2006 Yamaha PZ50 Snowmobile - Service Manual for PZ50W, PZ50GTW, PZ50FXW, PZ50MW, PZ50VTW, PZ50MPW 2007

Yamaha PZ50 Phazer & Venture Lite Service & Repair Manual - 2006-2007

This professional-grade technical document provides factory-precision repair and maintenance procedures for the Yamaha PZ50 series. By utilizing these step-by-step instructions, owners and technicians can ensure peak machine performance, maintain critical safety standards, and significantly reduce operational downtime through accurate diagnostics.

Model Range & Hardware Coverage

This manual provides verbatim coverage for the following models:

• Yamaha PZ50W (2006-2007)
• Yamaha PZ50GTW (2006-2007)
• Yamaha PZ50FXW (2006-2007)
• Yamaha PZ50MW (2006-2007)
• Yamaha PZ50VTW (2006-2007)
• Yamaha PZ50MPW (2006-2007)
• Trade Names Included: Phazer, Phazer GT, Phazer FX, Phazer Mountain Lite, Venture Lite, and Multi Purpose.
• Engine Architecture: 499cc Liquid-cooled, 4-stroke, DOHC, parallel 2-cylinder high-performance powerplant.

Service Advantages

• Precision Calibration: Exact specifications for throttle body synchronization and valve lash adjustments to maintain engine efficiency.
• Enhanced Longevity: Detailed wear limit tables for slide runners, brake pads, and drive tracks prevent premature component failure.
• Safety Assurance: Strict testing protocols for the Throttle Override System (T.O.R.S.) and braking systems to protect operators and bystanders.
• Pro-Grade Troubleshooting: Rapid electrical fault isolation through circuit diagrams and resistance values for sensors and ignition coils.

Documentation Scope

• Total Depth: Comprehensive 9-chapter service volume covering every mechanical and electrical system.
• Official Form Numbers: LIT-12618-02-58 / 8GC-28197-10.
• Format: Sequential, step-by-step instructions with integrated fault-correction arrows (e.g., Pitting → Replace).

Technical Identification & Factory Standards

Serial Number Locations:

• Frame VIN: Stamped on the right-hand side of the frame, positioned immediately below the front of the seat.
• Engine ID: Located on the left-hand side of the crankcase assembly.

Factory Specifications (Proof of Depth):

• Valve Clearance (Cold): Intake: 0.11–0.20 mm | Exhaust: 0.21–0.25 mm.
• Standard Compression: 1,450 kPa (206 psi) at 400 r/min at sea level.
• Spark Plug Gap: 0.6–0.7 mm (0.024–0.028 in) for NGK CR9EKB.
• Fuel Injection Pressure: Constant 300 kPa (42.7 psi) regulated.
• Idle Speed: Target range of 1,700–1,900 r/min.

Diagnostic & Visual Integration

• Exploded Views: High-resolution diagrams preceding every disassembly section for rapid part orientation.
• Electrical Schematics: Full-page wiring diagrams for 2007 PZ50, PZ50GT, FX, M, VT, and MP variants.
• System Routing: Visual guides for cable, harness, and hose routing to prevent interference and heat damage.
• Fault Codes: Complete ECU self-diagnostic tables including code "84" for T.O.R.S. activation.

Detailed Table of Contents

• Chapter 1: General Information (Identification, Special Tools, Preparation)
• Chapter 2: Periodic Inspection and Adjustment (Maintenance Charts, Tuning, Engine/Chassis setup)
• Chapter 3: Chassis (Steering, Skis, Front Suspension, Cowlings)
• Chapter 4: Power Train (Primary/Secondary Sheaves, Drive Chain, Brake System, Track)
• Chapter 5: Engine (Cylinder Head, Camshafts, Valves, Oil Pump, Crankcase, Pistons)
• Chapter 6: Cooling System (Radiator, Thermostat, Water Pump)
• Chapter 7: Fuel Injection System (ECU, Sensors, Diagnostic Mode, Injectors)
• Chapter 8: Electrical (Ignition, Starting System, Charging, Lighting, Grip Warmers)
• Chapter 9: Specifications (Torque Values, Clearances, Tightening Sequences)

Professional Utility

• Wear Limit Data: Includes specific tolerances such as 10.5 mm slide runner limit and 4.7 mm brake pad wear threshold to ensure component reliability and factory-grade performance.