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Yamaha PZ500D Owner's Manual

Summary of PZ500D

  • Page 1

    Owner’s manual snowmobile pz500d pz500mld vt500xld 8dj-28199-11 lit-12628-02-08 nted in japan 4 - 1.8 × 4 cr.

  • Page 2: Machine Identification

    Ess03100 machine identification identification numbers record a. Frame number: b. Engine number (primary i.D.): c. Key number: 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. 1 the frame numb...

  • Page 3: Introduction

    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 well- known for excellence in the field of snowmobiles. The most advanced production equipment and technology have made ...

  • Page 4: Warning

    Warning please read and understand this manual completely before operating the machine. Note: • yamaha continually seeks advancements in product design and quality. Therefore, while this manual con- tains the most current product information available at the time of printing, there may be minor disc...

  • Page 5: Contents

    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 safe...

  • Page 6

    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 adj...

  • Page 7

    1-1 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 autho- rized yamaha snowmobile dealer in the continental united states will be free from defects in material and workmanship for th...

  • Page 8

    1-2 special early-season warranty ex- tension 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. Yam...

  • Page 9

    1-3 when contacting yamaha motor corpora- tion, 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 possibili...

  • Page 10

    1-4 ess79500 yamaha extended service (y.E.S.) keep your yamaha protected even after your warranty expires with genuine yamaha ex- tended service (y.E.S.). • y.E.S. Is designed and administered by yamaha motor corporation to provide maximum owner satisfaction. You get un- interrupted factory-backed c...

  • Page 11: Location Of The

    2-1 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...

  • Page 12

    2-2 avertissement warning improper use of strap on the handlebar can result in severe injury or death. L’utilisation incorrecte de la poignÉe souple du guidon peut causer des blessures graves voire mortelles. • use strap only as an operator grip point to shift weight uphill to maintain balance durin...

  • Page 13: Safety Information

    3-1 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 operat- ing this machine. Become familiar with a...

  • Page 14

    3-2 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 f...

  • Page 15

    3-3 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 condi- ti...

  • Page 16

    –memo–.

  • Page 17: Description

    4-1 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 pz500 vt500xl pz500ml.

  • Page 18

    4-2 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 wa...

  • Page 19: Control Functions

    5-1 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 circu...

  • Page 20: Warning

    5-2 815-001 816-001 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 engin...

  • Page 21: Warning

    5-3 on off run off off stop idle or starting mode run trouble switch off on run throttle switch carburetor switch engine a b c 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 de- signed ...

  • Page 22: Caution:

    5-4 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 ...

  • Page 23: Warning

    5-5 ess27100 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 lever 1 to the right. Å to apply the parking brake ı to release the parking brake warning • ...

  • Page 24: Caution:

    5-6 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. 1 latch 2 shroud caution: be sure all cables and wires are in place when closing the shrou...

  • Page 25

    5-7 831-036 831-039 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. 1 grip warmer control knob knob position warmer temperature 2 turn clockwise higher 3 turn counterclockwise lower ess0...

  • Page 26: Caution:

    5-8 817-006 817-007 ess23701 drive select lever (shift lever) (vt500xl) the drive select lever is used to shift your machine into forward or reverse. After coming to a complete stop, move the lever to the desired direction. 1 drive select lever (shift lever) 2 push down 3 move to forward 4 move to r...

  • Page 27: Warning

    5-9 ess09500 backrest (vt500xl) this backrest is adjustable. Remove the mount bolts 1 and adjust the backrest posi- tion. Warning make sure that the mount bolts are tightened securely after adjusting. Backrest position: 2 front position 1 3 front position 2 4 rear position 1 5 rear position 2 6 rear...

  • Page 28: Pre-Operation Checks

    6-1 esb30000 pre-operation checks note: pre-operation checks should be made each time the machine is used. Warning the engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspe...

  • Page 29: Warning

    6-2 • be sure that snow and /or ice does not enter into the fuel tank when refueling. • do not use alcohol deicers or water absorbing additives with oxygenated fuel. • the tank should be filled with straight gasoline as specified. Ess33100 engine oil make sure that there is sufficient oil in the oil...

  • Page 30: Warning

    6-3 1 2 3 816-040 818-038 ess37000 brake (see page 8-14 ~ 8-15 for more details.) 1. Brake lever test the brake at slow speed when starting out to make sure it is working properly. If the brake does not provide proper braking performance, inspect the brake for wear or brake fluid leakage. Warning a ...

  • Page 31: Warning

    6-4 845-062 805-106 ess37100 brake fluid leakage apply the brake for a few minutes. Check to see if any brake fluid leaks out from the pipe joints or the master cylinder. Warning if brake fluid leakage is found, consult a yamaha dealer for immediate repairs. Caution: brake fluid may deteriorate pain...

  • Page 32: Warning

    6-5 820-026 ess34000 drive track (see page 8-19 ~ 8-21 for more details.) check the drive track for deflection, wear and damage. Adjust/replace if necessary. Warning do not operate the machine if you find damage to the drive track, or misadjustment. Drive track damage and/or failure could result in ...

  • Page 33: Caution:

    6-6 ess32200 slide runners check wear and damage. If the slide runners reach the wear limit, they should be replaced. 1 slide runners 2 wear limit wear limit height: 10 mm (0.4 in) caution: ride on fresh snow frequently. Operating on ice or hard packed snow will rapidly wear the slide runners. 820-0...

  • Page 34: Caution:

    6-7 819-052 ess36000 battery (vt500xl) (see page 8-25 for more details.) check the fluid level and fill if necessary. Use only distilled water if refilling is necessary. Ess36500 lights check the lights. Replace any burned out bulbs. Caution: avoid using the scraper or hot water for cleaning to prot...

  • Page 35

    6-8 ess36600 service tools and spare parts it is a good practice to carry service tools and spare parts with your machine so that minor repairs can be done by yourself. The following should be carried in the luggage box. • tool kit • flashlight • roll of plastic tape • steel wire • tow rope • emerge...

  • Page 36: Operation

    7-1 esg40100 operation ess40201 starting the engine warning • be sure to check “safety information” care- fully before starting the engine. • be sure the parking brake is applied. Note: be sure the engine stop switch is in the “on” position. 1. Fully open the starter lever (choke). 1 starter lever (...

  • Page 37: Caution:

    7-2 caution: • release the switch immediately after the engine starts. • if the engine fails to start, release the switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. Ess4160...

  • Page 38: Warning

    7-3 850-007 850-005 4. Wind the rope 3-counterclockwise turns on the primary sheave. 5. Grasp the screwdriver handle and pull briskly. Warning do not wind the emergency starter rope around your hand. 6. After the engine starts, put the starter lever (choke) in the “half-open” position. Warm up the e...

  • Page 39

    7-4 ess41301 riding your snowmobile getting to know your snowmobile a snowmobile is a rider active vehicle, and your riding position and your balance are the two basic factors of maneuvering your snowmobile. Riding your snowmobile requires skills acquired through practice over a period of time. Take...

  • Page 40: Warning

    7-5 to start out and accelerate 1. With the engine idling, release the parking brake. 2. Apply the throttle slowly and smoothly. The centrifu- gal clutch will engage and you will start to accelerate. Warning the operator should always keep both hands on the handlebars. Never put your feet outside th...

  • Page 41: Warning

    7-6 improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the snow- mobile to tip. If your snowmobile begins to tip while turning, lean more into the turn to regain balance. If necessary, gra...

  • Page 42: Warning

    7-7 riding downhill when riding downhill, keep speed to a minimum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow you to use engine compression to help slow the machine, and to keep the snowmobile from rolling freely down the hill....

  • Page 43: Warning

    7-8 ice or icy surface operating on ice or icy surfaces can be very dangerous. Traction for turning, stopping or starting is much less than that on snow. Warning when you have to operate on ice or icy surfaces, drive slowly and cautiously. Avoid rapid acceleration, turn- ing or braking. Steering is ...

  • Page 44: Warning

    7-9 warning drive track damage and/or failure could result in loss of braking ability and machine control, which could cause an accident. • always check the drive track for damage or misadjustment before operating the machine. • do not operate the machine if you find damage to the drive track. Cauti...

  • Page 45: Warning

    7-10 ess42910 driving warning be sure to read “safety information” and “riding your snowmobile” carefully before operating the machine. Note: be sure the engine is warmed up enough before riding. Pz500/pz500ml 1. Release the parking brake by moving the parking brake lever to the right. 2. Press the ...

  • Page 46: Warning

    7-11 2. Release the parking brake by moving the parking brake lever to the right. 3. Press the throttle lever slowly to move the machine. 4. Turn the handlebar in the desired direction. 5. Squeeze the brake lever to stop the machine. 6. Apply the parking brake – move the parking brake lever to the l...

  • Page 47

    7-12 ess45400 transporting when transporting your machine on a trailer or in a truck, observe the following recommendations to help protect your machine from damage: • make sure that the fuel level in the fuel tank is lower than the carburetors. Otherwise, the vibration and bumps from the road surfa...

  • Page 48: Periodic Maintenance

    8-1 esg50000 periodic maintenance ess50103 maintenance chart regular maintenance is most important for best performance and safe operation. Page initial 1 month or 800 km (500 mi) (40 hr) pre- operation check (daily) remarks item check condition. Adjust gap and clean. Replace if necessary. Check oil...

  • Page 49

    8-2 page initial 1 month or 800 km (500 mi) (40 hr) pre- operation check (daily) remarks item every seasonally or 3,200 km (2,000 mi) (160 hr) see note on page 8-3. ✽ it is recommended that these items be serviced by a yamaha dealer. Check for leakage. Retighten or replace gasket if necessary. More ...

  • Page 50

    8-3 page initial 1 month or 800 km (500 mi) (40 hr) pre- operation check (daily) remarks item every seasonally or 3,200 km (2,000 mi) (160 hr) whenever operating elevation is changed. Whenever operating elevation is changed. 8-23 8-23 ✽ it is recommended that these items be serviced by a yamaha deal...

  • Page 51: Caution:

    8-4 ess51101 tool kit the owner’s tool kit has the tools which are sufficient for most periodic maintenance and minor repair. A torque wrench is also necessary to properly tighten nuts and bolts. 1 tool kit Å pz500/pz500ml ı vt500xl caution: before starting the engine, make sure that the tool kit bo...

  • Page 52: Caution:

    8-5 spark plugs are produced in several different thread lengths. The thread length (reach) is the distance from the spark plug gasket seat to the end of the threaded portion. If the reach is too long, overheating and engine damage may result. If the reach is too short, spark plug fouling and poor p...

  • Page 53: Caution:

    8-6 ess54500 throttle cable adjustment caution: be sure the engine idle speed is adjusted first. 1. Loosen the adjuster locknut. 2. Turn the adjuster in or out until proper throttle lever free play is achieved. Throttle lever free play 1 : 1.0 ~ 2.0 mm (0.04 ~ 0.08 in) 2 locknut 3 adjuster 3. Tighte...

  • Page 54: Caution:

    8-7 ess55402 carburetor adjustment caution: • be sure this adjustment is serviced by a yamaha dealer. • be sure the carburetor silencer is installed during running to prevent engine damage. Under some operating conditions the carburator setting may have to be changed due to air temperature changes, ...

  • Page 55: Warning

    8-8 main jet replacement replace the main jet according to the setting chart which is available at an authorized yamaha dealer. Warning • never remove the drain plug or the float chamber while the engine is hot. Fuel will flow out from the float chamber which could ignite and cause injury. • place a...

  • Page 56: Caution:

    8-9 ess58401 high altitude adjustments operating at high altitude reduces the performance of a gasoline engine, about 3% for every 305 m (1000 ft) of elevation. This is because there is less air as altitude increases. Less air means less oxygen available for com- bustion. Your snowmobile can be adju...

  • Page 57: Warning

    8-10 ess63200 fan belt deflection check 1. Remove the fan cover. 2. Measure the fan belt deflection by applying 50 n {5 kg (11 lb)} of force at the center of belt. 1 deflection 2 50 n {5 kg (11 lb)} standard belt deflection: 8 mm (0.31 in)/50 n {5 kg (11 lb)} if the deflection exceeds the specificat...

  • Page 58

    8-11 note: apply the parking brake before replacement. 1. Remove the drive v-belt guard. 2. Rotate the secondary sliding sheave clockwise 1 and push 2 it so that it separates from the fixed sheave. 3. Pull 3 the belt up over the secondary fixed sheave. 4. Remove the belt from the secondary sheave an...

  • Page 59: Warning

    8-12 7. Tighten each adjusting bolt. Adjusting bolts tightening torque: 10 nm (1.0 m·kg, 7.2 ft·lb) 8. Install the v-belt over the primary sheave. 9. Rotate the secondary sliding sheave clockwise 7 and push 8 it so that it separates from the fixed sheave. 10. Install the belt 9 between the secondary...

  • Page 60: Warning

    8-13 ess66901 drive chain housing oil level checking warning the engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair. 1. Place the machine on a level surfa...

  • Page 61: Warning

    8-14 chain tension adjustment 1. Loosen the locknut. 2. Turn the adjuster bolt clockwise until it is finger-tight. 3. Hold the adjuster bolt in place while tightening the chain adjuster locknut. 1 locknut 2 adjuster bolt 807-042 ess61000 brake checking pad wear check the brake pads for wear. If the ...

  • Page 62: Warning

    8-15 ess61200 brake fluid replacement brake fluid replacement is necessary when the following components are replaced during the periodic maintenance or if they are damaged or leaking. A. All rubber seals of the master cylinder and caliper cylinder b. The brake system hose warning be sure the brake ...

  • Page 63: Warning

    8-16 ess67000 suspension the suspension can be adjusted to suit rider preference. A softer setting, for example, may provide greater rider comfort, while a stiffer setting may allow more precise handling and control over certain types of terrain or riding conditions. Warning be sure this adjustment ...

  • Page 64: Warning

    8-17 d 820-062a 1 2 3 4 5 6 7 softer harder 4 spring adjuster position preload Î standard (rear) ess68010 rear suspension spring preload the spring preload can be adjusted by turning the adjuster 1 . Warning be sure this adjustment is made by a yamaha dealer. Pz500 1 2 3 4 5 softer harder 2 spring a...

  • Page 65: Caution:

    8-18 820-065 note: be sure to make this adjustment when there is no load (rider or cargo) on the snowmobile. 1. Loosen the nut 1 1/2 or 3/4 turns, while holding the adjusting bolt 2 securely with a wrench so it does not move. Caution: never allow the adjusting bolt 2 to move while loosen- ing the nu...

  • Page 66: Warning

    8-19 ess59801 track adjustment warning a broken track, track fittings, or 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 rai...

  • Page 67: Warning

    8-20 track adjustment warning • be sure this adjustment is made by a yamaha dealer. • support the machine securely on a suitable stand before working underneath the machine. • operate the engine in a well-ventilated area. 1. Lift the rear of the machine onto a suitable stand to raise the track off t...

  • Page 68: Caution:

    8-21 caution: the adjusters should be turned an equal amount. 6. Recheck alignment and deflection. If necessary, repeat steps 3 to 5 until the proper adjustment is achieved. 7. Tighten the rear axle nut. Rear axle tightening torque: 75 nm (7.5 m·kg, 54.2 ft·lb) ess62900 ski alignment 1. Turn the han...

  • Page 69: Caution:

    8-22 819-040 caution: be sure the small gap 1 side of the holder faces forward 2 . 845-063 819-070 esu00236 handlebar adjustment (pz500ml) 1. Remove the handlebar cover 1 . 2. Loosen the handlebar bolts. 3. Move the handlebar up or down (± 7°) to adjust the handlebar height to the desired position. ...

  • Page 70: Warning

    8-23 ess66601 lubrication lubricate the following points. Lubricant: low-temperature grease 1 throttle cable ends warning apply a dab of grease onto the cable end only. Do not grease the brake/throttle cables themselves because they could become frozen, which could cause loss of control. 2 front sus...

  • Page 71: Warning

    8-24 ess64501 headlight bulb replacement 1. Lift up the shroud. 2. Disconnect the lead coupler. 3. Remove the bulb cover. 4. Remove the bulb holder by depressing and turning it counterclockwise. 1 bulb cover 5. Remove the bulb. Warning keep flammable products or your hands away from the hot bulb unt...

  • Page 72: Caution:

    8-25 830-002 ess65800 battery (vt500xl) replenishing the battery fluid 1. Check the fluid level. The level should be between the upper and lower level marks. 1 upper level 2 lower level 2. Add only distilled water if necessary. Caution: normal tap water contains minerals which are harmful to a batte...

  • Page 73: Warning

    8-26 ess65900 fuse replacement (vt500xl) warning be sure to use the specified fuse. A wrong fuse will cause electrical system damage and can be a fire hazard. Caution: be sure the main switch is turned off to prevent accidental short circuiting. 1. Lift up the shroud. 2. Replace the blown fuse with ...

  • Page 74: Troubleshooting

    9-1 816-022 3. Compression insufficient • loose cylinder head nuts ... Tighten nuts properly. • damaged gasket ... Replace gasket. • worn out piston and cylinder ... Consult dealer. B. Engine does not turn over with manual starter 1. Seized engine ... Seizure is caused by poor lubrication, inadequat...

  • Page 75

    9-2 f. Machine does not move 1. Clutch malfunction ... Consult dealer. 2. Drive track does not move ... Foreign object is caught in track, or slide runner has melted to track metal due to lack of lubrication. 3. Drive chain too tight, too loose, or broken ... Consult dealer. G. Drive belt twists 1. ...

  • Page 76: Storage

    10-1 ess70303 storage long term storage, requires some preven- tive procedures to guard against deteriora- tion. 1. Cleaning thoroughly clean the machine, inside and out, to remove the corrosive salts and acids that can accumulate. Use yamaha mud and grease release, or an equivalent, to loosen mud, ...

  • Page 77: Caution:

    10-2 caution: do not charge battery quickly. Charge for 10 hours at 1.6 amperes. 7. Track loosen the track, and block up the chassis so that the track is suspended above the ground. 8. Drive belt remove the drive belt and store sepa- rately. 9. Storage store the machine in a dry, well-venti- lated p...

  • Page 78: Specifications

    11-1 esg73000 specifications ess73200 dimensions pz500/pz500ml/vt500xl overall length overall width overall height dry weight ski tread 2760 mm (108.7 in): pz500 2970 mm (116.9 in): pz500ml/vt500xl 1200 mm ( 47.2 in): pz500/vt500xl 1120 mm ( 44.1 in): pz500ml 1230 mm ( 48.4 in): pz500/pz500ml 1330 m...

  • Page 79

    11-2 pz500/pz500ml/vt500xl ess77200 chassis molded rubber, fiber glass rod reinforced 381 mm (15.0 in) 25 ~ 30 mm (0.98 ~ 1.18 in)/ 100 n {10 kg (22 lb)}: pz500/vt500xl 20 ~ 25 mm (0.79 ~ 0.98 in)/ 100 n {10 kg (22 lb)}: pz500ml 752 mm (29.6 in): pz500 944 mm (37.2 in): pz500ml/vt500xl slide rail su...

  • Page 80

    11-3 ess78100 electric pz500/pz500ml/vt500xl ignition system spark plug type gap battery capacity maximum charge rate headlight bulb × quantity tail/brake light bulb × quantity meter light bulb × quantity indicator light bulb × quantity cdi br9es (ngk) 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) yb16al-a2/12 v ...

  • Page 81: Wiring Dia

    12-1 wiring dia gram a main harness head light b main harness sub harness c sub harness cord tail light d main harness wire sub lead lg y br /b yg l r /bb br w bl y /b w y /b br yb w /g w /r w /r w /g l g /y b l g /y b l g /y b b r /b gy br y /w b /r y /w b /r l g /y b y /r y /b g /r l b r r /w b r ...

  • Page 82

    12-2 1 cdi magneto 2 rectifier/regulator 3 fuse (vt500xl) 4 starter relay (vt500xl) 5 battery (vt500xl) 6 starter motor (vt500xl) 7 main switch 8 engine stop switch 9 accel switch 0 carburetor switch a cdi unit b ignition coil c spark plug d ground e voltage regulator f variable resistor g thumb war...

  • Page 83: Own

    Own lit-126 printed in japan 99 · 4 - 1.8 × 4 cr printed on recycled paper.