YAMAHA PZ500C, VT500XLC SERVICE MANUAL
SERVICE MANUAL
PZ500C
VT500XLC
LIT-12618-02-03 8DJ-28197-10
(981026)
0E001
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their
qualified mechanics. It is not possible to put an entire
mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have
a basic understanding of the mechanical concepts
and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to
this model may render it unfit and/or unsafe to use.
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.
0E011
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!
Failure to follow WARNING instructions could
in severe injury or death
a bystander, or a person inspecting or repairing the
snowmobile.
to the snowmobile operator,
CAUTION:
A CAUTION indicates special precautions that must
be taken to avoid damage to the snowmobile.
Note:
result
0E022
PZ500, VT500XL
SERVICE MANUAL
1998 by Yamaha Motor Corporation, U.S.A.
E
1st Edition, July 1998
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.
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
D
Pitting/Damage®Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before
each disassembly section to facilitate correct disassembly and assembly procedures.
1
2
0E031
ILLUSTRATED SYMBOLS
GEN
INFO
34
INSP
ADJ
POWR
CHAS
56
ENG
78
ELEC
9J
LMN
TR
CARB
SPEC
K
(Refer to the illustration)
Illustrated symbols1to8are designed as thumb
tabs to indicate the chapter’s number and content.
1 General information
2 Periodic inspection and adjustment
3 Chassis
4 Power train
5 Engine overhaul
6 Carburetion
7 Electrical
8 Specifications
Illustrated symbols9toOare used to identify the
specifications which appear.
9 Filling fluid
J Lubricant
K Tightening
L Wear limit, clearance
M Engine speed
N Special tool
O W,V,A
OPQ
RST
UVW
X
Illustrated symbolsPtoXin the exploded diagram
indicate grade of lubricant and location of lubrication
point.
P Apply locking agent (LOCTITE
Q Apply Yamabond No.5
R Apply engine oil
S Apply gear oil
T Apply molybdenum disulfide oil
U Apply wheel bearing grease
V Apply low - temperature lithium - soap base grease
W Apply molybdenum disulfide grease
X Use new one
â
â
)
0S042
INDEX
GENERAL INFORMATION
PERIODIC INSPECTION AND
ADJUSTMENT
CHASSIS
POWER TRAIN
ENGINE OVERHAUL
GEN
INFO
INSP
ADJ
CHAS
POWR
TR
ENG
1
2
3
4
5
CARBURETION
ELECTRICAL
SPECIFICATIONS
CARB
ELEC
SPEC
6
7
8
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...........................
LOCTITEâ 1-3...........................
SPECIAL TOOLS 1-4........................
FOR TUNE UP 1- 4.......................
FOR ENGINE SERVICE 1- 4...............
FOR POWER TRAIN SERVICE 1- 5.........
FOR CARBURETION SERVICE 1- 6........
FOR ELECTRICAL SERVICE 1- 6..........
POWER TRAIN 2-14........................
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT 2- 14......................
DRIVE V - BELT 2- 16......................
ENGAGEMENT SPEED CHECK 2- 18.......
PARKING BRAKE PAD INSPECTION 2- 18..
PARKING BRAKE ADJUSTMENT 2- 18......
BRAKE FLUID LEVEL INSPECTION 2- 19...
BRAKE PAD INSPECTION 2- 19............
BRAKE HOSE INSPECTION 2- 20..........
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM) 2 - 20.......
DRIVE CHAIN 2- 21.......................
TRACK TENSION ADJUSTMENT 2- 23......
SLIDE RUNNER INSPECTION 2- 25........
CHASSIS 2-26..............................
SKI/SKI RUNNER 2- 26....................
STEERING SYSTEM 2- 26.................
LUBRICATION 2 - 27......................
ELECTRICAL 2-29..........................
HEADLIGHT BEAM ADJUSTMENT 2- 29....
BATTERY INSPECTION 2 - 30..............
BATTERY CHARGING 2- 32...............
CHAPTER 2.
PERIODIC INSPECTIONS AND
ADJUSTMENTS
INTRODUCTION 2-1........................
PERIODIC MAINTENANCE TABLE 2-1........
ENGINE 2-3................................
SPARK PLUGS 2 - 3.......................
OIL PUMP 2- 4...........................
FUEL LINE INSPECTION 2- 5..............
COOLING FAN BELT INSPECTION 2- 6.....
CARBURETOR SYNCHRONIZATION 2- 9...
ENGINE IDLE SPEED ADJUSTMENT 2- 10..
THROTTLE CABLE FREEPLAY
ADJUSTMENT 2- 11......................
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK 2- 12...................
STARTER (CHOKE) CABLE
FREEPLAY ADJUSTMENT 2- 13...........
EXHAUST SYSTEM INSPECTION 2- 13.....
TUNING 2-33...............................
CARBURETOR TUNING 2- 33..............
CLUTCH 2- 39...........................
GEAR SELECTION 2- 41..................
HIGH ALTITUDE TUNING 2- 44............
FRONT SUSPENSION 2- 45...............
REAR SUSPENSION 2- 45.................
CHAPTER 3.
CHASSIS
STEERING 3-1.............................
INSPECTION 3- 3........................
INSTALLATION 3- 4.......................
SKI 3-6....................................
INSPECTION 3- 7........................
FRONT SUSPENSION 3-8...................
INSPECTION 3- 9........................
INSTALLATION 3 - 10......................
CHAPTER 4.
POWER TRAIN
CHAPTER 5.
ENGINE
PRIMARY SHEAVE AND DRIVE V -BELT 4-1...
REMOVAL 4- 3...........................
DISASSEMBLY 4- 3.......................
INSPECTION 4- 4........................
ASSEMBLY 4- 6..........................
INSTALLATION 4- 8.......................
SECONDARY SHEAVE 4-9..................
DISASSEMBLY 4- 11......................
INSPECTION 4- 11.......................
ASSEMBLY 4- 12.........................
INSTALLATION 4- 14......................
DRIVE CHAIN HOUSING 4-16................
WITHOUT REVERSE MODEL 4-16.........
INSPECTION 4- 17.......................
INSTALLATION 4- 18......................
WITH REVERSE MODEL 4- 19.............
INSPECTION 4- 21.......................
INSTALLATION 4- 22......................
JACKSHAFT 4-23..........................
INSPECTION 4- 24.......................
JACKSHAFT AND DRIVE CHAIN
HOUSING INSTALLATION 4- 25............
BRAKE 4-26...............................
BRAKE PAD REPLACEMENT 4- 27.........
BRAKE CALIPER DISASSEMBLY 4- 31......
BRAKE CALIPER INSPECTION
AND REPAIR 4 - 31........................
BRAKE CALIPER ASSEMBLY 4- 32.........
BRAKE CALIPER INSTALLATION 4-32......
INSPECTION 4- 34.......................
BRAKE MASTER CYLINDER
ASSEMBLY 4- 34.........................
SLIDE RAIL SUSPENSION 4-35..............
PZ500 4- 35..............................
VT500XL 4 - 36...........................
INSPECTION 4- 41.......................
FRONT AXLE AND TRACK 4-42..............
INSPECTION 4- 43.......................
INSTALLATION 4- 43......................
EXHAUST ASSEMBLY 5- 1...................
INSPECTION 5- 2........................
INSTALLATION 5- 2.......................
ENGINE ASSEMBLY 5-3.....................
INSTALLATION 5- 4.......................
CYLINDER HEAD AND CYLINDER 5-5........
REMOVAL 5- 7...........................
INSPECTION 5- 8........................
INSTALLATION 5 - 13......................
OIL PUMP, CDI MAGNETO, CRANKCASE
AND CRANKSHAFT 5-15....................
REMOVAL 5- 16..........................
INSPECTION 5- 16.......................
INSTALLATION 5 - 18......................
ENGINE COOLING FAN 5-20.................
REMOVAL 5- 21..........................
INSPECTION 5- 21.......................
INSTALLATION 5 - 23......................
RECOIL STARTER 5-24.....................
REMOVAL 5- 25..........................
INSPECTION 5- 25.......................
INSTALLATION 5 - 26......................
CHAPTER 6.
CARBURETION
CARBURETORS 6-1........................
REMOVAL 6- 4...........................
DISASSEMBLY 6- 4.......................
INSPECTION 6- 5........................
ASSEMBLY 6- 6..........................
INSTALLATION 6- 7.......................
FUEL PUMP 6-9............................
INSPECTION 6- 10.......................
INSTALLATION 6 - 10......................
CHAPTER 7.
ELECTRICAL
SWITCH INSPECTION 7-1...................
SWITCH INSPECTION 7- 1................
ELECTRICAL STARTING SYSTEM 7-2........
CIRCUIT DIAGRAM (VT500XL) 7- 2.........
TROUBLESHOOTING (VT500XL) 7- 3......
MAIN SWITCH (VT500XL) 7- 4.............
STARTER MOTOR (VT500XL) 7- 5.........
INSPECTION (VT500XL) 7- 6..............
ASSEMBLY (VT500XL) 7- 7................
CHARGING SYSTEM 7-8....................
CIRCUIT DIAGRAM (VT500XL) 7- 8.........
TROUBLESHOOTING (VT500XL) 7- 9......
BATTERY (VT500XL) 7 -10................
CHARGING COIL (VT500XL) 7 - 10..........
IGNITION SYSTEM 7-11.....................
CIRCUIT DIAGRAM 7- 11..................
TROUBLESHOOTING 7- 12................
SPARK PLUG CAP 7- 13..................
IGNITION COIL 7- 13.....................
CDI MAGNETO 7 - 13......................
SPARK PLUG 7 -14.......................
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) 7- 14...........................
HANDLEBAR SWITCH (RIGHT) 7- 15.......
CARBURETOR SWITCH 7- 15.............
MAIN SWITCH 7 -16......................
GRIP WARMER SYSTEM 7-26...............
CIRCUIT DIAGRAM 7- 26..................
TROUBLESHOOTING 7- 27................
GRIP AND THUMB WARMER COIL 7- 28....
VARIABLE RESISTOR (VT500XL) 7- 28.....
PASSENGER GRIP WARMER
(VT500XL) 7-28..........................
PASSENGER GRIP WARMER SWITCH
(VT500XL) 7-29..........................
CDI MAGNETO 7 - 29......................
CHAPTER 8.
SPECIFICATIONS
GENERAL SPECIFICATIONS 8-1.............
MAINTENANCE SPECIFICATIONS 8-3........
ENGINE 8- 3.............................
POWER TRAIN 8- 6.......................
CHASSIS 8- 9............................
ELECTRICAL 8 -10.......................
HIGH ALTITUDE SETTINGS 8- 12.............
PZ500/VT500XL 8 - 12.....................
TIGHTENING TORQUE 8-13.................
CABLE ROUTING 8-17......................
LIGHTING SYSTEM 7-17....................
CIRCUIT DIAGRAM 7- 17..................
TROUBLESHOOTING 7- 18................
BULB(S) 7- 19............................
HEADLIGHT BEAM SWITCH 7- 19..........
CDI MAGNETO 7 - 20......................
SIGNAL SYSTEM 7-21......................
CIRCUIT DIAGRAM 7- 21..................
TROUBLESHOOTING 7- 22................
TAIL/BRAKE LIGHT BULB 7- 24............
BRAKE LIGHT SWITCH 7- 24..............
GEAR POSITION SWITCH (VT500XL) 7- 24.
AC BACK BUZZER 7- 24..................
DC BACK BUZZER (VT500XL) 7- 25........
OIL LEVEL SWITCH 7- 25.................
GEN
MACHINE IDENTIFICATION
1E001
GENERAL INFORMATION
MACHINE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number1is located on the right - hand side of the frame
(just below the front of the seat).
ENGINE SERIAL NUMBER
The engine serial number is located on the right -hand side of the crankcase.
NOTE:
Designs and specifications are subject to change without notice.
INFO
1
1-1
GEN
IMPORTANT INFORMATION
1E011
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign material before removal and disassembly.
While cleaning, take care to protect the electrical parts, such as relays,
switches, motor, resistors, controllers, etc., from high pressure water
splashes.
2. Use proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” .
INFO
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 fire.
6. Be sure to keep to the tightening torque specifications. When tightening
bolts, nuts, and screws, start with those that have lager 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
GEN
IMPORTANT INFORMATION
GASKETS, OIL SEALS, AND O - RINGS
1. All gaskets, seals, and O - rings should be replaced when an engine is
overhauled. All gasket surfaces, oil seal lips, and O - rings must be
cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply
grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER PINS
All lock washers/plates1and 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.
INFO
BEARINGS AND OIL SEALS
Install the bearings1and oil seals2with their manufacturer’s 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 circlip1, make sure that the sharp edged corner2is positioned opposite
to the thrust3it receives. See the sectional view.
Shaft
4
LOCTITE
After installing fasteners that have LOCTITEâapplied, wait 24 hours before
using the machine. This will give the LOCTITE
â
â
time to dry properly.
1-3
GEN
SPECIAL TOOLS
1E021
SPECIAL TOOLS
Some special tools are necessary for a completely accurate tune - up and assembly. Using the correct special
tool will help prevent damage that can be caused by the use of improper tools or improvised techniques.
NOTE:
Be sure to use the correct part number when ordering the tool, since the part number may differ according to
country.
FOR TUNE UP
Sheave gauge
D
P/N: YS- 42421 -11(15 mm offset), YS - 42421 - 22(20 mm offset)
This gauge is used to measure the sheave distance and for offset adjustment.
Distance gauge
D
P/N: YS - 91047- 3 (for U.S.A./Canada)
90890- 01702 (for Europe)
This gauge is used to measure the distance of clutch center to center.
INFO
1E041
Dial gauge
D
P/N: YU - 03097 (for U.S.A./Canada)
90890- 03097 (for Europe)
This gauge is used for run out measurement.
1E071
FOR ENGINE SERVICE
Piston pin puller
D
P/N: YU - 01304 (for U.S.A./Canada)
90890- 01304 (for Europe)
This tool is used to remove the piston pin.
1E081
Rotor holding puller
D
P/N:YU- 33270 (for U.S.A./Canada)
90890- 01362 (for Europe)
This tool is used to remove the magneto rotor.
Rotor holding tool
D
P/N: YU - 01235 (for U.S.A./Canada)
90890- 01235 (for Europe)
This tool is used to remove the starter pulley.
Vacuum gauge
D
P/N: YS - 33275 (for U.S.A./Canada)
This gauge is used for carburetor synchronization.
Carb Sync Adapters2(Use with YS- 33275) (for U.S.A./Canada)
D
1
1-4
GEN
SPECIAL TOOLS
1E101
FOR POWER TRAIN SERVICE
Primary sheave holder
D
P/N: YS - 01880 (for U.S.A./Canada)
90890- 01701 (for Europe)
This tool is used to hold the primary sheave.
1E111
Primary sheave puller (18 mm)
D
P/N: YS - 01881- 11, YS - 01882 - 1
This tool is used for removing the primary sheave.
1E121
Clutch spider separator
D
P/N: YS - 28890- B (for U.S.A./Canada)
90890- 01711 (for Europe)
This tool is used when disassembling and assembling the primary sheave.
1E131
Clutch separator adapter
D
P/N: YS - 34480 (for U.S.A./Canada)
90890- 01740 (for Europe)
This tool is used when disassembling and assembling the primary sheave.
2
INFO
1E171
Clutch bushing jig kit
D
P/N: YS - 39752
This tool is used when removing and installing the primary sheave bushing.
Clutch bushing press
D
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).
1E141
Track clip installer
D
P/N: YS - 91045- A (for U.S.A./Canada)
90890- 01721 (for Europe)
This tool is used for installing the track clip.
Angle finder
D
P/N: YS - 42422
This tool is used for checking and adjusting the ski spindle camber.
1-5
GEN
SPECIAL TOOLS
FOR CARBURETION SERVICE
Mity vac
D
P/N: YB - 35956 (for U.S.A./Canada)
90890- 06756 (for Europe)
This tool is used to check the fuel pump.
1E151
FOR ELECTRICAL SERVICE
Pocket tester
D
P/N: YU - 03112 (for U.S.A./Canada)
90890- 03112 (for Europe)
This instrument is necessary for checking the electrical components.
1E161
Electro tester
D
P/N: YU - 33260- A (for U.S.A./Canada)
90890- 03021 (for Europe)
This instrument is invaluable for checking the electrical system.
INFO
1-6
GEN
INFO
1-7
INSP
Fan
belt
INTRODUCTION
2E007
PERIODIC INSPECTIONS AND ADJUSTMENTS
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 TABLE
ADJ
Item Remarks
Spark plugs
Engine oil
Fuel Check the fuel level.
Fuel filter
Fuel lines
Oil line
Carburetor
Fan belt
Manual starter
Engine stop switch
Throttle override system
Throttle lever
Exhaust system
Decarbonization More frequently if necessary.
Drive V-belt gaurd
Drive V-belt
Drive track/idler wheels
Check the condition. Adjust the gap and clean.
Replace if necessary.
Check the oil level.
Air bleed the oil pump, if necessary.
Check the condition.
Replace if necessary.
Check the fuel hose for cracks or damage.
Replace if necessary.
Check the oil hose for cracks or damage.
Replace if necessary.
Check throttle lever operation.
Adjust the jets.
Check wear and damage.
Replace if necessary.
Adjust fan belt if necessary.
Check the operation and rope damage.
Replace if necessary.
Check the operation.
Repair if necessary.
Check the operation.
Repair if necessary.
Check the operation.
Repair if necessary.
Check for leakage.
Retighten or replace gasket if necessary.
Check cracks, bends or damage.
Replace if necessary.
Check wear and damage.
Replace if necessary.
Check deflection, wear and damage.
Adjust/replace if necessary.
First
Pre-
operation
check
(daily)
month
or
first 800 km
(500 mi)
(40 hr)
Whenever operation condition
(elevation/temperature) is changed
Every
season
or every
3,200 km
(2,000 mi)
(160 hr)
2-1
INSP
/p g
Parking
brake
cable
end
ADJ
Item
Side runner
Brake/parking brake
Drive chain oil
Drive chain
Ski/ski runner
Steering system
Lights
Battery
Primary sheave
Secondary sheave
Steering column bearing Lubricate with specified grease.
Ski and front suspension Lubricate with specified grease.
Suspension component Lubricate with specified grease.
Parkingbrake cable end
and lever end/throttle cable
end
Shroud latches Make sure the shroud latches are hooked.
Fittings/fasteners
Service tools/spare parts Check proper placement.
Check 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.
Check oil level.
Replace.
Check deflection.
Adjust if necessary.
Check wear and damage.
Replace if necessary.
Check operation.
Adjust toe- out if necessary.
Check operation.
Replace bulbs if necessary.
Check fluid level.
Check specific gravity and breather pipe operation.
Charge/Correct if necessary.
Check engagement and shift speed.
Adjust if necessary. Whenever operating elevation is changed.
Check wear and damage.
Replace if necessary.
Lubricate with specified grease.
Lubricate with specified grease.
Adjust if necessary. Whenever operating elevation is changed.
Lubricate with specified grease.
Check cable damage.
Replace if necessary.
Check tightness.
Repair if necessary.
Remarks
First
Pre-
operation
check
(daily)
month
or
first 800 km
(500 mi)
(40 hr)
Initial at 80 km (50 Mi) and every 800 km (500
Mi) thereafter.
Every
season
or every
3,200 km
(2,000 mi)
(160 hr)
2
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper, replace the brake fluid. Regularly check the brake fluid
level and add fluid as required.
2. On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
2-2
INSP
SPARK PLUGS
2E011
ENGINE
SPARK PLUGS
1. Remove:
Spark plug caps
D
Spark plugs
D
2. Inspect:
Electrodes
D
Damage/wear®Replace the spark plug.
Insulator color
D
3. Measure:
Spark plug gap
D
Out of specification®Regap.
Use a wire thickness gauge.
Spark plug gap a:
1
2
a
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
ADJ
If necessary,clean the spark plugs with a spark
plug cleaner.
Standard spark plug:
BR9ES (NGK)
Before installing a spark plug, clean the gasket
surface and spark plug surface.
4. Install:
Spark plugs
D
Spark plug:
20 Nm (2.0 m S kg, 14 ft S lb)
NOTE:
Finger- tightenathe spark plug before torquing
it to specification.
b
2-3
INSP
OIL PUMP
2E021
OIL PUMP
Air bleeding
CAUTION:
The oil pump and oil delivery line must be bled in
the following cases:
D Any portion of the oil system has been discon-
nected.
D The machine has been turned on its side.
D The oil tank has been run empty.
D As part of the pre - delivery service.
1. Fill:
Oil tank
D
1
Recommended oil:
YAMALUBE 2 - cycle oil
Oil tank capacity:
3.3 L (2.9 Imp qt, 3.5 US qt)
ADJ
2. Remove:
Carburetors
D
Refer to “CARBURETORS” in CHAPTER 6.
3. Place a rag under the oil pump assembly to soak
up any spilled oil.
4. Disconnect:
Oil hose
D
5. Drain the oil until no more air bubbles appear in
the oil hose.
6. Connect:
Oil hose
D
7. Disconnect:
Oil delivery hose
D
8. Feed the “YAMALUBE 2 - cycle oil” into the oil de-
livery hose using an oil can for c omplete air
bleeding.
9. Connect:
Oil delivery hose
D
10. Remove:
Bleed bolt
D
Gasket (bleed bolt)
D
11. Drain the oil until no more air bubbles appear
from the bleed hole.
12. Inspect:
Gasket (bleed bolt)
D
Damage/wear®Replace.
1
2-4
OIL PUMP/FUEL LINE INSPECTION
13. Install:
Gasket (bleed bolt)
D
Bleed bolt
D
14. Install:
Carburetors
D
Refer to “CARBURETORS” in CHAPTER 6.
Cable adjustment
NOTE:
Before adjusting the oil pump cable, the throttle cable
distance should be adjusted.
Adjustment steps:
Pull back the adjuster cover.
D
Loosen the locknut1.
D
Turn the adjuster2in or out until the specified
D
distance is obtained.
INSP
ADJ
Oil pump cable adjusting lengtha:
18 ~ 20 mm (0.71 ~ 0.79 in)
Turning in®Lengthais increased.
Turning out®Lengthais decreased.
Tighten the locknut and push in the adjuster cov-
D
er.
Locknut:
0.8 Nm (0.08 m·kg, 0.58 ft·lb)
FUEL LINE INSPECTION
1. Remove:
Intake silencer
D
Refer to “FUEL PUMP” in CHAPTER 6.
2. Inspect:
Fuel hose
D
Fuel delivery hoses
D
Cracks/damage®Replace.
3. Install:
Intake silencer
D
Refer to “FUEL PUMP” in CHAPTER 6.
1
2
2-5
COOLING FAN BELT INSPECTION
COOLING FAN BELT INSPECTION
1. Remove:
Frame cross member
D
2. Remove:
Air duct stopper
D
Cooling fan grill
D
1
2
INSP
ADJ
1
3. Remove:
Recoil starter
D
Refer to “RECOIL STARTER” in CHAPTER 5.
4. Inspect:
Cooling fan belt
D
Wear/cracks/damage®Replace.
5. Inspect:
Cooling fan
D
Cracks/damage®Replace.
Refer to “ENGINE COOLING FAN” in CHAPTER 5.
1
1
2-6
COOLING FAN BELT INSPECTION
6. Measure:
Cooling fan belt deflection
D
Out of specification®Adjust.
NOTE:
Attach a spring scale to the center of the cooling fan
belt and apply a force of 4 ~ 6 kg (8.8 ~ 13.2 lb) to the
belt.
Cooling fan belt deflection a:
8 mm (0.31 in)/4 ~ 6 kg (8.8 ~ 13.2 lb)
INSP
ADJ
a
7. Adjust:
Cooling fan belt deflection
D
Adjustment steps:
Remove the drive pulley1and cooling fan belt
D
using the rotor holding tool.
2
Rotor holding tool:
90890- 01235, YU- 01235
Remove the driven pulley (outer sheave)1and
D
shim(s)2.
Adjust the cooling fan belt tension by adding or
D
removing a shim(s)2on the inside of the outer
sheave.
NOTE:
Always use at least one shim with part number
90214- 17017 when adjusting the cooling fan belt
deflection.
Adding a shim ® Belt tension decreases.
Removing a shim ® Belt tension increases.
2-7
Shims
Part Number Shim thickness
90214- 17017 0.5 mm (0.02 in)
90214- 17018 1.0 mm (0.04 in)
COOLING FAN BELT INSPECTION
â
Install the driven pulley outer sheave3.
D
Nut (driven pulley):
43 Nm (4.3 m · kg, 31 ft · lb)
Install the cooling fan belt4and drive pulley5.
D
NOTE:
Install the cooling fan belt4onto the drive pulley
and driven pulley3. Then install the drive pulley and
tighten the bolts to the specified torque.
Rotor holding tool:
90890- 01235, YU- 01235
Bolt (drive pulley):
23 Nm (2.3 m · kg, 17 ft · lb)
Recheck the cooling fan belt deflection.
If the deflection is out of specification, repeat the
above procedure.
INSP
ADJ
5
8. Install:
Recoil starter
D
Refer to “RECOIL STARTER” in CHAPTER 5.
9. Install:
Cooling fan grill
D
Air duct stopper
D
Screw 3 (cooling fan grill):
7 Nm (0.7 m · kg, 5.1 ft · lb)
Bolt4(cooling fan grill):
7 Nm (0.7 m · kg, 5.1 ft · lb)
10. Install:
Frame cross member
D
1
2
1
Bolt (frame cross member) 2:
48 Nm (4.8 m · kg, 35 ft · lb)
LOCTITE
Bolt (frame cross member) 3:
85 Nm (8.5 m · kg, 61 ft · lb)
2-8
CARBURETOR SYNCHRONIZATION
CARBURETOR SYNCHRONIZATION
1. Remove:
Y.E.I.S. chamber
D
2. Insert:
Carb sync adapters
D
(into the intake manifold opening)
Carb sync adapters:
YM- 33973
3. Attach:
Vacuum gauge
D
(to the carb sync adapters)
Vacuum gauge:
YS- 33275
4. Start the engine and let it warm up.
1
1
INSP
ADJ
Do not move the throttle lever more than necessary so the engine will not run faster than the revolutions at which the snowmoble starts to move.
Engine revolutions: 3,500 r/min
5. Adjust:
Engine idel speed
D
Refer to “ENGINE IDLE SPEED ADJUSTMENT”.
Engine idle speed:
1,300 ± 100 r/min
6. Adjust:
Carburetor synchronization
D
Adjustment steps:
Synchronize the carburetor (left) with the carbu-
D
retor (right) by turning synchronizing screw
until both gauges read the same.
Race the engine for less than a second, two or
D
three times, and check the sy nchroniz ation
again.
1
Vacuum pressure at idle speed:
26.06 ~ 27.26 kPa
(195 ~ 205 mmHg, 7.67 ~ 8.07 inHg)
Vacuum synchronous difference:
1.33 kPa (10 mmHg, 0.4 inHg)
2-9
CARBURETOR SYNCHRONIZATION/
ENGINE IDLE SPEED ADJUSTMENT
7. Remove:
Vacuum gauge
D
8. Install:
Y.E.I.S. chamber
D
Bolt (Y.E.I.S. chamber):
2 Nm (0.2 m · kg, 1.4 ft · lb)
2E101
ENGINE IDLE SPEED ADJUSTMENT
1. Adjust:
Engine idle speed
D
Adjustment steps:
Start the engine and let it warm up.
D
Turn the throttle stop screw1in or out until the
D
specified engine idle speed is obtained.
INSP
ADJ
Turning in ® Idle speed is increased.
Turning out ® Idle speed is decreased.
Engine idle speed:
1,300 ± 100 r/min
NOTE:
After adjusting the engine idle speed, the throttle
cable freeplay should be adjusted.
2-10
THROTTLE CABLE FREEPLAY ADJUSTMENT
2E131
THROTTLE CABLE FREEPLAY ADJUSTMENT
NOTE:
Before adjusting the throttle cable freeplay, the engine idle speed should be adjusted.
1. Measure:
Throttle cable freeplay
D
Out of specification®Adjust.
Throttle cable freeplay a:
1.0 ~ 2.0 mm (0.040 ~ 0.078 in)
INSP
ADJ
a
2. Adjust:
Throttle cable freeplay
D
Adjustment steps:
Loosen the locknut1.
D
Turn the adjusting nut2in or out until the speci-
D
fied freeplay is obtained.
Turning in ® Freeplay is increased.
Turning out ® Freeplay is decreased.
Tighten the locknut.
D
Lock nut:
0.8 Nm (0.08 m · kg, 0.58 ft · lb)
NOTE:
After adjusting the freeplay, turn the handlebar to
right and left, and make sure that the engine idling
does not run faster.
2-11
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK
2E122
THROTTLE OVERRIDE SYSTEM (T.O.R.S.)
CHECK
When checking T.O.R.S.:
D Be sure the parking brake is applied.
D Be sure the throttle lever moves smoothly.
D Do not run the engine up to the clutch engage-
ment speed. Otherwise, the machin e 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 thumb (above) and
fore finger (below) between throttle lever pivot
and switch housing2.
While holding as described above, press the
throttle lever3gradually.
The engine should stop immediately.
INSP
ADJ
1
If the engine does not stop, stop the engine by
turning the main switch to the “OFF” position
and check the electrical system.
2-12
STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT/
EXHAUST SYSTEM INSPECTION
2E131
STARTER (CHOKE) CABLE FREEPLAY ADJUSTMENT
1. Measure:
Starter cable freeplay
D
Out of specification®Adjust.
Starter cable freeplay a:
0.5 ~ 1.5 mm (0.020 ~ 0.059 in)
2. Adjust:
Starter cable freeplay
D
Adjustment steps:
Pull back the adjuster cover
D
Loosen the locknut2.
D
Turn the adjuster3in or out until the specified
D
freeplay is obtained.
INSP
ADJ
a
1
Turning in ® Freeplay is increased.
Turning out ® Freeplay is decreased.
Tighten the locknut and push in the adjuster
D
cover.
Locknut:
0.8 Nm (0.08 m · kg, 0.58 ft · lb)
EXHAUST SYSTEM INSPECTION
1. Open the shroud.
2. Remove:
Springs (exhaust joint and silencer)
D
3. Inspect:
Exhaust joint
D
Exhaust silencer
D
Cracks/damage®Replace.
Exhaust gaskets
D
Exhaust gasket
D
Exhaust gas leaks®Replace.
4. Check:
Tightening torque
D
1
2
3
4
2-13
Bolt (exhaust joint):
30 Nm (3.0 m · kg, 22 ft · lb)
5. Install:
Springs (exhaust joint and silencer)
D
Refer to “EXHAUST ASSEMBLY” in CHAPTER 5.
SHEAVE DISTANCE AND OFFSET ADJUSTMENT
POWER TRAIN
SHEAVE DISTANCE AND OFFSET ADJUSTMENT
1. Open the shroud
2. Remove:
Drive V -belt guard
D
Drive V -belt
D
3. Measure:
Sheave distance
D
Use the sheave gauge.
Out of specification®Adjust.
Sheave distance a:
267 ~ 270 mm (10.52 ~ 10.62 in)
a
INSP
ADJ
Sheave gauge:
YS- 91047 -3, 90890- 01702
4. Adjust:
Sheave distance
D
Adjustment steps:
Loosen the engine mounting bolts.
D
Adjust the position of the engine so that the
D
sheave distance is within the specification.
Tighten the engine mounting bolts.
D
Mounting bolt (front) 1:
90 Nm (9.0 m · kg, 65 ft · lb)
Mounting bolt (rear) 2:
57 Nm (5.7 m · kg, 41 ft · lb)
5. Measure:
Sheave offset
D
Use the sheave gauge.
Out of specification®Adjust.
b
2-14
Sheave offset b:
PZ500:
13.5 ~ 16.5 mm (0.53 ~ 0.64 in)
VT500XL:
18.5 ~ 21.5 mm (0.73 ~ 0.84 in)
Sheave gauge:
YS- 42421 - 1 (15 mm offset)
YS- 42421 - 2 (20 mm offset)
SHEAVE DISTANCE AND OFFSET ADJUSTMENT
6. Measure:
Secondary sheave freeplay (clearance)
D
Use a feeler gauge.
Out of specification®Adjust.
Secondary sheave freeplay (clearance)
c:
1.0 ~ 2.0 mm (0.0394 ~ 0.0787 in)
7. Adjust:
Secondary sheave freeplay (clearance)
D
Adjustment steps:
Apply the brake to lock the secondary sheave.
D
Remove the bolt1and washer2.
D
Adjust the secondary sheave freeplay (clear-
D
ance) by adding or removing a shim(s)3.
INSP
ADJ
c
Shim size:
Part number
90201- 222F0 0.5 mm (0.02 in)
90201- 225A4 1.0 mm (0.04 in)
Thickness
2-15
INSP
DRIVE V - BELT
DRIVE V- BELT
When installing the new belt, be sure the V - belt
is positioned 0 ~ 2 mm (0 ~ 0.08 in) below the edge
a of the secondary sheave.
If the V- belt is not properly installed, the clutch
engagement speed will be changed and the machine may move unexpectedly when the engine
is started.
Adjust the V- belt position by removing or adding
a spacer 1 on each adjusting bolt.
CAUTION:
As the V- belt wears, adjustment may be necessary to ensure proper clutch performance. When
the V -belt position reaches 3 mm (0.12 in), adjust
its position by adding a spacer onto each adjusting bolt.
ADJ
New belt width:
35.0 mm (1.38 in)
Belt wear limit width:
32.0 mm (1.26 in)
1. Measure:
V- belt position
D
a
NOTE:
Install the new V - belt onto the secondary sheave
only. Do not force the V- belt between the sheaves;
the sliding and fixed sheaves must touch each other.
Standard V -belt height a:
0 ~ 2 mm (0 ~ 0.08 in)
(below the edge of the sheave)
2-16
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