Yamaha Phazer Series PZ480P, PZ480R, PZ480T, PZ480W Service & Supplementary Service Manual, snowmobile 1989-1998

Yamaha Phazer PZ480 Series Service & Supplementary Manual - 1989-1998

This factory-authorized technical documentation serves as the primary reference for the maintenance and overhaul of the Yamaha Phazer series equipped with the 485cc axial fan-cooled two-stroke engine. It integrates critical synchronization data for Mikuni B38-32 dual carburetors and precise T.S.S. front suspension alignment specs to ensure factory-level handling. A vital maintenance insight for drivetrain longevity is the mandatory secondary sheave twist angle of 70° (PZ480/E) or 80° (PZ480ST); failure to set this preload correctly results in immediate shift performance degradation and accelerated V-belt thermal fatigue.

Technical Applicability & Serial Ranges

1995-1998 "W" Generation (LIT-12618-01-68)

• PZ480W (Phazer) | Starting Serial: 8BF-007101~
• PZ480EW (Phazer E) | Starting Serial: 8BG-009101~
• PZ480STW (Phazer ST) | Starting Serial: 8BH-006101~

1992-1994 "T" Generation (LIT-12618-01-47)

• PZ480T (Phazer II) | Starting Serial: 8AK-000101~
• PZ480ET (Phazer II LE) | Starting Serial: 8AL-000101~
• PZ480STT (Phazer II ST) | Starting Serial: 8AM-000101~

1990-1991 "R" Generation (LIT-12618-01-30)

• PZ480R (Phazer II) | Starting Serial: 88F-000101~
• PZ480ER (Phazer II LE) | Starting Serial: 88H-000101~
• PZ480STR (Phazer II ST) | Starting Serial: 88X-000101~

1989 "P" Base Generation (LIT-12618-01-23)

• PZ480P (Phazer) | Starting Serial: 87F-000101~
• PZ480EP (Phazer Deluxe) | Starting Serial: 87H-000101~

Operational Parameters & Asset Protection

• Ensures drivetrain reliability with precise V-belt wear limits (32 mm) and secondary sheave free play specs (1.0–2.0 mm).
• Facilitates high-altitude optimization through official jetting charts and clutch weight configurations.
• Safeguards structural components by enforcing strict torque sequences for the primary sheave (Initial 120 Nm, Final 60 Nm).

Document Metadata

• Print No: LIT-12618-PZ-50 (Combined Collection)
• Page Count: 175
• Document Type: PDF Service & Supplementary Manual

System Architecture & Factory Benchmarks

The documentation defines the engineering benchmarks for the 485cc parallel twin, specifying a 7.0:1 compression ratio and ignition timing of 16° B.T.D.C. at 7,000 r/min. For internal engine calibration, technicians must adhere to the piston-to-cylinder clearance of 0.045–0.050 mm and the cylinder head warp limit of 0.03 mm. Electronic diagnostics are supported by specific component values, including a grip warmer resistance of 0.8 Ω and dedicated CDI magneto output frequencies.

Visual Navigation Aids & Diagnostic Support

• Technical Exploded Views: Detailed schematics of the crankshaft assembly, primary/secondary sheaves, and the slide rail rear suspension.
• Electrical Schematics: Comprehensive wiring diagrams for manual and electric start (ER/EW) variants, including the T.O.R.S. (Throttle Override System).
• Tuning Matrices: Altitude-based gear ratio tables (16T to 22T sprockets) and Mikuni carburetor compensation graphs.

Table of Contents

• General Information: Machine ID, Special Tools, and Storage Specs.
• Periodic Inspections: Maintenance Intervals, Belt Inspection, and Engine Sync.
• Power Train: Sheave Overhaul, Chain Housing Service, and Track Tension.
• Engine Overhaul: Disassembly, Inspection, and Precision Reassembly.
• Carburetion: Mikuni B38-32 Tuning and Fuel Pump Diagnostics.
• Electrical: CDI Ignition, Charging Systems, and Starter Motor Service.
• Appendices: Global Torque Charts and Cable Routing Diagrams.

Operational Limits & Specifications

• Standard Idle Speed: 1,500–1,700 r/min
• Spark Plug Gap (NGK BR9ES): 0.7–0.8 mm (0.028–0.031 in)
• Chain Case Lubricant: API GL-3 SAE #75 or #80 (0.25 L capacity)
• Slide Rail Wear Limit: 10 mm (0.39 in) minimum thickness
• Primary Sheave Spider (Left-Hand Thread): 200 Nm (145 ft-lb)