YAMAHA PZ500D, PZ500MLD, VT500XLD USER MANUAL
OWNER’S MANUAL
SNOWMOBILE
PZ500D
PZ500MLD
VT500XLD
8DJ-28199-11LIT-12628-02-08
ESS03100
A
MACHINE IDENTIFICATION
Identification numbers record
A. FRAME NUMBER:
861-001
B
B. ENGINE NUMBER (PRIMARY I.D.):
C. KEY NUMBER:
861-015
C
Record your frame number, engine number (Primary I.D.)
and key number in the spaces provided, to assist you in
ordering spare parts from your Yamaha dealer.
860-002
1 The frame number is the nine-digit number stamped
on the frame of the machine. (See Fig. Å)
2 The model code number is the first three digits of the
frame number. (See Fig. Å)
3 The engine number is stamped in the location as
shown. (See Fig. ı)
4 Key number (See Fig. Ç)
Also, record and keep these I.D. numbers in a separate
place in case your machine is stolen.
ESS00000
INTRODUCTION
Congratulations! Your choice of a Yamaha snowmobile
assures you of the highest quality and dependability. Your
Yamaha snowmobile is manufactured by a company wellknown for excellence in the field of snowmobiles. The most
advanced production equipment and technology have
made Yamaha one of the best machine manufacturers.
We are confident that this snowmobile will meet the greatest expectations of our customers. This manual is designed to acquaint you with the operation of this snowmobile and minor maintenance required for satisfactory service.
Should major repairs ever be required, you are advised to
consult a nearby Yamaha dealer who has the techniques,
tools and parts to ensure your satisfaction. We hope that
the information within this booklet will help you enjoy many
hours of pleasure with your Yamaha snowmobile.
PZ500D
PZ500MLD
VT500XLD
OWNER’S MANUAL
©1999 by Yamaha Motor
Corporation, U.S.A.
1st Edition, April 1999
All rights reserved.
Any reprinting or
unauthorized use without
the written permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in Japan
P/N LIT-12628-02-08
WARNING
PLEASE READ AND UNDERSTAND THIS MANUAL
COMPLETELY BEFORE OPERATING THE MACHINE.
851-005
NOTE:
• Yamaha continually seeks advancements in product
design and quality. Therefore, while this manual contains the most current product information available at
the time of printing, there may be minor discrepancies
between your machine and this manual. If there is any
question concerning this manual, please consult your
Yamaha dealer.
• This manual should be considered a permanent part of
this machine and should remain with this machine when
resold.
Particularly important information is distinguished in this
manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in
severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
CAUTION
A CAUTION indicates special precautions that must be
taken to avoid damage to the machine.
:
NOTE:
A NOTE provides key information to make procedures
easier or clearer.
ESS01300
CONTENTS
YAMAHA MOTOR CORPORATION,
U.S.A. SNOWMOBILE LIMITED
WARRANTY ........................................ 1-1
YAMAHA EXTENDED SERVICE
(Y.E.S.).................................................1-4
LOCATION OF THE IMPORTANT
LABELS............................................... 2-1
SAFETY INFORMATION.....................3-1
DESCRIPTION.....................................4-1
CONTROL FUNCTIONS .....................5-1
MAIN SWITCH...................................5-1
STARTER LEVER (CHOKE) .............5-2
THROTTLE LEVER ...........................5-2
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) ..........................................5-3
OIL LEVEL WARNING LIGHT........... 5-3
ENGINE STOP SWITCH ...................5-4
BRAKE LEVER.................................. 5-4
PARKING BRAKE LEVER................. 5-5
V-BELT GUARD ................................ 5-5
V-BELT HOLDER .............................. 5-5
SHROUD LATCH ..............................5-6
HEADLIGHT BEAM SWITCH............ 5-6
GRIP WARMER CONTROL KNOB... 5-7
PASSENGER GRIP WARMER
SWITCH (VT500XL) .......................... 5-7
TRIP ODOMETER RESET KNOB..... 5-7
DRIVE SELECT LEVER
(SHIFT LEVER) (VT500XL)............... 5-8
SPARK PLUG HOLDER.................... 5-8
LUGGAGE BOX ................................5-8
BACKREST (VT500XL) .....................5-9
PRE-OPERATION CHECKS ...............6-1
FUEL..................................................6-1
ENGINE OIL ...................................... 6-2
THROTTLE LEVER ...........................6-2
MANUAL STARTER ..........................6-2
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK............................. 6-2
BRAKE...............................................6-3
BRAKE FLUID LEAKAGE ................. 6-4
V-BELT .............................................. 6-4
DRIVE V-BELT GUARD .................... 6-4
DRIVE TRACK...................................6-5
38-mm (1.5-in) HIGH-PROFILE PAT-
TERN DRIVE TRACK (PZ500ML)..... 6-5
SLIDE RUNNERS..............................6-6
STEERING SYSTEM.........................6-6
SKI/SKI RUNNER.............................. 6-7
LIGHTS.............................................. 6-7
BATTERY (VT500XL)........................ 6-7
FITTINGS/FASTENERS.................... 6-8
SERVICE TOOLS AND SPARE
PARTS............................................... 6-8
OPERATION........................................ 7-1
STARTING THE ENGINE..................7-1
EMERGENCY ENGINE STARTING.. 7-2
BREAK-IN.......................................... 7-3
RIDING YOUR SNOWMOBILE .........7-4
GETTING TO KNOW YOUR
SNOWMOBILE ..................................7-4
LEARNING TO RIDE YOUR
SNOWMOBILE ..................................7-4
TO START OUT AND
ACCELERATE................................... 7-5
BRAKING...........................................7-5
TURNING ..........................................7-5
RIDING UPHILL.................................7-6
RIDING DOWNHILL .......................... 7-7
CROSSING A SLOPE (SIDE HILL)... 7-7
ICE OR ICY SURFACE ..................... 7-8
HARD-PACKED SNOW .................... 7-8
OPERATION ON SURFACES
OTHER THAN SNOW OR ICE.......... 7-8
STRAP (PZ500ML)............................ 7-9
DRIVING.......................................... 7-10
STOPPING THE ENGINE ............... 7-11
TRANSPORTING ............................ 7-12
PERIODIC MAINTENANCE ................ 8-1
MAINTENANCE CHART ................... 8-1
TOOL KIT ..........................................8-4
SPARK PLUG INSPECTION............. 8-4
ENGINE IDLE SPEED
ADJUSTMENT...................................8-5
THROTTLE CABLE ADJUSTMENT.. 8-6
OIL PUMP CABLE ADJUSTMENT.... 8-6
CARBURETOR ADJUSTMENT ........ 8-7
HIGH ALTITUDE ADJUSTMENTS.... 8-9
FAN BELT........................................8-10
DRIVE V-BELT REPLACEMENT .... 8-10
DRIVE CHAIN HOUSING................ 8-13
BRAKE.............................................8-14
BRAKE FLUID REPLACEMENT ..... 8-15
PARKING BRAKE ...........................8-15
SUSPENSION ................................. 8-16
FULL RATE ADJUSTER .................8-18
TRACK ADJUSTMENT ...................8-19
SKI ALIGNMENT .............................8-21
HANDLEBAR ADJUSTMENT
(PZ500/VT500XL)............................ 8-21
HANDLEBAR ADJUSTMENT
(PZ500ML)....................................... 8-22
LUBRICATION.................................8-23
HEADLIGHT .................................... 8-24
BATTERY (VT500XL)...................... 8-25
FUSE REPLACEMENT (VT500XL). 8-26
TROUBLESHOOTING.........................9-1
STORAGE .........................................10-1
RETURN TO SERVICE AFTER
STORAGE ....................................... 10-2
SPECIFICATIONS .............................11-1
DIMENSIONS ..................................11-1
ENGINE ...........................................11-1
CHASSIS .........................................11-2
ELECTRIC .......................................11-3
WIRING DIAGRAM............................12-1
ESS79001
YAMAHA MOTOR CORPORATION, U.S.A.
SNOWMOBILE LIMITED WARRANTY
Yamaha Motor Corporation, U.S.A. hereby warrants that
new Yamaha snowmobiles purchased from an authorized Yamaha snowmobile dealer in the continental
United States will be free from defects in material and
workmanship for the period of time stated herein, subject
to certain stated limitations.
WARRANTY PERIOD:
1. All Yamaha snowmobiles shall be warranted for a
term of one (1) year from the date of purchase, plus
a special early-season extension (if applicable).
2. All Yamaha snowmobile clutch components are warranted against abnormal wear for one (1) year from
the date of purchase, plus a special early-season
extension (if applicable).
DURING THE PERIOD OF WARRANTY any au-
thorized Yamaha snowmobile dealer will, free of charge,
repair or replace, at Yamaha’s option, any part adjudged
defective by Yamaha due to faulty workmanship or
material from the factory. Parts used in warranty repairs
will be warranted for the balance of the snowmobile’s
warranty period. All parts replaced under warranty become the property of Yamaha Motor Corporation, U.S.A.
GENERAL EXCLUSIONS from this warranty shall
include any failures to the machine caused by:
1. Competition, racing, or non-Yamaha authorized
rental use.
2. Operation on surfaces other than snow or ice.
3. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts.
4. Abnormal strain, neglect, or abuse.
5. Lack of proper maintenance.
6. Accident or collision damage.
7. Modification to original parts.
SPECIFIC EXCLUSIONS from this warranty shall
include parts replaced due to normal wear or routine
maintenance including oil, spark plugs, clutch drive belts,
slide runners, and track.
THE CUSTOMER’S RESPONSIBILITY under this
warranty shall be to:
1. Operate and maintain the snowmobile as specified in
the appropriate Owner’s Manual.
2. Give notice to an authorized Yamaha snowmobile
dealer of any and all apparent defects within ten (10)
days after discovery, and make the machine available at that time for inspection and repairs at such
dealer’s place of business. You may locate your
nearest authorized Yamaha dealer through your
local telephone directory.
WARRANTY TRANSFER: To transfer any remain-
ing warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be
inspected and registered for warranty by an authorized
Yamaha snowmobile dealer. In order for this warranty to
remain in effect, this inspection and registration must
take place within ten (10) days after ownership transfer.
An inspection and registration fee will be charged for this
service.
YAMAHA MOTOR CORPORATION, U.S.A.
MAKES NO OTHER WARRANTY OF ANY
KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS
AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY
YAMAHA MOTOR CORPORATION, U.S.A.
AND EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS
ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION MAY
NOT APPLY TO YOU. ALSO EXCLUDED
FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO
NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL
DAMAGES, SO THE ABOVE EXCLUSION MAY
NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH VARY FROM STATE
TO STATE.
1-1
SPECIAL EARLY-SEASON WARRANTY EXTENSION
A special warranty extension is available for all new
Yamaha snowmobiles purchased between June 1 and
December 1.
All new Yamaha snowmobiles purchased between June
1 and December 1 will have the warranty extended to
November 30 of the following year.
YAMAHA MOTOR CORPORATION, U.S.A.
Post Office Box 6555
Cypress, California 90630
WARRANTY QUESTIONS AND
ANSWERS
Q. Will the warranty be void or cancelled if I do not
operate or maintain my new Yamaha exactly as
specified in the Owner’s Manual?
A. No. The warranty on a new Yamaha cannot be
“voided” or “cancelled.” However, if a particular failure is caused by operation or maintenance other than
as shown in the Owner’s Manual, that failure may not
be covered under warranty.
Q. What responsibility does my dealer have under this
warranty?
A. Each Yamaha snowmobile dealer is expected to:
1. Completely set up every new machine before sale.
2. Explain the operation, maintenance, and warranty
requirements to your satisfaction at the time of sale,
and upon your request at any later date.
3. In addition, each Yamaha snowmobile dealer is held
responsible for his setup, service and warranty repair
work.
Q. What costs are my responsibility during the warranty
period?
A. The customer’s responsibility includes all costs of
normal maintenance services, non-warranty repairs,
accident and collision damages, as well as oil, spark
plugs, clutch drive belts, and slide runners.
Q. What are some examples of “abnormal” strain, ne-
glect, or abuse?
A. These terms are general and overlap each other in
areas. Specific examples include: Running the machine out of oil, hitting an object submerged under
snow, operation on surfaces other than snow or ice,
operating the machine with a broken or damaged
part which causes another part to fail, and so on. If
you have any specific questions on operation or
maintenence, please contact your dealer for advice.
Q. May I perform any or all of the recommended main-
tenance shown in the Owner’s Manual instead of
having the dealer do them?
A. Yes, if you are a qualified snowmobile mechanic and
follow the procedures specified in the Owner’s and
Service Manual. We do recommend, however, that
items requiring special tools or equipment be done by
a Yamaha snowmobile dealer.
Q. Under what conditions is the clutch not covered by
warranty?
A. Clutches as well as clutch components wear with
use. Normal wear is not covered under warranty such
service is the customer’s responsibility. Abnormal
wear is, however, covered for one (1) year from the
date of purchase. Your Yamaha snowmobile dealer
possesses criteria as to what constitutes abnormal
wear.
Q. Whom should I contact if I have further questions
about this warranty?
A. Your Yamaha snowmobile dealer has the informa-
tion and experience necessary to answer almost any
questions about this warranty. If the dealer is not able
to do so, he is expected to contact Yamaha Motor
Corporation, U.S.A., for clarification or assistance.
CUSTOMER SERVICE
If your machine requires warranty service, you must take
it to any authorized Yamaha snowmobile dealer within
the continental United States. Be sure to bring your
warranty identification card or other valid proof of the
original date of purchase. If a question or problem arises
regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer
level, this person is in the best position to help you. If you
are still not satisfied and require additional assistance,
please write:
YAMAHA MOTOR CORPORATION
U.S.A.
CUSTOMER RELATIONS DEPART-
MENT
P.O. Box 6555
Cypress, California 90630
1-2
When contacting Yamaha Motor Corporation, U.S.A. be sure to include the model,
serial number, names, dates, and receipts.
CHANGE OF ADDRESS
The federal government requires each manufacturer of a
motor vehicle to maintain a complete, up-to-date list of all
first purchasers against the possibility of a safety-related
defect and recall. This list is compiled from the purchase
registrations sent to Yamaha Motor Corporation, U.S.A.
by the selling dealer at the time of your purchase.
If you should move after you have purchased your new
snowmobile, please advise us of your new address by
sending a postcard listing your snowmobile model name,
engine serial number, dealer number (or dealer’s name)
as it is shown on your warranty registration identification,
your name and new mailing address. Mail to:
YAMAHA MOTOR CORPORATION,
U.S.A.
WARRANTY DEPARTMENT
P.O. Box 6555
Cypress, California 90630
This will ensure that Yamaha Motor Corporation, U.S.A.
has an up-to-date registration record in accordance with
federal law.
1-3
ESS79500
YAMAHA EXTENDED SERVICE (Y.E.S.)
Keep your Yamaha protected even after your
warranty expires with genuine Yamaha Extended Service (Y.E.S.).
• Y.E.S. is designed and administered by
Yamaha Motor Corporation to provide
maximum owner satisfaction. You get uninterrupted factory-backed coverage for
extra peace of mind.
• Y.E.S. is flexible. You choose the plan that’s
right for you: 12 months, 24 months, or 36
months beyond your warranty period.
• Y.E.S. is designed and administered by the
same Yamaha people who handle your
warranty — and it shows in the comprehensive coverage benefits. There are no
mileage limitations. Coverage isn’t limited
to “moving parts” or the “drive train” like
many other plans. And Y.E.S. covers manufacturing defects just like the warranty. See
the sample contract at your Yamaha dealer
to see how comforting uninterrupted factory-backed protection can be.
• You don’t have to pay anything for covered
repairs.
There’s no deductible to pay, and repairs
aren’t “pro-rated.” You don’t have any
“out-of pocket” expenses for covered repairs.
• In addition, Travel and Recreation Inter-
ruption Protection (TRIP) is included at no
extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your
Yamaha needs covered service: replacement vehicle rental, emergency towing,
phone calls, even food and lodging when
you are away from home. This superb
coverage goes into effect when you purchase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during
your entire Y.E.S. plan period.
• Y.E.S. coverage is honored at any author-
ized Yamaha dealer nationwide.
• Y.E.S. coverage is transferrable to a new
owner if you sell or trade-in. That can make
your Yamaha much more valuable!
This excellent Y.E.S. plan coverage is only
available to Yamaha owners like you, and only
while your Yamaha is still within the Yamaha
Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can
show you how easy it is to protect your investment with Yamaha Extended Service.
We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and
you’ll rest easy knowing you’ll have strong
factory-backed protection even after your
Yamaha Limited Warranty expires. You can
also save money: Y.E.S. costs less within the
first 90 days after you buy your Yamaha. See
your dealer today!
A special note:
If visiting your dealer isn’t convenient, contact
Yamaha with your Primary ID number (your
engine number). We’ll be happy to help you
get the Y.E.S. coverage you need.
Yamaha Service Marketing P.O.Box 6555
Cypress, CA 90630
(714) 761-7631
1-4
ESB01500
LOCATION OF THE
IMPORTANT LABELS
Please read the following labels carefully before operating
this machine.
NOTE:
Maintain or replace safety and instruction labels, as necessary.
2
DO NOT OPERATE ENGINE WITHOUT
V-BELT OR DRIVE GUARD.
NE PAS FAIRE FONCTIONNER LE
MOTEUR SANS COURROIE EN V
OU PROTECTEUR D’EMBRAYAGE.
1 PZ500/PZ500ML
SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF
THE FOLLOWING:
•
Read the Owner’s Manual and all labels before operating this vehicle.
• This vehicle is a high performance machine.
It should be operated by an experienced operator.
•
Check throttle, brake, and steering for proper operation before starting engine.
• Set parking brake before attempting to start engine.
Never run this vehicle with the parking brake applied.
•
To stop engine in an emergency, push the engine stop switch down.
• Do not operate engine without drive belt or drive guard.
• Make sure the fuel tank cap is closed securely after refueling.
• Do not operate this vehicle on public roads.
You could collide with another vehicle.
• This vehicle is designed for operator only - no passengers.
•
Wear an approved helmet, eye protection, and adequate clothing for
snowmobiling.
WARNING
WARNING
AVERTISSEMENT
8BD-77762-00
AVERTISSEMENT
AFIN D’ÉVITER TOUT RISQUE DE BLESSURE SÉRIEUSE OU MÊME MORTELLE,
VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES:
•
Avant d’utiliser ce véhicule, lire le manuel du propriétaire et toutes les étiquettes.
• Ce véhicule est une machine à haute perfomance.
Elle doit être conduite par un conducteur expérimenté.
•
Avant de démarrer le moteur, vérifier l’opération du frein, de l’accélérateur
et de la direction.
•
Le frein de sécurité doit être appliqué lors du démarrage.
Ne pas rouler avec le frein de sécurité actionné.
•
En cas d’urgence, utiliser l’interrupteur d’arrêt du moteur.
•
Ne pas laisser tourner le moteur sans la courroie ou sans son garde.
• S’assurer que le bouchon du réservoir soit bien refermé après le remplissage.
•
Afin d’éviter tout risque de collision, ne pas rouler sur un chemin public.
• Ce véhicule est conçu pour un conducteur seul - aucun passager.
•
Toujours porter un casque approuvé et un habillement de motoneigiste.
Prévoir une protection pour les yeux.
8DS-77761-00
2-1
1 VT500XL
SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF
THE FOLLOWING:
•
Read the Owner’s Manual and all labels before operating this vehicle.
• This vehicle is a high performance machine.
It should be operated by an experienced operator.
Check throttle, brake, and steering for proper operation before starting engine.
•
• Set parking brake before attempting to start engine.
Never run this vehicle with the parking brake applied.
To stop engine in an emergency, push the engine stop switch down.
•
• Do not operate engine without drive belt or drive guard.
• Make sure the fuel tank cap is closed securely after refueling.
• Do not operate this vehicle on public roads.
You could collide with another vehicle.
Wear an approved helmet, eye protection, and adequate clothing for
•
snowmobiling.
• Check lever position (Forward or Reverse) before moving.
AFIN D’ÉVITER TOUT RISQUE DE BLESSURE SÉRIEUSE OU MÊME MORTELLE,
VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES:
•
Avant d’utiliser ce véhicule, lire le manuel du propriétaire et toutes les étiquettes.
• Ce véhicule est une machine à haute perfomance.
Elle doit être conduite par un conducteur expérimenté.
• Avant de démarrer le moteur, vérifier l’opération du frein, de l’accélérateur
et de la direction.
• Le frein de sécurité doit être appliqué lors du démarrage.
Ne pas rouler avec le frein de sécurité actionné.
• En cas d’urgence, utiliser l’interrupteur d’arrêt du moteur.
• Ne pas laisser tourner le moteur sans la courroie ou sans son garde.
• S’assurer que le bouchon du réservoir soit bien refermé après le remplissage.
Afin d’éviter tout risque de collision, ne pas rouler sur un chemin public.
•
• Toujours porter un casque approuvé et un habillement de motoneigiste.
Prévoir une protection pour les yeux.
Vérifier la position du levier (marche avant ou arrière) avant d’être en marche.
•
3 PZ500ML/VT500XL
WARNING
NO PASSENGER OR CARGO ON THIS TRACK COVER.
If was not designed to carry weight. It could bend or break under
load.
Anything placed here could block the view of the break/tail light
which could cause an accident.
WARNING
AVERTISSEMENT
8DM-77761-00
AUCUN PASSAGER OU MARCHANDISE SUR LE PROTECTEUR DE
CHENILLE.
Ce protecteur n’a pas été conçu pour supporter un poids. Il pourrait
s’incurver ou se briser sous la charge.
Tout objet ou personne placé à cet endroit pourrait bloquer la vue
des feux d’arrêt/amére et ainsi causer un accident.
AVERTISSEMENT
8CY-77762-00
4 PZ500ML
WARNING
Improper use of STRAP on the handlebar can result in
SEVERE INJURY or DEATH.
• Use strap only as an operator grip point to shift weight
uphill to maintain balance during traverse ( sidehill ) riding.
• Keep one hand on handlebar. Do not change speed or
direction abruptly.
• Only experienced operators should traverse slopes steep
enough to require strap use.
AVERTISSEMENT
L’utilisation incorrecte de la POIGNÉE SOUPLE du guidon peut
causer des BLESSURES GRAVES voire MORTELLES.
• S’agripper à la poignée seulement lors de la traversée latérale
de pentes pour garder l’équilibre lorsque l’on déplace son poids
du côté amont.
• Garder une main sur le guidon. Éviter toute accélération ou
freinage brusques.
• La traversée de pentes dont la raideur requiert l’utilisation de la
poignée est réservée aux pilotes expérimentés.
2-2
8ED-77761-00
851-005
851-004
ESS39203
SAFETY INFORMATION
When you ride your snowmobile, you must know and use
the following for your safety. Severe injury or death may
result if you ignore any of the following.
Before Operating
1. Read the Owner’s Manual and all labels before operating this machine. Become familiar with all of the operating controls and their function. Consult a Yamaha
dealer about any control or function you do not understand.
2. This machine was not manufactured for use on public
streets, roads, or highways. Such use is prohibited by
law, and you could collide with another vehicle.
3. PZ500 and PZ500ML are designed to carry the OPERATOR ONLY.
Passengers are prohibited. Carrying a passenger can
cause loss of control.
851-006
4. Do not operate the machine after drinking alcohol or
taking drugs. Your ability to operate the machine is
reduced by the influence of alcohol or drugs.
5. For safety and proper care of the machine, always
perform the pre-operation checks on pages 6-1 ~
6-8 before starting the engine. Check the throttle,
steering and brake operation every time before starting
the engine. Be sure the throttle lever moves freely and
it returns to the idle position when it is released.
6. Apply the parking brake before starting the engine.
Never drive the machine with the parking brake applied. This may overheat the brake disc and reduce
braking ability.
7. Do not allow anyone to stand behind the machine when
starting, inspecting or adjusting the machine. A broken
track, track fittings or debris thrown by the track could
be dangerous to the operator or bystanders.
3-1
851-003
8. Handle fuel with care; it is highly flammable.
• Never add fuel when the engine is running or hot.
Allow the engine to cool for several minutes after
running.
• Use an approved fuel container.
• Fill the fuel tank outdoors with extreme care. Never
remove the fuel cap indoors. Never fill the fuel tank
indoors.
• Never refuel while smoking or in the vicinity of an
open flame.
• Make sure the fuel tank cap is closed securely after
refueling. Wipe up any spilled fuel immediately.
9. If you swallow some gasoline, inhale a lot of gasoline
vapor, or get some gasoline into your eye(s), see your
doctor immediately. If any gasoline spills on your skin
or clothing, immediately wash your skin with soap and
water, and change your clothes.
10.Wear protective clothing. Wear an approved helmet,
and a face shield or goggles. Also, wear a good quality
snowmobile suit, boots, and a pair of snowmobile
gloves or mittens that will permit use of your thumbs
and fingers for operation of the controls.
851-001
851-002
Operation
1. Do not run the engine indoors, except when starting the
engine to transport the machine in or out of the building.
Open the outside doors; exhaust fumes are dangerous.
2. Be careful where you ride. There may be obstacles
hidden beneath the snow. Stay on established trails to
minimize your exposure to hazards. Ride slowly and
cautiously when you ride off of established trails. Hitting
a rock or stump, or running into wires could cause an
accident and injury.
3-2
3. This machine is not designed for use on surfaces other
than snow or ice. Use on dirt, sand, grass, rocks, or bare
pavement may cause loss of control and may damage
the machine.
4. Avoid operating on glare ice, or on snow which has a lot
of dirt or sand mixed in. Operation under such conditions will damage or result in rapid wear of ski runners,
drive track, slide runners and drive sprockets.
5. Always have other snowmobilers with you when going
on a ride. You may need help if you run out of fuel, have
an accident, or damage your snowmobile.
6. Many surfaces such as ice and hard-packed snow
require much longer stopping distances. Be alert, plan
ahead and begin decelerating early. The best braking
method on most surfaces is to release the throttle and
apply the brake gently – not suddenly.
Maintenance and Storage
1. Do not leave the machine on its left side for an extended
period of time. Fuel may leak out from the fuel breather
hose.
2. Modifications made to the machine not approved by
Yamaha, or the removal of original equipment may
render your machine unsafe for use and may cause
severe personal injury. Modifications may also make
your machine illegal to use.
3. Never store the machine with fuel in the fuel tank inside
a building where ignition sources are present such as
hot water and space heaters, open flame, spark, clothes
dryers, and the like. Allow the engine to cool before
storing in any enclosure.
4. Always refer to “STORAGE” for important details if the
machine is to be stored for an extended period.
5. Maintain or replace safety and instruction labels, as
necessary.
3-3
–MEMO–
PZ500
PZ500ML
ESG05100
DESCRIPTION
1 Windshield
2 Steering handlebar
3 Seat
4 Passenger grip warmer switch
(VT500XL)
5 Frame
6 Slide rail suspension
7 Drive track
8 Steering ski
VT500XL
4-1
VT500XL
9 Headlight
0 Shroud
A Luggage box
B Taillight
C Flap
D Side mirror (VT500XL)
E Brake lever
F Headlight beam switch
G Parking brake lever
H Strap (PZ500ML)
I Engine stop switch
J Throttle lever
K Drive select lever (VT500XL)
L Starter handle
M Shroud latch
N Main switch
O Starter lever
P Grip warmer control knob
Q “HIGH BEAM” indicator light
R Odometer
S Speedometer
T Tachometer
U “OIL LEVEL” warning indicator light
V Trip odometer reset knob
W Trip odometer
PZ500ML
4-2
AB
831-027
ESG05000
CONTROL FUNCTIONS
ESS08802
MAIN SWITCH
The main switch controls the following items.
1 OFF:
The ignition circuit is switched off.
The key can be removed only in this position.
2 ON:
The ignition circuit is switched on.
The engine can be started.
3 WARMER:
The grip and thumb warmer circuit is switched on.
Also, the ignition circuit is switched on and the engine can
be started.
NOTE:
The handlebar grips and throttle lever will heat electrically
after the engine starts.
4 START (VT500XL):
The starting circuit is switched on.
The starter motor starts.
NOTE:
The lights will come on after the engine starts.
CAUTION
:
Release the switch immediately after the engine starts.
Å PZ500/PZ500ML
ı VT500XL
5-1
815-001
816-001
ESS22200
STARTER LEVER (CHOKE)
Use this lever when starting and warming up a cold engine.
1 Starter lever (choke)
2 When starting a cold engine.
3 Warming up
4 When the engine is warm.
NOTE:
Refer to STARTING THE ENGINE for proper operation.
ESS21600
THROTTLE LEVER
Once the engine is running cleanly, squeezing 2 the throttle
lever 1 will increase the engine speed and cause engagement of the drive system. Regulate the speed of the machine
by varying the throttle position. Because the throttle is
spring-loaded, the machine will decelerate, and the engine
will return to an idle when the thumb is released 3.
WARNING
Check the throttle, brake, and steering for proper
operation before starting engine.
5-2
ESS22301
THROTTLE OVERRIDE SYSTEM (T.O.R.S.)
If the carburetor or throttle cable should malfunction during
operation, release the throttle lever. The T.O.R.S. is designed to interrupt the ignition and stop the engine if the
carburetor fails to return to idle when the lever is released.
WARNING
If T.O.R.S. stops the engine, 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.
A B C
MODE
SWITCH
A
Throttle switch
Idle
or
starting
OFF
Run Trouble
ON
OFF
816-003
Carburetor switch
Engine
Å Idle or starting
ON
RUN
OFF
RUN
OFF
STOP
ı Run
B
Ç Trouble
1 Carburetor switch
2 Throttle switch
3 Throttle cable
4 Throttle valve
816-004
a “ON”
b “OFF”
C
816-005
ESS21900
OIL LEVEL WARNING LIGHT
If the oil level falls below the lower level, this light comes on.
If the light comes on, add engine oil to the oil tank at the first
opportunity.
833-010
5-3
831-008
ESS20800
ENGINE STOP SWITCH
The engine stop switch 1 is used to stall the engine in an
emergency. Simply push 2 the engine stop switch, and
the engine will stop. To start the engine, pull 3 the engine
stop switch and see page 7-1 for more details. During the
first few rides, you should practice using the switch while
driving so that you can react quickly in an emergency.
ESS28100
BRAKE LEVER
The machine is stopped by braking the entire drive system.
Squeeze the brake lever towards the handlebar to stop the
machine.
818-035
1 Brake lever
2 Brake lever end
3 Handlebar end
NOTE:
When the brake is operated, the brake light will illuminate.
CAUTION
Be sure the brake lever end does not project out over
the handlebar end. This will help prevent brake lever
damage when the machine is placed on its side for
service.
:
5-4
ESS27100
A
PARKING BRAKE LEVER
When parking the machine or starting the engine, apply the
parking brake by moving the parking brake lever 1 to the
left.
To release the parking brake, move the parking brake
818-036
lever 1 to the right.
B
Å To apply the parking brake
ı To release the parking brake
WARNING
• Always set the parking brake before attempting to
start the engine.
818-037
• Never run the machine with the parking brake ap-
plied.
This may overheat the brake disc and reduce braking ability.
ESS28700
V-BELT GUARD
The V-belt guard is designed to cover the clutch and V-belt
in case parts break or come loose.
WARNING
845-062
• Be sure the V-belt guard is tightened securely
before operating the machine.
• Never run the engine without the V-belt or with the
V-belt guard removed.
845-061
ESS08100
V-BELT HOLDER
Keep a spare V-belt for emergency use by putting it into the
holder provided.
CAUTION
:
Be sure the V-belt is installed securely in the holder.
5-5
ESS29100
SHROUD LATCH
To open the shroud, unhook the latch, then slowly raise the
shroud forward until it stops. When closing the shroud,
slowly lower it to its home position, then hook the shroud
latches.
845-023
831-045
1 Latch
2 Shroud
CAUTION
:
Be sure all cables and wires are in place when closing
the shroud.
WARNING
• Do not drive the machine with the shroud open or
unlatched or with the shroud removed.
• Keep your body and clothing away from rotating
parts when servicing with the shroud open.
• Do not touch the hot muffler and engine during or
immediately after operation.
ESS28300
HEADLIGHT BEAM SWITCH
Push the switch to change the head light beam alternately
to high or low.
1 Headlight beam switch
2 Push
3 High beam
4 Low beam
5-6
ESS09000
GRIP WARMER CONTROL KNOB
This knob controls the electrically heated handlebar grips
and throttle lever when the main switch is in the “WARMER”
position.
831-039
831-036
833-019
1 Grip warmer control knob
Knob position Warmer temperature
2 Turn clockwise Higher
3 Turn counterclockwise Lower
ESS08900
PASSENGER GRIP WARMER SWITCH (VT500XL)
This switch controls the electrically heated passenger
grips.
1 Passenger grip warmer switch
2 ON
3 OFF
ESS29900
TRIP ODOMETER RESET KNOB
Use the knob to reset the trip odometer.
1 Reset knob
2 Push
5-7
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