Hi,

Does anyone have a service manual for a 1990 PZ480EP (Yamaha part # 87F-28197-10)?

I need the Primary & Secondary clutch charts showing the specifications for each spring & weight. (Color, Part #, Gram weight, Pre-load, Rate, etc.)

The dealers don't seem to have this information, and I can't find a service manual to purchase.

Thanks

The part number you have listed for the service manual is quite old, the new part number is LIT-12618-PZ-50. And I do have this manual, it does not give a complete list of springs and weights and only list a couple of them. Your dealer should have a spring and weight listing that is in the Tech Update bulletins, but they will be from way back in the early 90's. So either your dealer has not dealt with snowmobiles that long or they are not that great of a dealer.

I can give you the specs from the service manual.

Standard specs:

87F-17632-00 weight - 48.5g

Primary spring
Green-Yellow 90501-501G3
outside diameter - 55mm
wire diameter - 5.0mm
pre-load/set length - 21.5 kg/mm (47.4 lb/in)
spring rate - 15.5 N/mm (1.58 kg/mm, 88.5 lb/in)
number of coils - 5.16
free length - 75.1mm

Secondary spring
Green-Yellow 90508-50793
outside diameter - 65mm
wire diameter - 5.0mm
twist angle 75* (C-2)
doesn't list rates

High altitude settings:

8VO-17632-00 weight - 46.1g

Primary spring
Brown-White 90501-55485
pre-load/set length - 25.0 kg/mm (55.1 lb/in)
spring rate - 24.5 N/mm (2.5 kg/mm, 140 lb/in)
number of coils - 4.5
free length - 71.5 mm

Secondary spring
list same spring as standard spec above


From the 1991 section of the service manual

additional weights:
87M-W176A-00 - 48.0g
82M-W176A-90 - 45.5g

additional primary springs:
Gold-Pink - 90501-554E8
pre-load/set length - 20.0 kg/mm (44.1 lb/in)
spring rate - 24.5 N/mm (2.5 kg/mm, 140 lb/in)
number of coils - 4.5
free length - 71.5 mm

Blue-Green - 90501-45534
pre-load/set length - 25.0 kg/mm (55.1 lb/in)
spring rate - 10.38 N/mm (1.06 kg/mm, 59.36 lb/in)
number of coils - 4.68
free length - 85.1 mm

Green-White - 90501-50396
pre-load/set length - 20.0 kg/mm (44.1 lb/in)
spring rate - 19.59 N/mm (2.0 kg/mm, 112 lb/in)
number of coils - 4.7
free length - 71.5 mm

additional secondary spring:
White - 90508-50746
outside diameter - 65mm
wire diameter - 5.0mm
free length - 93.5mm
twist angle 50* (A-2)
721 kg mm/rad torsional spring rate





Also I have 1 of the 3 pages from the Tech Update bulletin regarding springs from 1988 on my website showing all the springs available at the time, I still need to post the other 2 pages when I get time to scan them. The first and second page show primary springs and the third shows secondary springs. Most of these springs are usable on a Phazer.

Go to

http://www.zenitram-inc.com/kgmz.htm

and then click on the Phazer manual button.

I wil try and get the 2 additional pages posted in the next couple of days.

kgmz

I can't thank you enough for your response. I really appreciate your taking the time and effort to provide this information. This is exactly what I'm looking for.

My blue/white primary spring is probably on page 2, and this will really help me determine if it needs to be replaced. (Free Length, mm) My feeling is that it is a little weak, but with the other information you posted, I should be able to come up with something that is close to what I need.

Thanks Again

Current configuration with AAEN Pipe:

Primary:

Weight: 87F
Spring: Blue/White

Secondary:

Spring: Green/Yellow
Twist Angle: 75* (C2)

I have posted the additional spring pages to my website.

specs for your blue/white spring

Blue-White - 90501-55388
pre-load/set length - 40.0 kg/mm
spring rate - 2.4 kg/mm
number of coils - 4.6
free length - 78.2 mm

kgmz

Thanks to you, I'll be back in the saddle in no time.


Thanks again.