1986 Yamaha Phazer Service Manual

The 1986 Yamaha Phazer is a high-performance snowmobile featuring a 485cc two-stroke engine, slide rail suspension system, and advanced chassis design. This service manual provides comprehensive technical information for maintenance, repair, and troubleshooting procedures. Below are key sections covering specifications, maintenance schedules, engine service, chassis repair, electrical systems, and troubleshooting guidelines.

General Specifications

Technical specifications for the 1986 Yamaha Phazer snowmobile.

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

1. Pre-ride inspection: Check fuel, oil, track tension, and brakes before each use.
2. Every 500 miles: Clean air filter, check spark plugs, inspect drive belt.
3. Every 1,000 miles: Change engine oil, inspect suspension components.
4. Every 2,000 miles: Replace spark plugs, check carburetor synchronization.
5. Seasonal: Flush cooling system, lubricate chassis points, store properly.

WARNING! Always disconnect spark plug wires before performing maintenance to prevent accidental starting.

Engine Service

Comprehensive engine maintenance and repair procedures.

1. Cylinder and piston: Inspect for wear, measure clearances, replace if necessary.
2. Crankshaft: Check runout and bearing condition.
3. Carburetor: Clean and adjust float level, main jet, and pilot jet settings.
4. Ignition timing: Set to 0.9mm BTDC at 3,000 RPM.
5. Compression test: Should read 120-140 PSI per cylinder.

CAUTION! Use genuine Yamaha parts for replacement to ensure proper fit and performance.

Fuel System

• Fuel Type: Premium unleaded gasoline (87 octane minimum)
• Oil Injection: Yamaha injection system with separate oil tank
• Fuel Filter: Replace every season or 2,000 miles
• Carburetor Settings: Main jet #180, Pilot jet #40, Needle clip 3rd position
• Fuel Lines: Inspect for cracks and replace if deteriorated
• Tank Vent: Ensure proper ventilation to prevent vapor lock

Chassis & Suspension

Frame inspection and suspension maintenance procedures.

Front Suspension: Double A-arm with hydraulic shocks, check for worn bushings and ball joints.

Rear Suspension: Slide rail system with torsion springs, inspect slides for wear and replace if grooved.

Track: Adjust tension to 1/2 inch deflection under 10 lbs pressure. Skis: Check alignment and carbides for wear. Steering: Lubricate tie rods and steering post bearings annually.

Electrical System

Wiring diagram reference and component testing procedures.

1. Battery: 12V maintenance-free, check voltage and connections.
2. Stator: Test output - 14V AC at 3,000 RPM.
3. CDI Unit: Check for spark and proper timing advance.
4. Lights: Headlight 60/55W, taillight 5W, replace if dim or inoperative.
5. Kill Switch: Test continuity and function for safety.

Tip: Use dielectric grease on all electrical connections to prevent corrosion.

Drive System

Drive clutch, driven clutch, and track drive system maintenance.

1. Drive Belt: Yamaha 8DN-17641-00, inspect for cracks and wear.
2. Primary Clutch: Clean sheaves, check weights and spring tension.
3. Secondary Clutch: Inspect helix and spring for proper operation.
4. Chaincase: Check oil level and chain tension annually.
5. Jackshaft: Inspect bearings and seals for leaks.
6. Track Drive: Lubricate bearings and check for proper alignment.

WARNING! Always relieve tension from drive system before performing maintenance.

Brake System

Mechanical disc brake maintenance and adjustment procedures.

Cooling System

Liquid cooling system maintenance and winterization.

Coolant: Yamaha coolant or 50/50 ethylene glycol mix. Capacity: 2.1 quarts. System Pressure: 13-15 PSI radiator cap. Hoses: Inspect for cracks and leaks. Heat Exchanger: Clean fins and check for damage.

CAUTION! Never open radiator cap when engine is hot to prevent burns.

Troubleshooting

Reset: Clear trouble codes by disconnecting battery for 10 minutes.

Service: Contact authorized Yamaha dealer for technical support and genuine parts.