

f
Y B G

O/B D

O/B

d
B

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. magneto Rectifier/regulator Main switch Main fuse Load control relay Battery Engine stop switch Grip warmer Thumb warmer ECU (engine control unit) Grip/thumb warmer adjustment switch Passenger grip warmer relay Passenger grip warmer switch Passenger grip warmer Multi-function meter Ignition fuse Signal fuse

ELEC

PZ50VT/PZ50MP PZ50VT (STANDARD)/PZ50MP (OPTION) PZ50/PZ50GT/PZ50M/PZ50VT/ PZ50MP PZ50FX

8-43

GRIP WARMER SYSTEM

TROUBLESHOOTING
GRIP WARMER AND THUMB WARMER DO NOT OPERATE.

ELEC

Check the main fuse and ignition fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY Replace the main fuse and/or ignition fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK NO CONTINUITY Replace the right handlebar switch and/or main switch.

Check the grip and thumb warmer. OK NO CONTINUITY Replace the grip and/or thumb warmer.

Check the grip/thumb warmer adjustment switch. CORRECT NO CONTINUITY Replace the left handlebar switch.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the grip warmer systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the grip warmer systems wiring.

Correct the connection and/or replace the speedometer unit, rectifier/regulator, and/or ECU.

8-44

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 FAULTY Replace the main fuse, ignition fuse, and/or signal fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the engine stop switch and main switch. Refer to IGNITION SYSTEM. OK NO CONTINUITY Replace the right handlebar switch and/or main switch.

Check the passenger grip warmer. OK NO CONTINUITY Replace the passenger grip warmer.

Check the passenger grip warmer switch. OK NO CONTINUITY Replace the passenger grip warmer switch.

Check the passenger grip warmer relay. OK FAULTY Replace the passenger grip warmer relay.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the grip warmer systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the grip warmer systems wiring.

Correct the connection and/or replace the rectifier/ regulator and/or ECU.

8-45

GRIP WARMER SYSTEM

1 2
B W 1 + B B

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. Grip warmer resistance: PZ50/PZ50GT/PZ50M/PZ50VT/ PZ50MP: 1.53 ~ 1.87 at 20 C (68 F) (Black Black) PZ50FX: 6.12 ~ 7.48 at 20 C (68 F) (Black Black) Thumb warmer resistance: 37.0 ~ 45.2 at 20 C (68 F) (White Black)

GRIP/THUMB WARMER ADJUSTMENT SWITCH

1. Disconnect: Grip/thumb warmer adjustment switch coupler 2. Connect: Pocket tester (to the grip/thumb warmer adjustment switch coupler) 3. Check: Grip/thumb warmer adjustment switch continuity Faulty Replace the left handlebar switch. Switch position THUMB OFF GRIP Continuity Color code Y/W B/L Y/L

8-46

GRIP WARMER SYSTEM

ELEC

PASSENGER GRIP WARMER (PZ50VT)

1 +

G B Y

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. Passenger grip warmer resistance (high): 8.82 ~ 10.78 (Green Black) Passenger grip warmer resistance (low): 14.67 ~17.93 (Yellow Black)

PASSENGER GRIP WARMER SWITCH (PZ50VT)

1

G/R O/B Y/L

1. Disconnect: Passenger grip warmer switch coupler 2. Connect: Pocket tester (to the passenger grip warmer switch coupler) 3. Check: Passenger grip warmer switch continuity Faulty Replace. Switch position Color code G/R O/B Y/L

LO OFF
+

G/R O/B Y/L

HI Continuity

8-47

GRIP WARMER SYSTEM

ELEC

3 4
L/R L/R O/B Y/L

PASSENGER GRIP WARMER RELAY (PZ50VT/PZ50MP)

1. Remove: Passenger grip warmer relay Inspection steps: Connect the pocket tester ( 1) and battery (12 V) to the passenger grip warmer relay terminals as shown. Positive battery terminal Blue/Red 1 Negative battery terminal Yellow/Blue 2 Positive tester probe Blue/Red 3 Negative tester probe Orange/Black 4 If passenger grip warmer relay does not have continuity between the blue/red and orange/ black terminals, replace it.

8-48

ELEC

8-49

COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP)

CIRCUIT DIAGRAM

D R/W B/L G/W Ch L/R G B O/B G Y B A R/W R/W WIRE HARNESS WIRE HARNESS O (BLACK) B A R/L R/L R/L R/B B B B R/L G/B (GLAY) L Y B/L B A O R/W Gy/R R/W R/B A R/B R/B (BLACK) Gy/R Gy/R A Gy/R G/B A G/B G/B
W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

E F R/G R/W

N
L/R

R/B G/B R/L O Gy/R R/W W/L Sb Br/R L/B W/R R/W O R/W R/L L/R R/L R/L Y G B

R/L G/B R/B R/W Gy/R O

R/L B

B R/L

G/W B/L Ch

G L/R O/B B

Br/R Sb W/L W/R L/B

R/G R/L

WIRE HARNESS O

SUB-WIRE HARNESS 1 WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

WIRE HARNESS

SUB-WIRE HARNESS 2

GEAR MOTOR SUB-WIRE HARNESS

K L
R/L

R/L

O P

B/L Gy (BLACK)

Gy B

Gy B/L

M L
(GLAY) R/L

R/L B

(BLACK)

WWW

2
L/W R/Y B Br (BLACK)

R/Y L/W

(GLAY)

WWW

W WW

OFF ON START

R R/W Br Br/W

R S
L W/B B/L (BLACK) B/L W/B L W B (BLACK) L P O/R B/W L W/Y B/L

3
Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B O/B Y/R B/R Y/R Y/G Y/G B W Y/G B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G (GRAY) Lg O/B L/R Y/R O Gy/R B B

Br

(BLACK)

L W/Y B/L

L B/L Y (BLACK)

B R/W L/W (BLACK) R R/W (10A) R R/G R/G L/W R/W

R R L/R R/L R/B G/B

(40A)

5
P Br

T
L P/W B/L

R Br

7 D
L/R Br B/W B/Y B/Y

A J
R/W L/W L/W

U
B/L P/W L (BLACK)

R W R R R B B R B RUN STOP CLOSE OPEN B Br Br/W (BLACK) B W/R Y/R Y/R W/L B B B Lg B W/L W/R Ch C Ch Ch B B W/L E B B Ch Lg Br/B Y/R Br/R B/R W/R Lg Y/R B/R B B B B Ch (BLACK) Y/R W R/W Br (BLACK) E Ch B/L (BLACK) B/R B Lg Lg R

Br

Br/L

6 0 9
B/Y B

8 B E
B/R W/L W/R

L Y W/Y W/B P/W P G/W Br/W W

V
L P B/L B/L P W B (BLACK) (BLACK) L (BLACK)

W Br/L

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP)

8-50
C
G

G/W C G/W

G/W

~ } | { z y F a

X [
R/G Y/R R/G Br/R Br/B (BLACK) B/L C B/L B/L

G/W B/L

R/G

O/B

L/W

L/R

Br/R

R/Y

Br/R R/W

E E
B B B

O/B

w E H I

Br/R L

Br/W Br/W B/L R/G R/G B Y/R B

G W/B

R/W

G/Y

O/B B

G/Y L

\
Sb R/G R/G B Sb/W (BLACK)

]
Y/R

Y
B L/B Sb/W B/L

(BLACK)

B B L L (BLACK) (BLACK)

Sb/W Sb Br/R E Br/R Sb E Sb

Sb/W L/B L/B E L/B Ch Br/R Sb L/B

Y/W Ch Y/L Y/L Y/W Y/W Y/L B/L

L L/R

L/W L/R D L/R OFF ON L/R G

R/W R/W G/B L/Y R/B Ch B/R Y (BLACK)

k g
G L/R

Z ^
L/B Br/R Sb

u
B/R L/Y G/B

HI LO

L/W Y Lg G B

m e
LO OFF HI

O/B

L/W (BLACK)

Lg L/W G G D Y/L O/B G/R

Lg

Y Lg

t l
R/B G/B

n j
G B Ch Ch G/B Ch R/B (GRAY) Ch Y/L B B D B B B G/R Ch

G B

o i h
L Y B G L/R B G L/R G

Y/L O/B G/R (BLACK) (BLACK) Y/L G/R G/R Y/L G/R Y/L

L/R L/R Y/L O/B L/R O/B

c f
Y/L Y B G B G/R

L/R

Y/L

YG

ELEC

YG

f
Y B G

O/B D

O/B

d
B

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. magneto Rectifier/regulator Main switch Main fuse Load control relay Battery Diode ECU (engine control unit) Coolant temperature sensor Radiator fan motor Radiator fan motor relay Ignition fuse Radiator fan motor fuse

ELEC

PZ50M/PZ50VT/PZ50MP

8-51

COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP)

TROUBLESHOOTING
THE RADIATOR FAN MOTOR DOES NOT MOVE

ELEC

Check the main fuse, ignition fuse, and radiator fan motor fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY Replace the main fuse, ignition fuse, and/or radiator fan motor fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the main switch. Refer to IGNITION SYSTEM. OK NO CONTINUITY Replace the main switch.

Check the radiator fan motor. OK FAULTY Replace the radiator fan motor.

Check the radiator fan motor relay. OK FAULTY Replace the radiator fan motor relay.

Check the coolant temperature sensor. Refer to SIGNAL SYSTEM. OK FAULTY Replace the coolant temperature sensor.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Correct the connection and/or replace the rectifier/ regulator and/or the ECU.

8-52

COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP)

RADIATOR FAN MOTOR

ELEC

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 ( 1) and battery (12 V) to the radiator fan motor relay terminals as shown. Positive battery terminal Red/White 1 Negative battery terminal Green/Yellow 2 Positive tester probe Brown/Red 3 Negative tester probe Blue 4 If radiator fan motor relay does not have continuity between the brown/red and blue terminals, replace it.

8-53

DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP)

CIRCUIT DIAGRAM

D R/W L/R G B O/B G Y B A R/W R/W WIRE HARNESS WIRE HARNESS O (BLACK) B A R/L R/L R/L R/B B B B R/L G/B (GLAY) L Y B/L B A O R/W Gy/R R/W R/B A R/B R/B (BLACK) Gy/R Gy/R A Gy/R G/B A G/B G/B
W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

E F R/G R/W

N
L/R

R/B G/B R/L O Gy/R R/W G L/R O/B B W/L Sb Br/R L/B W/R R/W O R/W R/L L/R R/L R/L R/L R/L Y G B

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

Br/R Sb W/L W/R L/B

R/G R/L

WIRE HARNESS O

SUB-WIRE HARNESS 1 WIRE HARNESS

WIRE HARNESS

FUEL PUMP SUB-WIRE HARNESS SUB-WIRE HARNESS 3 HEADLIGHT SUB-WIRE HARNESS

WIRE HARNESS

SUB-WIRE HARNESS 2

GEAR MOTOR SUB-WIRE HARNESS

K L O P M L
(GLAY) R/L

R/L B

B/L Gy (BLACK)

Gy B

Gy B/L

(BLACK)

WWW

2
L/W R/Y B Br (BLACK)

R/Y L/W

(GLAY)

WWW

W WW

OFF ON START

R R/W Br Br/W

R S
L W/B B/L (BLACK) B/L W/B L W B (BLACK) L P O/R B/W L W/Y B/L

3
Gy R/W R/W L/W B/Y Br/L G/Y L/Y O/B O/B Y/R B/R Y/R Y/G Y/G B W Y/G B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G (GRAY) Lg O/B L/R Y/R O Gy/R B B

Br

(BLACK)

L W/Y B/L

L B/L Y (BLACK)

B R/W L/W (BLACK) R R/W (10A) R R/G R/G L/W R/W

R R L/R R/L R/B G/B

(40A)

5
P Br

T
L P/W B/L

R Br

7 D
L/R Br B/W B/Y B/Y

A J
R/W L/W L/W

U
B/L P/W L (BLACK)

R W R R

Br R B B R B RUN STOP CLOSE OPEN B Br Br/W (BLACK) B W/R Y/R Y/R W/L B B B Lg B W/L W/R Ch C Ch Ch B B W/L E B B Ch Lg Br/B Y/R Br/R B/R W/R Lg Y/R B/R B B Ch Ch (BLACK) Y/R W E R/W Br (BLACK) B/L (BLACK) B/R B Lg Lg

Br/L

6 9
B/Y B

8 B E
B/R W/L W/R

L Y W/Y W/B P/W P G/W Br/W W

V
L P B/L B/L P W B (BLACK) (BLACK) L (BLACK)

W Br/L

0 C

(4A)

(3A)

(20A)

(15A)

(7.5A)

(20A)

DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP)

8-54
F a [ E E E
B B B

G/W C G/W

G/W

~ } | { z y

X
R/G Y/R R/G Br/R Br/B (BLACK) B/L C B/L B/L

G/W B/L (DARK GREEN)

R/G

O/B

L/W

L/R

Br/R

R/Y

Br/R R/W

B B

O/B

Br/R L

Br/W Br/W B/L R/G R/G B Y/R B

G W/B

R/W

G/Y

O/B B

G/Y L

\
Sb R/G R/G B Sb/W (BLACK)

]
Y/R

Y
B L/B Sb/W B/L

(BLACK)

H I

B B L L (BLACK) (BLACK)

Sb/W Sb Br/R E Br/R Sb E Sb

Sb/W L/B L/B E L/B Ch Br/R Sb L/B

Y/W Ch Y/L Y/L Y/W Y/W Y/L B/L

L L/R

L/W L/R D L/R OFF ON L/R G

LO OFF HI

R/W R/W G/B L/Y R/B Ch B/R Y (BLACK)

k g
G L/R

Z ^
L/B Br/R Sb

u
B/R L/Y G/B Y/L O/B G/R G G D

HI LO

L/W Y Lg G B

m e

O/B

L/W (BLACK)

Lg L/W

Lg

Y Lg

t l
R/B G/B

n j
G B Ch Ch G/B Ch R/B (GRAY) Ch Y/L B B D B B B G/R Ch

G B

o i h
L Y B G L/R B G L/R G

Y/L O/B G/R (BLACK) (BLACK) Y/L G/R G/R Y/L G/R Y/L

L/R L/R Y/L O/B L/R O/B

c f
Y/L Y B G B G/R

L/R

Y/L

YG

ELEC

YG

f
Y B G

O/B D

O/B

d
B

B F B

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. magneto Rectifier/regulator Main switch Main fuse Load control relay Battery Drive position switch Reverse position switch ECU (engine control unit) Gear motor relay 1 Gear motor relay 2 Gear motor relay 3 Gear motor Ignition fuse Gear motor fuse

ELEC

8-55

DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP)

TROUBLESHOOTING
CANNOT SHIFT TO DRIVE OR REVERSE.

ELEC

Check the main fuse, ignition fuse, and gear motor fuse. Refer to FUSE INSPECTION in CHAPTER 2. OK FAULTY Replace the main fuse, ignition fuse, and/or gear motor fuse.

Check the battery. Refer to BATTERY INSPECTION in CHAPTER 2. OK OUT OF SPECIFICATION Replace and/or charge the battery. Refer to BATTERY INSPECTION in CHAPTER 2.

Check the stator coil. Refer to CHARGING SYSTEM. OK OUT OF SPECIFICATION Replace the stator coil assembly.

Check the main switch. Refer to IGNITION SYSTEM. OK NO CONTINUITY Replace the main switch.

Check the drive position switch and reverse position switch. Refer to SIGNAL SYSTEM. OK FAULTY Replace the drive position switch and/or reverse position switch.

Check the gear motor. OK FAULTY Replace the gear motor.

Check the gear motor relay 1, 2, and 3. CORRECT FAULTY Replace the gear motor relay 1, 2, and/or 3.

Check the load control relay. Refer to LIGHTING SYSTEM. OK FAULTY Replace the load control relay.

Check the drive/reverse selecting systems wiring. Refer to CIRCUIT DIAGRAM. OK FAULTY Properly connect or repair the drive/reverse selecting systems wiring.

Correct the connection and/or replace the rectifier/ regulator and/or ECU.
8-56

DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP)

GEAR MOTOR

ELEC

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 : Connect the battery (12 V) to the gear motor terminals as shown.
L/B Br/R Sb

Positive battery terminal Sky blue 1 Negative battery terminal Blue/Black 2 Check that the pinion gear 3 turns clockwise. Incorrect Replace the gear motor.

NOTE:
The pinion gear should rotate clockwise and stop in the reverse position. Drive position inspection steps : Connect the battery (12 V) to the gear motor terminals as shown. Positive battery terminal Brown/Red 4 Negative battery terminal Sky blue 5

L/B Br/R

Sb

5
Check that the pinion gear 3 turns counterclockwise. Incorrect Replace the gear motor.

NOTE:
The pinion gear should rotate counterclockwise and stop in the drive position. 2. Install: Gear motor Refer to SECONDARY SHAFT AND REVERSE GEAR CASE in CHAPTER 4.

8-57

DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP)

GEAR MOTOR RELAY 1

ELEC

1
R/G Y/R R/G Br/R Br/B

1. Remove: Gear motor relay 1 (with the black coupler) Inspection steps: Connect the pocket tester ( 1) to the gear motor relay 1 terminals as shown. 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. Connect the pocket tester ( 1) and battery (12 V) to the gear motor relay 1 terminals as shown. Positive battery terminal Red/Green 3 Negative battery terminal Brown/Black 4 Positive tester probe Red/Green 5 Negative tester probe Yellow/Red 6 If gear motor relay 1 does not have continuity between the red/green and yellow/red terminals, replace it.

5 6
R/G Y/R R/G Br/R Br/B

GEAR MOTOR RELAY 2

1
Sb R/G R/G B Sb/W

1. Remove: Gear motor relay 2 (with the black coupler) Inspection steps: Connect the pocket tester ( 1) to the gear motor relay 2 terminals as shown. Positive tester probe Sky blue 1 Negative tester probe Black 2 If gear motor relay 2 does not have continuity between the sky blue and black terminals, replace it.

8-58

DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP)

ELEC

5 6
R/G Sb R/G B Sb/W

Connect the pocket tester ( 1) and battery (12 V) to the gear motor relay 2 terminals as shown. 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 If gear motor relay 2 does not have continuity between the sky blue and red/green terminals, replace it.

GEAR MOTOR RELAY 3

1. Remove: Gear motor relay 3 Inspection steps: Connect the pocket tester ( 1) and battery (12 V) to the gear motor relay 3 terminals as shown. Positive battery terminal Yellow/Red 1 Negative battery terminal Sky blue/White 2 Positive tester probe Black 3 Negative tester probe Blue/Black 4
B L/B Y/R Sb/W

3 4

If gear motor relay 3 does not have continuity between the black and blue/black terminals, replace it.

8-59

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model Model code number: 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) 8GR1 (PZ50MP Canada) 8GR2 (PZ50MP Europe) 2,820 mm (111.0 in) (PZ50/PZ50GT/PZ50FX) 3,195 mm (125.8 in) (PZ50M) 3,150 mm (124.0 in) (PZ50VT USA/Canada) 3,160 mm (124.4 in) (PZ50VT Europe/PZ50MP) 1,215 mm (47.8 in) (PZ50/PZ50GT/PZ50FX/PZ50VT USA/Canada) 1,165 mm (45.9 in) (PZ50M) 1,265 mm (49.8 in) (PZ50VT Europe/PZ50MP) 1,190 mm (46.9 in) (PZ50/PZ50FX) 1,340 mm (52.8 in) (PZ50GT/PZ50M) 1,380 mm (54.3 in) (PZ50VT/PZ50MP) 215 kg (474.0 lb) (PZ50 USA/Canada) 217 kg (478.4 lb) (PZ50 Europe) 221 kg (487.2 lb) (PZ50GT USA/Canada/PZ50FX USA/ Canada) 222 kg (489.4 lb) (PZ50GT Europe/PZ50FX Europe) 233 kg (513.7 lb) (PZ50M USA/Canada) 234 kg (515.9 lb) (PZ50M Europe) 268 kg (590.8 lb) (PZ50VT USA/Canada) 271 kg (597.4 lb) (PZ50VT Europe) 262 kg (577.6 lb) (PZ50MP Canada) 272 kg (599.7 lb) (PZ50MP Europe) 3.7 m (12.14 ft) (PZ50/PZ50GT/PZ50FX) 4.0 m (13.12 ft) (PZ50M) 4.2 m (13.78 ft) (PZ50VT/PZ50MP) 3.4 m (11.16 ft) (PZ50/PZ50GT/PZ50FX) 4.2 m (13.78 ft) (PZ50M) 3.9 m (12.80 ft) (PZ50VT/PZ50MP)

Dimensions: Overall length

Overall width

Overall height

Weight: Dry weight

Minimum turning radius: Clockwise

Counterclockwise

9-1

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

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Liquid-cooled, 4-stroke, DOHC Backward-inclined parallel 2-cylinder 499 cm3 (30.45 cu.in) 77.0 53.6 mm (3.03 2.11 in) 12.4 : 1 58.8 kw (80.0 PS)/11,250 r/min 51.0 Nm (5.2 kgf)/9,000 r/min 20.27 ~ 22.93 kPa (0.20 ~ 0.23 kg/cm2, 2.88 ~ 3.26 psi) 1,450 kPa (14.5 kg/cm2, 206 psi) at 400 r/min Electric starter Dry sump API SE, SF, SG or higher SAE 0W-30 2.45 L (2.16 Imp qt, 2.59 US qt) 2.63 L (2.31 Imp qt, 2.78 US qt) 3.00 L (2.64 Imp qt, 3.17 US qt) 2.00 L (1.76 Imp qt, 2.11 US qt) Cartridge (paper) Gear oil GL-3 75W or 80W 0.25 L (0.22 Imp qt, 0.26 US qt) 93.3 ~ 122.7 kPa (0.93 ~ 1.23 kg/cm2, 13.2 ~ 17.5 psi) 3.60 L (3.17 Imp qt, 3.81 US qt) (PZ50/PZ50GT/PZ50FX/ PZ50M) 3.70 L (3.26 Imp qt, 3.91 US qt) (PZ50VT/PZ50MP) Premium unleaded gasoline Pump Octane (R + M)/2; 91 or higher (USA/Canada) Research Octane; 95 or higher (Europe) 30.1 L (6.6 Imp gal, 8.0 US gal) (PZ50/PZ50GT/PZ50FX/ PZ50M) 36.0 L (7.9 Imp gal, 9.5 US gal) (PZ50VT/PZ50MP) TSK43 1 KEIHIN CR9EKB NGK 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Fuel: Type

Tank capacity

Throttle body: Type/Quantity Manufacture Spark plug: Type Manufacture Gap

9
9-2

GENERAL SPECIFICATIONS
Model Transmission: Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP V-Belt 3.80 ~ 0.95 : 1 Automatic centrifugal engagement Chain 2.28 (41/18) (PZ50/PZ50FX) 2.05 (41/20) (PZ50GT) 2.41 (41/17) (PZ50M USA/Canada) 2.16 (41/19) (PZ50M Europe) 2.37 (45/19) (PZ50VT USA/Canada) 2.50 (45/18) (PZ50VT Europe/PZ50MP) No (PZ50) Yes (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) 2.73 (PZ50GT) 3.04 (PZ50FX) 3.21 (PZ50M USA/Canada) 2.88 (PZ50M Europe) 3.16 (PZ50VT USA/Canada) 3.33 (PZ50VT Europe/PZ50MP) Monocoque 18.0 1,080 mm (42.5 in) (PZ50/PZ50GT/PZ50FX/PZ50VT/ PZ50MP) 980 mm (38.6 in) (PZ50M) Double wishbone Slide rail suspension Internal drive type 355.6 mm (14.00 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 381.0 mm (15.00 in) (PZ50VT) 406.4 mm (16.00 in) (PZ50MP) 769 mm (30.28 in) (PZ50/PZ50GT/PZ50FX) 1,084 mm (42.68 in) (PZ50M) 985 mm (38.78 in) (PZ50VT/PZ50MP) 30 ~ 35 mm (1.18 ~ 1.38 in) Caliper type disc brake Handlebar, left hand operated T.C.I. A.C. magneto

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

9-3

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 MAINTENANCE SPECIFICATIONS

ENGINE
Model Cylinder head: Volume (with spark plug) <Warpage limit>

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 13.82 ~ 14.62 cm3 (0.84 ~ 0.89 cu.in) 0.10 mm (0.0039 in) Lines indicate straight edge measurement.

Cylinder: Material Bore size <Taper limit> <Out of round> Camshaft: Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance Camshaft dimensions Intake A <Limit> B A <Limit> Exhaust A <Limit> B B <Limit> Camshaft runout

Aluminum alloy with dispersion coating 77.000 ~ 77.010 mm (3.0315 ~ 3.0319 in) 0.050 mm (0.0020 in) 0.050 mm (0.0020 in) Chain drive (left) 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in) 21.959 ~ 21.972 mm (0.8645 ~ 0.8650 in) 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in)

30.450 ~ 30.550 mm (1.1988 ~ 1.2028 in) 30.350 mm (1.1949 in) 22.610 ~ 22.710 mm (0.8902 ~ 0.8941 in) 22.510 mm (0.8862 in) 30.700 ~ 30.800 mm (1.2087 ~ 1.2126 in) 30.600 mm (1.2047 in) 22.593 ~ 22.693 mm (0.8895 ~ 0.8934 in) 22.493 mm (0.8856 in) 0.03 mm (0.0012 in)

Timing chain: Model/Number of links Tensioning system

98XRH2015/118 Automatic

9-5

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 <Limit> Exhaust <Limit> Valve guide inside diameter Intake <Limit> Exhaust <Limit> Valve-stem-to-valve-guide clearance Intake <Limit> Exhaust <Limit> Valve stem runout limit

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP

0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in)

23.4 ~ 23.6 mm (0.9213 ~ 0.9291 in) 24.9 ~ 25.1 mm (0.9803 ~ 0.9882 in)
B

1.76 ~ 2.90 mm (0.0693 ~ 0.1142 in) 1.76 ~ 2.90 mm (0.0693 ~ 0.1142 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) 0.5 ~ 0.9 mm (0.0197 ~ 0.0354 in) 0.5 ~ 0.9 mm (0.0197 ~ 0.0354 in) 3.975 ~ 3.990 mm (0.1565 ~ 0.1571 in) 3.945 mm (0.1553 in) 3.960 ~ 3.975 mm (0.1559 ~ 0.1565 in) 3.930 mm (0.1547 in) 4.000 ~ 4.012 mm (0.1575 ~ 0.1580 in) 4.050 mm (0.1594 in) 4.000 ~ 4.012 mm (0.1575 ~ 0.1580 in) 4.050 mm (0.1594 in) 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.10 mm (0.0039 in) 0.01 mm (0.0004 in)

Valve seat width Intake <Limit> Exhaust <Limit>

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) 1.9 mm (0.0748 in)

9-6

MAINTENANCE SPECIFICATIONS
Model Valve spring: Free length Intake <Limit> Exhaust <Limit> 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 <Limit> Exhaust <Limit> Valve lifter hole inside diameter Intake <Limit> Exhaust <Limit> Piston: Piston size (D) Measuring point (H) D Piston to-cylinder clearance <Limit> Piston pin bore off set Off-set direction Piston pin bore inside diameter <Limit> Piston pin: Piston pin outside diameter <Limit> Piston pin length Piston pin to piston pin bore clearance <Limit>

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP

36.51 mm (1.44 in) 34.68 mm (1.37 in) 37.92 mm (1.49 in) 36.02 mm (1.42 in) 30.13 mm (1.19 in) 30.50 mm (1.20 in) 120.7 ~ 138.9 N (12.3 ~ 14.2 kg, 27.1 ~ 31.2 lb) 150.6 ~ 173.2 N (15.4 ~ 17.7 kg, 33.9 ~ 38.9 lb) 2.5/1.6 mm (0.06 in) 2.5/1.7 mm (0.07 in) Clockwise Clockwise

19.982 ~ 19.988 mm (0.7867 ~ 0.7869 in) 19.957 mm (0.7857 in) 22.482 ~ 22.488 mm (0.8851 ~ 0.8854 in) 22.457 mm (0.8841 in) 20.000 ~ 20.018 mm (0.7874 ~ 0.7881 in) 20.048 mm (0.7893 in) 22.500 ~ 22.518 mm (0.8858 ~ 0.8865 in) 22.548 mm (0.8877 in) 76.955 ~ 76.970 mm (3.0297 ~ 3.0303 in) 11.0 mm (0.43 in) 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.120 mm (0.0047 in) 0.5 mm (0.0197 in) Intake side 17.002 ~ 17.013 mm (0.6694 ~ 0.6698 in) 17.043 mm (0.6710 in) 16.991 ~ 17.000 mm (0.6689 ~ 0.6693 in) 16.971 mm (0.6681 in) 42.7 ~ 43.0 mm (1.6811 ~ 1.6929 in) 0.002 ~ 0.022 mm (0.0001 ~ 0.0009 in) 0.072 mm (0.0028 in)

9-7

MAINTENANCE SPECIFICATIONS
Model 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: Crank pin outside diameter Crankshaft:
C

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP

Barrel 0.90 2.75 mm (0.035 0.108 in) No Taper 0.80 2.75 mm (0.031 0.108 in) 1.50 2.25 mm (0.059 0.089 in) 0.15 ~ 0.25 mm (0.006 ~ 0.010 in) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.10 ~ 0.40 mm (0.004 ~ 0.016 in) 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.040 ~ 0.160 mm (0.0016 ~ 0.0063 in) Chrome plated/parkerizing Ferox coating 17.005 ~ 17.018 mm (0.6695 ~ 0.6700 in) 37.000 ~ 37.016 mm (1.4567 ~ 1.4573 in) 0.034 ~ 0.058 mm (0.0013 ~ 0.0023 in) 0 = White 1 = Blue 2 = Black 3 = Brown 33.976 ~ 34.000 (1.3376 ~ 1.3386 in)

A B

Measuring point 1 Measuring point 2 Width A Width B Crankshaft runout C Big end side clearance D Crankshaft-journal-to-crankshaft-journalbearing clearance Bearing color code

57.5 mm (2.26 in) 88.0 mm (3.46 in) 61.0 ~ 61.6 mm (2.402 ~ 2.425 in) 144.0 ~ 145.2 mm (5.67 ~ 5.72 in) 0.03 mm (0.0012 in) 0.160 ~ 0.262 mm (0.0063 ~ 0.0103 in) 0.020 ~ 0.044 mm (0.0008 ~ 0.0017 in) 0 = White 1 = Blue 2 = Black 3 = Brown 4 = Green

9-8

MAINTENANCE SPECIFICATIONS
Model Throttle body: Type Quantity Manufacturer I.D. mark Throttle valve (Th.V) Throttle cable free play Engine idle speed Fuel pump: Type Model/Manufacturer Oil filter: Oil filter type Bypass valve opening pressure Oil pump: Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Relief valve operating pressure Oil pressure (hot) Cooling system: Filler cap opening pressure Thermostat opening temperature Valve lift Water pump type Coolant type Coolant mixing ratio (coolant: water) Capacity

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP TSK43 1 KEIHIN 8GC1 00 N503-89A00 ( = 8) 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) 1,700 ~ 1,900 r/min Electrical 8GC/DENSO Cartridge (paper) 78 ~ 118 kPa (0.78 ~ 1.18 kg/cm2, 11.1 ~ 16.8 psi) Trochoidal Less than 0.12 mm (0.005 in) 0.09 ~ 0.15 mm (0.004 ~ 0.006 in) 430 ~ 550 kPa (4.3 ~ 5.5 kg/cm2, 61.1 ~ 78.2 psi) 50 kPa (0.5 kg/cm2, 7.11 psi) at 1,500 r/min 93.3 ~ 122.7 kPa (0.93 ~ 1.23 kg/cm2, 13.2 ~ 17.5 psi) 80.0 ~ 84.0 C (176.0 ~ 183.2 F) 7.0 mm/95.0 C (0.28 in/203.0 F) Single-suction centrifugal pump (Impeller type) High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors 3 : 2 (60% : 40%) 3.60 L (3.17 Imp qt, 3.81 US qt) (PZ50/PZ50GT/PZ50FX/ PZ50M) 3.70 L (3.26 Imp qt, 3.91 US qt) (PZ50VT/PZ50MP) 0.15 mm (0.0059 in)

Max. impeller shaft tilt

9-9

MAINTENANCE SPECIFICATIONS
POWER TRAIN
Model Transmission: Type Range of ratio Engagement speed r/min

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP V-belt automatic 3.80 ~ 0.95 : 1 3,700 ~ 4,100 r/min (PZ50/PZ50GT/PZ50FX) 4,100 ~ 4,500 r/min (PZ50M USA/Canada) 3,900 ~ 4,300 r/min (PZ50M Europe) 3,300 ~ 3,700 r/min (PZ50VT USA/Canada) 2,900 ~ 3,300 r/min (PZ50VT Europe/PZ50MP) 10,800 ~ 11,800 r/min 267 ~ 270 mm (10.51 ~ 10.63 in) 14.5 ~ 17.5 mm (0.57 ~ 0.69 in) 1.0 ~ 2.0 (0.04 ~ 0.08 in) 0.5 ~ 1.5 mm (0.02 ~ 0.06 in) 8GS-17641-00/MITSUBOSHI 1,132 ~ 1,138 mm (44.6 ~ 44.8 in) 34.1 mm (1.34 in) 32.5 mm (1.28 in) 90501-606G9 (PZ50/PZ50GT/PZ50FX) 90501-605G7 (PZ50M) 90501-556G7 (PZ50VT USA/Canada) 90501-526G4 (PZ50VT Europe/PZ50MP) Pink-Blue-Pink (PZ50/PZ50GT/PZ50FX) Green-Yellow-Green (PZ50M) Yellow-Blue-Yellow (PZ50VT USA/Canada) Blue-Gold-Blue (PZ50VT Europe/PZ50MP) 60.0 mm (2.36 in) 6.0 mm (0.236 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 5.5 mm (0.217 in) (PZ50VT USA/Canada) 5.2 mm (0.205 in) (PZ50VT Europe/PZ50MP) 196 N (20.0 kg, 44.1 lb) (PZ50/PZ50GT/PZ50FX/PZ50VT USA/Canada) 235 N (24.0 kg, 52.9 lb) (PZ50M) 147 N (15.0 kg, 33.1 lb) (PZ50VT Europe/PZ50MP) 29.4 N/mm (3.00 kg/mm, 168 lb/in) (PZ50/PZ50GT/ PZ50FX) 26.9 N/mm (2.74 kg/mm, 153 lb/in) (PZ50M) 24.5 N/mm (2.50 kg/mm, 140 lb/in) (PZ50VT USA/Canada) 19.6 N/mm (2.00 kg/mm, 112 lb/in) (PZ50VT Europe/ PZ50MP) 4.86 (PZ50/PZ50GT/PZ50FX) 5.00 (PZ50M) 4.36 (PZ50VT USA/Canada) 4.32 (PZ50VT Europe/PZ50MP)

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

9-10

MAINTENANCE SPECIFICATIONS
Model Free length

SPEC

Set length Primary sheave weight arm: Part number (with bush) Weight (without bush and rivets)

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 (2.87 in) (PZ50VT Europe/PZ50MP) 65.4 mm (2.57 in) 8GC-17605-00 (PZ50/PZ50GT/PZ50FX/PZ50VT/PZ50MP) 8DN-17605-30 (PZ50M) 47.28 g (1.669 oz) (PZ50/PZ50GT/PZ50FX/PZ50VT/ PZ50MP) 39.76 g (1.404 oz) (PZ50M) Rivet

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

90261-06019 (PZ50/PZ50GT/PZ50FX) 90261-06015 (PZ50M USA/Canada) 90261-06034 (PZ50M Europe) 90261-06033 (PZ50VT/PZ50MP) Steel 13.3 mm (0.524 in) (PZ50/PZ50GT/PZ50FX) 10.3 mm (0.406 in) (PZ50M USA/Canada) 13.9 mm (0.547 in) (PZ50M Europe) 17.2 mm (0.677 in) (PZ50VT/PZ50MP) 3 pcs 3 pcs None (PZ50M) 90261-06015 (PZ50/PZ50GT/PZ50FX) 90261-06033 (PZ50VT/PZ50MP) Steel 10.3 mm (0.406 in) (PZ50/PZ50GT/PZ50FX) 17.2 mm (0.677 in) (PZ50VT/PZ50MP) 3 pcs 3 pcs None (PZ50M USA/Canada) 90261-06015 (PZ50/PZ50GT/PZ50FX) 90261-06034 (PZ50M Europe/PZ50VT USA/Canada) 90261-06033 (PZ50VT Europe/PZ50MP) Steel 10.3 mm (0.406 in) (PZ50/PZ50GT/PZ50FX) 13.9 mm (0.547 in) (PZ50M Europe/PZ50VT USA/ Canada) 17.2 mm (0.677 in) (PZ50VT Europe/PZ50MP) 3 pcs 3 pcs

9-11

MAINTENANCE SPECIFICATIONS
Model Secondary sheave spring: Part number Color code Outside diameter Wire diameter Hole position Sheave side-spring seat side (twist angle)

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 90508-55007 (PZ50/PZ50GT/PZ50FX/PZ50M) 90508-58007 (PZ50VT/PZ50MP) Red (PZ50/PZ50GT/PZ50FX/PZ50M) Blue (PZ50VT/PZ50MP) 66.0 mm (2.598 in) 5.5 mm (0.217 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 5.8 mm (0.228 in) (PZ50VT/PZ50MP) A-1 (45) (PZ50/PZ50GT/PZ50FX) B-1 (55) (PZ50M) A-1 (50) (PZ50VT/PZ50MP)

Spring rate Compression

Torsion

Number of coils Free length Torque cam angle Drive chain: Type

10.58 N/mm (1.08 kg/mm, 60.41 lb/in) (PZ50/PZ50GT/ PZ50FX/PZ50M) 11.33 N/mm (1.16 kg/mm, 64.69 lb/in) (PZ50VT/PZ50MP) 9,131 N mm/rad (931 kg mm/rad, 52,137 lb in/rad) (PZ50/PZ50GT/PZ50FX/PZ50M) 10,098 N mm/rad (1,030 kg mm/rad, 57,659 lb in/rad) (PZ50VT/PZ50MP) 5.33 (PZ50/PZ50GT/PZ50FX/PZ50M) 5.99 (PZ50VT/PZ50MP) 85 mm (3.35 in) 39 (PZ50/PZ50GT/PZ50FX) 37 (PZ50M/PZ50VT/PZ50MP) Borg Warner Morse TEC 23RH302.5-80ASM (PZ50/ PZ50GT/PZ50FX/PZ50M) Borg Warner Morse TEC 23RH302.5-82ASM (PZ50VT/ PZ50MP) 80L (PZ50/PZ50GT/PZ50FX/PZ50M) 82L (PZ50VT/PZ50MP) 2.28 (41/18) (PZ50/PZ50FX) 2.05 (41/20) (PZ50GT) 2.41 (41/17) (PZ50M USA/Canada) 2.16 (41/19) (PZ50M Europe) 2.37 (45/19) (PZ50VT USA/Canada) 2.50 (45/18) (PZ50VT Europe/PZ50MP) 133.35 mm (5.25 in) 137.35 mm (5.41 in)

Number of links Secondary reduction ratio

Maximum 14 link drive chain section length <Limit>

9-12

MAINTENANCE SPECIFICATIONS
Model Track: Part number

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 (16.0 in) (PZ50MP) 3,072.4 mm (120.96 in) (PZ50/PZ50GT/PZ50FX) 3,648.5 mm (143.64 in) (PZ50M/PZ50VT/PZ50MP) 64.0 mm (2.52 in) 48 (PZ50/PZ50GT/PZ50FX) 57 (PZ50M/PZ50VT/PZ50MP) 5.1 mm (0.20 in) (PZ50/PZ50GT/PZ50FX/PZ50VT/ PZ50MP) 5.5 mm (0.22 in) (PZ50M) 25.4 mm (1.00 in) (PZ50/PZ50GT/PZ50FX) 50.8 mm (2.00 in) (PZ50M) 31.8 mm (1.25 in) (PZ50MP/PZ50VT) 30 ~ 35 mm (1.18 ~ 1.38 in) 221.0 mm (8.70 in) (PZ50/PZ50FX) 209.0 mm (8.23 in) (PZ50GT) 205.0 mm (8.07 in) (PZ50M) 184.0 mm (7.24 in) (PZ50VT) 216.0 mm (8.50 in) (PZ50MP) 412.0 mm (16.22 in) (PZ50/PZ50FX) 407.0 mm (16.02 in) (PZ50GT) 364.0 mm (14.33 in) (PZ50M) 292.0 mm (11.50 in) (PZ50VT) 313.0 mm (12.32 in) (PZ50MP) 40.00 N/mm (4.08 kg/mm, 228.40 lb/in) (PZ50/PZ50FX) 25.00 N/mm (2.55 kg/mm, 142.75 lb/in) (PZ50GT USA/ Canada) 18.00 N/mm (1.84 kg/mm, 102.78 lb/in) (PZ50GT Europe) 22.00 N/mm (2.24 kg/mm, 125.62 lb/in) (PZ50M) 28.00 N/mm (2.86 kg/mm, 159.88 lb/in) (PZ50VT USA/ Canada) 23.00 N/mm (2.35 kg/mm, 131.33 lb/in) (PZ50VT Europe) 31.00 N/mm (3.16 kg/mm, 177.01 lb/in) (PZ50MP) 2,500 N mm/deg (254.9 kg mm/deg, 14,274 lb in/deg) (PZ50/PZ50FX/PZ50VT Europe/PZ50MP) 2,100 N mm/deg (214.1 kg mm/deg, 11,991 lb in/deg) (PZ50GT) 1,700 N mm/deg (173.3 kg mm/deg, 9,707 lb in/deg) (PZ50M) 3,000 N mm/deg (305.9 kg mm/deg, 17,130 lb in/deg) (PZ50VT USA/Canada)

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

9-13

MAINTENANCE SPECIFICATIONS
Model Suspension wire diameter Front

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)

Rear

Shock absorber: Damping force Front Extension

Compression

830.0 N/0.3 m/s (84.6 kg/0.3 m/s, 186.6 lb/0.3 m/s) (PZ50) 660.0 N/0.3 m/s (67.3 kg/0.3 m/s, 148.4 lb/0.3 m/s) (PZ50GT USA/Canada) 630.0 N/0.3 m/s (64.2 kg/0.3 m/s, 141.6 lb/0.3 m/s) (PZ50GT Europe) 610.0 N/0.3 m/s (62.2 kg/0.3 m/s, 137.1 lb/0.3 m/s) (PZ50FX/PZ50M) 760.0 N/0.3 m/s (77.5 kg/0.3 m/s, 170.8 lb/0.3 m/s) (PZ50VT USA/Canada/PZ50MP) 520.0 N/0.3 m/s (53.0 kg/0.3 m/s, 116.9 lb/0.3 m/s) (PZ50VT Europe) 690.0 N/0.3 m/s (70.4 kg/0.3 m/s, 155.1 lb/0.3 m/s) (PZ50) 500.0 N/0.3 m/s (51.0 kg/0.3 m/s, 112.4 lb/0.3 m/s) (PZ50GT USA/Canada) 400.0 N/0.3 m/s (40.8 kg/0.3 m/s, 89.9 lb/0.3 m/s) (PZ50GT Europe) 610.0 N/0.3 m/s (62.2 kg/0.3 m/s, 137.1 lb/0.3 m/s) (PZ50FX) 710.0 N/0.3 m/s (72.4 kg/0.3 m/s, 159.6 lb/0.3 m/s) (PZ50M) 770.0 N/0.3 m/s (78.5 kg/0.3 m/s, 173.1 lb/0.3 m/s) (PZ50VT USA/Canada) 920.0 N/0.3 m/s (93.8 kg/0.3 m/s, 206.8 lb/0.3 m/s) (PZ50VT Europe) 810.0 N/0.3 m/s (82.6 kg/0.3 m/s, 182.1 lb/0.3 m/s) (PZ50MP)

9-14

MAINTENANCE SPECIFICATIONS
Model Rear Extension

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, 326.0 lb/0.3 m/s) (PZ50GT USA/Canada) 1,710.0 N/0.3 m/s (174.4 kg/0.3 m/s, 384.4 lb/0.3 m/s) (PZ50GT Europe) 3,070.0 N/0.3 m/s (313.0 kg/0.3 m/s, 690.1 lb/0.3 m/s) (PZ50FX) 1,430.0 N/0.3 m/s (145.8 kg/0.3 m/s, 321.5 lb/0.3 m/s) (PZ50M) 1,260.0 N/0.3 m/s (128.5 kg/0.3 m/s, 283.2 lb/0.3 m/s) (PZ50VT USA/Canada) 530.0 N/0.3 m/s (54.0 kg/0.3 m/s, 119.1 lb/0.3 m/s) (PZ50VT Europe/PZ50MP) 730.0 N/0.3 m/s (74.4 kg/0.3 m/s, 164.1 lb/0.3 m/s) (PZ50) 630.0 N/0.3 m/s (64.2 kg/0.3 m/s, 141.6 lb/0.3 m/s) (PZ50GT USA/Canada) 980 N/0.3 m/s (99.9 kg/0.3 m/s, 220.3 lb/0.3 m/s) (PZ50GT Europe) 1,470.0 N/0.3 m/s (149.9 kg/0.3 m/s, 330.5 lb/0.3 m/s) (PZ50FX) 710.0 N/0.3 m/s (72.4 kg/0.3 m/s, 159.6 lb/0.3 m/s) (PZ50M) 530.0 N/0.3 m/s (54.0 kg/0.3 m/s, 119.1 lb/0.3 m/s) (PZ50VT USA/Canada) 840.0 N/0.3 m/s (85.7 kg/0.3 m/s, 188.8 lb/0.3 m/s) (PZ50VT Europe/PZ50MP) 18.3 mm (0.72 in) 10.5 mm (0.41 in) Quadruple polyethylene 9 T (PZ50/PZ50GT/PZ50FX/PZ50VT/PZ50MP) 8 T (PZ50M) High molecular weight polyethylene with rubber 178.0 mm (7.01 in) DOT 4 9.4 mm (0.37 in) 4.7 mm (0.19 in) 0.08 ~ 0.20 mm (0.0031 ~ 0.0079 in) 43.5 ~ 46.5 mm (1.713 ~ 1.831 in) 200.0 mm (7.87 in) 4.0 mm (0.16 in) 3.5 mm (0.14 in)

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

9-15

MAINTENANCE SPECIFICATIONS
CHASSIS
Model Frame: Frame material Seat height Luggage box location Steering: Lock-to-lock angle

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Monocoque (Aluminum and Steel) 719 mm (28.31 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 724 mm (28.50 in) (PZ50VT/PZ50MP) Not available (left) (right) 32.4 (R ski) 37.6 (L ski) 37.6 (R ski) 32.4 (L ski) Toe-out 0 ~ 15 mm (0 ~ 0.59 in) 18.0 1,080 mm (42.5 in) (PZ50/PZ50GT/PZ50FX/PZ50VT/ PZ50MP) 980 mm (38.6 in) (PZ50M) Plastic 1,021.0 mm (40.20 in) (PZ50/PZ50GT/PZ50FX/PZ50M/ PZ50VT USA/Canada) 1,073.0 mm (42.24 in) (PZ50VT Europe/PZ50MP) 132.0 mm (5.20 in) (PZ50/PZ50GT/PZ50FX/PZ50VT USA/Canada) 182.0 mm (7.17 in) (PZ50M) 180.0 mm (7.09 in) (PZ50VT Europe/PZ50MP) Steel No 6 mm (0.24 in) 13 mm (0.51 in) (PZ50/PZ50GT/PZ50FX/PZ50VT USA/ Canada) 24 mm (0.95 in) (PZ50M/PZ50VT Europe/PZ50MP) Independent wishbone 235.0 mm (9.25 in) (PZ50/PZ50FX) 214.0 mm (8.43 in) (PZ50GT) 220.0 mm (8.66 in) (PZ50M) 181.0 mm (7.13 in) (PZ50VT USA/Canada) 182.0 mm (7.17 in) (PZ50VT Europe) 224.0 mm (8.82 in) (PZ50MP) Coil spring 30 N/mm (3.06 kg/mm, 171.3 lb/in) (PZ50) 21 N/mm (2.14 kg/mm, 119.9 lb/in) (PZ50GT) 26 N/mm (2.65 kg/mm, 148.5 lb/in) (PZ50FX) 21~ 32 N/mm (2.14 ~ 3.26 kg/mm, 119.9 ~ 182.7 lb/in) (PZ50M) 55 N/mm (5.61 kg/mm, 314.0 lb/in) (PZ50VT USA/Canada) 15 ~ 35 N/mm (1.53 ~ 3.57 kg/mm, 85.6 ~ 199.8 lb/in) (PZ50VT Europe) 24 N/mm (2.45 kg/mm, 137.0 lb/in) (PZ50MP)

Ski alignment Toe-out size Caster angle Ski stance (center to center)

Ski: Ski material Length

Width

Ski runner material Ski cover Ski runner wear limit Plastic ski wear limit

Ski suspension (front suspension): Type Travel

Spring type Spring rate

9-16

MAINTENANCE SPECIFICATIONS
Model Wire diameter

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/0.3 m/s) (PZ50FX) 490 N/0.3 m/s (50.0 kg/0.3 m/s, 110.2 lb/0.3 m/s) (PZ50M) 640 N/0.3 m/s (65.3 kg/0.3 m/s, 143.9 lb/0.3 m/s) (PZ50VT USA/Canada) 740 N/0.3 m/s (75.5 kg/0.3 m/s, 166.4 lb/0.3 m/s) (PZ50VT Europe) 730 N/0.3 m/s (74.4 kg/0.3 m/s, 164.1 lb/0.3 m/s) (PZ50MP) 890 N/0.3 m/s (90.8 kg/0.3 m/s, 200.1 lb/0.3 m/s) (PZ50) 670 N/0.3 m/s (68.3 kg/0.3 m/s, 150.6 lb/0.3 m/s) (PZ50GT) 885 N/0.3 m/s (90.2 kg/0.3 m/s, 198.9 lb/0.3 m/s) (PZ50FX) 850 N/0.3 m/s (86.7 kg/0.3 m/s, 191.1 lb/0.3 m/s) (PZ50M) 970 N/0.3 m/s (98.9 kg/0.3 m/s, 218.1 lb/0.3 m/s) (PZ50VT USA/Canada) 1,440 N/0.3 m/s (146.8 kg/0.3 m/s, 323.7 lb/0.3 m/s) (PZ50VT Europe) 820 N/0.3 m/s (83.6 kg/0.3 m/s, 184.3 lb/0.3 m/s) (PZ50MP)

Shock absorber: Damping force Extension

Compression

9-17

MAINTENANCE SPECIFICATIONS
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.: Magneto model/Manufacturer Standard Stator coil resistance (color code) ECU model/Manufacturer 12 V 5 at 1,800 r/min Digital type F6T567/MITSUBISHI 6.0 mm (0.24 in) 1.19 ~ 1.61 at 20 C (68 F) 8.5 ~ 11.5 k at 20 C (68 F) A.C. magneto 14 V/less than 35 A at 5,000 r/min

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP

F4T39471/MITSUBISHI 14 V 31.5 A, 440 W at 5,000 r/min 0.22 ~ 0.26 at 20 C (68 F) (White White) F8T83571/MITSUBISHI (PZ50/PZ50GT/PZ50FX/PZ50VT/ PZ50MP) F8T83572/MITSUBISHI (PZ50M) Short circuit type FH012/SHINDENGEN 14.2 ~ 14.8 V 50 A 40 V 1.32 YUASA YTX14-BS 12V-12Ah 12 A Constant mesh type 8GC/MORIC 0.90 kW 0.009 ~ 0.011 at 20 C (68 F) More than 100 k at 20 C (68 F) 10.8 mm (0.43 in) 3.65 mm (0.14 in) 5.28 ~ 7.92 N (538 ~ 808 g, 19.01 ~ 28.51 oz) 24.5 mm (0.96 in) 23.5 mm (0.93 in) 1.5 mm (0.06 in) MS5F-571/JIDECO 180 A 4.18 ~ 4.62 at 20 C (68 F)

Rectifier/regulator: Type Model/Manufacturer No load regulated voltage (DC) Capacity (DC) Withstand voltage Battery: Specific gravity Manufacturer Type Ten hour rate amperage Electric starter system: Type Starter motor: Model/Manufacturer Output Armature coil resistance Continuity check Insulation check Brush Overall length <Wear limit> Spring pressure Commutator diameter <Wear limit> Mica undercut Starter relay: Model/Manufacturer Amperage rating Coil resistance

9-18

MAINTENANCE SPECIFICATIONS
Model T.P.S. (throttle position sensor): Model/Manufacturer Resistance Oil level switch: Model/Manufacturer Fuel sender: Model/Manufacturer Sender resistance Full Empty Headlight relay: Model/Manufacturer Coil resistance Grip warmer: Heater resistance (left)

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 8GC/KEIHIN 4 ~ 6 k at 20 C (68 F) (Blue Black/Blue) 8GC/ASTI 8GC/NIPPON SEIKI 10 ~ 12 at 20 C (68 F) 179 ~ 185 at 20 C (68 F) 5DM/OMRON 94.5 ~ 115.5 at 20 C (68 F) 1.53 ~ 1.87 at 20 C (68 F) (Black Black) (PZ50/ PZ50GT/PZ50M/PZ50VT/PZ50MP) 6.12 ~ 7.48 at 20 C (68 F) (Black Black) (PZ50FX) 1.53 ~ 1.87 at 20 C (68 F) (Black Black) (PZ50/ PZ50GT/PZ50M/PZ50VT/PZ50MP) 6.12 ~ 7.48 at 20 C (68 F) (Black Black) (PZ50FX) 37.0 ~ 45.2 at 20 C (68 F) (White Black) 8.82 ~ 10.78 (Green Black) (PZ50VT) 14.67 ~ 17.93 (Yellow Black) (PZ50VT) Fuse 40 A 1 10 A 1 20 A 1 7.5 A 1 20 A 1 3 A 1 (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) 15 A 1 (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) 4 A 1 (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) 20 A 1 15 A 1 (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) 10 A 1 7.5 A 1 4 A 1 (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) 3 A 1 (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) 8CC/MITSUBISHI 5.21 ~ 6.37 k at 0 C (32 F) 0.290 ~ 0.354 k at 80 C (176 F) 90 ~ 110 C (194 ~ 230 F) 85 ~ 105 C (185 ~ 221 F)

(right)

Thumb warmer: Heater resistance Passenger grip warmer: Heater resistance (high) Heater resistance (low) Circuit breaker: Type Amperage for individual circuit Main fuse Fuel injection system fuse Headlight fuse Signal fuse Ignition fuse Auxiliary DC jack fuse Radiator fan motor fuse Gear motor fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Coolant temperature sensor: Model/Manufacturer Resistance Indicator light (ON) (OFF)

9-19

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 at 20 C (68 F) (Gray Black) 5PS/DENSO 8FP/MITSUBISHI 290 ~ 390 k at 80 C (176 F) 8GC/MITSUBISHI 504 ~ 616 k at 20 C (68 F)

9-20

TIGHTENING TORQUE TIGHTENING TORQUE

ENGINE
Parts to be tightened Spark plug Cylinder head bolt (M10 1.25) Cylinder head bolt Camshaft cap and cylinder head Cylinder head cover Cylinder identification sensor Ignition coil Camshaft and camshaft sprocket Oil check bolt Timing chain tensioner Timing chain guide (intake) Thermostat housing cover Coolant temperature sensor Hose band Water pump Coolant reservoir tank Radiator Radiator fan motor Water jacket joint Knock sensor Oil cooler Rear engine mounting bolt spacer Engine mounting nut Engine mounting bracket Oil pan Oil pan engine oil drain bolt Oil filter cartridge Oil filter bolt Oil pressure switch Oil pump OIl pump drive chain guide Oil pump housing cover Oil tank engine oil drain bolt Oil tank and frame Exhaust pipe joint Exhaust pipe joint upper cover Exhaust pipe joint lower cover Exhaust pipe band Exhaust pipe/muffler Muffler dumper holder Muffler end cover Crankcase (M9 1.25) Crankcase (M6 1.0) Primary sheave drive shaft cover Primary sheave drive shaft assembly bolt Balancer shaft drive gear Balancer shaft driven gear Tightening torque Nm m kg ft lb 13 1.3 9.4 See NOTE.*1 12 1.2 8.7 9 0.9 6.5 12 1.2 8.7 8 0.8 5.8 10 1.0 7.2 24 2.4 17 10 1.0 7.2 12 1.2 8.7 12 1.2 8.7 10 1.0 7.2 23 2.3 17 2 0.2 1.4 12 1.2 8.7 10 1.0 7.2 10 1.0 7.2 8 0.8 5.8 10 1.0 7.2 27 2.7 19 10 1.0 7.2 7 0.7 5.1 40 4.0 29 23 2.3 17 10 1.0 7.2 30 3.0 22 17 1.7 12 30 3.0 22 15 1.5 11 12 1.2 8.7 10 1.0 7.2 5 0.5 3.6 16 1.6 11 10 1.0 7.2 25 2.5 18 6 0.6 4.3 8 0.8 5.8 18 1.8 13 33 3.3 24 10 1.0 7.2 10 1.0 7.2 See NOTE.*2 12 1.2 8.7 12 1.2 8.7 12 1.2 8.7 75 7.5 54 50 5.0 36
9-21

SPEC

Remarks

Apply the engine oil.

Apply LOCTITE Apply LOCTITE

Apply LOCTITE

Apply LOCTITE

Apply LOCTITE (PZ50/PZ50GT/PZ50FX/PZ50M) Apply the engine oil. Apply the engine oil.

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. magneto lead holder Starter motor Fuel pump Fuel tank Starter motor lead Throttle cable locknut Rectifier/regulator Frame ground lead (rectifier/regulator) Engine ground lead (water jacket joint) Frame rear cross member (front) Frame rear cross member (rear) Tightening torque Nm m kg ft lb 10 1.0 7.2 50 5.0 36 See NOTE.*3 130 13.0 94 12 1.2 8.7 12 1.2 8.7 12 1.2 8.7 10 1.0 7.2 7 0.7 5.1 10 1.0 7.2 12 1.2 8.7 7 0.7 5.1 10 1.0 7.2 7 0.7 5.1 6 0.6 4.3 7 0.7 5.1 7 0.7 5.1 10 1.0 7.2 25 2.5 18 30 3.0 22

SPEC
Remarks

Apply LOCTITE

Apply the engine oil. Apply LOCTITE Apply LOCTITE Apply LOCTITE Apply LOCTITE Apply LOCTITE

NOTE:
*1: Tighten the cylinder head bolts to 25 Nm (2.5 m kg, 18 ft lb) in the proper tightening sequence, loosen and retighten the cylinder head bolts to 25 Nm (2.5 m kg, 18 ft lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 175 ~ 185 in the proper tightening sequence. *2: Tighten the crankcase bolts to 15 Nm (1.5 m kg, 11 ft lb) in the proper tightening sequence, loosen and retighten the crankcase bolts to 15 Nm (1.5 m kg, 11 ft lb) in the proper tightening sequence, and then tighten the crankcase bolts further to reach the specified angle 65 ~ 70 in the proper tightening sequence. *3: Tighten the connecting rod nuts to 20 Nm (2.0 m kg, 14 ft lb), and then tighten the connecting rod nuts further to reach the specified angle 120 ~ 130.

9-22

TIGHTENING TORQUE
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)

SPEC

Frame and secondary shaft assembly Gear motor and secondary shaft assembly Right reverse gear case and left reverse gear case Drive position switch Reverse position switch Battery bracket Brake caliper bracket and drive chain cover Brake caliper bleed screw Brake caliper retaining pin Brake hose union bolt Parking brake assembly and drive chain cover Lever and parking brake assembly Brake master cylinder holder and brake master cylinder Brake master cylinder holder and parking brake lever Parking brake cable and parking brake lever Parking brake cable locknut Slide rail suspension mounting bolt (M10) Slide rail suspension mounting bolt (M10) (front side) Slide rail suspension mounting bolt (M10) (rear side) Stopper band Shock absorber and front pivot arm Shock absorber and front suspension bracket Shaft and sliding frame Front pivot arm and connecting arm

Remarks m kg ft lb See NOTE. Apply engine oil. 200 20.0 145 Left-hand thread. Apply LOCTITE 14 1.4 10 6 0.6 4.3 60 6.0 43 7 0.7 5.1 24 2.4 17 16 1.6 11 25 2.5 18 48 4.8 35 Apply LOCTITE 24 2.4 17 9 0.9 6.5 Apply LOCTITE (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 10 1.0 7.2 (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 17 1.7 12 (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 6 0.6 4.3 (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 17 1.7 12 (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 17 1.7 12 (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 23 2.3 17 48 4.8 35 6 0.6 4.3 18 1.8 13 30 3.0 22 10 1.0 7.2 16 1.6 11 10 1.0 7.2 Nm 23 10 6 72 72 110 4 49 49 60 110 2.3 1.0 0.6 7.2 7.2 11.0 0.4 4.9 4.9 6.0 11.0 17 7.2 4.3 52 52 80 2.9 35 35 43 80

Tightening torque

Apply LOCTITE (PZ50VT/PZ50MP) Apply LOCTITE (PZ50/PZ50GT/PZ50FX/PZ50M) Apply LOCTITE (PZ50/PZ50GT/PZ50FX/PZ50M)

(PZ50/PZ50GT/PZ50FX/PZ50M)

9-23

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 Suspension wheel Front suspension bracket shaft and sliding frame Set bolt (wheel bracket) Shock absorber and connecting arm Pull rod, shock absorber, and rear suspension bracket Rear suspension bracket shaft and sliding frame Rear pivot arm and pull rod Shock absorber and rear pivot arm 2-up adjusting block Set bolt (collar) Rear pivot arm joint Rear pivot arm and rear pivot arm bracket Rear pivot arm bracket and sliding frame Rear pivot arm bracket stopper and sliding frame Wheel bracket, shaft, and sliding frame Rear pivot arm and control rod stopper Control rod adjusting locknut Control rod shaft and sliding frame Rear axle Set bolt (front axle) Bearing holder (front axle) Bearing holder (front axle) Speed sensor Bearing housing Gear unit (speed sensor) Tightening torque Nm 72 60 72 72 60 60 6 49 49 60 49 49 60 9 35 72 72 60 60 60 25 72 75 9 24 24 24 24 40

SPEC

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) 4.9 35 (PZ50VT/PZ50MP) 6.0 4.9 4.9 6.0 0.9 3.5 7.2 7.2 6.0 6.0 6.0 2.5 7.2 7.5 0.9 2.4 2.4 2.4 2.4 4.0 43 35 35 43 6.5 25 52 52 43 43 43 18 52 54 6.5 17 17 17 17 29 (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50/PZ50GT/PZ50FX/PZ50M) Apply LOCTITE (PZ50/PZ50GT/PZ50FX/PZ50M) Apply LOCTITE (PZ50/PZ50GT/PZ50FX/PZ50M) (PZ50/PZ50GT/PZ50FX/PZ50M) (PZ50M) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) Apply LOCTITE Inside Apply LOCTITE Outside

NOTE:
Tightening steps: 1. Tighten the bolt to a torque at 120 Nm (12.0 m kg, 85 ft lb). 2. Loosen the bolt completely. 3. Retighten the bolt to a torque of 60 Nm (6.0 m kg, 43 ft lb).

9-24

TIGHTENING TORQUE
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 joint bracket Steering joint bracket and steering column Steering column and relay rod Relay rod and steering control arm Steering column (upper) Steering column (lower) Steering control arm and steering control arm bracket Steering control arm bracket and frame Steering control arm and steering shaft Steering shaft and steering arm Steering arm pinch bolt Steering shaft end locknut Pivot arm bracket Pivot arm bracket and relay arm Pivot arm bracket and pivot arm shaft Pivot arm shaft and idler arm Relay arm and idler arm Idler arm and tie rod Tie rod and steering knuckle Tie rod end locknut Ski Ski runner Ski and ski handle (M8 55) Ski and ski handle (M8 100) Tightening torque Nm 23 16 18 10 8 8 47 23 10 23 7 11 23 7 8 8 23 7 8 7 23 10 15 20 21 16 21 21 23 23 35 25 21 35 30 25 35 38 90 38 38 25 28 25 48 19 12 17 m kg ft lb 2.3 17 1.6 11 1.8 13 1.0 7.2 0.8 5.8 0.8 5.8 4.7 34 2.3 17 1.0 7.2 2.3 17 0.7 5.1 1.1 8.0 2.3 17 0.7 5.1 0.8 5.8 0.8 5.8 2.3 17 0.7 5.1 0.8 5.8 0.7 5.1 2.3 17 1.0 7.2 1.5 11 2.0 14 2.1 15 1.6 11 2.1 15 2.1 15 2.3 17 2.3 17 3.5 25 2.5 2.1 3.5 3.0 2.5 3.5 3.8 9.0 3.8 3.8 2.5 2.8 2.5 4.8 1.9 1.2 1.7 18 15 25 22 18 25 27 65 27 27 18 20 18 35 14 8.7 12

SPEC
Remarks

(PZ50GT/PZ50FX/PZ50M) (PZ50VT/PZ50MP) (PZ50/PZ50GT/PZ50FX/PZ50M) (PZ50/PZ50GT/PZ50FX/PZ50M) (PZ50/PZ50GT/PZ50FX/PZ50M) (PZ50/PZ50GT/PZ50FX/PZ50M) (PZ50/PZ50GT/PZ50FX/PZ50M) (PZ50VT/PZ50MP) (PZ50/PZ50GT/PZ50FX/PZ50M) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP)

(PZ50VT/PZ50MP) (PZ50VT/PZ50MP)

Apply LOCTITE

Apply LOCTITE

9-25

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

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) 3.4 25 (PZ50/PZ50FX/PZ50M) 0.7 5.1 (PZ50GT/PZ50VT/PZ50MP) 3.4 25

9-26

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. Components should be at room temperature. A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm

SPEC
General torque specifications Nm 6 15 30 55 85 130 m kg 0.6 1.5 3.0 5.5 8.5 13.0 ft lb 4.3 11 22 40 61 94

A: Distance across flats B: Outside thread diameter

DEFINITION OF UNITS
Unit mm cm kg N Nm m kg Pa N/mm L cm3 r/min Read Millimeter Centimeter Kilogram Newton Newton meter Meter kilogram Pascal Newtons per millimeter Liter Cubic centimeter Rotations per minute
-3

Definition 10 meter 10-2 meter 103 gram 1 kg m/sec Nm m kg N/m2 N/mm

2

Measurement Length Length Weight Force Torque Torque Pressure Spring rate Volume or capacity Engine speed

9-27

GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS

SPEC

9-28

CABLE ROUTING

SPEC

1 2 3 4 5

[ Z Y X W V U T
S R Q P O

6 7 8

0 A B C

N M L K J

E F G

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. 9 To the oil level switch 0 Fasten the sub-wire harness, parking brake cable, and brake hose to the steering gate with the plastic band. A Main switch B Fuel tank breather hose C Throttle cable D To the brake caliper E To the tail/brake light F Fuel pump lead G Fuel hose H Fasten the fuel pump lead at the white tape to the fuel hose with the plastic band. I Fuel pump coupler J Fuel pump K To the multi-function meter L 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.

SPEC

9-30

CABLE ROUTING

SPEC

1 2 3 4 5

[ Z Y X W V U T
S R Q P O

6 7 8

0 A B C

N M L K J

E F G

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. magneto lead coupler X Fuel pump lead coupler Y Intake air pressure sensor coupler Z Headlight coupler [ Intake air temperature sensor coupler

SPEC

9-32

CABLE ROUTING

SPEC

^ 1 2 3 4

\ [

Z Y X W V 7 8 9 0 A 6

U T S R Q P O

B C D E F

N G

9-33

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. 4 Headlight lead coupler 5 Wire harness 6 Radiator fan motor lead coupler 7 To the oil level switch 8 Right handlebar switch lead couplers 9 Route the fuel hose and sub-wire harness over the wire harness and fuel tank breather hose. 0 Fasten the sub-wire harness, parking brake cable, and brake hose to the steering gate with the plastic band. A Fasten the sub-wire harness and fuel tank breather hose to the steering gate with the plastic band. B To parking brake C Fuel tank breather hose D Main switch E Tail/brake light harness coupler F To the brake caliper G Throttle cable H To the tail/brake light I Fuel pump lead J Fuel hose K Fasten the fuel pump lead at the white tape to the fuel hose with the plastic band. L Fuel pump coupler M Fuel pump N To the multi-function meter

SPEC

9-34

CABLE ROUTING

SPEC

^ 1 2 3 4

\ [

Z Y X W V 7 8 9 0 A 6

U T S R Q P O

B C D E F

N G

9-35

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. W Sub-wire harness coupler X Rectifier/regulator Y Crankshaft position sensor coupler Z Fuel pump coupler [ Intake air pressure sensor coupler \ Intake air temperature sensor coupler ] To the Headlight _ Fasten the headlight lead coupler to the frame front cross member with the plastic band.

SPEC

9-36

CABLE ROUTING

SPEC

3 L

4 K J A 5 6 I H G F E D C A XY W Z O B 0 9 8 7

V Q 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. (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 6 Sub-wire harness coupler 7 Gear motor coupler (PZ50GT/ PZ50FX/PZ50M/PZ50VT/ PZ50MP) 8 Fuel tank breather hose 9 Wire harness 0 Fasten the wire harness and fuel tank breather hose to the steering gate with the plastic band, making sure to fasten the hose before and after the bend in the hose. A Route the wire harness under the steering gate. B Cylinder #1 ignition coil lead C Fasten the cylinder identification sensor lead to the cylinder head cover with the plastic band. D Cylinder identification sensor lead coupler E To the auxiliary DC jack (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) F Fasten the cylinder #1 ignition coil lead and cylinder #2 ignition coil lead with the plastic band. Position the plastic band 20 mm (0.79 in) from the cylinder #1 ignition coil coupler. Install the plastic band on the leads protective sleeves.

SPEC

9-38

CABLE ROUTING

SPEC

3 L

4 K J A 5 6 I H G F E D C A XY W Z O B 0 9 8 7

V Q R T A S

9-39

CABLE ROUTING
G H I J K 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. To the speed sensor To the frame ground lead Fasten the cylinder identification sensor lead and wire harness with the plastic band as shown in the illustration, making sure to position the band halfway between where the lead and where the sub-wire harness branch off from the wire harness. Location where the sub-wire harness branches off from the wire harness. To the throttle position sensor coupler and oil pressure switch coupler To the Rectifier/regulator

SPEC

L M N O P Q R S T

U V W

9-40

CABLE ROUTING

SPEC

9A 8 7 6 5 4 3 2 1

0 AB

E F G H

I J
B

M 9 0 A Q 3 E R P A 1 2 N 3

L 9 6 8

K 0 A B C

9-41

CABLE ROUTING
1 2 3 4 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. Rectifier/regulator Frame ground lead Wire harness Speed sensor coupler Fuel tank breather hose Fasten the speed sensor lead and fuel tank breather hose to the frame rear cross member with the plastic band. To the auxiliary DC jack (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) Fasten the speed sensor lead and fuel tank breather hose with the holder. Drive guard Fasten the speed sensor lead and fuel tank breather hose with a plastic locking tie. Fasten the speed sensor lead and fuel tank breather hose with the holder. Be sure to bend the holder so that the lead and hose will not come loose. Fasten the speed sensor lead with the holder. Be sure to bend the holder so that the lead will not come loose. Speed sensor

SPEC

5 6 7 8

9 0 A B C D

G H

9-42

CABLE ROUTING

SPEC

9A 8 7 6 5 4 3 2 1

0 AB

E F G H

I J
B

M 9 0 A Q 3 E R P A 1 2 N 3

L 9 6 8

K 0 A B C

9-43

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.

SPEC

9-44

CABLE ROUTING

SPEC

4 5 2 3 1 a \ ^ ] \ [ Z Y X

B C D E F G

O W V

H I J

U T S

L K N M P O R Q

PZ50 b O f Q R c d e N T j h g m k l i g h i j h g n m PZ50GT/PZ50FX/PZ50M

PZ50VT/PZ50MP i k l

9-45

CABLE ROUTING
1 2 3 4 5 6 7 8 9 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. Oil level switch coupler Oil tank breather hose Radiator outlet pipe Radiator fan motor coupler (PZ50M/PZ50VT/PZ50MP) Knock sensor coupler Radiator inlet hose Fasten the wire harness, radiator fan motor lead and knock sensor lead to the radiator outlet pipe with the plastic band, making sure to align the radiator fan motor coupler with the wire harness joint coupler. Install the plastic band with its buckle positioned to the outside of the pipe and its end facing rearward. (PZ50M/PZ50VT/PZ50MP) Coolant temperature sensor coupler Fasten the wire harness and radiator fan motor lead to the radiator outlet hose with the plastic band. Install the plastic band with its buckle positioned to the outside of the hose and its end facing rearward. (PZ50M/ PZ50VT/PZ50MP)

SPEC

0 A B C D E F

G H

9-46

CABLE ROUTING

SPEC

4 5 2 3 1 a \ ^ ] \ [ Z Y X

B C D E F G

O W V

H I J

U T S

L K N M P O R Q

PZ50 b O f Q R c d e N T j h g m k l i g h i j h g n m PZ50GT/PZ50FX/PZ50M

PZ50VT/PZ50MP i k l

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. N Starter motor lead O Negative battery lead P Fasten the starter motor lead, negative battery lead, and wire harness at the white tape to the oil tank with the plastic band. Face the end of the plastic band upward. Q Positive battery lead coupler R Negative battery lead coupler S Fasten the fuse box lead and negative battery leads with the plastic band. The buckle of the plastic band on the right side of the leads. T ECU lead U ECU V DC back buzzer lead (PZ50GT/ PZ50FX/PZ50M/PZ50VT/ PZ50MP) W Positive battery lead X To the tail/brake light Y Tail/brake light lead Z Fasten the tail/brake light lead to the frame rear cross member with the plastic band, making sure to route the lead to the inside of the cross member. Install the plastic band with its buckle positioned towards the front of the machine and its end facing to the right.

SPEC

9-48

CABLE ROUTING

SPEC

4 5 2 3 1 a \ ^ ] \ [ Z Y X

B C D E F G

O W V

H I J

U T S

L K N M P O R Q

PZ50 b O f Q R c d e N T j h g m k l i g h i j h g n m PZ50GT/PZ50FX/PZ50M

PZ50VT/PZ50MP i k l

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. b Battery c Fuse box d Main fuse e Starter relay f Starter relay lead g Load control relay h Fuel injection system relay i Headlight relay j Radiator fan motor relay (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) k Gear motor relay 1 (PZ50GT/ PZ50FX/PZ50M/PZ50VT/ PZ50MP) l Gear motor relay 2 (PZ50GT/ PZ50FX/PZ50M/PZ50VT/ PZ50MP) m Gear motor relay 3 (PZ50GT/ PZ50FX/PZ50M/PZ50VT/ PZ50MP) n Passenger grip warmer relay (PZ50VT/PZ50MP)

SPEC

9-50

CABLE ROUTING

SPEC

4 5

6 7 8 9

2 1 e d

f A B A D B E F G H I J
C

C BA

b c a ^ [ \ ]

Z Y X W V

K L M N O P Q R

S T

U I c 1 h B-B C 6 c 5 b 5 C i 1 A-A 6 c b C g

9-51

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. (Except for PZ50) 9 Route the left handlebar switch leads behind the handlebar. 0 Brake master cylinder A Left grip warmer B Brake light switch C Corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) D Auxiliary DC jack (PZ50GT/ PZ50FX/PZ50M) E Rectifier/regulator F Cylinder identification sensor coupler G A.C. magneto coupler H Speed sensor lead I Pressure regulator hose J Fuel tank breather hose K Throttle body heater hose L Throttle position sensor M Fasten the A.C. magneto lead, oil pressure switch lead, and pressure regulator hose with the holder. N Knock sensor O Fasten the A.C. magneto lead, water pump outlet hose, and knock sensor lead with the plastic band.

SPEC

9-52

CABLE ROUTING

SPEC

4 5

6 7 8 9

2 1 e d

f A B A D B E F G H I J
C

C BA

b c a ^ [ \ ]

Z Y X W V

K L M N O P Q R

S T

U I c 1 h B-B C 6 c 5 b 5 C i 1 A-A 6 c b C g

9-53

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. S Oil pressure switch coupler T Starter motor U Oil tank outlet hose V Oil tank inlet hose W Throttle body heater outlet hose X Water pump inlet hose Y To the wire harness Z Route the water pump outlet hose and throttle body heater outlet hose behind the engine mounting bracket. [ Coolant temperature sensor \ Throttle body heater inlet hose ] Thermostat cover _ To the parking brake a To the brake caliper b Brake hose c Throttle cable d Main switch e Pass 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 holder.

SPEC

9-54

CABLE ROUTING

SPEC

4 5

6 7 8 9

2 1 e d

f A B A D B E F G H I J
C

C BA

b c a ^ [ \ ]

Z Y X W V

K L M N O P Q R

S T

U I c 1 h B-B C 6 c 5 b 5 C i 1 A-A 6 c b C g

9-55

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. Be sure to position the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) and corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) towards the front and fasten the throttle cable at the throttle cable adjusting nut. h Position the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) and corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) towards the front of the guide. i 10 mm (0.39 in)

SPEC

9-56

CABLE ROUTING

SPEC

4 5

6 7

2 1

e A e b c d B B A C D E F G H I J K L M N O P Q B A0

a _ ] Z \ [

Y X W V U

R S

T H b 1 g B-B C 6 b 5 a 5 B 1 A-A 6 b a B f

9-57

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. 9 Brake master cylinder 0 Left grip warmer A Brake light switch B Corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) C Auxiliary DC jack D Rectifier/regulator E Cylinder identification sensor coupler F A.C. magneto coupler G Speed sensor lead H Pressure regulator hose I Fuel tank breather hose J Throttle position sensor K Throttle body heater hose L Fasten the A.C. magneto lead, oil pressure switch lead, and pressure regulator hose with the holder. M Knock sensor N Fasten the A.C. magneto lead, water pump outlet hose, and knock sensor lead with the plastic band. O Route the A.C. magneto lead behind the idling adjusting screw remote adjustment cable.

SPEC

9-58

CABLE ROUTING

SPEC

4 5

6 7

2 1

e A e b c d B B A C D E F G H I J K L M N O P Q B A0

a _ ] Z \ [

Y X W V U

R S

T H b 1 g B-B C 6 b 5 a 5 B 1 A-A 6 b a B f

9-59

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. R Oil pressure switch coupler S Starter motor T Oil tank outlet hose U Oil tank inlet hose V Throttle body heater outlet hose W Water pump inlet hose X To the wire harness Y Route the water pump outlet hose and throttle body heater outlet hose behind the engine mounting bracket. Z Coolant temperature sensor [ Throttle body heater inlet hose \ Thermostat cover ] To the parking brake _ To the brake caliper a Brake hose b Throttle cable c Main switch d Pass 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 holder.

SPEC

9-60

CABLE ROUTING

SPEC

4 5

6 7

2 1

e A e b c d B B A C D E F G H I J K L M N O P Q B A0

a _ ] Z \ [

Y X W V U

R S

T H b 1 g B-B C 6 b 5 a 5 B 1 A-A 6 b a B f

9-61

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. Be sure to position the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) and corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) towards the front and fasten the throttle cable at the throttle cable adjusting nut. g Position the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) and corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) towards the front of the guide.

SPEC

9-62

CABLE ROUTING

SPEC

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.

SPEC

9-64

CABLE ROUTING

SPEC

PZ50/PZ50GT/PZ50FX/PZ50M

PZ50VT/PZ50MP

6 5 2 7

8 3

9 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. 9 Connect the tail/brake light coupler, and then place it in the tail/ brake light cover.

SPEC

9-66

YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER

PRINTED IN U.S.A. 2006.07 CR (E)

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. magneto Rectifier/regulator Main switch Main fuse Load control relay Fuel injection system fuse Starter relay Starter motor Battery Diode Engine stop switch Throttle switch Grip warmer Thumb warmer Oil pressure switch ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Fuel injection system relay Injector #1 Injector #2 Fuel pump Throttle position sensor Speed sensor Cylinder identification sensor Cylinder-#1 intake air pressure sensor Cylinder-#2 intake air pressure sensor Knock sensor Coolant temperature sensor Intake air temperature sensor Grip/thumb warmer adjustment switch CO adjustment coupler Engine ground Frame ground Brake light switch Tail/brake light Fuel sender Oil level switch Speedometer unit Multi-function meter Warning light Low coolant temperature indicator light Knock control system indicator light High beam indicator light Headlight Headlight relay Headlight beam switch Ignition fuse Signal fuse Headlight fuse

COLOR CODE
B ..............Black Br.............Brown Ch............Chocolate G .............Green Gy............Gray L ..............Blue Lg ............Light green O .............Orange P ..............Pink R..............Red W .............White Y ..............Yellow B/L ...........Black/Blue B/R ..........Black/Red B/W .........Black/White B/Y ..........Black/Yellow Br/L..........Brown/Blue Br/R .........Brown/Red Br/W ........Brown/White G/B ..........Green/Black G/W .........Green/White Gy/R ........Gray/Red L/R...........Blue/Red L/W ..........Blue/White L/Y ...........Blue/Yellow P/W .........Pink/White R/B ..........Red/Black R/G ..........Red/Green R/L...........Red/Blue R/W .........Red/White R/Y ..........Red/Yellow W/B .........White/Black W/Y .........White/Yellow YG ...........Yellow/Green Y/L ...........Yellow/Blue Y/R ..........Yellow/Red Y/W .........Yellow/White

WIRING DIAGRAM PZ50 2007

8GC-0F001-00
A R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O B G/W B/L Ch C R/G R/W R/L B B R/L B/L G/W Ch SUB-WIRE HARNESS 2 O A O
Y/R L/R Br/L Lg B R/B O B G/B Gy/R

R/W A R/W R/W O R/G R/L

K
L/R R/L L/R R/L R/L

SUB-WIRE WIRE HARNESS HARNESS 1

FUEL PUMP WIRE HARNESS SUB-WIRE HARNESS

WIRE HARNESS

H I J I

R/W O R/W (BLACK)

R/L R/L

R/W Gy/R Gy/R A Gy/R

Gy/R R/W (BLACK)

L
R/B A R/B R/B R/L R/L R/B

A R/L

N
B B B B

R/L B

B/L Gy (BLACK)

Gy B

1 2
WWW W WW

Gy B/L R/Y L/W

(BLACK)

M
G/B A G/B G/B

WWW (GLAY)

(GLAY) R/L R/L G/B (GLAY)

4
OFF ON START

W/L

Y Br/W B/Y W/Y Y/W P/W Gy G/W L/W P Y/L

Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L

R R/W Br Br/W

L/W R/Y B Br

(BLACK)

3
B

Br

L Y B/L Gy R/W R/W L/W R R (40A) R R/W L/W R/W (BLACK) R R R R R R R B R/G R/G L/W R/W (10A) B/Y Br/L L/Y Br B/W B/Y B/Y L W/Y B/L L W/B B/L (BLACK) B/L W/B L W B (BLACK) L

(BLACK)

P
P O/R B/W L W/Y B/L

O Gy/R B B L/R R/L R/B G/B L Y W/Y W/B P/W P G/W Br/W W W B/L Y/L Y/W W B (BLACK) (BLACK)

L B/L Y (BLACK)

5
R

A
L/W R/W

R Br R W Br Br/L

7
B B L/W

B
RUN STOP Br Br/W (BLACK)

C
CLOSE OPEN

Y/R B/Y B/R Y/R Lg

Q
L P/W B/L

R
B/L P/W L (BLACK)

8 9

6
W Br/L

B/L (BLACK) Ch Ch (BLACK)

Y/R

Y/G Y/G

0
B B

D
B B

R/W Br (BLACK)

F
Lg

Y/G (GRAY)

L P B/L

S
B/L P L (BLACK)

W (7.5A) (20A)

W (20A)

B B/R B B B B/R B/R

Ch Lg

G/W C G/W

G/W

l k j
L/W L/R R/Y

E
B

B W Lg Lg B

U
Ch B/L Br/W Br/W B/L (BLACK) B/L C B/L B/L

G/W B/L (DARK GREEN)

D
B B B

Lg

Ch

Ch Ch

Y
L/W R/W

Y/W Ch Y/L Y/L Y/W Y/W Y/L B/L

a c d e b

R/W G/B L/Y R/B Ch (BLACK) Y L/R

Ch

i
Lg L/W L G

HI LO

L/W Y Lg G B Lg L/W (BLACK)

[
OFF ON G G/B

G L/R

L/R G

L/Y G/B R/B

Y Lg

G B

_ f
Y G Ch B Y Ch Ch R/B (GRAY) Ch

]
G B Ch G/B

L/R G

L Y B

G L/R B B

YG G Y B

YG

Z
B

g
B B

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. magneto Rectifier/regulator Main switch Main fuse Load control relay Fuel injection system fuse Starter relay Starter motor Battery Diode Engine stop switch Throttle switch DC back buzzer Grip warmer Thumb warmer Oil pressure switch Drive position switch Reverse position switch ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Fuel injection system relay Injector #1 Injector #2 Fuel pump Throttle position sensor Speed sensor Cylinder identification sensor Cylinder-#1 intake air pressure sensor Cylinder-#2 intake air pressure sensor Knock sensor Coolant temperature sensor Intake air temperature sensor Grip/thumb warmer adjustment switch Gear motor relay 1 Gear motor relay 2 Gear motor relay 3 Gear motor CO adjustment coupler Engine ground Passenger grip d Frame ground e Passenger grip warmer switch f Passenger grip warmer g Brake light switch h Tail/brake light i Fuel sender j Oil level switch k Speedometer unit l Multi-function meter m Warning light n Low coolant temperature indicator light o Knock control system indicator light p Drive position indicator light q Reverse position indicator light r High beam indicator light s Headlight t Headlight relay u Headlight beam switch v Radiator fan motor w Radiator fan motor relay x Auxiliary DC jack y Ignition fuse z Radiator fan motor fuse { Signal fuse | Headlight fuse } Auxiliary DC jack fuse ~ Gear motor fuse PZ50VT/PZ50MP PZ50M/PZ50VT/ PZ50MP PZ50VT (STANDARD)/PZ50MP (OPTION) PZ50VT/PZ50MP (STANDARD)/ PZ50GT/PZ50FX/ PZ50M (OPTION) PZ50GT/PZ50M/ PZ50VT/PZ50MP PZ50FX B ..............Black Br.............Brown Ch............Chocolate G..............Green Gy............Gray L ..............Blue Lg ............Light green O..............Orange P ..............Pink R..............Red Sb ............Sky blue W .............White Y ..............Yellow B/L ...........Black/Blue B/W..........Black/White B/R ..........Black/Red B/Y...........Black/Yellow Br/B .........Brown/Black Br/L..........Brown/Blue Br/R .........Brown/Red Br/W ........Brown/White G/B ..........Green/Black G/R ..........Green/Red G/W .........Green/White G/Y ..........Green/Yellow Gy/R ........Gray/Red L/B ...........Blue/Black L/R...........Blue/Red L/W ..........Blue/White L/Y ...........Blue/Yellow O/B ..........Orange/Black O/R ..........Orange/Red P/W..........Pink/White R/B ..........Red/Black R/G ..........Red/Green R/L...........Red/Blue R/W .........Red/White R/Y ..........Red/Yellow Sb/W........Sky blue/ White W/B..........White/Black W/L ..........White/Blue W/R .........White/Red W/Y..........White/Yellow YG ...........Yellow/Green Y/L ...........Yellow/Blue Y/R ..........Yellow/Red Y/W..........Yellow/White

WIRING DIAGRAM PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 2007

8GK-0F001-00/8GN-0F001-00/8GJ-0F001-00

A R/B G/B R/L O Gy/R R/W R/L G/B R/B R/W Gy/R O SUB-WIRE HARNESS 1 B G/W B/L Ch C B/L G/W Ch SUB-WIRE HARNESS 2 L/R G B O/B D G L/R O/B B SUB-WIRE HARNESS 3 Br/R Sb W/L W/R L/B E W/L Sb Br/R L/B W/R GEAR MOTOR SUB-WIRE HARNESS R/L B B R/L FUEL PUMP SUB-WIRE HARNESS

F R/W Y G B G Y B HEADLIGHT SUB-WIRE HARNESS A R/W R/W R/G R/L R/G R/W

N
L/R R/L L/R R/L R/L

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

O O A O
Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

K L M L

R/W O R/W (BLACK)

R/L R/L

R/W Gy/R Gy/R A Gy/R

Gy/R R/W (BLACK)

O
R/B A R/B R/B R/L R/L R/B

A R/L

Q
B B B B L Y B/L

R/L B

B/L Gy (BLACK)

Gy B

1 2
WWW W WW

Gy B/L R/Y L/W

(BLACK)

P
G/B A G/B G/B

WWW (GLAY)

(GLAY) R/L R/L G/B (GLAY)

4
OFF ON START

W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L

Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L

R R/W Br Br/W

L/W R/Y B Br

(BLACK)

3
B R (BLACK) B

Br

Gy R/W R/W L/W R R (40A) R B/Y Br/L G/Y L/Y O/B O/B

5
R R R R

R/W L/W (BLACK) R/G R/G L/W R/W (10A) R/W

O Gy/R B B L/R R/L R/B G/B L Y W/Y W/B P/W P G/W Br/W W W B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G W B (BLACK) (BLACK)

L W/Y B/L L W/B B/L (BLACK) B/L W/B L W B (BLACK) L

S
P O/R B/W L W/Y B/L

L B/L Y (BLACK)

P Br O/B L/R Y/R B/R Y/R Y/G B B

R Br R W Br Br/L

7
R/W B B L/W

A
L/W

Y/R Lg

T
L P/W B/L

D
L/R Br B/W B/Y B/Y

U
B/L P/W L (BLACK)

6
W Br/L

R R R B B

8 9

Y/G

W (4A)

W (3A)

W (7.5A) (20A)

W (15A)

R (20A)

0
B B

B
RUN STOP Br Br/W (BLACK)

C
CLOSE OPEN

B/Y

G
Lg

Y/G (GRAY) B/R W/L W/R

L P B/L

V
B/L P L (BLACK)

~ } | { z y
R/G O/B L/W L/R Br/R R/Y Br/R R/W

B/L (BLACK) Ch Ch (BLACK) Y/R Y/R Y/R Y/R B/R B/R B B

E
B B/R W/R

G/W C G/W

G/W

X [
R/G Y/R R/G Br/R Br/B (BLACK) Br/B Y/R Br/R B/L C B/L B/L

G/W B/L (DARK GREEN)

B B

R/W Br (BLACK)

F
B

B W

Lg Lg Ch Lg

E W/R W/L

G W/B O/B B

O/B

w
R/W G/Y L

x
B

Br/R L G/Y

B B

B B

B B

B Lg

E W/L

a
W/L

Br/W Br/W B/L (BLACK) B/L Sb/W

E E
B B B

W/R Ch C Ch Ch Sb R/G R/G B Sb/W (BLACK)

R/G R/G B

Y/R B

B B L L (BLACK) (BLACK)

\
Sb/W Sb

]
Y/R Sb/W L/B L/B E L/B

Y
B L/B

v
L R/W L/W Y Lg G B

Br/R

E Br/R

Y/W Ch Y/L Y/L Y/W Ch Y/W Y/L B/L

Sb E Sb

L/W

k m n o l p q r

u
Lg L/W L G

R/W G/B L/Y R/B Ch B/R Y (BLACK) B/R L/Y G/B R/B G/B

L/R

L/R D L/R

g
OFF ON G G D

G L/R L/R G

O/B

Br/R Sb L/B

HI LO

e
LO OFF HI

L/W (BLACK)

^
L/R L/R Y/L G/R

L/B Br/R

Sb

Lg

Y Lg

G B

Y/L O/B G/R L Y B G L/R B

Y F Y YG G Y B

G F G

j
Ch Ch R/B (GRAY) Ch Ch

i
G B Ch G/B

G L/R G

Y/L O/B G/R

(BLACK) (BLACK)

c
O/B

Y/L O/B L/R

L/R O/B Y/L

G/R Y/L

G/R Y/L

YG

Y G Y B

f
Y/L B B D B B B G/R Y B G Y/L B G/R

f
Y B G

O/B D

s
B B F B B

d
B

SUPPLEMENTARY SERVICE MANUAL

2008

PZ50X PZ50GTX PZ50RTX PZ50MTX PZ50VTX PZ50MPX

LIT-12618-02-67

8GC-28197-11

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for the PZ50X, PZ50GTX, PZ50RTX, PZ50MTX, PZ50VTX, PZ50MPX. For complete information, on service procedures, it is necessary to use this Supplementary Service Manual together with following manual: PZ50W, PZ50GTW, PZ50FXW, PZ50MW, PZ50VTW, PZ50MPW SERVICE MANUAL: 8GC-28197-10 (LIT-12618-02-58)

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

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 mechanics 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. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. 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. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

HOW TO USE THIS MANUAL

Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the snowmobile operator, a bystander, or a person inspecting or repairing the snowmobile. A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile. A NOTE provides key information that can make procedures easier or clearer.

CAUTION:
NOTE:

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g., Bearings Pitting/damage Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures.

GEN INFO
3

INSP ADJ
4

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapters number and content.
1 2 3 4 5 6 7 8 9 General information Periodic inspection and adjustment Chassis Power train Engine Cooling system Fuel injection system Electrical Specifications

CHAS
5

POWR TR
6

ENG
7

COOL
8

FI
9

ELEC

SPEC
0 A B
T.

Illustrated symbols 0 to F are used to identify the specifications which appear.

0 A B C D E F Filling fluid Lubricant Tightening torque Wear limit, clearance Engine speed Special tool Electrical data (, V, A)
R.

G
LT

5
L

Illustrated symbols G to R in the exploded diagram indicate grade of lubricant and location of lubrication point.
G H I J K L M N O P Q R Apply locking agent (LOCTITE) Apply Yamabond No.5 Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply brake fluid Apply wheel bearing grease Apply low-temperature lithium-soap-based grease Apply molybdenum disulfide grease Apply silicone grease ESSO beacon 325 grease or Aeroshell grease #7A Use new one

E
M
B

G
N
LS

M
O
M

BF

P
S

New

INDEX
GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SPECIFICATIONS
GEN INFO

1 2 3 4 5 6 7
+

INSP ADJ

CHAS

POWR TR

ENG

COOL

FI

ELEC

8 9

SPEC

PERIODIC INSPECTION AND ADJUSTMENT

TUNING ................................................................1 FRONT SUSPENSION ...................................1 AIR PRESSURE ADJUSTMENT (PZ50RT) ...3 REAR SUSPENSION .....................................5

CHASSIS ..................................................... 52 ELECTRICAL ............................................... 54 TIGHTENING TORQUE..................................... 57 ENGINE ....................................................... 57 POWER TRAIN............................................ 59 CHASSIS ..................................................... 61 GENERAL TORQUE SPECIFICATIONS .......... 63 DEFINITION OF UNITS ..................................... 63 CABLE ROUTING ............................................. 64

CHASSIS
COWLINGS ........................................................10 PZ50/PZ50GT/PZ50RT/PZ50MT..................10 STEERING..........................................................12 PZ50/PZ50GT/PZ50RT/PZ50MT..................12 FRONT SUSPENSION .......................................15 PZ50/PZ50RT/PZ50MT ................................15 PZ50GT/PZ50VT/PZ50MP ...........................17 INSTALLATION ............................................19

POWER TRAIN
SLIDE RAIL SUSPENSION................................20 PZ50/PZ50GT/PZ50RT/PZ50MT..................20 PZ50VT/PZ50MP..........................................24

ENGINE
SEAT AND FUEL TANK ....................................29 PZ50/PZ50GT/PZ50RT/PZ50MT..................29 BALANCER ........................................................31 REMOVAL ....................................................33 INSTALLATION ............................................33

FUEL INJECTION SYSTEM

THROTTLE BODY..............................................35 INJECTORS..................................................35

SPECIFICATIONS
GENERAL SPECIFICATIONS ...........................37 MAINTENANCE SPECIFICATIONS ..................41 ENGINE ........................................................41 POWER TRAIN.............................................46

FRONT SUSPENSION

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

TUNING
FRONT SUSPENSION
Spring preload 1. Adjust: Spring preload Adjustment steps: Loosen the locknut 1. Turn the spring seat 2 in or out. PZ50GT Spring seat distance Preload Standard Shorter Harder Min. 172 mm (6.77 in) 182 mm (7.17 in) Longer Softer Max. 182 mm (7.17 in)

2 1 a
Length a

PZ50MT Europe Spring seat distance Preload Length a Standard Shorter Harder Min. 215 mm (8.46 in) 225 mm (8.86 in) Longer Softer Max. 226 mm (8.90 in)

PZ50VT Europe/PZ50MP Spring seat distance Preload Length a Standard Shorter Harder Min. 205 mm (8.07 in) 215 mm (8.46 in) Longer Softer Max. 216 mm (8.50 in)

Turn the adjusting ring 3 to the proper position. PZ50/PZ50MT USA/Canada/PZ50VT USA/ Canada Spring adjuster position Preload Standard 1 2 3 4 5

Softer 1

Harder

PZ50MT Europe/PZ50VT Europe/PZ50MP PZ50GT PZ50/PZ50MT USA/Canada/PZ50VT USA/Canada

FRONT SUSPENSION
CAUTION:

INSP ADJ

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 (PZ50GT) The rebound damping force can be adjusted by turning the adjuster 1.
20 clicks out 12 clicks out 3 clicks out

b 1 a

Adjuster position Rebound damping force

Minimum

Standard

Maximum

Turns out b* 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. The shock absorber can be damaged and rebound damping force adjustments cannot be made. Do not turn the adjuster in direction b more than 20 clicks. Even if the adjuster is continually turned after 20 clicks, there will be no change in the rebound damping force. Be sure to stop the adjuster at a position where there is a click.

FRONT SUSPENSION/ AIR PRESSURE ADJUSTMENT (PZ50RT)

b 1 a

INSP ADJ

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 Compression damping force

Minimum

Standard

Maximum

Turns out b* 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. The shock absorber can be damaged and compression damping force adjustments cannot be made. Do not turn the adjuster in direction b more than 12 clicks. Even if the adjuster is continually turned after 12 clicks, there will be no change in the compression damping force. Be sure to stop the adjuster at a position where there is a click.

AIR PRESSURE ADJUSTMENT (PZ50RT)

CAUTION:
The left and right shock absorber air pressure must be set to the same setting. Uneven settings can cause poor handling and loss of stability. This snowmobile is equipped with FOX shock absorbers as standard equipment. The air pressure of the shock absorbers can be adjusted using the shock absorber pump 1 included with your snowmobile.

AIR PRESSURE ADJUSTMENT (PZ50RT)

Adjustment steps:

INSP ADJ

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. Place the snowmobile on a level surface and apply the parking brake. 2. Lift the front of the snowmobile onto a suitable stand to raise the skis off the ground. 3. Remove the air valve cap 1 from the shock absorber. 4. Install the hose connector 2 of the shock absorber pump onto the air valve of the shock absorber and tighten it approximately six turns until the pressure registers on the pump gauge.

CAUTION:
Do not overtighten the connector onto the air valve as this will damage the connector seal.

NOTE:
If the shock absorber has no air pressure, the gauge reading will be zero. 5. To increase the air pressure, operate the pump a few times. The pressure should increase slowly. If the pressure increases rapidly, check to make sure that the pump is properly connected and tightened onto the air valve. To decrease the air pressure, push the black bleed valve button 3.

NOTE:
To allow pressure to escape from the pump and the shock absorber, push the button halfway down and hold it. To allow only a small amount of pressure to escape, push the button all the way down and quickly release it.

AIR PRESSURE ADJUSTMENT (PZ50RT)/ REAR SUSPENSION

NOTE:

INSP ADJ

6. Remove the hose connector from the air valve. 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/cm, 50 psi) to 1,034 kPa (10.3 kgf/cm, 150 psi) Recommended air pressure: 483 kPa (4.8 kgf/cm, 70 psi)

CAUTION:
Do not exceed 1,034 kPa (10.3 kgf/cm, 150 psi). 7. Install the air valve cap.

NOTE:
If the front suspension bottoms too easily or rolls too much during cornering, increase the air pressure by 34 kPa (0.3 kgf/cm, 5 psi). If the suspension is too firm and you want a more compliant ride, decrease the air pressure by 34 kPa (0.3 kgf/cm, 5 psi).

REAR SUSPENSION
Stopper band 1. Adjust: Stopper band length

CAUTION:
Make sure the left and right rear suspension stopper bands are adjusted evenly. (PZ50VT, PZ50MP)

NOTE:
This adjustment affects the handling characteristics of the machine.

REAR SUSPENSION

INSP ADJ

1
No.1 No.2 No.3 No.4 No.5

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. Standard setting: No. 1 hole (PZ50/PZ50VT Europe/PZ50MP) No. 2 holes (PZ50GT/PZ50RT) No. 3 holes (PZ50MT) No. 4 hole (PZ50VT USA/Canada) Tighten the stopper band nuts.

1 2

1 No.1 No.2 No.3 No.4

T.

Stopper band nut: 4 Nm (0.4 m kg, 2.9 ft lb)

PZ50/PZ50GT/PZ50RT/PZ50MT PZ50VT/PZ50MP

Choosing other settings:

CAUTION:
The standard settings work well under most general riding conditions. The suspension can be adjusted to work better in one condition, but only at the expense of another. Keep this in mind when you adjust the suspension. : No. 5 hole : No. 4 hole (shortest) More weight on skis: Heavy steering/ oversteer More maneuverability Favors: hardpack snow, ice, smooth trails, tight turns

PZ50/PZ50GT/PZ50RT/PZ50MT PZ50VT/PZ50MP

R.

No. 1 hole (longest) Less weight on skis: Light steering/ understeer Better acceleration and speed Favors: deep snow, straight line acceleration, top speed

REAR SUSPENSION
Spring preload 1. Adjust: Spring preload

INSP ADJ

Adjustment step: Front side Loosen the locknut 1. Turn the spring seat 2 in or out. PZ50GT Europe/PZ50RT USA/Canada/ PZ50MT Europe Spring seat distance Preload Length a Standard Shorter Harder Min. 180 mm (7.09 in) 190 mm (7.48 in) Longer Softer Max. 191 mm (7.52 in)

PZ50RT Europe Spring seat distance Preload Length a Standard Shorter Harder Min. 178 mm (7.01 in) 188 mm (7.40 in) Longer Softer Max. 189 mm (7.44 in)

PZ50VT Europe/PZ50MP Spring seat distance Preload Length a Standard Shorter Harder Min. 194 mm (7.64 in) 204 mm (8.03 in) Longer Softer Max. 205 mm (8.07 in)

PZ50GT Europe/PZ50RT/PZ50MT Europe/ PZ50VT Europe/PZ50MP

REAR SUSPENSION

INSP ADJ

Turn the adjusting ring 3 to the proper position. PZ50/PZ50GT USA/Canada/PZ50MT USA/ Canada/PZ50VT USA/Canada Spring adjuster position Preload Standard 1 2 3 4 5

Softer 1

Harder

WARNING
This shock absorber contains highly pressurized nitrogen gas. Do not tamper with or attempt to open the shock absorber assembly. Do not subject the shock absorber assembly to flames or high heat, which could cause it to explode.
PZ50/PZ50GT USA/Canada/PZ50MT USA/Canada/PZ50VT USA/Canada

Rear side Turn the adjuster 1 to proper position. Spring adjuster position Spring rate Standard S Soft M Medium M H Hard

WARNING
Always adjust both spring preload (left and right) to the same setting. Uneven adjustment can cause poor handling and loss of stability.

REAR SUSPENSION

INSP ADJ

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 Damping force

Minimum

Standard

Maximum

Turns out b* 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. The shock absorber can be damaged and damping force adjustments cannot be made. Do not turn the adjuster in direction b more than 20 clicks. Even if the adjuster is continually turned after 20 clicks, there will be no change in the damping force. Be sure to stop the adjuster at a position where there is a click.

COWLINGS

CHAS

CHASSIS
COWLINGS
PZ50/PZ50GT/PZ50RT/PZ50MT

: 8 Nm (0.8 m kg, 5.8 ft lb) 12

PZ50RT

2 3 18 19

6 11 16 15 13 19 17 20 14

8 9

10
Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Cowling removal Windshield Front panel Air filter case cover Headlight cover Left side panel Right side panel Left side cover Right side cover Left lower cover Right lower cover Headlight coupler Headlight assembly Cylinder-#2 intake air pressure sensor coupler Qty 1 1 1 1 1 1 1 1 1 1 2 1 1

Remarks Remove the parts in the order listed below. PZ50GT

Disconnect.

10

COWLINGS
: 8 Nm (0.8 m kg, 5.8 ft lb) 12 4

CHAS

PZ50RT

2 3 18 19

6 11 16 15 13 19 17 20 14

8 9

10
Order 14 15 16 17 18 19 20 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 Air filter case assembly pad (left and right) Intake air pressure sensor hose Qty 1 1 1 1 1 2 2 Remarks Disconnect. Disconnect. Disconnect. Disconnect.

For installation, reverse the removal procedure.

11

STEERING STEERING
PZ50/PZ50GT/PZ50RT/PZ50MT

CHAS

7 Nm (0.7 m kg, 5.1 ft lb)

: 10 Nm (1.0 m kg, 7.2 ft lb) : 15 Nm (1.5 m kg, 11 ft lb) : 16 Nm (1.6 m kg, 11 ft lb) : 20 Nm (2.0 m kg, 14 ft lb) 19 7 18 2 5
LT

8 20

17

23

3 4 24 25 4

21

9 22

12 11 10 13 14 13 15 16

9 2
LT

Order

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Job name/Part name Handlebar removal Windshield/left side panel/right side panel Windshield bracket Wind deflector (left and right) Wind deflector bracket holder Wind deflector bracket Multi-function meter coupler Multi-function meter Multi-function meter bracket Steering pad Plastic band Thumb warmer lead coupler Engine stop switch coupler Throttle switch coupler Grip warmer lead connector Grip thumb warmer adjustment switch lead coupler

Qty

1 2 2 2 1 1 1 1 2 1 1 2 2 1

Remarks Remove the parts in the order listed below. Refer to COWLINGS. PZ50GT/PZ50RT/PZ50MT PZ50RT PZ50RT PZ50RT

PZ50GT/PZ50RT/PZ50MT Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.

12

STEERING
:
7 Nm (0.7 m kg, 5.1 ft lb)

CHAS

: 10 Nm (1.0 m kg, 7.2 ft lb) : 15 Nm (1.5 m kg, 11 ft lb) : 16 Nm (1.6 m kg, 11 ft lb) : 20 Nm (2.0 m kg, 14 ft lb) 19 7 18 2 5
LT

8 20

17

23

3 4 24 25 4

21

9 22

12 11 10 13 14 13 15 16

9 2
LT

Order 15 16 17 18 19 20 21 22 23 24 25

Job name/Part name Brake light switch coupler Headlight beam switch coupler Right handlebar switch cover Throttle cable holder Throttle cable Left handlebar switch Brake master cylinder holder Master cylinder assembly Handlebar holder Handlebar Steering joint

Qty 1 1 1 1 1 1 1 1 2 1 1

Remarks Disconnect. Disconnect.

NOTE:
After installing all parts, refer to CABLE ROUTING, to check the cable and lead routings. For installation, reverse the removal procedure.

13

STEERING
1 2

CHAS

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.

14

FRONT SUSPENSION FRONT SUSPENSION

PZ50/PZ50RT/PZ50MT

CHAS

: 28 Nm (2.8 m kg, 20 ft lb) : 34 Nm (3.4 m kg, 24 ft lb)

4 5

: 45 Nm (4.5 m kg, 32 ft lb) : 90 Nm (9.0 m kg, 65 ft lb) : 65 Nm (6.5 m kg, 47 ft lb)

12 11 10 4

3 2

10 16 16 16 15
LT

5 8 7

New

14 17 13
Order Job name/Part name Front suspension removal Air filter case cover Pivot arm cover Ski Shock absorber Shock absorber Shock absorber Collar Bushing Tie rod Steering knuckle Upper arm ball joint Upper arm Bushing Stabilizer holder Bushing Qty

1 2 3 4 5 6 7 8 9 10 11 12

1 1 1 2 4 1 1 1 1 2 1 1

Remarks Remove the parts in the order listed below. Refer to COWLINGS. Refer to STEERING. Refer to SKI in CHAPTER 3. PZ50/PZ50MT USA/Canada PZ50RT PZ50MT Europe PZ50/PZ50MT PZ50/PZ50MT Disconnect.

15

FRONT SUSPENSION
: 28 Nm (2.8 m kg, 20 ft lb) : 34 Nm (3.4 m kg, 24 ft lb) 4 5

CHAS

: 45 Nm (4.5 m kg, 32 ft lb) : 90 Nm (9.0 m kg, 65 ft lb) : 65 Nm (6.5 m kg, 47 ft lb)

12 11 10 4

3 2

10 16 16 16 15
LT

5 8 7

New

14 17 13
Order 13 14 15 16 17 Job name/Part name Stabilizer joint Stabilizer Lower arm Bushing Lower arm ball joint Qty 1 1 1 4 1 Remarks

For installation, reverse the removal procedure.

16

FRONT SUSPENSION
PZ50GT/PZ50VT/PZ50MP

CHAS

: 7 Nm (0.7 m kg, 5.1 ft lb) : 28 Nm (2.8 m kg, 20 ft lb)

4 5

: 34 Nm (3.4 m kg, 24 ft lb) : 45 Nm (4.5 m kg, 32 ft lb) : 90 Nm (9.0 m kg, 65 ft lb) : 65 Nm (6.5 m kg, 47 ft lb)

12 11 10 4

10 16 16 2 16 15 13 13 14 17 7
LT

5 8

New

Order

1 2 3 4 5 6 7 8 9 10 11 12

Job name/Part name Front suspension removal Air filter case cover Pivot arm cover Ski Shock absorber Shock absorber Shock absorber Collar Bushing Tie rod Steering knuckle Upper arm ball joint Upper arm Bushing Stabilizer holder Bushing

Qty

1 1 1 2 4 1 1 1 1 2 1 1

Remarks Remove the parts in the order listed below. Refer to COWLINGS. Refer to STEERING. Refer to SKI in CHAPTER 3. PZ50GT PZ50VT USA/Canada PZ50VT Europe/PZ50MP

Disconnect.

17

FRONT SUSPENSION
: 7 Nm (0.7 m kg, 5.1 ft lb) : 28 Nm (2.8 m kg, 20 ft lb) 4 5

CHAS

: 34 Nm (3.4 m kg, 24 ft lb) : 45 Nm (4.5 m kg, 32 ft lb) : 90 Nm (9.0 m kg, 65 ft lb) : 65 Nm (6.5 m kg, 47 ft lb)

12 11 10 4

10 16 16 2 16 15 13 13 14 17 7
LT

5 8

New

Order 13 14 15 16 17

Job name/Part name Stabilizer bracket Stabilizer Lower arm Bushing Lower arm ball joint

Qty 2 1 1 4 1

Remarks

For installation, reverse the removal procedure.

18

FRONT SUSPENSION

CHAS

INSTALLATION

2 3 a

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 handling and loss of stability may result. (PZ50GT/ PZ50VT/PZ50MP)

2 3 a

1
NOTE:

Install the stabilizer holder in the direction shown in the illustration. (PZ50/PZ50RT/PZ50MT) The stabilizer force can be adjusted by changing the installation positions of the stabilizer, bushing, and stabilizer holder. (PZ50GT/PZ50VT/ PZ50MP)
a b c d e PZ50/PZ50RT/PZ50MT PZ50GT/PZ50VT/PZ50MP Forward Very hard Hard Medium Soft

Stabilizer, bushing, and stabilizer holder standard installation positions:

d (PZ50GT) b (PZ50VT/PZ50MP)

a 1

2. Install: Shock absorber 1

NOTE:
Install the shock absorber with the air valve a facing outward. (PZ50RT) Install the shock absorber with the charging valve b facing inward. (PZ50MT Europe/PZ50VT Europe/PZ50MP)

b
19

SLIDE RAIL SUSPENSION

POWR TR

POWER TRAIN
SLIDE RAIL SUSPENSION
PZ50/PZ50GT/PZ50RT/PZ50MT

: 4 Nm (0.4 m kg, 2.9 ft lb) 8 9 5 3 2 4 6 5 3 1 B 8 0 A 7 0 : 49 Nm (4.9 m kg, 35 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 110 Nm (11.0 m kg, 80 ft lb)

Order 1 2 3 4 5 6 7 8 9 0 A B

Job name/Part name Slide rail suspension disassembly Stopper band Front shock absorber Bushing Collar Bushing Collar Front pivot arm Bushing Shaft Collar Shaft Shaft

Qty 1 1 2 1 2 1 1 2 1 2 1 1

Remarks Remove the parts in the order listed below.

20

SLIDE RAIL SUSPENSION

G J C New D E I H

POWR TR

: 6 Nm (0.6 m kg, 4.3 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) O

K F
LT

P H I G

F N M

L L M N E
LT

D New C

PZ50MT

Order C D E

Job name/Part name Suspension wheel Circlip Spring end guide

Qty 2 2 2

Remarks

NOTE:
Apply grease to the inner surface of each spring end guide.

F G H I J K L M N O P

Spring end guide bracket Wheel bracket Suspension wheel Bushing Shaft Front suspension bracket Suspension wheel Collar Wheel bracket Connecting arm Collar

2 2 2 2 1 1 2 2 2 1 2

21

SLIDE RAIL SUSPENSION

: 35 Nm (3.5 m kg, 25 ft lb) : 49 Nm (4.9 m kg, 35 ft lb) : 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) Z Y W ] R X R Z V New ^ \

POWR TR

LT

LT

U T S

LT

LT

Order Q R S T U V W X Y Z [ \ ] _

Job name/Part name Rear shock absorber Collar Rear pivot arm joint Torsion spring Rear pivot arm protector Circlip Adjuster Rear pivot arm Shaft Guide wheel Rear pivot arm bracket Shaft Collar Stopper

Qty 1 2 2 2 2 2 2 1 1 2 1 1 4 4

Remarks

22

SLIDE RAIL SUSPENSION

POWR TR

: 60 Nm (6.0 m kg, 43 ft lb) : 75 Nm (7.5 m kg, 54 ft lb) a

PZ50MT

b h i

d g k c f

e e

k b d

j PZ50MT i h PZ50MT

Order a b c d e f g h i j k

Job name/Part name Rear axle Guide wheel Guide wheel Collar Tension adjuster Collar Collar Suspension wheel Wheel bracket Shaft Sliding frame

Qty 1 2 1 2 2 1 1 2 2 1 2

Remarks

For assembly, reverse the disassembly procedure.

23

SLIDE RAIL SUSPENSION

PZ50VT/PZ50MP

POWR TR

6 New 7 I H J I J 6 I 3 1 4
2 3 K

: 4 Nm (0.4 m kg, 2.9 ft lb)

6 Nm (0.6 m kg, 4.3 ft lb) B : : 49 Nm (4.9 m kg, 35 ft lb)

8 59

L M

: 60 Nm (6.0 m kg, 43 ft lb)

D

: 72 Nm (7.2 m kg, 52 ft lb) 0 F C G E

D B

N M K New L

Order 1 2 3 4 5 6 7 8 9 0 A B C

Job name/Part name Slide rail suspension disassembly Stopper band Shaft Collar Collar Front pivot arm Bushing Shaft Collar Shaft Collar Wheel bracket Suspension wheel Shaft

Qty 2 1 2 1 1 2 1 2 1 1 2 2 1

Remarks Remove the parts in the order listed below.

24

SLIDE RAIL SUSPENSION

6 New 7 I H J I J 6 I 3 1 4
2 3 K

POWR TR

: 4 Nm (0.4 m kg, 2.9 ft lb)

6 Nm (0.6 m kg, 4.3 ft lb) B : : 49 Nm (4.9 m kg, 35 ft lb)

8 59

L M

: 60 Nm (6.0 m kg, 43 ft lb)

D

: 72 Nm (7.2 m kg, 52 ft lb) 0 F C G E

D B

N M K New L

Order D E F G H I J K L M

Job name/Part name Bushing Connecting arm Collar Front suspension bracket Front shock absorber Bushing Collar Suspension wheel Circlip Spring end guide

Qty 2 1 1 1 1 4 2 2 2 2

Remarks

NOTE:
Apply grease to the inner surface of each spring end guide.

Spring end guide bracket

25

SLIDE RAIL SUSPENSION

: 6 Nm (0.6 m kg, 4.3 ft lb) : 9 Nm (0.9 m kg, 6.5 ft lb) : 25 Nm (2.5 m kg, 18 ft lb) : 49 Nm (4.9 m kg, 35 ft lb) o U V U V X P O R Q R O P \
Order O P Q R S T U V W X Y Z [ \ ] _ a b Job name/Part name Suspension wheel Wheel bracket Shaft Bushing Rear suspension bracket Pull rod Collar Bushing Rear shock absorber Collar Lock lever guide plate Lock lever Collar 2-up adjusting block 2-up adjusting block plate Collar Guide wheel Torsion spring Qty 2 2 1 2 1 2 4 4 1 2 2 2 2 2 2 2 2 2

POWR TR

: 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) g i i h j i i

New n m pq p q r s

T X T W V U c U l k New d

a ^ ] Z [ Y
Remarks

26

SLIDE RAIL SUSPENSION

: 6 Nm (0.6 m kg, 4.3 ft lb) : 9 Nm (0.9 m kg, 6.5 ft lb) : 25 Nm (2.5 m kg, 18 ft lb) : 49 Nm (4.9 m kg, 35 ft lb) o U V U V X P O R Q R O P \
Order c d e f g h i j k l m n o p q r s Job name/Part name Rear pivot arm protector Bushing Shaft Rear pivot arm Collar Shaft Bushing Collar Circlip Adjuster Control rod stopper Circlip Control rod Locknut Adjuster nut Suspension wheel Suspension wheel bracket Qty 2 2 1 1 2 1 4 1 2 2 1 2 2 2 2 4 4

POWR TR

: 60 Nm (6.0 m kg, 43 ft lb) : 72 Nm (7.2 m kg, 52 ft lb) g i i h j i i

New n m pq p q r s

T X T W V U c U l k New d

a ^ ] Z [ Y
Remarks

27

SLIDE RAIL SUSPENSION

POWR TR

: 75 Nm (7.5 m kg, 54 ft lb) t

v y { x w

z { z v u

Order t u v w x y z {

Job name/Part name Rear axle Guide wheel Collar Collar Guide wheel Collar Tension adjuster Sliding frame

Qty 1 2 2 1 1 1 2 2

Remarks

For assembly, reverse the disassembly procedure.

28

SEAT AND FUEL TANK

ENG

ENGINE
SEAT AND FUEL TANK
PZ50/PZ50GT/PZ50RT/PZ50MT

7 4 6 14 3 14 18 11 13 (6) 12

: 7 Nm (0.7 m kg, 5.1 ft lb) : 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) 15 1 (4) 2 8 8

16

10

8 19 9 5 7

17 6
Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job name/Part name Seat and fuel tank removal Seat Rear cover Main switch coupler Fuel tank cover Fuel tank side cover band Fuel tank side cover (left and right) Rear side cover (left and right) Plastic band Tail/brake light coupler Tail/brake light assembly Fuel pump coupler Fuel hose connector holder Fuel hose Qty 1 1 1 1 2 2 2 4 1 1 1 1 1

Remarks Remove the parts in the order listed below.

Disconnect.

Disconnect. Disconnect. Disconnect.

29

SEAT AND FUEL TANK

7 4 6 14 3 14 18 11 13 (6) 12

ENG

: 7 Nm (0.7 m kg, 5.1 ft lb) : 8 Nm (0.8 m kg, 5.8 ft lb) : 10 Nm (1.0 m kg, 7.2 ft lb) 15 1 2 8 8

(4) 16

10

8 19 9 5 7

17 6
Order 14 15 16 17 18 19 Job name/Part name Plastic band Fuel tank assembly Fuel sender coupler Fuel hose Fuel pump Fuel tank lower plate Qty 6 1 1 2 1 1 Remarks

Disconnect. Disconnect.

For installation, reverse the removal procedure.

30

BALANCER BALANCER

ENG

15

LT

18 19 10 9 New 11 16 6 7 5 New 4 14

13 12

17

2 1 3 New

(2)

: 10 Nm (1.0 m kg, 7.2 ft lb) : 12 Nm (1.2 m kg, 8.7 ft lb) : 50 Nm (5.0 m kg, 36 ft lb) : 75 Nm (7.5 m kg, 54 ft lb) (4) New (10)
Qty
LT

Order

Job name/Part name Balancer shaft removal Engine Cylinder head A.C. magneto rotor/starter clutch gear

Remarks Remove the parts in the order listed below. Refer to ENGINE ASSEMBLY in CHAPTER 5. Refer to CYLINDER HEAD in CHAPTER 5. Refer to A.C. MAGNETO ROTOR AND STARTER CLUTCH in CHAPTER 5.

1 2 3 4 5 6 7 8 9 10

Primary sheave drive shaft cover Gasket Primary sheave drive shaft assembly Lock washer Balancer shaft driven gear Balancer weight Straight key Balancer shaft Lock washer Balancer shaft drive gear

1 1 1 2 1 1 1 1 1 1

31

BALANCER

ENG

15

LT

18 19 10 9 New 11 16 6 7 5 New 4 14

13 12

17

2 1 3 New

(2)

: 10 Nm (1.0 m kg, 7.2 ft lb) : 12 Nm (1.2 m kg, 8.7 ft lb) : 50 Nm (5.0 m kg, 36 ft lb) : 75 Nm (7.5 m kg, 54 ft lb) (4) New (10)
Qty 1 1 1 1 1 1 1 1 1 Remarks
LT

Order 11 12 13 14 15 16 17 18 19

Job name/Part name Circlip Bearing Circlip Bearing Bearing retainer Bearing Bearing Circlip Bearing

For installation, reverse the removal procedure.

32

BALANCER
REMOVAL

ENG

4 6

1. Straighten the lock washer tabs. 2. Loosen: Balancer shaft drive gear bolt 1 Balancer shaft driven gear nut 2

2 3

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.

NOTE:
Place an aluminum plate 3 or 4 between the teeth of the balancer shaft drive gear 5 and balancer shaft driven gear 6.

INSTALLATION
1. Install: Balancer shaft drive gear Lock washer Balancer shaft drive gear bolt

NOTE:
Align the shallow groove a in the balancer shaft drive gear with the low spline b of the crankshaft.

b
2. Install: Straight key 1 Balancer weight 2 Balancer shaft driven gear 3 Lock washer 4 Balancer shaft driven gear nut 5 Balancer shaft drive gear bolt

32 4

5 1

NOTE:
Align the punch mark a on the balancer shaft driven gear with the punch mark b on the balancer shaft drive gear. 3. Tighten: Balancer shaft driven gear nut Balancer shaft drive gear bolt Balancer shaft driven gear nut: 50 Nm (5.0 m kg, 36 ft lb) Balancer shaft drive gear bolt: 75 Nm (7.5 m kg, 54 ft lb)

a b

3 1

T.

R.

33

BALANCER
CAUTION:
2 4

ENG

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.

4. Tighten: Primary sheave drive shaft cover bolt 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.

T.

R.

34

THROTTLE BODY

FI

FUEL INJECTION SYSTEM

THROTTLE BODY
INJECTORS

8 New 7

11 1 11

5 New 6
E E

New 9 10 12
E

New

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

Qty 1 1 1 1 1 1 1 1 4 1 2 1

Remarks Remove the parts in the order listed below.

For installation, reverse the removal procedure.

35

FI

36

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model Model code number: PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 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) 2,820 mm (111.0 in) (PZ50/PZ50GT/PZ50RT) 3,195 mm (125.8 in) (PZ50MT) 3,150 mm (124.0 in) (PZ50VT USA/Canada) 3,160 mm (124.4 in) (PZ50VT Europe/PZ50MP) 1,215 mm (47.8 in) (PZ50/PZ50GT/PZ50RT/PZ50VT USA/Canada) 1,165 mm (45.9 in) (PZ50MT) 1,265 mm (49.8 in) (PZ50VT Europe/PZ50MP) 1,190 mm (46.9 in) (PZ50/PZ50RT/PZ50MT) 1,340 mm (52.8 in) (PZ50GT) 1,380 mm (54.3 in) (PZ50VT/PZ50MP) 216 kg (476.2 lb) (PZ50) 222 kg (489.4 lb) (PZ50GT USA/Canada/PZ50RT USA/ Canada) 223 kg (491.6 lb) (PZ50GT Europe/PZ50RT Europe) 234 kg (515.9 lb) (PZ50MT USA/Canada) 235 kg (518.1 lb) (PZ50MT Europe) 269 kg (593.0 lb) (PZ50VT USA/Canada) 272 kg (599.7 lb) (PZ50VT Europe) 263 kg (579.8 lb) (PZ50MP Canada) 273 kg (601.9 lb) (PZ50MP Europe) 3.7 m (12.14 ft) (PZ50/PZ50GT/PZ50RT) 4.0 m (13.12 ft) (PZ50MT) 4.2 m (13.78 ft) (PZ50VT/PZ50MP) 3.4 m (11.16 ft) (PZ50/PZ50GT/PZ50RT) 4.2 m (13.78 ft) (PZ50MT) 3.9 m (12.80 ft) (PZ50VT/PZ50MP)

Dimensions: Overall length

Overall width

Overall height

Weight: Dry weight

Minimum turning radius: Clockwise

Counterclockwise

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GENERAL SPECIFICATIONS
Model Engine: Engine type Cylinder type Displacement Bore stroke Compression ratio Maximum horse 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 Recommended grade 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

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Liquid-cooled, 4-stroke, DOHC Backward-inclined parallel 2-cylinder 499 cm3 (30.45 cu.in) 77.0 53.6 mm (3.03 2.11 in) 12.4 : 1 58.8 kw (80.0 PS)/11,250 r/min 51.0 Nm (5.2 kgf)/9,000 r/min 20.27 ~ 22.93 kPa (0.20 ~ 0.23 kg/cm2, 2.88 ~ 3.26 psi) 900 kPa (9.0 kg/cm2, 128.0 psi) at 400 r/min Electric starter Dry sump YAMALUBE 4-S (0W-30) or SAE 0W-30 (USA/Canada) SAE 10W-30 (Europe) API service SG type or higher, JASO standard MA 2.45 L (2.16 Imp qt, 2.59 US qt) 2.63 L (2.31 Imp qt, 2.78 US qt) 3.00 L (2.64 Imp qt, 3.17 US qt) 2.00 L (1.76 Imp qt, 2.11 US qt) Cartridge (paper) SAE 75W or 80W API GL-4 Gear oil 0.25 L (0.22 Imp qt, 0.26 US qt) 93.3 ~ 122.7 kPa (0.93 ~ 1.23 kg/cm2, 13.2 ~ 17.5 psi) 3.60 L (3.17 Imp qt, 3.81 US qt) (PZ50/PZ50GT/PZ50RT/ PZ50MT) 3.70 L (3.26 Imp qt, 3.91 US qt) (PZ50VT/PZ50MP) Premium unleaded gasoline Pump Octane (R + M)/2; 91 or higher (USA/Canada) Research Octane; 95 or higher (Europe) 26.7 L (5.9 Imp gal, 7.1 US gal) (PZ50/PZ50GT/PZ50RT/ PZ50MT) 32.9 L (7.2 Imp gal, 8.7 US gal) (PZ50VT USA/Canada/ PZ50MP Canada) 36.0 L (7.9 Imp gal, 9.5 US gal) (PZ50VT Europe/ PZ50MP Europe) TSK43 1 KEIHIN CR9EKB NGK 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Fuel: Type

Tank capacity

Throttle body: Type/Quantity Manufacture Spark plug: Type Manufacture Gap

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GENERAL SPECIFICATIONS
Model Transmission: Primary reduction system Primary reduction ratio Clutch type Secondary reduction system Secondary reduction ratio

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP V-Belt 3.80 ~ 0.95 : 1 Automatic centrifugal engagement Chain 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) No (PZ50) Yes (PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP) 2.73 (PZ50GT) 3.04 (PZ50RT) 3.21 (PZ50MT USA/Canada) 2.88 (PZ50MT Europe) 3.16 (PZ50VT USA/Canada) 3.33 (PZ50VT Europe/PZ50MP) Monocoque 18.0 1,080 mm (42.5 in) (PZ50/PZ50GT/PZ50RT/PZ50VT/ PZ50MP) 980 mm (38.6 in) (PZ50MT) Double wishbone Slide rail suspension Internal drive type 355.6 mm (14.00 in) (PZ50/PZ50GT/PZ50RT/PZ50MT) 381.0 mm (15.00 in) (PZ50VT) 406.4 mm (16.00 in) (PZ50MP) 769 mm (30.28 in) (PZ50/PZ50GT/PZ50RT) 1,084 mm (42.68 in) (PZ50MT) 985 mm (38.78 in) (PZ50VT/PZ50MP) 30 ~ 35 mm (1.18 ~ 1.38 in) Caliper type disc brake Handlebar, left hand operated T.C.I. A.C. magneto

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

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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/PZ50RT/PZ50MT/PZ50VT/PZ50MP Halogen bulb 12 V, 60/55 W 2 LED LED LED LED LED LED LED (PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP) LED (PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP)

40

MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS

ENGINE
Model Cylinder head: Volume (with spark plug) <Warpage limit>

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 13.82 ~ 14.62 cm3 (0.84 ~ 0.89 cu.in) 0.10 mm (0.0039 in) Lines indicate straight edge measurement.

Cylinder: Material Bore size <Taper limit> <Out of round> Camshaft: Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance Camshaft dimensions Intake A <Limit> B A <Limit> Exhaust A <Limit> B B <Limit> Camshaft runout

Aluminum alloy with dispersion coating 77.000 ~ 77.010 mm (3.0315 ~ 3.0319 in) 0.050 mm (0.0020 in) 0.050 mm (0.0020 in) Chain drive (left) 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in) 21.959 ~ 21.972 mm (0.8645 ~ 0.8650 in) 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in)

30.450 ~ 30.550 mm (1.1988 ~ 1.2028 in) 30.350 mm (1.1949 in) 22.610 ~ 22.710 mm (0.8902 ~ 0.8941 in) 22.510 mm (0.8862 in) 30.700 ~ 30.800 mm (1.2087 ~ 1.2126 in) 30.600 mm (1.2047 in) 22.593 ~ 22.693 mm (0.8895 ~ 0.8934 in) 22.493 mm (0.8856 in) 0.03 mm (0.0012 in)

Timing chain: Model/Number of links Tensioning system

98XRH2015/118 Automatic

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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 <Limit> Exhaust <Limit> Valve guide inside diameter Intake <Limit> Exhaust <Limit> Valve-stem-to-valve-guide clearance Intake <Limit> Exhaust <Limit> Valve stem runout limit

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP

0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in)

23.4 ~ 23.6 mm (0.9213 ~ 0.9291 in) 24.9 ~ 25.1 mm (0.9803 ~ 0.9882 in)
B

1.76 ~ 2.90 mm (0.0693 ~ 0.1142 in) 1.76 ~ 2.90 mm (0.0693 ~ 0.1142 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 0.5 ~ 0.9 mm (0.0197 ~ 0.0354 in) 0.5 ~ 0.9 mm (0.0197 ~ 0.0354 in) 3.975 ~ 3.990 mm (0.1565 ~ 0.1571 in) 3.945 mm (0.1553 in) 3.960 ~ 3.975 mm (0.1559 ~ 0.1565 in) 3.930 mm (0.1547 in) 4.000 ~ 4.012 mm (0.1575 ~ 0.1580 in) 4.050 mm (0.1594 in) 4.000 ~ 4.012 mm (0.1575 ~ 0.1580 in) 4.050 mm (0.1594 in) 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.10 mm (0.0039 in) 0.01 mm (0.0004 in)

Valve seat width Intake <Limit> Exhaust <Limit>

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in)

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MAINTENANCE SPECIFICATIONS
Model Valve spring: Free length Intake <Limit> Exhaust <Limit> 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 <Limit> Exhaust <Limit> Valve lifter hole inside diameter Intake <Limit> Exhaust <Limit> Piston: Piston size (D) Measuring point (H) D Piston to-cylinder clearance <Limit> Piston pin bore off set Off-set direction Piston pin bore inside diameter <Limit> Piston pin: Piston pin outside diameter <Limit> Piston pin length Piston pin to piston pin bore clearance <Limit>

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP

36.51 mm (1.44 in) 34.68 mm (1.37 in) 37.92 mm (1.49 in) 36.02 mm (1.42 in) 30.13 mm (1.19 in) 30.50 mm (1.20 in) 120.7 ~ 138.9 N (12.3 ~ 14.2 kg, 27.1 ~ 31.2 lb) 150.6 ~ 173.2 N (15.4 ~ 17.7 kg, 33.9 ~ 38.9 lb) 2.5/1.6 mm (0.06 in) 2.5/1.7 mm (0.07 in) Clockwise Clockwise

19.982 ~ 19.988 mm (0.7867 ~ 0.7869 in) 19.957 mm (0.7857 in) 22.482 ~ 22.488 mm (0.8851 ~ 0.8854 in) 22.457 mm (0.8841 in) 20.000 ~ 20.018 mm (0.7874 ~ 0.7881 in) 20.048 mm (0.7893 in) 22.500 ~ 22.518 mm (0.8858 ~ 0.8865 in) 22.548 mm (0.8877 in) 76.955 ~ 76.970 mm (3.0297 ~ 3.0303 in) 11.0 mm (0.43 in) 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.120 mm (0.0047 in) 0.5 mm (0.0197 in) Intake side 17.002 ~ 17.013 mm (0.6694 ~ 0.6698 in) 17.043 mm (0.6710 in) 16.991 ~ 17.000 mm (0.6689 ~ 0.6693 in) 16.971 mm (0.6681 in) 42.7 ~ 43.0 mm (1.6811 ~ 1.6929 in) 0.002 ~ 0.022 mm (0.0001 ~ 0.0009 in) 0.072 mm (0.0028 in)

43

MAINTENANCE SPECIFICATIONS
Model 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: Crank pin outside diameter Crankshaft:
C

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP

Barrel 0.90 2.75 mm (0.035 0.108 in) No Taper 0.80 2.75 mm (0.031 0.108 in) 1.50 2.25 mm (0.059 0.089 in) 0.15 ~ 0.25 mm (0.006 ~ 0.010 in) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.10 ~ 0.40 mm (0.004 ~ 0.016 in) 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.040 ~ 0.160 mm (0.0016 ~ 0.0063 in) Chrome plated/parkerizing Ferox coating 17.005 ~ 17.018 mm (0.6695 ~ 0.6700 in) 37.000 ~ 37.016 mm (1.4567 ~ 1.4573 in) 0.034 ~ 0.058 mm (0.0013 ~ 0.0023 in) 0 = White 1 = Blue 2 = Black 3 = Brown 33.976 ~ 34.000 (1.3376 ~ 1.3386 in)

A B

Measuring point 1 Measuring point 2 Width A Width B Crankshaft runout C Big end side clearance D Crankshaft-journal-to-crankshaft-journalbearing clearance Bearing color code

57.5 mm (2.26 in) 88.0 mm (3.46 in) 61.0 ~ 61.6 mm (2.402 ~ 2.425 in) 144.0 ~ 145.2 mm (5.67 ~ 5.72 in) 0.03 mm (0.0012 in) 0.160 ~ 0.262 mm (0.0063 ~ 0.0103 in) 0.020 ~ 0.044 mm (0.0008 ~ 0.0017 in) 0 = White 1 = Blue 2 = Black 3 = Brown 4 = Green

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MAINTENANCE SPECIFICATIONS
Model Throttle body: Type Quantity Manufacturer I.D. mark Throttle valve (Th.V) Throttle cable free play Engine idle speed Fuel pump: Type Model/Manufacturer Oil filter: Oil filter type Bypass valve opening pressure Oil pump: Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Relief valve operating pressure Oil pressure (hot) Cooling system: Filler cap opening pressure Thermostat opening temperature Valve lift Water pump type Coolant type Coolant mixing ratio (coolant: water) Capacity

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP TSK43 1 KEIHIN 8GC3 10 N503-89A00 ( = 8) 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) 1,700 ~ 1,900 r/min Electrical 8GC/DENSO Cartridge (paper) 78 ~ 118 kPa (0.78 ~ 1.18 kg/cm2, 11.1 ~ 16.8 psi) Trochoidal Less than 0.12 mm (0.005 in) 0.09 ~ 0.15 mm (0.004 ~ 0.006 in) 430 ~ 550 kPa (4.3 ~ 5.5 kg/cm2, 61.1 ~ 78.2 psi) 50 kPa (0.5 kg/cm2, 7.11 psi) at 1,500 r/min 93.3 ~ 122.7 kPa (0.93 ~ 1.23 kg/cm2, 13.2 ~ 17.5 psi) 80.0 ~ 84.0 C (176.0 ~ 183.2 F) 7.0 mm/95.0 C (0.28 in/203.0 F) Single-suction centrifugal pump (Impeller type) High quality silicate-free ethylene glycol antifreeze containing corrosion inhibitors 3 : 2 (60% : 40%) 3.60 L (3.17 Imp qt, 3.81 US qt) (PZ50/PZ50GT/PZ50RT/ PZ50MT) 3.70 L (3.26 Imp qt, 3.91 US qt) (PZ50VT/PZ50MP) 0.15 mm (0.0059 in)

Max. impeller shaft tilt

45

MAINTENANCE SPECIFICATIONS
POWER TRAIN
Model Transmission: Type Range of ratio Engagement speed r/min

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP V-belt automatic 3.80 ~ 0.95 : 1 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) 10,800 ~ 11,800 r/min 267 ~ 270 mm (10.51 ~ 10.63 in) 14.5 ~ 17.5 mm (0.57 ~ 0.69 in) 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) 0.5 ~ 1.5 mm (0.02 ~ 0.06 in) 8GS-17641-00/MITSUBOSHI 1,132 ~ 1,138 mm (44.6 ~ 44.8 in) 34.1 mm (1.34 in) 32.5 mm (1.28 in) 90501-606G9 (PZ50/PZ50GT/PZ50RT) 90501-605G7 (PZ50MT) 90501-556G7 (PZ50VT USA/Canada) 90501-526G4 (PZ50VT Europe/PZ50MP) Pink-Blue-Pink (PZ50/PZ50GT/PZ50RT) Green-Yellow-Green (PZ50MT) Yellow-Blue-Yellow (PZ50VT USA/Canada) Blue-Gold-Blue (PZ50VT Europe/PZ50MP) 60.0 mm (2.36 in) 6.0 mm (0.236 in) (PZ50/PZ50GT/PZ50RT/PZ50MT) 5.5 mm (0.217 in) (PZ50VT USA/Canada) 5.2 mm (0.205 in) (PZ50VT Europe/PZ50MP) 196 N (20.0 kg, 44.1 lb) (PZ50/PZ50GT/PZ50RT/PZ50VT USA/Canada) 235 N (24.0 kg, 52.9 lb) (PZ50MT) 147 N (15.0 kg, 33.1 lb) (PZ50VT Europe/PZ50MP) 29.4 N/mm (3.00 kg/mm, 168 lb/in) (PZ50/PZ50GT/ PZ50RT) 26.9 N/mm (2.74 kg/mm, 153 lb/in) (PZ50MT) 24.5 N/mm (2.50 kg/mm, 140 lb/in) (PZ50VT USA/Canada) 19.6 N/mm (2.00 kg/mm, 112 lb/in) (PZ50VT Europe/ PZ50MP) 4.86 (PZ50/PZ50GT/PZ50RT) 5.00 (PZ50MT) 4.36 (PZ50VT USA/Canada) 4.32 (PZ50VT Europe/PZ50MP)

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

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MAINTENANCE SPECIFICATIONS
Model Free length

SPEC

Set length Primary sheave weight arm: Part number (with bush) Weight (without bush and rivets)

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 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) 65.4 mm (2.57 in) 8GC-17605-00 (PZ50/PZ50GT/PZ50RT/PZ50VT/PZ50MP) 8DN-17605-30 (PZ50MT) 47.28 g (1.669 oz) (PZ50/PZ50GT/PZ50RT/PZ50VT/ PZ50MP) 39.76 g (1.404 oz) (PZ50MT) Rivet

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

90261-06019 (PZ50/PZ50GT/PZ50RT) 90261-06015 (PZ50MT USA/Canada) 90261-06034 (PZ50MT Europe) 90261-06033 (PZ50VT/PZ50MP) Steel 13.3 mm (0.524 in) (PZ50/PZ50GT/PZ50RT) 10.3 mm (0.406 in) (PZ50MT USA/Canada) 13.9 mm (0.547 in) (PZ50MT Europe) 17.2 mm (0.677 in) (PZ50VT/PZ50MP) 3 pcs 3 pcs None (PZ50MT) 90261-06015 (PZ50/PZ50GT/PZ50RT) 90261-06033 (PZ50VT/PZ50MP) Steel 10.3 mm (0.406 in) (PZ50/PZ50GT/PZ50RT) 17.2 mm (0.677 in) (PZ50VT/PZ50MP) 3 pcs 3 pcs None (PZ50MT USA/Canada) 90261-06015 (PZ50/PZ50GT/PZ50RT) 90261-06034 (PZ50MT Europe/PZ50VT USA/Canada) 90261-06033 (PZ50VT Europe/PZ50MP) Steel 10.3 mm (0.406 in) (PZ50/PZ50GT/PZ50RT) 13.9 mm (0.547 in) (PZ50MT Europe/PZ50VT USA/ Canada) 17.2 mm (0.677 in) (PZ50VT Europe/PZ50MP) 3 pcs 3 pcs

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MAINTENANCE SPECIFICATIONS
Model Secondary sheave spring: Part number Color code Outside diameter Wire diameter Hole position Sheave side-spring seat side (twist angle)

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 90508-55007 (PZ50/PZ50GT/PZ50RT/PZ50MT) 90508-58007 (PZ50VT/PZ50MP) Red (PZ50/PZ50GT/PZ50RT/PZ50MT) Blue (PZ50VT/PZ50MP) 66.0 mm (2.598 in) 5.5 mm (0.217 in) (PZ50/PZ50GT/PZ50RT/PZ50MT) 5.8 mm (0.228 in) (PZ50VT/PZ50MP) A-1 (45) (PZ50/PZ50GT/PZ50RT) B-1 (55) (PZ50MT) A-1 (50) (PZ50VT/PZ50MP)

Spring rate Compression

Torsion

Number of coils Free length Torque cam angle Drive chain: Type

10.58 N/mm (1.08 kg/mm, 60.41 lb/in) (PZ50/PZ50GT/ PZ50RT/PZ50MT) 11.33 N/mm (1.16 kg/mm, 64.69 lb/in) (PZ50VT/PZ50MP) 9,131 N mm/rad (931 kg mm/rad, 52,137 lb in/rad) (PZ50/PZ50GT/PZ50RT/PZ50MT) 10,098 N mm/rad (1,030 kg mm/rad, 57,659 lb in/rad) (PZ50VT/PZ50MP) 5.33 (PZ50/PZ50GT/PZ50RT/PZ50MT) 5.99 (PZ50VT/PZ50MP) 85 mm (3.35 in) 39 (PZ50/PZ50GT/PZ50RT) 37 (PZ50MT/PZ50VT/PZ50MP) Borg Warner Morse TEC 23RH302.5-80ASM (PZ50/ PZ50GT/PZ50RT/PZ50MT) Borg Warner Morse TEC 23RH302.5-82ASM (PZ50VT/ PZ50MP) 80L (PZ50/PZ50GT/PZ50RT/PZ50MT) 82L (PZ50VT/PZ50MP) 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) 133.35 mm (5.25 in) 137.35 mm (5.41 in)

Number of links Secondary reduction ratio

Maximum 14 link drive chain section length <Limit>

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MAINTENANCE SPECIFICATIONS
Model Track: Part number

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 8GK-47110-00 (PZ50/PZ50RT) 8GN-47110-00 (PZ50GT) 8GP-47110-00 (PZ50MT) 8ET-47110-10 (PZ50VT) 8GR-47110-00 (PZ50MP) 355.6 mm (14.0 in) (PZ50/PZ50GT/PZ50RT/PZ50MT) 381.0 mm (15.0 in) (PZ50VT) 406.4 mm (16.0 in) (PZ50MP) 3,072.4 mm (120.96 in) (PZ50/PZ50GT/PZ50RT) 3,648.5 mm (143.64 in) (PZ50MT/PZ50VT/PZ50MP) 64.0 mm (2.52 in) 48 (PZ50/PZ50GT/PZ50RT) 57 (PZ50MT/PZ50VT/PZ50MP) 5.1 mm (0.20 in) (PZ50/PZ50GT/PZ50RT/PZ50VT/ PZ50MP) 5.5 mm (0.22 in) (PZ50MT) 25.4 mm (1.00 in) (PZ50/PZ50GT/PZ50RT) 50.8 mm (2.00 in) (PZ50MT) 31.8 mm (1.25 in) (PZ50VT/PZ50MP) 30 ~ 35 mm (1.18 ~ 1.38 in) 221.0 mm (8.70 in) (PZ50/PZ50GT/PZ50RT) 205.0 mm (8.07 in) (PZ50MT) 184.0 mm (7.24 in) (PZ50VT) 216.0 mm (8.50 in) (PZ50MP) 412.0 mm (16.22 in) (PZ50/PZ50GT/PZ50RT) 364.0 mm (14.33 in) (PZ50MT) 292.0 mm (11.50 in) (PZ50VT) 313.0 mm (12.32 in) (PZ50MP) 40.00 N/mm (4.08 kg/mm, 228.40 lb/in) (PZ50/PZ50GT/ PZ50RT Europe) 33.00 N/mm (3.36 kg/mm, 188.43 lb/in) (PZ50RT USA/ Canada) 22.00 N/mm (2.24 kg/mm, 125.62 lb/in) (PZ50MT USA/ Canada) 29.40 N/mm (3.00 kg/mm, 167.87 lb/in) (PZ50MT Europe) 34.00 N/mm (3.47 kg/mm, 194.14 lb/in) (PZ50VT USA/ Canada) 31.00 N/mm (3.16 kg/mm, 177.01 lb/in) (PZ50VT Europe/ PZ50MP) 2,500 N mm/deg (254.9 kg mm/deg, 14,274 lb in/deg) (PZ50/PZ50RT/PZ50MP) 2,100 N mm/deg (214.1 kg mm/deg, 11,991 lb in/deg) (PZ50GT) 1,700 N mm/deg (173.3 kg mm/deg, 9,707 lb in/deg) (PZ50MT) 3,000 N mm/deg (305.9 kg mm/deg, 17,130 lb in/deg) (PZ50VT)

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

49

MAINTENANCE SPECIFICATIONS
Model Suspension wire diameter Front

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 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) 11.2 mm (0.441 in) (PZ50/PZ50RT/PZ50MP) 10.9 mm (0.429 in) (PZ50GT) 10.3 mm (0.406 in) (PZ50MT) 11.5 mm (0.453 in) (PZ50VT)

Rear

Shock absorber: Damping force Front Extension

Compression

830.0 N/0.3 m/s (84.6 kg/0.3 m/s, 186.6 lb/0.3 m/s) (PZ50) 870.0 N/0.3 m/s (88.7 kg/0.3 m/s, 195.6 lb/0.3 m/s) (PZ50GT/PZ50VT Europe/PZ50MP) 920.0 N/0.3 m/s (93.8 kg/0.3 m/s, 206.8 lb/0.3 m/s) (PZ50RT USA/Canada) 1,690.0 N/0.3 m/s (172.3 kg/0.3 m/s, 379.9 lb/0.3 m/s) (PZ50RTEurope) 610.0 N/0.3 m/s (62.2 kg/0.3 m/s, 137.1 lb/0.3 m/s) (PZ50MT USA/Canada) 1,600.0 N/0.3 m/s (163.1 kg/0.3 m/s, 359.7 lb/0.3 m/s) (PZ50MT Europe) 770.0 N/0.3 m/s (78.5 kg/0.3 m/s, 173.1 lb/0.3 m/s) (PZ50VT USA/Canada) 690.0 N/0.3 m/s (70.4 kg/0.3 m/s, 155.1 lb/0.3 m/s) (PZ50) 640.0 N/0.3 m/s (65.3 kg/0.3 m/s, 143.9 lb/0.3 m/s) (PZ50GT/PZ50MP) 680.0 N/0.3 m/s (69.3 kg/0.3 m/s, 152.9 lb/0.3 m/s) (PZ50RT USA/Canada) 1,030.0 N/0.3 m/s (105.0 kg/0.3 m/s, 231.5 lb/0.3 m/s) (PZ50RT Europe) 710.0 N/0.3 m/s (72.4 kg/0.3 m/s, 159.6 lb/0.3 m/s) (PZ50MT USA/Canada) 1,550.0 N/0.3 m/s (158.1 kg/0.3 m/s, 348.4 lb/0.3 m/s) (PZ50MT Europe) 800.0 N/0.3 m/s (81.6 kg/0.3 m/s, 179.8 lb/0.3 m/s) (PZ50VT USA/Canada) 720.0 N/0.3 m/s (73.4 kg/0.3 m/s, 161.9 lb/0.3 m/s)

50

MAINTENANCE SPECIFICATIONS
Model Rear Extension

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/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, 326.0 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) 1,170.0 N/0.3 m/s (119.3 kg/0.3 m/s, 263.0 lb/0.3 m/s) (PZ50VT USA/Canada) 1,330.0 N/0.3 m/s (135.6 kg/0.3 m/s, 299.0 lb/0.3 m/s) (PZ50VT Europe/PZ50MP) 730.0 N/0.3 m/s (74.4 kg/0.3 m/s, 164.1 lb/0.3 m/s) (PZ50) 630.0 N/0.3 m/s (64.2 kg/0.3 m/s, 141.6 lb/0.3 m/s) (PZ50GT) 1,070.0 N/0.3 m/s (109.1 kg/0.3 m/s, 240.5 lb/0.3 m/s) (PZ50RT USA/Canada) 1,150.0 N/0.3 m/s (117.3 kg/0.3 m/s, 258.5 lb/0.3 m/s) (PZ50RT Europe) 710.0 N/0.3 m/s (72.4 kg/0.3 m/s, 159.6 lb/0.3 m/s) (PZ50MT) 610.0 N/0.3 m/s (62.2 kg/0.3 m/s, 137.1 lb/0.3 m/s) (PZ50VT USA/Canada) 1,870.0 N/0.3 m/s (190.7 kg/0.3 m/s, 420.4 lb/0.3 m/s) (PZ50VT Europe/PZ50MP) 18.3 mm (0.72 in) 10.5 mm (0.41 in) Quadruple polyethylene 9 T (PZ50/PZ50GT/PZ50RT/PZ50VT/PZ50MP) 8 T (PZ50MT) High molecular weight polyethylene with rubber 178.0 mm (7.01 in) DOT 4 9.4 mm (0.37 in) 4.7 mm (0.19 in) 0.08 ~ 0.20 mm (0.0031 ~ 0.0079 in) 43.5 ~ 46.5 mm (1.713 ~ 1.831 in) 200.0 mm (7.87 in) 4.0 mm (0.16 in) 3.5 mm (0.14 in)

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

51

MAINTENANCE SPECIFICATIONS
CHASSIS
Model Frame: Frame material Seat height Luggage box location Steering: Lock-to-lock angle

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP Monocoque (Aluminum and Steel) 719 mm (28.31 in) (PZ50/PZ50GT/PZ50RT/PZ50MT) 724 mm (28.50 in) (PZ50VT/PZ50MP) Not available (left) (right) 32.4 (R ski) 37.6 (L ski) 37.6 (R ski) 32.4 (L ski) Toe-out 0 ~ 15 mm (0 ~ 0.59 in) 18.0 1,080 mm (42.5 in) (PZ50/PZ50GT/PZ50RT/PZ50VT/ PZ50MP) 980 mm (38.6 in) (PZ50MT) Plastic 1,021.0 mm (40.20 in) (PZ50/PZ50GT/PZ50RT/PZ50MT/ PZ50VT USA/Canada) 1,073.0 mm (42.24 in) (PZ50VT Europe/PZ50MP) 132.0 mm (5.20 in) (PZ50/PZ50GT/PZ50RT/PZ50VT USA/Canada) 182.0 mm (7.17 in) (PZ50MT) 180.0 mm (7.09 in) (PZ50VT Europe/PZ50MP) Steel No 6 mm (0.24 in) 13 mm (0.51 in) (PZ50/PZ50GT/PZ50RT/PZ50VT USA/ Canada) 24 mm (0.95 in) (PZ50MT/PZ50VT Europe/PZ50MP) Independent wishbone 219.0 mm (8.62 in) (PZ50/PZ50RT) 198.0 mm (7.80 in) (PZ50GT) 220.0 mm (8.66 in) (PZ50MT) 165.0 mm (6.50 in) (PZ50VT USA/Canada) 166.0 mm (6.54 in) (PZ50VT Europe) 208.0 mm (8.19 in) (PZ50MP) Coil spring (PZ50/PZ50GT/PZ50MT/PZ50VT/PZ50MP) Air spring (PZ50RT) 30 N/mm (3.06 kg/mm, 171.3 lb/in) (PZ50) 28 N/mm (2.86 kg/mm, 159.9 lb/in) (PZ50GT) 21~ 32 N/mm (2.14 ~ 3.26 kg/mm, 119.9 ~ 182.7 lb/in) (PZ50MT USA/Canada) 27 N/mm (2.75 kg/mm, 154.2 lb/in) (PZ50MT Europe) 34 N/mm (3.47 kg/mm, 194.1 lb/in) (PZ50VT USA/Canada) 35 N/mm (3.57 kg/mm, 199.9 lb/in) (PZ50VT Europe/ PZ50MP)

Ski alignment Toe-out size Caster angle Ski stance (center to center)

Ski: Ski material Length

Width

Ski runner material Ski cover Ski runner wear limit Plastic ski wear limit

Ski suspension (front suspension): Type Travel

Spring type Spring rate

52

MAINTENANCE SPECIFICATIONS
Model Wire diameter

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 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

Compression

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) 490 N/0.3 m/s (50.0 kg/0.3 m/s, 110.2 lb/0.3 m/s) (PZ50MT USA/Canada) 480 N/0.3 m/s (48.9 kg/0.3 m/s, 107.9 lb/0.3 m/s) (PZ50MT Europe) 660 N/0.3 m/s (67.3 kg/0.3 m/s, 148.4 lb/0.3 m/s) (PZ50VT USA/Canada) 2,690 N/0.3 m/s (274.3 kg/0.3 m/s, 604.7 lb/0.3 m/s) (PZ50VT Europe/PZ50MP) 890 N/0.3 m/s (90.8 kg/0.3 m/s, 200.0 lb/0.3 m/s) (PZ50) 630 N/0.3 m/s (64.2 kg/0.3 m/s, 141.6 lb/0.3 m/s) (PZ50GT) 850 N/0.3 m/s (86.7 kg/0.3 m/s, 191.1 lb/0.3 m/s) (PZ50MT USA/Canada) 540 N/0.3 m/s (55.1 kg/0.3 m/s, 121.4 lb/0.3 m/s) (PZ50MT Europe) 970 N/0.3 m/s (98.9 kg/0.3 m/s, 218.1 lb/0.3 m/s) (PZ50VT USA/Canada) 1,020 N/0.3 m/s (104.0 kg/0.3 m/s, 229.3 lb/0.3 m/s) (PZ50VT Europe/PZ50MP)

53

MAINTENANCE SPECIFICATIONS
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.: Magneto model/Manufacturer Standard Stator coil resistance (color code) ECU model/Manufacturer

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 12 V 5 at 1,800 r/min Digital type F6T567/MITSUBISHI 6.0 mm (0.24 in) 1.19 ~ 1.61 at 20 C (68 F) 8.5 ~ 11.5 k at 20 C (68 F) A.C. magneto 14 V/less than 35 A at 5,000 r/min F4T39471/MITSUBISHI 14 V 31.5 A, 440 W at 5,000 r/min 0.22 ~ 0.26 at 20 C (68 F) (White White) F8T83573/MITSUBISHI (PZ50/PZ50GT/PZ50RT/PZ50VT/ PZ50MP) F8T83574/MITSUBISHI (PZ50MT) Short circuit type FH012/SHINDENGEN 14.2 ~ 14.8 V 50 A 40 V YUASA YTX14-BS 12V-12Ah 1.2 A Constant mesh type 8GC/YAMAHA 0.90 kW 0.009 ~ 0.011 at 20 C (68 F) More than 100 k at 20 C (68 F) 10.8 mm (0.43 in) 3.65 mm (0.14 in) 5.28 ~ 7.92 N (538 ~ 808 g, 19.01 ~ 28.51 oz) 24.5 mm (0.96 in) 23.5 mm (0.93 in) 1.5 mm (0.06 in) MS5F-571/JIDECO 180 A 4.18 ~ 4.62 at 20 C (68 F)

Rectifier/regulator: Type Model/Manufacturer No load regulated voltage (DC) Capacity (DC) Withstand voltage Battery: Manufacturer Type Ten hour rate amperage Electric starter system: Type Starter motor: Model/Manufacturer Output Armature coil resistance Continuity check Insulation check Brush Overall length <Wear limit> Spring pressure Commutator diameter <Wear limit> Mica undercut Starter relay: Model/Manufacturer Amperage rating Coil resistance

54

MAINTENANCE SPECIFICATIONS
Model T.P.S. (throttle position sensor): Model/Manufacturer Resistance Oil level switch: Model/Manufacturer Fuel sender: Model/Manufacturer Sender resistance Full Empty Headlight relay: Model/Manufacturer Coil resistance Grip warmer: Heater resistance (left)

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 8GC3/KEIHIN 4 ~ 6 k at 20 C (68 F) (Blue Black) 8FA/ASTI 8GC/NIPPON SEIKI 10 ~ 12 at 20 C (68 F) 179 ~ 185 at 20 C (68 F) 5DM/OMRON 94.5 ~ 115.5 at 20 C (68 F) 1.53 ~ 1.87 at 20 C (68 F) (Black Black) (PZ50/ PZ50VT/PZ50MP) 6.12 ~ 7.48 at 20 C (68 F) (Black Black) (PZ50GT/ PZ50RT/PZ50MT) 1.53 ~ 1.87 at 20 C (68 F) (Black Black) (PZ50/ PZ50VT/PZ50MP) 6.12 ~ 7.48 at 20 C (68 F) (Black Black) (PZ50GT/ PZ50RT/PZ50MT) 37.0 ~ 45.2 at 20 C (68 F) (White Black) 8.82 ~ 10.78 (Green Black) (PZ50VT) 14.67 ~ 17.93 (Yellow Black) (PZ50VT) Fuse 40 A 1 10 A 1 20 A 1 7.5 A 1 20 A 1 3 A 1 (PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP) 15 A 1 4 A 1 (PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP) 20 A 1 15 A 1 10 A 1 7.5 A 1 4 A 1 (PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP) 3 A 1 (PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP) 8CC/MITSUBISHI 5.21 ~ 6.37 k at 0 C (32 F) 0.290 ~ 0.354 k at 80 C (176 F) 90 ~ 110 C (194 ~ 230 F) 85 ~ 105 C (185 ~ 221 F)

(right)

Thumb warmer: Heater resistance Passenger grip warmer: Heater resistance (high) Heater resistance (low) Circuit breaker: Type Amperage for individual circuit Main fuse Fuel injection system fuse Headlight fuse Signal fuse Ignition fuse Auxiliary DC jack fuse Radiator fan motor fuse Gear motor fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Reserve fuse Coolant temperature sensor: Model/Manufacturer Resistance Indicator light (ON) (OFF)

55

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/PZ50RT/PZ50MT/PZ50VT/PZ50MP 8EK/NIPPON SEIKI 8GC/NIPPON SEIKI 8GC/MITSUBISHI 189 ~ 231 at 20 C (68 F) (Gray Black) 5PS/DENSO 8FP/MITSUBISHI 290 ~ 390 k at 80 C (176 F) 8GC/MITSUBISHI 504 ~ 616 k at 20 C (68 F)

56

TIGHTENING TORQUE TIGHTENING TORQUE

ENGINE
Parts to be tightened Spark plug Cylinder head bolt (M10 1.25) Cylinder head bolt Camshaft cap and cylinder head Cylinder head cover Cylinder identification sensor Ignition coil Camshaft and camshaft sprocket Oil check bolt Timing chain tensioner Timing chain guide (intake) Thermostat housing cover Coolant temperature sensor Hose band Water pump Coolant reservoir tank Radiator Radiator fan motor Water jacket joint Knock sensor Oil cooler Rear engine mounting bolt spacer Front engine mounting nut (left and right) Rear engine mounting nut Engine mounting bracket Oil pan Oil pan engine oil drain bolt Oil filter cartridge Oil filter bolt Oil pressure switch Oil pump OIl pump drive chain guide Oil pump housing cover Oil tank engine oil drain bolt Oil tank and frame Exhaust pipe joint Exhaust pipe joint upper cover Exhaust pipe joint lower cover Exhaust pipe band Exhaust pipe/muffler Muffler dumper holder Muffler end cover Crankcase (M9 1.25) Crankcase (M6 1.0) Primary sheave drive shaft cover Primary sheave drive shaft assembly bolt Balancer shaft drive gear Tightening torque Nm m kg ft lb 13 1.3 9.4 See NOTE.*1 12 1.2 8.7 9 0.9 6.5 12 1.2 8.7 8 0.8 5.8 10 1.0 7.2 24 2.4 17 10 1.0 7.2 12 1.2 8.7 12 1.2 8.7 10 1.0 7.2 23 2.3 17 2 0.2 1.4 12 1.2 8.7 10 1.0 7.2 10 1.0 7.2 8 0.8 5.8 10 1.0 7.2 27 2.7 19 10 1.0 7.2 7 0.7 5.1 65 6.5 47 40 4.0 29 23 2.3 17 10 1.0 7.2 30 3.0 22 17 1.7 12 30 3.0 22 15 1.5 11 12 1.2 8.7 10 1.0 7.2 5 0.5 3.6 16 1.6 11 10 1.0 7.2 25 2.5 18 6 0.6 4.3 8 0.8 5.8 18 1.8 13 33 3.3 24 10 1.0 7.2 10 1.0 7.2 See NOTE.*2 12 1.2 8.7 12 1.2 8.7 12 1.2 8.7 75 7.5 54
57

SPEC

Remarks

Apply the engine oil.

Apply LOCTITE Apply LOCTITE

Apply LOCTITE

Apply LOCTITE

Apply LOCTITE (PZ50/PZ50GT/PZ50RT/PZ50MT) Apply the engine oil. Apply the engine oil.

TIGHTENING TORQUE
Parts to be tightened Balancer shaft driven gear Bearing retainer 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. magneto lead holder Starter motor Fuel pump Fuel tank Starter motor lead Throttle cable locknut Rectifier/regulator Frame ground lead (rectifier/regulator) Engine ground lead (water jacket joint) Frame rear cross member (front) Frame rear cross member (rear) Tightening torque Nm m kg ft lb 50 5.0 36 10 1.0 7.2 See NOTE.*3 130 13.0 94 12 1.2 8.7 12 1.2 8.7 12 1.2 8.7 10 1.0 7.2 7 0.7 5.1 10 1.0 7.2 12 1.2 8.7 7 0.7 5.1 10 1.0 7.2 7 0.7 5.1 6 0.6 4.3 7 0.7 5.1 7 0.7 5.1 10 1.0 7.2 25 2.5 18 30 3.0 22

SPEC
Remarks

Apply LOCTITE Apply the engine oil. Apply LOCTITE Apply LOCTITE Apply LOCTITE Apply LOCTITE Apply LOCTITE

NOTE:
*1: Tighten the cylinder head bolts to 25 Nm (2.5 m kg, 18 ft lb) in the proper tightening sequence, loosen and retighten the cylinder head bolts to 25 Nm (2.5 m kg, 18 ft lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 175 ~ 185 in the proper tightening sequence. *2: Tighten the crankcase bolts to 15 Nm (1.5 m kg, 11 ft lb) in the proper tightening sequence, loosen and retighten the crankcase bolts to 15 Nm (1.5 m kg, 11 ft lb) in the proper tightening sequence, and then tighten the crankcase bolts further to reach the specified angle 65 ~ 70 in the proper tightening sequence. *3: Tighten the connecting rod nuts to 20 Nm (2.0 m kg, 14 ft lb), and then tighten the connecting rod nuts further to reach the specified angle 120 ~ 150.

58

TIGHTENING TORQUE
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)

SPEC

Frame and secondary shaft assembly Gear motor and secondary shaft assembly Right reverse gear case and left reverse gear case Drive position switch Reverse position switch Battery bracket Brake caliper bracket and drive chain cover Brake caliper bleed screw Brake caliper retaining pin Brake hose union bolt Parking brake assembly and drive chain cover Lever and parking brake assembly Brake master cylinder holder and brake master cylinder Brake master cylinder holder and parking brake lever Parking brake cable and parking brake lever Parking brake cable locknut Slide rail suspension mounting bolt (M10) Slide rail suspension mounting bolt (M10) (front side) Slide rail suspension mounting bolt (M10) (rear side) Stopper band Shock absorber and front pivot arm Shock absorber and front suspension bracket Shaft and sliding frame Front pivot arm and connecting arm

Remarks m kg ft lb See NOTE. Apply engine oil. 200 20.0 145 Left-hand thread. Apply LOCTITE 14 1.4 10 6 0.6 4.3 60 6.0 43 7 0.7 5.1 24 2.4 17 16 1.6 11 25 2.5 18 48 4.8 35 Apply LOCTITE 24 2.4 17 9 0.9 6.5 Apply LOCTITE (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) 10 1.0 7.2 (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) 17 1.7 12 (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) 6 0.6 4.3 (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) 17 1.7 12 (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) 17 1.7 12 (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) 23 2.3 17 48 4.8 35 6 0.6 4.3 18 1.8 13 30 3.0 22 10 1.0 7.2 16 1.6 11 10 1.0 7.2 Nm 23 10 6 72 72 110 4 49 49 60 110 2.3 1.0 0.6 7.2 7.2 11.0 0.4 4.9 4.9 6.0 11.0 17 7.2 4.3 52 52 80 2.9 35 35 43 80

Tightening torque

Apply LOCTITE (PZ50VT/PZ50MP) Apply LOCTITE (PZ50/PZ50GT/PZ50RT/PZ50MT) Apply LOCTITE (PZ50/PZ50GT/PZ50RT/PZ50MT)

(PZ50/PZ50GT/PZ50RT/PZ50MT)

59

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 Suspension wheel Front suspension bracket shaft and sliding frame Set bolt (wheel bracket) Shock absorber and connecting arm Pull rod, shock absorber, and rear suspension bracket Rear suspension bracket shaft and sliding frame Rear pivot arm and pull rod Shock absorber and rear pivot arm 2-up adjusting block Set bolt (collar) Rear pivot arm joint Rear pivot arm and rear pivot arm bracket Rear pivot arm bracket and sliding frame Rear pivot arm bracket stopper and sliding frame Wheel bracket, shaft, and sliding frame Rear pivot arm and control rod stopper Control rod adjusting locknut Control rod shaft and sliding frame Rear axle Set bolt (front axle) Bearing holder (front axle) Bearing holder (front axle) Speed sensor Bearing housing Gear unit (speed sensor) Tightening torque Nm 72 60 72 72 60 60 6 49 49 60 49 49 60 9 35 72 72 60 60 60 25 72 75 9 24 24 24 24 40

SPEC

Remarks m kg ft lb 7.2 52 (PZ50VT/PZ50MP) 6.0 43 7.2 52 7.2 52 Apply LOCTITE (PZ50MT) 6.0 43 6.0 43 0.6 4.3 4.9 35 (PZ50/PZ50GT/PZ50RT/PZ50MT) 4.9 35 (PZ50VT/PZ50MP) 6.0 4.9 4.9 6.0 0.9 3.5 7.2 7.2 6.0 6.0 6.0 2.5 7.2 7.5 0.9 2.4 2.4 2.4 2.4 4.0 43 35 35 43 6.5 25 52 52 43 43 43 18 52 54 6.5 17 17 17 17 29 (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50/PZ50GT/PZ50RT/PZ50MT) Apply LOCTITE (PZ50/PZ50GT/PZ50RT/PZ50MT) Apply LOCTITE (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50MT) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) Apply LOCTITE Inside Apply LOCTITE Outside

NOTE:
Tightening steps: 1. Tighten the bolt to a torque at 120 Nm (12.0 m kg, 85 ft lb). 2. Loosen the bolt completely. 3. Retighten the bolt to a torque of 60 Nm (6.0 m kg, 43 ft lb).

60

TIGHTENING TORQUE
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/fuel tank side cover bolt (rear side) Rear side cover bolt Fuel tank side cover bolt (front side) 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 Wind deflector bracket and wind deflector bolt Multi-function meter bracket Steering joint and steering joint bracket Steering joint bracket and steering column Steering column and relay rod Relay rod and steering control arm Steering column (upper) Steering column (lower) Steering control arm and steering control arm bracket Steering control arm bracket and frame Steering control arm and steering shaft Steering shaft and steering arm Steering arm pinch bolt Steering shaft end locknut Pivot arm bracket Pivot arm bracket and relay arm Pivot arm bracket and pivot arm shaft Pivot arm shaft and idler arm Relay arm and idler arm Idler arm and tie rod Tie rod and steering knuckle Tie rod end locknut Ski Tightening torque Nm 23 16 18 10 8 8 47 23 10 8 8 23 7 11 23 7 8 8 23 7 8 7 23 10 15 7 20 21 16 21 21 23 23 35 25 21 35 30 25 35 38 90 65 65 25 28 25 48 m kg ft lb 2.3 17 1.6 11 1.8 13 1.0 7.2 0.8 5.8 0.8 5.8 4.7 34 2.3 17 1.0 7.2 0.8 5.8 0.8 5.8 2.3 17 0.7 5.1 1.1 8.0 2.3 17 0.7 5.1 0.8 5.8 0.8 5.8 2.3 17 0.7 5.1 0.8 5.8 0.7 5.1 2.3 17 1.0 7.2 1.5 11 0.7 5.1 2.0 14 2.1 15 1.6 11 2.1 15 2.1 15 2.3 17 2.3 17 3.5 25 2.5 2.1 3.5 3.0 2.5 3.5 3.8 9.0 6.5 6.5 2.5 2.8 2.5 4.8 18 15 25 22 18 25 27 65 47 47 18 20 18 35

SPEC
Remarks

(PZ50GT/PZ50RT/PZ50MT) (PZ50VT/PZ50MP) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50VT/PZ50MP) (PZ50/PZ50GT/PZ50RT/PZ50MT) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP) Apply LOCTITE (PZ50RT) (PZ50VT/PZ50MP) (PZ50VT/PZ50MP)

Apply LOCTITE

Apply LOCTITE

61

TIGHTENING TORQUE
Parts to be tightened 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 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 19 12 17 45 45 90 45 45 65 65 45 34 7 34 m kg ft lb 1.9 14 1.2 8.7 1.7 12 4.5 33 4.5 33 9.0 65 4.5 32 4.5 32 6.5 47 6.5 47 4.5 32 3.4 25 0.7 5.1 3.4 25

SPEC
Remarks

Apply LOCTITE

(PZ50/PZ50RT/PZ50MT) (PZ50/PZ50RT/PZ50MT) (PZ50GT/PZ50VT/PZ50MP)

62

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. Components should be at room temperature. A (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm

SPEC
General torque specifications Nm 6 15 30 55 85 130 m kg 0.6 1.5 3.0 5.5 8.5 13.0 ft lb 4.3 11 22 40 61 94

A: Distance across flats B: Outside thread diameter

DEFINITION OF UNITS
Unit mm cm kg N Nm m kg Pa N/mm L cm3 r/min Read Millimeter Centimeter Kilogram Newton Newton meter Meter kilogram Pascal Newtons per millimeter Liter Cubic centimeter Rotations per minute
-3

Definition 10 meter 10-2 meter 103 gram 1 kg m/sec Nm m kg N/m2 N/mm

2

Measurement Length Length Weight Force Torque Torque Pressure Spring rate Volume or capacity Engine speed

63

CABLE ROUTING

SPEC

1 2 3 4 5 6

\ [ Z Y X W V U
T S R Q P

7 8 9

A B C D

O N M L K

F G H

64

CABLE ROUTING CABLE ROUTING

PZ50/PZ50GT/PZ50RT/PZ50MT
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 Radiator fan motor lead coupler 6 Bundle the slack in the wire harness and fasten it with the plastic band. 7 Right handlebar switch lead couplers 8 Route the sub-wire harness over the wire harness and fuel tank breather hose. 9 Fasten the wire harness and fuel tank breather hose to the frame rear cross member with the plastic band. 0 To the oil level switch A Fasten the wire harness, parking brake cable, and brake hose to the frame rear cross member with the plastic band. B Main switch C Fuel tank breather hose D Throttle cable E To the brake caliper F To the tail/brake light G Fuel pump lead H Fuel hose I Fasten the fuel pump lead at the white tape to the fuel hose with the plastic band. J Fuel pump coupler K Fuel pump L To the multi-function meter M 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.

SPEC

65

CABLE ROUTING

SPEC

1 2 3 4 5 6

\ [ Z Y X W V U
T S R Q P

7 8 9

A B C D

O N M L K

F G H

66

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 terminal and the Rectifier/regulator using the same nut. T Sub-wire harness coupler U Left handlebar switch lead couplers V Rectifier/regulator W Connect the wire harness coupler to the Rectifier/regulator coupler shown in the illustration. X Crankshaft position sensor coupler Y Fuel sender lead coupler Z Intake air pressure sensor coupler [ Headlight coupler \ Intake air temperature sensor coupler

SPEC

67

CABLE ROUTING

SPEC

68

CABLE ROUTING
PZ50GT/PZ50MT

SPEC

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. 4 Route the grip warmer sub-wire harness along the wire harness. 5 Grip warmer sub-wire harness 6 Connect the grip warmer subwire harness coupler to the wire harness coupler, making sure to connect the end of the sub-wire harness that is marked with tape.

69

CABLE ROUTING

SPEC

a 1 2 3 4

] \

[ Z Y X W V 7

U T S R Q P

8 9 0 A B C D E F

70

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. 4 Headlight lead coupler 5 Wire harness 6 Radiator fan motor lead coupler 7 To the oil level switch 8 Right handlebar switch lead couplers 9 Route the fuel hose and sub-wire harness over the wire harness and fuel tank breather hose. 0 Fasten the wire harness, parking brake cable, and brake hose to the frame rear cross member with the plastic band. A Fasten the wire harness and fuel tank breather hose to the frame rear cross member with the plastic band. B To parking brake C Fuel tank breather hose D Main switch E Tail/brake light harness coupler F To the brake caliper G Throttle cable H To the tail/brake light I Fuel pump lead J Fuel hose K Fasten the fuel pump lead at the white tape to the fuel hose with the plastic band. L Fuel pump coupler M Fuel pump N To the multi-function meter

SPEC

71

CABLE ROUTING

SPEC

a 1 2 3 4

] \

[ Z Y X W V 7

U T S R Q P

8 9 0 A B C D E F

72

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 hose along the frame rear cross member. 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. W Sub-wire harness coupler X Rectifier/regulator Y Connect the wire harness coupler to the Rectifier/regulator coupler shown in the illustration. Z Crankshaft position sensor coupler [ Fuel sender coupler \ Intake air pressure sensor coupler ] Intake air temperature sensor coupler _ To the Headlight a Fasten the headlight lead to the frame front cross member with the plastic band.

SPEC

73

CABLE ROUTING

SPEC

3 M

L 4 K A B 5 6 I H V G F E D C W Q R B A 0 9 87

U S T A 6 X 7

74

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 reservoir tank with the plastic band. Install the plastic band with its buckle positioned on top of the coolant reservoir tank and its end facing to the right. (PZ50GT/ PZ50RT/PZ50MT/PZ50VT/ PZ50MP) 6 Sub-wire harness 7 Gear motor (Except for PZ50) 8 Gear motor coupler (PZ50GT/ PZ50RT/PZ50MT/PZ50VT/ PZ50MP) 9 Fuel tank breather hose 0 Wire harness A Fasten the wire harness and fuel tank breather hose to the frame rear cross member with the plastic band, making sure to fasten the hose before and after the bend in the hose. B Cylinder #1 ignition coil lead C Route the wire harness under the frame rear cross member. D Fasten the cylinder identification sensor lead to the cylinder head cover with the plastic band. E Cylinder identification sensor lead coupler F To the auxiliary DC jack (PZ50GT/PZ50RT/PZ50MT)

SPEC

75

CABLE ROUTING

SPEC

3 M

L 4 K A B 5 6 I H V G F E D C W Q R B A 0 9 87

U S T A 6 X 7

76

CABLE ROUTING
G H I J K Cylinder #2 ignition coil lead Auxiliary DC jack lead Frame ground lead To the speed sensor Connect the sub-wire harness coupler to the wire harness coupler. To the handlebar switch Speed sensor lead coupler Throttle position sensor coupler Oil pressure switch coupler To the auxiliary DC jack lead (PZ50VT/PZ50MP) To the Rectifier/regulator Wire harness To the sub-wire harness To the throttle position sensor To the frame ground lead To the speed sensor To oil pressure switch coupler. Fasten the sub-wire harness at the white tape with the plastic band.

SPEC

L M N O P Q R S T U V W X

77

CABLE ROUTING

SPEC

8 A 9 0A 7 6 5 4 3 2 1

D E F G

H I
B

L 8 9 0 Q 3 D R P A 1 2 M 3

J 9 0 A B

N O

78

CABLE ROUTING
1 2 3 4 To the oil pressure switch Throttle position sensor coupler Fuel hose Fasten the corrugated tube and wire harness to the frame front cross member with the plastic band. (PZ50/PZ50GT/PZ50RT/ PZ50MT) Sub-wire harness coupler Fasten the corrugated tube to the headlight stay with the plastic band. (PZ50/PZ50GT/PZ50RT/ PZ50MT) Fasten the fuel hose with the hose clamp. Face the ends of the hose clamp outward, angled 45 downward. Rectifier/regulator Frame ground lead Wire harness Speed sensor coupler Fuel tank breather hose Fasten the speed sensor lead and fuel tank breather hose to the frame rear cross member with the plastic band. To the auxiliary DC jack (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) Fasten the speed sensor lead and fuel tank breather hose with the holder. Drive guard Fasten the speed sensor lead and fuel tank breather hose with a plastic locking tie. Fasten the speed sensor lead and fuel tank breather hose with the holder. Be sure to bend the holder so that the lead and hose will not come loose. Fasten the speed sensor lead with the holder. Be sure to bend the holder so that the lead will not come loose. Speed sensor

SPEC

5 6

8 9 0 A B C

F G

79

CABLE ROUTING

SPEC

8 A 9 0A 7 6 5 4 3 2 1

D E F G

H I
B

L 8 9 0 Q 3 D R P A 1 2 M 3

J 9 0 A B

N O

80

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. (PZ50VT/PZ50MP) O Auxiliary DC jack lead (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.

SPEC

81

CABLE ROUTING

SPEC

4 5 2 3 1 ] Z \ [ Z Y X W V ^ O U T

B C D E F G H I J

S R

L K N M P O

PZ50 _ O d a b c Q N
A

PZ50VT/PZ50MP g h h f e l k i j g

e f

PZ50GT/PZ50RT/PZ50MT h f e k i j A g

82

CABLE ROUTING
1 2 3 4 5 6 7 8 9 To the main switch To the main switch To the fuel sender 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. Install the plastic band with its buckle positioned on top of the wire harness and its end facing to the left. Oil level switch coupler Oil tank breather hose Radiator outlet pipe Radiator fan motor coupler Knock sensor coupler Radiator inlet hose Fasten the wire harness, radiator fan motor lead and knock sensor lead to the radiator outlet pipe with the plastic band, making sure to align the radiator fan motor coupler with the wire harness joint coupler. Install the plastic band with its buckle positioned to the outside of the pipe and its end facing rearward. Coolant temperature sensor coupler Fasten the wire harness and radiator fan motor lead to the radiator outlet hose with the plastic band. Install the plastic band with its buckle positioned to the outside of the hose and its end facing rearward.

SPEC

0 A B C D E F

G H

83

CABLE ROUTING

SPEC

4 5 2 3 1 ] Z \ [ Z Y X W V ^ O U T

B C D E F G H I J

S R

L K N M P O

PZ50 _ O d a b c Q N
A

PZ50VT/PZ50MP g h h f e l k i j g

e f

PZ50GT/PZ50RT/PZ50MT h f e k i j A g

84

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 front 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. N Starter motor lead O Negative battery lead P Fasten the starter motor lead, negative battery lead, and wire harness at the white tape to the oil tank with the plastic band. Face the end of the plastic band upward. Q Negative battery lead coupler R ECU lead S ECU T DC back buzzer lead (PZ50GT/ PZ50RT/PZ50MT/PZ50VT/ PZ50MP) U Positive battery lead V To the tail/brake light W Tail/brake light lead X Fasten the tail/brake light lead to the frame rear cross member with the plastic band, making sure to route the lead to the inside of the cross member. Install the plastic band with its buckle positioned towards the rear of the machine and its end facing to the right.

SPEC

85

CABLE ROUTING

SPEC

4 5 2 3 1 ] Z \ [ Z Y X W V ^ O U T

B C D E F G H I J

S R

L K N M P O

PZ50 _ O d a b c Q N
A

PZ50VT/PZ50MP g h h f e l k i j g

e f

PZ50GT/PZ50RT/PZ50MT h f e k i j A g

86

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 (PZ50GT/PZ50RT/PZ50MT/ PZ50VT/PZ50MP) ] Fasten the wire harness, brake hose, and parking brake cable with the plastic band. _ Battery a Fuse box b Main fuse c Starter relay d Starter relay lead e Load control relay f Fuel injection system relay g Headlight relay h Radiator fan motor relay i Gear motor relay 1 (PZ50GT/ PZ50RT/PZ50MT/PZ50VT/ PZ50MP) j Gear motor relay 2 (PZ50GT/ PZ50RT/PZ50MT/PZ50VT/ PZ50MP) k Gear motor relay 3 (PZ50GT/ PZ50RT/PZ50MT/PZ50VT/ PZ50MP) l Passenger grip warmer relay (PZ50VT/PZ50MP)

SPEC

87

CABLE ROUTING

SPEC

56b C jk

3c

6 7 8 9

2 1 e d

f A B A D B E F G H I J
C

C BA

b c a ^ [ \ ]

Z Y X W V

K L M N O P Q R

S T I c 1 h B-B C 6 c 5 b 5 C i 1 A-A 6 c b C g U

88

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 bracket. (Except for PZ50) 8 Route the parking brake cable behind the top rod of the windshield bracket. (Except for PZ50) 9 Route the left handlebar switch leads behind the handlebar. 0 Brake master cylinder A Left grip warmer lead B Brake light switch lead C Corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) D Auxiliary DC jack (PZ50GT/ PZ50RT/PZ50MT) (optional) E Rectifier/regulator F Crankshaft position sensor coupler G A.C. magneto coupler H Speed sensor lead I Pressure regulator hose J Fuel tank breather hose K Throttle body heater hose L Throttle position sensor coupler M Fasten the A.C. magneto lead, oil pressure switch lead, and pressure regulator hose with the holder. N Knock sensor O Fasten the A.C. magneto lead, water pump outlet hose, and knock sensor lead with the plastic band.

SPEC

89

CABLE ROUTING

SPEC

56b C jk

3c

6 7 8 9

2 1 e d

f A B A D B E F G H I J
C

C BA

b c a ^ [ \ ]

Z Y X W V

K L M N O P Q R

S T I c 1 h B-B C 6 c 5 b 5 C i 1 A-A 6 c b C g U

90

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. R Route the oil pressure switch lead under the idling adjusting screw, making sure that the lead is not too taut. S Oil pressure switch coupler T Starter motor U Oil tank outlet hose V Oil tank inlet hose W Throttle body heater outlet hose X Water pump inlet hose Y To the wire harness Z Route the water pump outlet hose and throttle body heater outlet hose behind the engine mounting bracket. [ Coolant temperature sensor \ Throttle body heater inlet hose ] Thermostat cover _ To the parking brake a To the brake caliper b Brake hose c Throttle cable d Main switch e Pass 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, multi-function unit lead, and brake hose with the holder.

SPEC

91

CABLE ROUTING

SPEC

56b C jk

3c

6 7 8 9

2 1 e d

f A B A D B E F G H I J
C

C BA

b c a ^ [ \ ]

Z Y X W V

K L M N O P Q R

S T I c 1 h B-B C 6 c 5 b 5 C i 1 A-A 6 c b C g U

92

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. Be sure to position the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) and corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) towards the front and fasten the throttle cable at the throttle cable adjusting nut. h Position the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) and corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) towards the front of the guide. i 10 mm (0.39 in) j Steering pad k Install the steering pad, making sure not to pinch the cables, leads, etc.

SPEC

93

CABLE ROUTING

SPEC

5 6a B hi
6 7 8 9

3 b
3 4 5

2 1

A
e d

A
C

B A0 D E F G H I J K L M N O P Q

a _ ] Z \ [

Y X W V U

R S I b T 1 g 6 b 5 a 5 B 1 6 b a B f

B-B C

A-A

94

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. 9 Brake master cylinder 0 Left grip warmer lead A Brake light switch lead B Corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) C Auxiliary DC jack D Rectifier/regulator E Crankshaft position sensor coupler. F A.C. magneto coupler G Fuel tank breather hose H Speed sensor lead I Pressure regulator hose J Throttle position sensor coupler K Throttle body heater hose L Fasten the A.C. magneto lead, oil pressure switch lead, and pressure regulator hose with the holder. M Knock sensor N Fasten the A.C. magneto lead, water pump outlet hose, and knock sensor lead with the plastic band. O Route the A.C. magneto lead behind the idling adjusting screw.

SPEC

95

CABLE ROUTING

SPEC

5 6a B hi
6 7 8 9

3 b
3 4 5

2 1

A
e d

A
C

B A0 D E F G H I J K L M N O P Q

a _ ] Z \ [

Y X W V U

R S I b T 1 g 6 b 5 a 5 B 1 6 b a B f

B-B C

A-A

96

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. R Oil pressure switch coupler S Starter motor T Oil tank outlet hose U Oil tank inlet hose V Throttle body heater outlet hose W Water pump inlet hose X To the wire harness Y Route the water pump outlet hose and throttle body heater outlet hose behind the engine mounting bracket. Z Coolant temperature sensor [ Throttle body heater inlet hose \ Thermostat cover ] To the parking brake _ To the brake caliper a Brake hose b Throttle cable c Main switch d Pass 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 holder.

SPEC

97

CABLE ROUTING

SPEC

5 6a B hi
6 7 8 9

3 b
3 4 5

2 1

A
e d

A
C

B A0 D E F G H I J K L M N O P Q

a _ ] Z \ [

Y X W V U

R S I b T 1 g 6 b 5 a 5 B 1 6 b a B f

B-B C

A-A

98

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. Be sure to position the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) and corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) towards the front and fasten the throttle cable at the throttle cable adjusting nut. g Position the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) and corrugated tube (left grip warmer lead, grip/thumb warmer adjustment switch lead, brake light switch lead, and headlight beam switch lead) towards the front of the guide. h Steering pad i Install the steering pad, making sure not to pinch the cables, leads, etc.

SPEC

99

CABLE ROUTING

SPEC

100

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.

SPEC

101

CABLE ROUTING

SPEC

PZ50/PZ50GT/PZ50RT/PZ50MT

PZ50VT/PZ50MP

2 6

9 4

0 5

102

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 with the plastic band. Install the plastic band with its buckle positioned to the inside of the tail/ brake light lead and its end facing downward. 4 Fasten the tail/brake light lead at the white tape with the plastic band. Face the end of the plastic band downward. 5 Tail/brake light 6 Passenger grip warmer switch coupler 7 Connect the passenger grip warmer coupler, and then place it in the rear lower cover. 8 Passenger grip warmer switch 9 Fasten the tail/brake light lead to the rear carrier with the plastic band. 0 Connect the tail/brake light coupler, and then place it in the tail/ brake light cover.

SPEC

103

YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER

PRINTED IN U.S.A. 2007.11 CR (E)

WIRING DIAGRAM PZ50 2008 8GC-0F001-20

1 Crankshaft position sensor 2 A.C. magneto 3 Rectifier/regulator 4 Main switch 5 Main fuse 6 Load control relay 7 Fuel injection system fuse 8 Starter relay 9 Starter motor 0 Battery A Diode B Engine stop switch C Throttle switch D Grip warmer E Thumb warmer F Oil pressure switch G ECU (engine control unit) H Cylinder-#1 ignition coil I Spark plug J Cylinder-#2 ignition coil K Fuel injection system relay L Injector #1 M Injector #2 N Fuel pump O Throttle position sensor P Speed sensor Q Cylinder identification sensor R Cylinder-#1 intake air pressure sensor S Cylinder-#2 intake air pressure sensor T Knock sensor U Coolant temperature sensor V Intake air temperature sensor W Grip/thumb warmer adjustment switch X CO adjustment coupler Y Engine ground Z Frame ground [ Brake light switch \ Tail/brake light ] Fuel sender _ Oil level switch a Speedometer unit b Multi-function meter c Warning light d Low coolant temperature indicator light e Knock control system indicator light f High beam indicator light g Headlight h Headlight relay i Headlight beam switch j Radiator fan motor k Radiator fan motor relay l Ignition fuse m Radiator fan motor fuse n Signal fuse o Headlight fuse

COLOR CODE
B ..............Black Br.............Brown Ch............Chocolate G..............Green Gy............Gray L ..............Blue Lg ............Light green O..............Orange P ..............Pink R..............Red W .............White Y ..............Yellow B/L ...........Black/Blue B/R ..........Black/Red B/W..........Black/White B/Y...........Black/Yellow Br/L..........Brown/Blue Br/R .........Brown/Red Br/W ........Brown/White G/B ..........Green/Black G/W .........Green/White Gy/R ........Gray/Red L/R...........Blue/Red L/W ..........Blue/White L/Y ...........Blue/Yellow P/W..........Pink/White R/B ..........Red/Black R/G ..........Red/Green R/L...........Red/Blue R/W .........Red/White R/Y ..........Red/Yellow W/B..........White/Black W/Y..........White/Yellow YG ...........Yellow/Green Y/L ...........Yellow/Blue Y/R ..........Yellow/Red Y/W..........Yellow/White

WIRING DIAGRAM PZ50 2008

8GC-0F001-20
A R/L R /B R/L G /B R /B R/L G /B R/L G/W B/L Ch B R/G R/W B/L G/W Ch R/G R/L R/W
O

K
L/R R/L L/R R/L

SUB-WIRE WIRE HARNESS HARNESS 1

WIRE HARNESS SUB-WIRE HARNESS 2

H I J I

R/W O R/W (BLACK)

R/W
Y/R Gy L/R Br/L Lg R/B O B G/B Gy/R B

L
Gy/R R/W (BLACK) R/B A R/B R/B R/L A R/L R/L R/B

N
B

Gy/R

R/L B

B/L Gy (BLACK)

Gy B

1 2

Gy B/L R/Y L/W

(BLACK) G/B
Ch W Y Br/W B/Y W/Y Y/W P/W Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L

M
A G/B G/B

WWW

(GRAY) R/L A R/L R/L G/B (GRAY) L Y B/L L W/Y B/L

(GRAY) WWW W WW

4
OFF ON START

R R/W Br Br/W

L/W R/Y B Br

(BLACK)

O
L B (GRAY) Y Y L B/L (GRAY)

3
B

Br

(BLACK)

Gy R/W R/W L/W R R (40A) R R/W L/W R/W (BLACK) R R R R R B R/G R/G L/W R/W (10A) B/Y Br/L Gy L/Y Br R/W B/Y B/Y

P
P O/R B/W L W/Y B/L

O Gy/R B B L/R R/L R/B G/B L Y W/Y W/B P/W P G/W Br/W W W B/L Y/L Y/W W B (BLACK) (BLACK)

L W/B B/L (BLACK) B/L W/B L

W B

5
R

(BLACK)

A
L/W R/W

R Br R W Br Br/L

7
B B L/W

B
RUN STOP Br Br/W (BLACK)

C
CLOSE OPEN

Y/R B/Y B/R Y/R Lg

Q
L P/W B/L

R
B/L P/W L (BLACK)

8 6
W Br/L

B/L (BLACK) Ch Ch (BLACK)

Y/R

Y/G Y/G

0
B B

D
B B

R/W Br (BLACK)

F
Lg

Y/G (GRAY)

L P B/L

S
B/L P L (BLACK)

W (7.5A) (20A)

W (15A)

R (20A)

B B/R B B B B/R

Ch Lg

G/W B G/W

G/W

o n m l
L/W L/R Br/R R/Y
Br/R R/W

E
B

B W Lg Lg B

U
Ch B/L Br/W Br/W B/L (BLACK) B/L B B/L B/L

G/W B/L (DARK GREEN)

B/R

k
R/W

Br/R

D
B
Gy

L L Gy L B

Lg

Ch

Ch Ch

B L
(BLACK)

B L
(BLACK)

j
B R/W

Y/W Ch Y/L Y/ L Y/W Y/W Y/L B/L

a
c d e b

L/W

R/W G/B L/Y R/B Ch B/R Y (BLACK)

Ch L/R

i
Lg L/W L G

HI LO

L/W Y Lg G B L/W (BLACK) Lg Y Lg

[
OFF ON G G/B

G L/R

L/R G

L/Y G/B R/B

G B

^ f
Y G Ch B Y Ch Ch R/B (GRAY) Ch

]
G B Ch G/B

L/R G

L Y B

G L/R B B

YG G Y B

YG

Z
B

g
B B

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
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 sensor A.C. magneto Rectifier/regulator Main switch Main fuse Load control relay Fuel injection system fuse Starter relay Starter motor Battery Diode Engine stop switch Throttle switch DC back buzzer Grip warmer subwire harness Grip warmer Thumb warmer Oil pressure switch Drive position switch Reverse position switch ECU (engine control unit) Cylinder-#1 ignition coil Spark plug Cylinder-#2 ignition coil Fuel injection system relay Injector #1 Injector #2 Fuel pump Throttle position sensor Speed sensor Cylinder identification sensor Cylinder-#1 intake air pressure sensor Cylinder-#2 intake air pressure sensor Knock sensor Coolant temperature sensor Intake air temperature sensor Grip/thumb warmer adjustment switch Gear motor relay 1 Gear motor relay 2 Gear motor relay 3 Gear motor CO adjustment coupler d Passenger grip warmer relay e Frame ground f Passenger grip warmer switch g Passenger grip warmer h Brake light switch i Tail/brake light j Fuel sender k Oil level switch l Speedometer unit m Multi-function meter n Warning light o Low coolant temperature indicator light p Knock control system indicator light q Drive position indicator light r Reverse position indicator light s High beam indicator light t Headlight u Headlight relay v Headlight beam switch w Radiator fan motor x Radiator fan motor relay y Auxiliary DC jack z Ignition fuse { Radiator fan motor fuse | Signal fuse } Headlight fuse ~ Auxiliary DC jack fuse Gear motor fuse B ..............Black Br.............Brown Ch............Chocolate G..............Green Gy............Gray L ..............Blue Lg ............Light green O..............Orange P ..............Pink R..............Red Sb ............Sky blue W .............White Y ..............Yellow B/L ...........Black/Blue B/W..........Black/White B/R ..........Black/Red B/Y...........Black/Yellow Br/B .........Brown/Black Br/L..........Brown/Blue Br/R .........Brown/Red Br/W ........Brown/White G/B ..........Green/Black G/R ..........Green/Red G/W .........Green/White G/Y ..........Green/Yellow Gy/R ........Gray/Red L/B ...........Blue/Black L/R...........Blue/Red L/W ..........Blue/White L/Y ...........Blue/Yellow O/B ..........Orange/Black O/R ..........Orange/Red P/W..........Pink/White R/B ..........Red/Black R/G ..........Red/Green R/L...........Red/Blue R/W .........Red/White R/Y ..........Red/Yellow Sb/W........Sky blue/ White W/B..........White/Black W/L ..........White/Blue W/R .........White/Red W/Y..........White/Yellow YG ...........Yellow/Green Y/L ...........Yellow/Blue Y/R ..........Yellow/Red Y/W..........Yellow/White

PZ50VT/PZ50MP PZ50VT (STANDARD)/PZ50MP (OPTION) PZ50VT/PZ50MP (STANDARD)/ PZ50GT/PZ50RT/ PZ50MT (OPTION) PZ50RT PZ50GT/PZ50MT

WIRING DIAGRAM PZ50GT/PZ50RT/PZ50MT/PZ50VT/PZ50MP 2008

8GK-0F001-20/8GN-0F001-20/8GJ-0F001-20

A R/L R/B R/L G/B R/B R/L G/B R/L SUB-WIRE HARNESS 1 G/W B/L Ch B B/L G/W Ch SUB-WIRE HARNESS 2 L/R G B O/B C G L/R O/B B SUB-WIRE HARNESS 3 Br/R Sb W/L W/R L/B D W/L Sb Br/R L/B W/R GEAR MOTOR SUB-WIRE HARNESS

E Y G B G Y B R/W HEADLIGHT SUB-WIRE HARNESS R/G R/L R/G R/W

O
L/R R/L L/R R/L

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

L M N M

R/W O R/W (BLACK)

R/W
Y/L Y/R G/Y B R/B O L/R Br/L Lg Sb/W B G/B Gy/R

P
Gy/R R/W (BLACK) R/B A R/B R/B R/L A R/L R/L R/B

R
B

Gy/R

R/L B

B/L Gy (BLACK)

Gy B

1 2
WWW W WW

Gy B/L R/Y L/W

(BLACK) G/B
W Y Br/W B/Y W/Y Y/W P/W W/L B/R W/R O/B Br/B Gy G/W L/W P Y/L Y/G R/L R/W L/Y Ch L W/B R/W Lg B/L

Q
A G/B G/B

WWW (GRAY)

(GRAY) R/L A R/L R/L G/B (GRAY) L Y B/L

4
OFF ON START

R R/W Br Br/W

L/W R/Y B Br

(BLACK)

S
L B (GRAY) Y L W/Y B/L L Y L W/Y B/L

3
B R (BLACK) B

Br

Gy R/W R/W L/W R R (40A) R B/Y Br/L G/Y L/Y O/B O/B

T
P O/R B/W

5
R R R R

R/W L/W (BLACK) R/G R/G L/W R/W (10A) R/W

O Gy/R B B L/R R/L R/B G/B L Y W/Y W/B P/W P G/W Br/W W W B/L Y/L Y/W Br/B Sb/W Y/L R/GR/G W B (BLACK) (BLACK)

B/L L W/B B/L (BLACK) B/L W/B L W B (BLACK) L (GRAY)

P Br O/B L/R Y/R B/R Y/R Y/G B B

R Br R W Br Br/L

7
R/W B B L/W

A
L/W

Y/R Lg

U
L P/W B/L

D
L/R Br R/ W B/Y B/Y B/Y

V
B/L P/W L (BLACK)

6
W Br/L

8
R R B B

Y/G

W (4A)

W (3A)

W (7.5A) (20A)

W (15A)

R (20A)

0
B B

B
RUN STOP Br Br/W (BLACK)

C
CLOSE OPEN

H
Lg

Y/G (GRAY) B/R W/L W/R

L P B/L

W
B/L P L (BLACK)

~ } | { z
R/G O/B L/W L/R Br/R R/Y Br/R R/W

B/L (BLACK) Ch Ch (BLACK) Y/R Y/R Y/R Y/R B/R B/R B B

F
B B/R W/R

G/W B G/W

G/W

Y
\
R/G Y/R R/G Br/R Br/B (BLACK) Br/B Y/R Br/R B/L B B/L B/L

G/W B/L (DARK GREEN)

B B

R/W Br (BLACK)

G
B

B W

Lg Lg Ch Lg

D W/R W/L

G W/B O/B B

O/B

x
R/W G/Y L L
B B L L (BLACK) (BLACK)

y
B

Br/R L G/Y

B B

B B

B B

B Lg

D W/L

b
W/L

Br/W Br/W B/L (BLACK) B/L Sb/W

F
B B

F
B

W/R Ch B Ch Ch Sb R/G R/G B Sb/W (BLACK)

R/G R/G B

Y/R B

]
Sb/W Sb

^
Y/R Sb/W L/B L/B D L/B

Z
B L/B

w
L R/W L/W Y Lg G B

I l n o p
G E G L /R

Br/R

D Br/R

Y/W Ch Y/L Y/L Y/W Ch Y/W Y/L B/L

Sb D Sb

L/W

v
Lg L/W L G

R/W G/B L/Y R/B Ch B/R Y (BLACK) B/R L/Y G/B

L/R C L/R

h
OFF ON G G C

G L/R L/R G

O/B

Br/R Sb L/B

HI LO

f
LO OFF HI

L/W (BLACK)

a
L/R L/R Y/L G/R

L/B Br/R

Sb

Lg

Y Lg

G B

Y/L O/B G/R L Y B G L/R B

R/B

G/B

Y E Y YG G Y B

q r s
Y G Y B Ch

k
Ch Ch R/B (GRAY) Ch

j
G B Ch G/B

G L/R G

Y/L O/B G/R

(BLACK) (BLACK)

d
O/B

Y/L O/B L/R

L/R O/B Y/L

Y/R B/R B/R B

B/R B Y/R B/R

G/R Y/L

G/R Y/L

YG

g
Y/L B B C B B B G/R Y B G Y/L B G/R

g
Y B G

O/B C

t
B B E B B

B
Y/R

Y/R

B B

Y/R B

B B

E
B

e
B
Y/R B

F
B

F
B Y/R B