1984-1989 Yamaha Snowmobile Clymer Repair Service Workshop Manual

Description

456 page, 1984-1989 Yamaha Snowmobile Clymer Repair Service Workshop Manual This Clymer Yamaha Snowmobile 1984-1989 Shop Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1984-1989 Yamaha PZ480 and 1987-1989 Yamaha EX570 snowmobiles.

 

Yamaha snowmobile repair topics covered include general information, troubleshooting, lubrication, maintenance and tune-up, engine, fuel and exhaust system, electrical system, oil injection system, liquid cooling system, recoil starter, drive system, disk brake, chaincase, jackshaft and driveshaft, front suspension and steering, track and rear suspension, off-season storage, and wiring diagrams..

 

QUICK REFERENCE DATA

 

CHAPTER ONE, GENERAL INFORMATION

 

Manual organization, Notes, cautions and warnings, Safety first, Service hints, Engine and chassis serial numbers, Engine operation, Torque specifications, Fasteners, Lubricants, RTV gasket sealant, Threadlock, Basic hand tools, Precision measuring tools, Special tools, Mechanic’s tips, Ball bearing replacement, Oil seals, Snowmobile operation, Snowmobile safety, Snowmobile code of ethics

 

CHAPTER TWO, TROUBLESHOOTING

 

Operating requirements, Troubleshooting instruments, Ignition system (1984 PZ480H) , Ignition system (1984 PZ480SEH) , Ignition system (1985-on PZ480 and EX570) , Battery charging system (PZ480 and EX570 with electric start) , Lighting system, Electric starting system, Fuel system, Engine, Two-stroke pressure testing, Power train, Skis and steering, Track assembly

 

CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP

 

Pre-ride checks, Break-in procedure, Lubrication, Maintenance, Engine tune-up

 

CHAPTER FOUR, HIGH-ALTITUDE AND REAR SUSPENSION ADJUSTMENT

 

High-altitude carburetor tuning, High-altitude clutch tuning, Gearing, Suspension adjustment

 

CHAPTER FIVE, ENGINE (PZ480)

 

Engine lubrication, Service precautions, Serial numbers, Servicing engine in frame, Engine, Engine top end, Cylinder, Piston, wrist pin and piston rings, Reed valve assembly, Cooling fan, Drive gear unit, Crankcase and crankshaft

 

CHAPTER SIX, ENGINE (EX570)

 

Engine lubrication, Service precautions, Serial numbers, Servicing engine in frame, Engine, Engine top end, Cylinder, Piston, wrist pin and piston rings, Crankcase and crankshaft

 

CHAPTER SEVEN, FUEL AND EXHAUST SYSTEMS

 

Air box, Carburetor (PZ480 and 1987 EX570) ,  Carburetor (1988-on EX570) ,  Fuel pump (PZ480) , Fuel pump (EX570) , Fuel tank, Exhaust system, Exhaust system repair

 

CHAPTER EIGHT, ELECTRICAL SYSTEM

 

Battery, Battery charging system (PZ480 and EX570 with electric start) , Electric starting system, Capacitor discharge ignition (CDI) ,  Ignition coil, Ignition unit, Rectifier, Voltage regulator, Switches, Instrument panel warning light check (EX570) ,  Oil level gauge testing (EX570) , Thermoswitch testing, Throttle override system (1985-on) , Hand warmer assembly, Lighting system, Meter assembly, Fuses, Wiring diagrams

 

CHAPTER NINE, OIL INJECTION SYSTEM

 

System components, Oil pump service, Component replacement

 

CHAPTER TEN, LIQUID COOLING SYSTEM

 

Thermostat, Water pump, Heat exchanger, Hoses

 

CHAPTER ELEVEN, RECOIL STARTER

 

CHAPTER TWELVE, DRIVE SYSTEM

 

Drive unit, Primary sheave assembly, Secondary sheave, Drive belt, Primary sheave service, Secondary sheave service

 

CHAPTER THIRTEEN, BRAKE, CHAINCASE, JACKSHAFT AND DRIVESHAFT

 

Drive chain and sprockets, Chaincase, brake caliper and jackshaft, Driveshaft

 

CHAPTER FOURTEEN, FRONT SUSPENSION AND STEERING

 

Skies, Front suspension (PZ480) , Front suspension (EX570) , Steering assembly (PZ480) ,  Steering assembly (EX570)

 

CHAPTER FIFTEEN, TRACK AND REAR SUSPENSION

 

Rear suspension, Slide runner, Rear shock absorbers, Front pivot arm, Rear pivot arm, Suspension and guide wheels, Track

 

CHAPTER SIXTEEN, OFF-SEASON STORAGE

 

INDEX

 

WIRING DIAGRAMS