Snowmobile Yamaha Phazer PZ50 (2007-2008 year). Manual - part 33

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SECONDARY SHAFT AND REVERSE GEAR CASE

REMOVAL

1. Check that the gear motor is in the drive posi-

tion.

NOTE:

Before removing the gear motor from the reverse
gear case, make sure that the drive position indica-
tor light on the speedometer unit is on.

2. Remove:

• Drive chain parts

Refer to “DRIVE CHAIN”.

• Secondary sheave assembly

Refer to “SECONDARY SHEAVE”.

3. Remove:

• Exhaust pipe/muffler assembly 1 
• Exhaust pipe joint upper cover
• Exhaust pipe joints 2 
• Exhaust pipe joint lower cover 3 

NOTE:

Slide the exhaust pipe/muffler assembly rearward
as shown in the illustration.

1

3

2

4. Remove:

• Secondary shaft assembly 1 

Removal steps:

• Slide the secondary shaft assembly to the left

until the right end of the assembly is past the
frame.

• Lift up the right end of the secondary shaft

assembly, and then pull it outward to remove.

1

1

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INSPECTION

1. Inspect:

• Secondary shaft

Scratches (excessive)/damage 

→ Replace.

• Splines

Wear/damage 

→ Replace the secondary

shaft.

• Bearing contact surface

Scratches/wear/damage 

→ Replace the sec-

ondary shaft.
Refer to “SECONDARY SHAFT”.

2. Inspect:

• Right reverse gear case
• Left reverse gear case
• Shift fork

Pitting/wear/damage 

→ Replace.

• Oil seal

Wear/damage 

→ Replace.

• Bearings

Pitting/damage 

→ Replace.

3. Inspect:

• Reverse driven gear
• Reverse drive gear
• Counter axle
• Middle shaft
• Dog gear

Pitting/wear/damage 

→ Replace.

• Chain

Wear/damage 

→ Replace.

Shift 

→ Clean or replace.

ASSEMBLY

1. Install:

• Oil seal 1 

NOTE:

Press the oil seal onto the left reverse gear case as
shown.

È 0.5 ~ 1.5 mm (0.02 ~ 0.06 in)

È

1

2. Install:

• Dog gear 1 

NOTE:

Install the dog gear with its side 

È toward the mid-

dle shaft.

È 30 mm (1.18 in)
É 33 mm (1.30 in)

È

É

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SECONDARY SHAFT AND REVERSE GEAR CASE

INSTALLATION

1. Install:

• Secondary shaft assembly

Installation steps:

• Install the secondary shaft assembly.
• Install the secondary shaft assembly bolts 1.
• Install the bearing holder bolts 2.
• Tighten the secondary shaft assembly bolts 1.

• Tighten the bearing holder bolts 2.

• Tighten the set bolts 3.

T

 

R

.

.

Secondary shaft assembly bolt:

10 Nm (1.0 m · kg, 7.2 ft · lb)

T

 

R

.

.

Bearing holder bolt:

24 Nm (2.4 m · kg, 17 ft · lb)

T

 

R

.

.

Set bolt (secondary shaft):

9 Nm (0.9 m · kg, 6.5 ft · lb)
LOCTITE

®

1

1

2

3

2. Install:

• Shift arm
• Gear motor

Installation steps:

• Check that the gear motor is in the drive posi-

tion.
Refer to “GEAR MOTOR” in CHAPTER 8.

• Install the shift arm 1 onto the gear motor,

making sure that the center of the projection 

a

on the shift arm is within the range shown in the
illustration.

• Slide the shift fork 2 toward the middle shaft,

making sure to fit the projection 

a on the shift

arm into the slot 

b in the shift fork.

• After installing the shift arm and gear motor,

turn the secondary shaft by hand and check that
the middle shaft turns in the same direction.

1

a

b

a

2

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SECONDARY SHAFT AND REVERSE GEAR CASE

3. Install:

• Drive chain parts

Refer to “DRIVE CHAIN”.

4. Check:

• Secondary shaft stiffness

CAUTION:

When the secondary shaft is operated in peri-
odic motion, and if its movement is heavy,
install it again correctly.

SECONDARY SHAFT AND DRIVE CHAIN 
INSTALLATION

1. Install:

• Secondary shaft
• Drive chain parts

Refer to “SECONDARY SHAFT”.