Yamaha PZ500D User manual

OWNER’S MANUAL
SNOWMOBILE
PZ500D
PZ500MLD
VT500XLD
8DJ-28199-11LIT-12628-02-08
NTED IN JAPAN
4 -1.8 ×4 CR

ESS03100
MACHINE IDENTIFICATION
Identification numbers record
A. FRAME NUMBER:
B. ENGINE NUMBER (PRIMARY I.D.):
C. KEY NUMBER:
Record your frame number, engine number (Primary I.D.)
and key number in the spaces provided, to assist you in
ordering spare parts from your Yamaha dealer.
1The frame number is the nine-digit number stamped
on the frame of the machine. (See Fig. Å)
2The model code number is the first three digits of the
frame number. (See Fig. Å)
3The engine number is stamped in the location as
shown. (See Fig. ı)
4Key number (See Fig. Ç)
Also, record and keep these I.D. numbers in a separate
place in case your machine is stolen.
B
C
A
861-001
860-002
861-015

ESS00000 INTRODUCTION
Congratulations! Your choice of a Yamaha snowmobile
assuresyouofthehighestqualityanddependability.Your
Yamahasnowmobile is manufactured bya company well-
knownforexcellenceinthefieldofsnowmobiles.Themost
advanced production equipment and technology have
made Yamaha one of the best machine manufacturers.
Weare confident that this snowmobilewill meet the great-
est expectations of our customers. This manual is de-
signed to acquaint you with the operation of this snowmo-
bile and minor maintenance required for satisfactory ser-
vice.
Should major repairs ever be required, you are advised to
consult a nearby Yamaha dealer who has the techniques,
tools and parts to ensure your satisfaction. We hope that
theinformationwithinthisbookletwillhelpyouenjoymany
hours of pleasure with your Yamaha snowmobile.
PZ500D
PZ500MLD
VT500XLD
OWNER’S MANUAL
©1999 by Yamaha Motor
Corporation, U.S.A.
1st Edition, April 1999
All rights reserved.
Any reprinting or
unauthorized use without
the written permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in Japan
P/N LIT-12628-02-08

WARNING
PLEASE READ AND UNDERSTAND THIS MANUAL
COMPLETELY BEFORE OPERATING THE MACHINE.
NOTE:
•Yamaha continually seeks advancements in product
design and quality. Therefore, while this manual con-
tains the most current product information available at
the time of printing, there may be minor discrepancies
between your machine and this manual. If there is any
question concerning this manual, please consult your
Yamaha dealer.
•Thismanual should beconsidered a permanent part of
thismachineandshouldremainwiththismachinewhen
resold.
Particularly important information is distinguished in this
manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in
severe injury or death to the machine operator, a by-
stander, or a person inspecting or repairing the machine.
CAUTION:
A CAUTION indicates special precautions that must be
taken to avoid damage to the machine.
NOTE:
A NOTE provides key information to make procedures
easier or clearer.
851-005

ESS01300 CONTENTS
YAMAHA MOTOR CORPORATION,
U.S.A. SNOWMOBILE LIMITED
WARRANTY ........................................ 1-1
YAMAHA EXTENDED SERVICE
(Y.E.S.).................................................1-4
LOCATION OF THE IMPORTANT
LABELS............................................... 2-1
SAFETY INFORMATION..................... 3-1
DESCRIPTION..................................... 4-1
CONTROL FUNCTIONS ..................... 5-1
MAIN SWITCH................................... 5-1
STARTER LEVER (CHOKE) ............. 5-2
THROTTLE LEVER ........................... 5-2
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) .......................................... 5-3
OIL LEVEL WARNING LIGHT........... 5-3
ENGINE STOP SWITCH ...................5-4
BRAKE LEVER.................................. 5-4
PARKING BRAKE LEVER................. 5-5
V-BELT GUARD ................................ 5-5
V-BELT HOLDER .............................. 5-5
SHROUD LATCH .............................. 5-6
HEADLIGHT BEAM SWITCH............ 5-6
GRIP WARMER CONTROL KNOB... 5-7
PASSENGER GRIP WARMER
SWITCH (VT500XL) .......................... 5-7
TRIP ODOMETER RESET KNOB..... 5-7
DRIVE SELECT LEVER
(SHIFT LEVER) (VT500XL)............... 5-8
SPARK PLUG HOLDER.................... 5-8
LUGGAGE BOX ................................5-8
BACKREST (VT500XL) ..................... 5-9
PRE-OPERATION CHECKS ............... 6-1
FUEL..................................................6-1
ENGINE OIL ......................................6-2
THROTTLE LEVER ........................... 6-2
MANUAL STARTER .......................... 6-2
THROTTLE OVERRIDE SYSTEM
(T.O.R.S.) CHECK............................. 6-2
BRAKE............................................... 6-3
BRAKE FLUID LEAKAGE ................. 6-4
V-BELT .............................................. 6-4
DRIVE V-BELT GUARD .................... 6-4
DRIVE TRACK................................... 6-5
38-mm (1.5-in) HIGH-PROFILE PAT-
TERN DRIVE TRACK (PZ500ML)..... 6-5
SLIDE RUNNERS.............................. 6-6
STEERING SYSTEM......................... 6-6
SKI/SKI RUNNER.............................. 6-7
LIGHTS.............................................. 6-7
BATTERY (VT500XL)........................ 6-7
FITTINGS/FASTENERS.................... 6-8
SERVICE TOOLS AND SPARE
PARTS............................................... 6-8
OPERATION........................................ 7-1
STARTING THE ENGINE.................. 7-1
EMERGENCY ENGINE STARTING.. 7-2
BREAK-IN.......................................... 7-3
RIDING YOUR SNOWMOBILE ......... 7-4
GETTING TO KNOW YOUR
SNOWMOBILE .................................. 7-4
LEARNING TO RIDE YOUR
SNOWMOBILE .................................. 7-4
TO START OUT AND
ACCELERATE................................... 7-5
BRAKING........................................... 7-5
TURNING .......................................... 7-5
RIDING UPHILL................................. 7-6
RIDING DOWNHILL .......................... 7-7
CROSSING A SLOPE (SIDE HILL)... 7-7
ICE OR ICY SURFACE .....................7-8
HARD-PACKED SNOW .................... 7-8
OPERATION ON SURFACES
OTHER THAN SNOW OR ICE.......... 7-8
STRAP (PZ500ML)............................ 7-9
DRIVING..........................................7-10
STOPPING THE ENGINE ...............7-11
TRANSPORTING ............................ 7-12

PERIODIC MAINTENANCE ................ 8-1
MAINTENANCE CHART ................... 8-1
TOOL KIT .......................................... 8-4
SPARK PLUG INSPECTION............. 8-4
ENGINE IDLE SPEED
ADJUSTMENT................................... 8-5
THROTTLE CABLE ADJUSTMENT.. 8-6
OIL PUMP CABLE ADJUSTMENT.... 8-6
CARBURETOR ADJUSTMENT ........ 8-7
HIGH ALTITUDE ADJUSTMENTS.... 8-9
FAN BELT........................................ 8-10
DRIVE V-BELT REPLACEMENT ....8-10
DRIVE CHAIN HOUSING................ 8-13
BRAKE.............................................8-14
BRAKE FLUID REPLACEMENT .....8-15
PARKING BRAKE ........................... 8-15
SUSPENSION ................................. 8-16
FULL RATE ADJUSTER .................8-18
TRACK ADJUSTMENT ...................8-19
SKI ALIGNMENT .............................8-21
HANDLEBAR ADJUSTMENT
(PZ500/VT500XL)............................ 8-21
HANDLEBAR ADJUSTMENT
(PZ500ML).......................................8-22
LUBRICATION................................. 8-23
HEADLIGHT ....................................8-24
BATTERY (VT500XL)...................... 8-25
FUSE REPLACEMENT (VT500XL). 8-26
TROUBLESHOOTING......................... 9-1
STORAGE .........................................10-1
RETURN TO SERVICE AFTER
STORAGE .......................................10-2
SPECIFICATIONS .............................11-1
DIMENSIONS .................................. 11-1
ENGINE ........................................... 11-1
CHASSIS .........................................11-2
ELECTRIC ....................................... 11-3
WIRING DIAGRAM............................ 12-1

1-1
ESS79001 YAMAHA MOTOR CORPORATION, U.S.A.
SNOWMOBILE LIMITED WARRANTY
YamahaMotorCorporation,U.S.A.herebywarrantsthat
new Yamaha snowmobiles purchased from an autho-
rized Yamaha snowmobile dealer in the continental
United States will be free from defects in material and
workmanshipfortheperiodoftimestatedherein,subject
to certain stated limitations.
WARRANTY PERIOD:
1. All Yamaha snowmobiles shall be warranted for a
term of one (1) year from the date of purchase, plus
a special early-season extension (if applicable).
2. AllYamahasnowmobileclutchcomponentsarewar-
ranted against abnormal wear for one (1) year from
the date of purchase, plus a special early-season
extension (if applicable).
DURING THE PERIOD OF WARRANTY any au-
thorizedYamahasnowmobile dealer will,freeofcharge,
repairor replace,atYamaha’soption, anypartadjudged
defective by Yamaha due to faulty workmanship or
material from the factory. Parts used in warranty repairs
will be warranted for the balance of the snowmobile’s
warranty period. All parts replaced under warranty be-
comethepropertyofYamahaMotorCorporation,U.S.A.
GENERAL EXCLUSIONS from this warranty shall
include any failures to the machine caused by:
1. Competition, racing, or non-Yamaha authorized
rental use.
2. Operation on surfaces other than snow or ice.
3. Installationofpartsoraccessories that are not quali-
tatively equivalent to genuine Yamaha parts.
4. Abnormal strain, neglect, or abuse.
5. Lack of proper maintenance.
6. Accident or collision damage.
7. Modification to original parts.
SPECIFIC EXCLUSIONS from this warranty shall
include parts replaced due to normal wear or routine
maintenanceincludingoil,sparkplugs,clutchdrivebelts,
slide runners, and track.
THECUSTOMER’SRESPONSIBILITYunderthis
warranty shall be to:
1. Operateandmaintainthesnowmobileasspecifiedin
the appropriate Owner’s Manual.
2. Give notice to an authorized Yamaha snowmobile
dealerofany and allapparentdefectswithin ten (10)
days after discovery, and make the machine avail-
able at that time for inspection and repairs at such
dealer’s place of business. You may locate your
nearest authorized Yamaha dealer through your
local telephone directory.
WARRANTY TRANSFER: To transfer any remain-
ing warranty from the original purchaser to any subse-
quent purchaser, it is imperative that the machine be
inspected and registered for warranty by an authorized
Yamahasnowmobile dealer. In order for this warranty to
remain in effect, this inspection and registration must
take place within ten (10) days after ownership transfer.
Aninspection andregistrationfeewillbechargedforthis
service.
YAMAHA MOTOR CORPORATION, U.S.A.
MAKES NO OTHER WARRANTY OF ANY
KIND, EXPRESSED OR IMPLIED. ALL IM-
PLIEDWARRANTIESOFMERCHANTABILITY
AND FITNESS FOR A PARTICULAR PUR-
POSE WHICH EXCEED THE OBLIGATIONS
AND TIME LIMITS STATED IN THIS WAR-
RANTY ARE HEREBY DISCLAIMED BY
YAMAHA MOTOR CORPORATION, U.S.A.
AND EXCLUDED FROM THIS WARRANTY.
SOMESTATESDONOTALLOWLIMITATIONS
ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION MAY
NOT APPLY TO YOU. ALSO EXCLUDED
FROM THIS WARRANTY ARE ANY INCIDEN-
TAL OR CONSEQUENTIAL DAMAGES IN-
CLUDING LOSS OF USE. SOME STATES DO
NOT ALLOW THE EXCLUSION OR LIMITA-
TION OF INCIDENTAL OR CONSEQUENTIAL
DAMAGES,SOTHEABOVEEXCLUSIONMAY
NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LE-
GAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH VARY FROM STATE
TO STATE.

1-2
SPECIAL EARLY-SEASON WARRANTY EX-
TENSION
A special warranty extension is available for all new
Yamaha snowmobiles purchased between June 1 and
December 1.
AllnewYamahasnowmobilespurchasedbetweenJune
1 and December 1 will have the warranty extended to
November 30 of the following year.
YAMAHA MOTOR CORPORATION, U.S.A.
Post Office Box 6555
Cypress, California 90630
WARRANTY QUESTIONS AND
ANSWERS
Q. Whatcosts aremyresponsibility duringthewarranty
period?
A. The customer’s responsibility includes all costs of
normalmaintenanceservices,non-warrantyrepairs,
accidentand collision damages, as well as oil,spark
plugs, clutch drive belts, and slide runners.
Q. What are some examples of “abnormal” strain, ne-
glect, or abuse?
A. These terms are general and overlap each other in
areas. Specific examples include: Running the ma-
chine out of oil, hitting an object submerged under
snow, operation on surfaces other than snow or ice,
operating the machine with a broken or damaged
part which causes another part to fail, and so on. If
you have any specific questions on operation or
maintenence, please contact your dealer for advice.
Q. May I perform any or all of the recommended main-
tenance shown in the Owner’s Manual instead of
having the dealer do them?
A. Yes,ifyouare aqualifiedsnowmobilemechanicand
follow the procedures specified in the Owner’s and
Service Manual. We do recommend, however, that
itemsrequiringspecialtoolsorequipmentbedoneby
a Yamaha snowmobile dealer.
Q. Under what conditions is the clutch not covered by
warranty?
A. Clutches as well as clutch components wear with
use.Normalwearisnotcoveredunderwarrantysuch
service is the customer’s responsibility. Abnormal
wear is, however, covered for one (1) year from the
date of purchase. Your Yamaha snowmobile dealer
possesses criteria as to what constitutes abnormal
wear.
Q. Will the warranty be void or cancelled if I do not
operate or maintain my new Yamaha exactly as
specified in the Owner’s Manual?
A. No. The warranty on a new Yamaha cannot be
“voided” or “cancelled.” However, if a particular fail-
ureiscausedbyoperationormaintenanceotherthan
asshownintheOwner’sManual,thatfailuremaynot
be covered under warranty.
Q. What responsibility does my dealer have under this
warranty?
A. Each Yamaha snowmobile dealer is expected to:
1. Completely set up every new machine before sale.
2. Explain the operation, maintenance, and warranty
requirements to your satisfaction at the time of sale,
and upon your request at any later date.
3. Inaddition,eachYamahasnowmobiledealer is held
responsibleforhissetup,serviceandwarrantyrepair
work.
Q. Whom should I contact if I have further questions
about this warranty?
A. Your Yamaha snowmobile dealer has the informa-
tionandexperiencenecessarytoansweralmostany
questionsaboutthiswarranty.Ifthedealerisnotable
to do so, he is expected to contact Yamaha Motor
Corporation, U.S.A., for clarification or assistance.
CUSTOMER SERVICE
Ifyourmachinerequireswarrantyservice,youmusttake
it to any authorized Yamaha snowmobile dealer within
the continental United States. Be sure to bring your
warranty identification card or other valid proof of the
originaldateofpurchase.Ifaquestionor problem arises
regardingwarranty, first contact the owner of the dealer-
ship.Sinceallwarrantymattersarehandledatthedealer
level,this personisinthe bestpositionto helpyou.If you
are still not satisfied and require additional assistance,
please write:
YAMAHA MOTOR CORPORATION
U.S.A.
CUSTOMER RELATIONS DEPART-
MENT
P.O. Box 6555
Cypress, California 90630

1-3
When contacting Yamaha Motor Corpora-
tion, U.S.A. be sure to include the model,
serial number, names, dates, and receipts.
CHANGE OF ADDRESS
Thefederalgovernmentrequireseachmanufacturerofa
motorvehicletomaintainacomplete,up-to-datelistofall
firstpurchasers againstthepossibilityofa safety-related
defectand recall. This list is compiledfrom the purchase
registrations sent to Yamaha Motor Corporation, U.S.A.
by the selling dealer at the time of your purchase.
If you should move after you have purchased your new
snowmobile, please advise us of your new address by
sendingapostcardlistingyoursnowmobilemodelname,
engine serial number, dealer number (or dealer’s name)
asitisshownonyourwarrantyregistrationidentification,
your name and new mailing address. Mail to:
YAMAHA MOTOR CORPORATION,
U.S.A.
WARRANTY DEPARTMENT
P.O. Box 6555
Cypress, California 90630
This will ensure that Yamaha Motor Corporation, U.S.A.
has an up-to-date registration record in accordance with
federal law.

1-4
ESS79500
YAMAHA EXTENDED SERVICE (Y.E.S.)
Keep your Yamaha protected even after your
warranty expires with genuine Yamaha Ex-
tended Service (Y.E.S.).
•Y.E.S. is designed and administered by
Yamaha Motor Corporation to provide
maximum owner satisfaction. You get un-
interrupted factory-backed coverage for
extra peace of mind.
•Y.E.S. is flexible. You choose the plan that’s
right for you: 12 months, 24 months, or 36
months beyond your warranty period.
•Y.E.S. is designed and administered by the
same Yamaha people who handle your
warranty — and it shows in the compr-
ehensive coverage benefits. There are no
mileage limitations. Coverage isn’t limited
to “moving parts” or the “drive train” like
many other plans. And Y.E.S. covers manu-
facturing defects just like the warranty. See
the sample contract at your Yamaha dealer
to see how comforting uninterrupted fac-
tory-backed protection can be.
•You don’t have to pay anything for covered
repairs.
There’s no deductible to pay, and repairs
aren’t “pro-rated.” You don’t have any
“out-of pocket” expenses for covered re-
pairs.
•In addition, Travel and Recreation Inter-
ruption Protection (TRIP) is included at no
extra cost. TRIP gives you up to $150 reim-
bursement per occurrence for any reason-
able expenses you incur because your
Yamaha needs covered service: replace-
ment vehicle rental, emergency towing,
phone calls, even food and lodging when
you are away from home. This superb
coverage goes into effect when you pur-
chase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during
your entire Y.E.S. plan period.
•Y.E.S. coverage is honored at any author-
ized Yamaha dealer nationwide.
•Y.E.S. coverage is transferrable to a new
owner if you sell or trade-in. That can make
your Yamaha much more valuable!
This excellent Y.E.S. plan coverage is only
available to Yamaha owners like you, and only
while your Yamaha is still within the Yamaha
Limited Warranty period. So visit your author-
ized Yamaha dealer to get all the facts. He can
show you how easy it is to protect your invest-
ment with Yamaha Extended Service.
We urge you to act now. You’ll get the excel-
lent benefits of TRIP coverage right away, and
you’ll rest easy knowing you’ll have strong
factory-backed protection even after your
Yamaha Limited Warranty expires. You can
also save money: Y.E.S. costs less within the
first 90 days after you buy your Yamaha. See
your dealer today!
A special note:
If visiting your dealer isn’t convenient, contact
Yamaha with your Primary ID number (your
engine number). We’ll be happy to help you
get the Y.E.S. coverage you need.
Yamaha Service Marketing P.O.Box 6555
Cypress, CA 90630
[phone]

2-1
SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF
THE FOLLOWING:
• Read the Owner’s Manual and all labels before operating this vehicle.
• This vehicle is a high performance machine.
It should be operated by an experienced operator.
•
Check throttle, brake, and steering for proper operation before starting engine.
• Set parking brake before attempting to start engine.
Never run this vehicle with the parking brake applied.
•
To stop engine in an emergency, push the engine stop switch down.
• Do not operate engine without drive belt or drive guard.
• Make sure the fuel tank cap is closed securely after refueling.
• Do not operate this vehicle on public roads.
You could collide with another vehicle.
• This vehicle is designed for operator only - no passengers.
•
Wear an approved helmet, eye protection, and adequate clothing for
snowmobiling.
AFIN D’ÉVITER TOUT RISQUE DE BLESSURE SÉRIEUSE OU MÊME MORTELLE,
VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES:
• Avant d’utiliser ce véhicule, lire le manuel du propriétaire et toutes les étiquettes.
• Ce véhicule est une machine à haute perfomance.
Elle doit être conduite par un conducteur expérimenté.
• Avant de démarrer le moteur, vérifier l’opération du frein, de l’accélérateur
et de la direction.
• Le frein de sécurité doit être appliqué lors du démarrage.
Ne pas rouler avec le frein de sécurité actionné.
• En cas d’urgence, utiliser l’interrupteur d’arrêt du moteur.
• Ne pas laisser tourner le moteur sans la courroie ou sans son garde.
• S’assurer que le bouchon du réservoir soit bien refermé après le remplissage.
•
Afin d’éviter tout risque de collision, ne pas rouler sur un chemin public.
• Ce véhicule est conçu pour un conducteur seul - aucun passager.
•
Toujours porter un casque approuvé et un habillement de motoneigiste.
Prévoir une protection pour les yeux.
8DS-77761-00
AVERTISSEMENT
WARNING
AVERTISSEMENT
WARNING
NE PAS FAIRE FONCTIONNER LE
MOTEUR SANS COURROIE EN V
OU PROTECTEUR D’EMBRAYAGE.
DO NOT OPERATE ENGINE WITHOUT
V-BELT OR DRIVE GUARD.
8BD-77762-00
ESB01500 LOCATION OFTHE
IMPORTANT LABELS
Pleasereadthefollowinglabelscarefullybeforeoperating
this machine.
NOTE:
Maintainorreplacesafetyandinstructionlabels,asneces-
sary.
1PZ500/PZ500ML
2

2-2
AVERTISSEMENT
WARNING
Improper use of STRAP on the handlebar can result in
SEVERE INJURY or DEATH. L’utilisation incorrecte de la POIGNÉE SOUPLE du guidon peut
causer des BLESSURES GRAVES voire MORTELLES.
• Use strap only as an operator grip point to shift weight
uphill to maintain balance during traverse ( sidehill ) riding.
• Keep one hand on handlebar. Do not change speed or
direction abruptly.
• Only experienced operators should traverse slopes steep
enough to require strap use.
• S’agripper à la poignée seulement lors de la traversée latérale
de pentes pour garder l’équilibre lorsque l’on déplace son poids
du côté amont.
• Garder une main sur le guidon. Éviter toute accélération ou
freinage brusques.
• La traversée de pentes dont la raideur requiert l’utilisation de la
poignée est réservée aux pilotes expérimentés.
8ED-77761-00
AVERTISSEMENT
WARNING
NO PASSENGER OR CARGO ON THIS TRACK COVER.
If was not designed to carry weight. It could bend or break under
load.
Anything placed here could block the view of the break/tail light
which could cause an accident.
8CY-77762-00
AUCUN PASSAGER OU MARCHANDISE SUR LE PROTECTEUR DE
CHENILLE.
Ce protecteur n’a pas été conçu pour supporter un poids. Il pourrait
s’incurver ou se briser sous la charge.
Tout objet ou personne placé à cet endroit pourrait bloquer la vue
des feux d’arrêt/amére et ainsi causer un accident.
AVERTISSEMENT
WARNING
SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF
THE FOLLOWING:
• Read the Owner’s Manual and all labels before operating this vehicle.
• This vehicle is a high performance machine.
It should be operated by an experienced operator.
•
Check throttle, brake, and steering for proper operation before starting engine.
• Set parking brake before attempting to start engine.
Never run this vehicle with the parking brake applied.
•
To stop engine in an emergency, push the engine stop switch down.
• Do not operate engine without drive belt or drive guard.
• Make sure the fuel tank cap is closed securely after refueling.
• Do not operate this vehicle on public roads.
You could collide with another vehicle.
•
Wear an approved helmet, eye protection, and adequate clothing for
snowmobiling.
• Check lever position (Forward or Reverse) before moving.
AFIN D’ÉVITER TOUT RISQUE DE BLESSURE SÉRIEUSE OU MÊME MORTELLE,
VEUILLEZ SUIVRE LES RECOMMANDATIONS SUIVANTES:
• Avant d’utiliser ce véhicule, lire le manuel du propriétaire et toutes les étiquettes.
• Ce véhicule est une machine à haute perfomance.
Elle doit être conduite par un conducteur expérimenté.
• Avant de démarrer le moteur, vérifier l’opération du frein, de l’accélérateur
et de la direction.
• Le frein de sécurité doit être appliqué lors du démarrage.
Ne pas rouler avec le frein de sécurité actionné.
• En cas d’urgence, utiliser l’interrupteur d’arrêt du moteur.
• Ne pas laisser tourner le moteur sans la courroie ou sans son garde.
• S’assurer que le bouchon du réservoir soit bien refermé après le remplissage.
•
Afin d’éviter tout risque de collision, ne pas rouler sur un chemin public.
• Toujours porter un casque approuvé et un habillement de motoneigiste.
Prévoir une protection pour les yeux.
•
Vérifier la position du levier (marche avant ou arrière) avant d’être en marche.
8DM-77761-00
1VT500XL
3PZ500ML/VT500XL
4PZ500ML

3-1
ESS39203 SAFETY INFORMATION
When you ride your snowmobile, you must know and use
the following for your safety. Severe injury or death may
result if you ignore any of the following.
Before Operating
1. Readthe Owner’sManualandalllabelsbeforeoperat-
ing this machine. Become familiar with all of the oper-
ating controls and their function. Consult a Yamaha
dealer about any control or function you do not under-
stand.
2. This machine was not manufactured for use on public
streets, roads, or highways. Such use is prohibited by
law, and you could collide with another vehicle.
3. PZ500 and PZ500ML are designed to carry the OP-
ERATOR ONLY.
Passengers are prohibited. Carrying a passenger can
cause loss of control.
4. Do not operate the machine after drinking alcohol or
taking drugs. Your ability to operate the machine is
reduced by the influence of alcohol or drugs.
5. For safety and proper care of the machine, always
perform the pre-operation checks on pages 6-1 ~
6-8 before starting the engine. Check the throttle,
steeringandbrakeoperationeverytimebeforestarting
the engine. Be sure the throttle lever moves freely and
it returns to the idle position when it is released.
6. Apply the parking brake before starting the engine.
Never drive the machine with the parking brake ap-
plied. This may overheat the brake disc and reduce
braking ability.
7. Donotallowanyonetostandbehindthemachinewhen
starting,inspectingor adjustingthemachine.Abroken
track, track fittings or debris thrown by the track could
be dangerous to the operator or bystanders.
851-005
851-004
851-006

3-2
8. Handle fuel with care; it is highly flammable.
•Never add fuel when the engine is running or hot.
Allow the engine to cool for several minutes after
running.
•Use an approved fuel container.
•Fill the fuel tank outdoors with extreme care. Never
remove the fuel cap indoors. Never fill the fuel tank
indoors.
•Never refuel while smoking or in the vicinity of an
open flame.
•Makesure the fuel tank cap is closedsecurely after
refueling. Wipe up any spilled fuel immediately.
9. If you swallow some gasoline, inhale a lot of gasoline
vapor, or get some gasoline into your eye(s), see your
doctor immediately. If any gasoline spills on your skin
or clothing, immediately wash your skin with soap and
water, and change your clothes.
10.Wear protective clothing. Wear an approved helmet,
andafaceshieldorgoggles.Also,wearagoodquality
snowmobile suit, boots, and a pair of snowmobile
gloves or mittens that will permit use of your thumbs
and fingers for operation of the controls.
Operation
1. Donotruntheengineindoors,exceptwhenstartingthe
enginetotransportthemachineinoroutofthebuilding.
Opentheoutsidedoors;exhaustfumesaredangerous.
2. Be careful where you ride. There may be obstacles
hidden beneath the snow. Stay on established trails to
minimize your exposure to hazards. Ride slowly and
cautiouslywhenyourideoffofestablishedtrails.Hitting
a rock or stump, or running into wires could cause an
accident and injury.
851-003
851-001
851-002

3-3
3. Thismachine isnotdesigned foruseon surfacesother
thansnoworice.Useondirt,sand,grass,rocks,orbare
pavement may cause loss of control and may damage
the machine.
4. Avoidoperatingonglareice,oronsnowwhichhasalot
of dirt or sand mixed in. Operation under such condi-
tions will damage or result in rapid wear of ski runners,
drive track, slide runners and drive sprockets.
5. Always have other snowmobilers with you when going
onaride.Youmayneedhelpifyourunoutoffuel,have
an accident, or damage your snowmobile.
6. Many surfaces such as ice and hard-packed snow
require much longer stopping distances. Be alert, plan
ahead and begin decelerating early. The best braking
method on most surfaces is to release the throttle and
apply the brake gently – not suddenly.
Maintenance and Storage
1. Donotleavethemachineonitsleftsideforanextended
period of time. Fuel may leak out from the fuel breather
hose.
2. Modifications made to the machine not approved by
Yamaha, or the removal of original equipment may
render your machine unsafe for use and may cause
severe personal injury. Modifications may also make
your machine illegal to use.
3. Neverstorethemachinewithfuelinthefueltankinside
a building where ignition sources are present such as
hotwaterandspaceheaters,openflame,spark,clothes
dryers, and the like. Allow the engine to cool before
storing in any enclosure.
4. Always refer to “STORAGE” for important details if the
machine is to be stored for an extended period.
5. Maintain or replace safety and instruction labels, as
necessary.

–MEMO–

4-1
ESG05100 DESCRIPTION
1Windshield
2Steering handlebar
3Seat
4Passenger grip warmer switch
(VT500XL)
5Frame
6Slide rail suspension
7Drive track
8Steering ski
PZ500
VT500XL
PZ500ML

4-2
9Headlight
0Shroud
ALuggage box
BTaillight
CFlap
DSide mirror (VT500XL)
EBrake lever
FHeadlight beam switch
GParking brake lever
HStrap (PZ500ML)
IEngine stop switch
JThrottle lever
KDrive select lever (VT500XL)
LStarter handle
MShroud latch
NMain switch
OStarter lever
PGrip warmer control knob
Q“HIGH BEAM” indicator light
ROdometer
SSpeedometer
TTachometer
U“OIL LEVEL” warning indicator light
VTrip odometer reset knob
WTrip odometer
VT500XL
PZ500ML

5-1
ESG05000 CONTROL FUNCTIONS
ESS08802
MAIN SWITCH
The main switch controls the following items.
1OFF:
The ignition circuit is switched off.
The key can be removed only in this position.
2ON:
The ignition circuit is switched on.
The engine can be started.
3WARMER:
The grip and thumb warmer circuit is switched on.
Also, the ignition circuit is switched on and the engine can
be started.
NOTE:
The handlebar grips and throttle lever will heat electrically
after the engine starts.
4START (VT500XL):
The starting circuit is switched on.
The starter motor starts.
NOTE:
The lights will come on after the engine starts.
CAUTION:
Releasetheswitchimmediatelyaftertheenginestarts.
ÅPZ500/PZ500ML
ıVT500XL
831-027
AB

5-2
815-001
816-001
ESS22200
STARTER LEVER (CHOKE)
Usethisleverwhenstartingandwarmingupacoldengine.
1Starter lever (choke)
2When starting a cold engine.
3Warming up
4When the engine is warm.
NOTE:
Refer to STARTING THE ENGINE for proper operation.
ESS21600
THROTTLE LEVER
Oncetheengineisrunningcleanly,squeezing2thethrottle
lever 1will increase the engine speed and cause engage-
mentofthedrivesystem.Regulatethespeedofthemachine
by varying the throttle position. Because the throttle is
spring-loaded, the machine will decelerate, and the engine
will return to an idle when the thumb is released 3.
WARNING
Check the throttle, brake, and steering for proper
operation before starting engine.