Yamaha PZ50W PZ50GTW PZ50FXW PZ50MX PZ50VTM PZ50MPW Service Manual – PDF DOWNLOAD

Description

Yamaha PZ50W PZ50GTW PZ50FXW PZ50MX PZ50VTM PZ50MPW Service Manual – PDF DOWNLOAD

DESCRIPTION:

Yamaha PZ50W PZ50GTW PZ50FXW PZ50MX PZ50VTM PZ50MPW Service Manual – PDF DOWNLOAD

FOREWORD:

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s edumtion into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha generators have a basic under-, standing of the mechanical precepts and pro-V cedures inherent to generator repair technology. Vifithout such knowledge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company Ltd. is continually striving to further improve all models manufac‘ tured 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.

MANUAL FORMAT:

The procedures in this manual are organized in a sequential, step-by-step format. The infor- mation has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explana— tions of all cflsassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course.

•  Bearings
• Pitting/damage —> Replace.

TABLE OF CONTENTS:

Yamaha PZ50W PZ50GTW PZ50FXW PZ50MX PZ50VTM PZ50MPW Service Manual – PDF DOWNLOAD

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
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
(TORS) CHECK 2-16
COMPRESSION PRESSURE
MEASUREMENT 2-17
ENGINE OIL LEVEL INSPECTION 2-19
ENGINE OIL REPLACEMENT 2-20
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 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
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
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 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
AC 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 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
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
(TORS) 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
AC MAGNETO 8-21
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

YAMAHA PZ50W PZ50GTW PZ50FXW PZ50MX PZ50VTM PZ50MPW SERVICE MANUAL – PDF DOWNLOAD:

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