Yamaha PZ500C VT500XLC Service Repair Manual – PDF DOWNLOAD
DESCRIPTION:
Yamaha PZ500C VT500XLC Service Repair Manual – PDF DOWNLOAD
FOREWORD:
- This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanics education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical concepts and procedures inherent in snowmobile repair.
- Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
MANUAL FORMAT:
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g.,
- Bearings
Pitting/Damage ® Replace.
TABLE OF CONTENTS:
Yamaha PZ500C VT500XLC Service Repair Manual – PDF DOWNLOAD
MACHINE IDENTIFICATION 1-1
FRAME SERIAL NUMBER 1-1
ENGINE SERIAL NUMBER 1-1
IMPORTANT INFORMATION 1-2
PREPARATION FOR REMOVAL AND
DISASSEMBLY1-2
ALL REPLACEMENT PARTS1-2
GASKETS, OIL SEALS,
AND O-RINGS1-3
LOCK WASHERS/PLATES AND
COTTER PINS1-3
BEARINGS AND OIL SEALS1-3
CIRCLIPS1-3
LOCTITEâ1-3
SPECIAL TOOLS 1-4
FOR TUNE UP1-4
FOR ENGINE SERVICE1-4
FOR POWER TRAIN SERVICE 1-5
FOR CARBURETION SERVICE 1-6
FOR ELECTRICAL SERVICE 1-6
CHAPTER 2
PERIODIC INSPECTIONS AND
ADJUSTMENTS
INTRODUCTION 2-1
PERIODIC MAINTENANCE TABLE 2-1
ENGINE 2-3
SPARK PLUGS2-3
OIL PUMP2-4
FUEL LINE INSPECTION 2-5
COOLING FAN BELT INSPECTION 2-6
CARBURETOR SYNCHRONIZATION2-9
ENGINE IDLE SPEED ADJUSTMENT 2-10
THROTTLE CABLE FREEPLAY
ADJUSTMENT 2-11
THROTTLE OVERRIDE SYSTEM
(TORS) CHECK2-12
STARTER (CHOKE) CABLE
FREEPLAY ADJUSTMENT2-13
EXHAUST SYSTEM INSPECTION 2-13
POWER TRAIN 2-14
SHEAVE DISTANCE AND OFFSET
ADJUSTMENT 2-14
DRIVE V-BELT 2-16
ENGAGEMENT SPEED CHECK2-18
PARKING BRAKE PAD INSPECTION 2-18
PARKING BRAKE ADJUSTMENT 2-18
BRAKE FLUID LEVEL INSPECTION2-19
BRAKE PAD INSPECTION 2-19
BRAKE HOSE INSPECTION 2-20
AIR BLEEDING
(HYDRAULIC BRAKE SYSTEM)2-20
DRIVE CHAIN2-21
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 CHARGING2-32
TUNING2-33
CARBURETOR TUNING 2-33
CLUTCH2-39
GEAR SELECTION 2-41
HIGH ALTITUDE TUNING 2-44
FRONT SUSPENSION2-45
REAR SUSPENSION 2-45
CHAPTER 3
CHASSIS
STEERING 3-1
INSPECTION 3-3
INSTALLATION3-4
SKI 3-6
INSPECTION 3-7
FRONT SUSPENSION3-8
INSPECTION 3-9
INSTALLATION 3-10
CHAPTER 4
POWER TRAIN
PRIMARY SHEAVE AND DRIVE V-BELT4-1
REMOVAL4-3
DISASSEMBLY4-3
INSPECTION 4-4
ASSEMBLY 4-6
INSTALLATION4-8
SECONDARY SHEAVE 4-9
DISASSEMBLY 4-11
INSPECTION4-11
ASSEMBLY 4-12
INSTALLATION 4-14
DRIVE CHAIN HOUSING 4-16
WITHOUT REVERSE MODEL 4-16
INSPECTION4-17
INSTALLATION 4-18
WITH REVERSE MODEL 4-19
INSPECTION4-21
INSTALLATION 4-22
JACKSHAFT 4-23
INSPECTION4-24
JACKSHAFT AND DRIVE CHAIN
HOUSING INSTALLATION 4-25
BRAKE4-26
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
INSPECTION4-34
BRAKE MASTER CYLINDER
ASSEMBLY 4-34
SLIDE RAIL SUSPENSION 4-35
PZ500 4-35
VT500XL4-36
INSPECTION4-41
FRONT AXLE AND TRACK 4-42
INSPECTION4-43
INSTALLATION 4-43
CHAPTER 5
ENGINE
EXHAUST ASSEMBLY5-1
INSPECTION 5-2
INSTALLATION5-2
ENGINE ASSEMBLY 5-3
INSTALLATION5-4
CYLINDER HEAD AND CYLINDER 5-5
REMOVAL5-7
INSPECTION 5-8
INSTALLATION 5-13
OIL PUMP, CDI MAGNETO, CRANKCASE
AND CRANKSHAFT 5-15
REMOVAL 5-16
INSPECTION5-16
INSTALLATION 5-18
ENGINE COOLING FAN 5-20
REMOVAL 5-21
INSPECTION5-21
INSTALLATION 5-23
RECOIL STARTER 5-24
REMOVAL 5-25
INSPECTION5-25
INSTALLATION 5-26
CHAPTER 6
CARBURETION
CARBURETORS 6-1
REMOVAL6-4
DISASSEMBLY6-4
INSPECTION 6-5
ASSEMBLY 6-6
INSTALLATION6-7
FUEL PUMP 6-9
INSPECTION6-10
INSTALLATION 6-10
CHAPTER 7
ELECTRICAL
SWITCH INSPECTION7-1
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 PLUG7-14
THROTTLE OVERRIDE SYSTEM
(TORS)7-14
HANDLEBAR SWITCH (RIGHT)7-15
CARBURETOR SWITCH 7-15
MAIN SWITCH 7-16
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
GRIP WARMER SYSTEM7-26
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 TRAIN8-6
CHASSIS 8-9
ELECTRICAL8-10
HIGH ALTITUDE SETTINGS 8-12
PZ500/VT500XL 8-12
TIGHTENING TORQUE 8-13
CABLE ROUTING 8-17
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
Bowen Alistair –
Quick and easy to understand