Yamaha PZ500/DX, VT500XL/LT, Phazer & Venture XL Snowmobile Service Manual (1999) - Diagnostic & Repair Procedures
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Sample pages from the Yamaha PZ500/DX, VT500XL/LT, Phazer & Venture XL Snowmobile Service Manual (1999) - Diagnostic & Repair Procedures manual
Purchase Information
Technical Specifications
- Document Number / Seller:
- 28211 / Sarah Campbell
- File Size:
- 5.50 MB
- File Type:
- Language:
- English
- Pages:
- 354
- Printable:
- Yes
- Estimated Download Time:
- 0.11 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Snowmobile
- Brand:
- Yamaha
- Reviewed and Approved:
- Jan 2, 2026
Yamaha Models and Parts Covered in this Snowmobile Manual
- Yamaha PZ500 (1999)
- Yamaha PZ500DX (1999)
- Yamaha VT500XL (1999)
- Yamaha VT500LT (1999)
- Yamaha Phazer (1999)
- Yamaha Phazer Deluxe (1999)
- Yamaha Phazer 500 (1999)
- Yamaha Phazer 500 Deluxe (1999)
- Yamaha Venture (1999)
- Yamaha Venture 500 XL (1999)
- Yamaha Venture XL (1999)
- Yamaha Venture 500 (1999)
Complete Manual Information
Yamaha PZ500 & VT500 Series Snowmobile Service Manual - 1999
This factory-issued service manual provides the definitive engineering framework for the maintenance and overhaul of Yamaha 485cc air-cooled powerplants and Proaction chassis systems. Integrated into this documentation is the critical requirement for secondary sheave offset calibration, where a variance of just 1.0 mm (0.04 in) can dictate the longevity of the drive V-belt and the efficiency of power transfer to the track. Adherence to these factory-specified tolerances ensures peak operational reliability and prevents catastrophic drivetrain failure during high-load maneuvers.
Machine Identification & Technical Applicability
Technical coverage is stratified by chassis configuration and transmission variant to ensure precise part selection and adjustment data.
Standard 485cc Fan-Cooled Series (1999)
- Model PZ500 (Phazer): Base chassis configuration featuring manual recoil starting and standard drive chain housing.
- Model PZ500DX (Phazer Deluxe): Premium trim utilizing electric start integration and specific electrical harness routing.
Extended Track & Utility Series (1999)
- Model VT500XL (Venture XL): Long-track chassis equipped with high-capacity fuel systems and reverse transmission gearsets.
- Model VT500LT (Venture 500): Specific high-altitude calibrated variants designed for utility and deep snow operation.
Operational Parameters & Service ROI
- Factory Precision: Direct access to the 200 Nm (145 ft lb) spider torque specification eliminates guesswork during primary sheave rebuilding, maintaining rotational balance.
- Service Efficiency: Illustrated symbols and thumb-tab indexing allow technicians to transition rapidly between carburetion tuning and electrical troubleshooting.
- Safety Compliance: Specific procedures for the Throttle Override System (T.O.R.S.) check and hydraulic brake bleeding ensure the vehicle meets factory safety benchmarks.
Engineering Metadata
- Document Type: Service Manual
- Technical Revision: OS042 / 0E031
- Engine Displacement: 485 cm³ Air-Cooled 2-Stroke
- Applicable Model Year: 1999
System Calibration & Factory Benchmarks
Reliability is maintained through strict adherence to internal clearances and pressure thresholds. The engine architecture requires a piston-to-cylinder clearance of 0.045–0.050 mm (0.0018–0.0020 in), while the crankshaft deflection must remain below 0.03 mm (0.0012 in) at the center journals to prevent harmonic vibration.
System Architecture & Navigation Aids
The manual utilizes exploded views with 24 distinct illustrated symbols to identify lubricant points, locking agent requirements (Loctite), and mandatory replacement components like circlips and cotter pins. These visual aids ensure that reassembly follows factory protocols for torque and lubrication.
Table of Contents
- Chapter 1: General Information (Machine ID, Special Tools, Consumables)
- Chapter 2: Periodic Inspection and Adjustment (Maintenance Table, Engine, Power Train, Chassis)
- Chapter 3: Chassis (Steering, Ski, Front Suspension, Leading Arm)
- Chapter 4: Power Train (Primary Sheave, Secondary Sheave, Chain Housing, Brake)
- Chapter 5: Engine Overhaul (Cylinder Head, CDI Magneto, Crankcase, Crankshaft)
- Chapter 6: Carburetion (Mikuni B38-32/2 Disassembly and Tuning)
- Chapter 7: Electrical (Starting System, Ignition, Lighting, Grip Warmers)
- Chapter 8: Specifications (Torque Sequences, High Altitude Settings, Cable Routing)
Operational Limits & Specifications
- Engine Idle Speed: 1,300 ± 100 r/min
- Spark Plug Type / Gap: NGK BR9ES / 0.7–0.8 mm (0.028–0.031 in)
- Oil Tank Capacity: 3.3 L (3.5 US qt) YAMALUBE 2-cycle oil
- Brake Fluid Type: DOT 4 Hydraulic
- Drive Chain Housing: 0.25 L (8.45 US oz) SAE #75 or #80 Gear Oil (API GL-3)
- Track Deflection: 25–30 mm (0.98–1.18 in) under 10 kg (22 lb) force
Download Instructions for Yamaha Snowmobile Manual
Frequently Asked Questions - Yamaha Snowmobile Manual
Is this manual suitable for beginners?
Yes, this Yamaha manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Snowmobile maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (5.50 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Yamaha Snowmobile manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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