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Yamaha MZ360, Service Manual

The Yamaha MZ360 service manual is a comprehensive guide that provides users with detailed instructions for the proper maintenance and repair of their MZ360 engine. This invaluable manual can be downloaded for free at manualshive.com, ensuring users have the necessary resources to keep their Yamaha MZ360 running smoothly.

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CHECKING THE RECOIL STARTER 
(MX360)............................................... 3-14
ASSEMBLING THE RECOIL 

STARTER (MX360) ............................. 3-15

FLYWHEEL............................................... 3-17

MZ360/MZ400 ..................................... 3-17
MX360 ................................................. 3-18
REMOVING THE FLYWHEEL............. 3-19
INSTALLING THE FLYWHEEL............ 3-20
INSTALLING THE TCI UNIT ............... 3-20

GOVERNOR ............................................. 3-22

THROTTLE LEVER ASSEMBLY 
(MX360BA6A0) ................................... 3-22
THROTTLE LEVER ASSEMBLY 
(MX360C46A5/MX360AA6A0/
MX360AA6A5/MX360AA6A6) ............. 3-23
GOVERNOR ARM ASSEMBLY 
(MX360KA6D0 for KOR) ..................... 3-24
GOVERNOR ARM ASSEMBLY 

(MZ360/MZ400/MX360KA6D0 

except for KOR) ................................... 3-25
FLYWEIGHT SHAFT ASSEMBLY 

(MZ360/MZ400)................................... 3-26
FLYWEIGHT SHAFT ASSEMBLY 

(MX360)............................................... 3-27
REMOVING THE FLYWEIGHT 

SHAFT ASSEMBLY AND 

GOVERNOR FORK............................. 3-28
DISASSEMBLING THE FLYWEIGHT 
SHAFT ASSEMBLY............................. 3-28
CHECKING THE FLYWEIGHT 

SHAFT ASSEMBLY............................. 3-28
ASSEMBLING THE FLYWEIGHT 

SHAFT ASSEMBLY............................. 3-29
INSTALLING THE FLYWEIGHT 

SHAFT ASSEMBLY AND 

GOVERNOR FORK............................. 3-29
INSTALLING THE THROTTLE 

LEVER ASSEMBLY (Equipped 

models)................................................ 3-30
ADJUSTING THE GOVERNOR .......... 3-30

ENGINE SWITCH AND OIL WARNING 

UNIT.......................................................... 3-31

ENGINE SWITCH ............................... 3-32

CYLINDER HEAD COVER, CYLINDER 
HEAD........................................................ 3-33

CHECKING THE ROCKER ARM........ 3-35

CHECKING THE PUSH ROD..............3-35
CHECKING THE CYLINDER HEAD ...3-35
INSTALLING THE CYLINDER HEAD 
ASSEMBLY ..........................................3-36

VALVE .......................................................3-37

REMOVING THE VALVES AND 

VALVE SPRINGS.................................3-38
CHECKING THE VALVES AND 

VALVE SPRINGS.................................3-38
CHECKING THE VALVE SEATS .........3-40
VALVE LAPPING .................................3-42
INSTALLING THE VALVES AND 

VALVE SPRINGS.................................3-43

PISTON, CAMSHAFT, CRANKCASE, 

AND CRANKSHAFT.................................3-44

MZ360/MZ400 .....................................3-44
MX360 .................................................3-46
REMOVING THE BALANCER 

SHAFT, CAMSHAFT, AND VALVE 

LIFTER ................................................3-48
CHECKING THE BALANCER 

SHAFT .................................................3-48
CHECKING THE CAMSHAFT.............3-48
CHECKING THE VALVE LIFTER ........3-50
INSTALLING THE VALVE LIFTER, 
BALANCER SHAFT, AND 

CAMSHAFT .........................................3-50
CHECKING THE CRANKCASE 

COVER ................................................3-50
INSTALLING THE CRANKCASE 

COVER ................................................3-51
CHECKING THE CYLINDER AND 
PISTON................................................3-51
CHECKING THE CRANKCASE ..........3-53
CHECKING THE PISTON PIN ............3-53
CHECKING THE PISTON RINGS .......3-54
CHECKING THE CRANKSHAFT ........3-55
CHECKING THE CONNECTING 

ROD OIL CLEARANCE .......................3-56
INSTALLING THE PISTON AND 

PISTON RING......................................3-57
INSTALLING THE CRANKSHAFT.......3-57
SELECTING THE CRANKSHAFT 

SHIM....................................................3-59

Summary of Contents for MZ360

Page 1: ...SERVICE MANUAL MZ360 MX360 MZ400 7HC F8197 E1 2019 03 1 7HC F8197 E1_cover indd 1 2 2019 03 13 10 20 44 ...

Page 2: ...7HC F8197 E1_cover indd 3 4 2019 03 13 10 20 44 ...

Page 3: ...E MANUAL 2018 by Yamaha Motor Powered Products Co Ltd 1st Edition March 2019 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Powered Products Co Ltd is expressly prohibited ...

Page 4: ...ons and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol...

Page 5: ...han the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruction chart accompanies the exploded diagram provid...

Page 6: ...ant to every machine SYMBOL DEFINITION SYMBOL DEFINITION Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data Replace the part with a new one Lithium soap base grease Molybdenum disulfide grease Engine oil Silicone fluid Apply locking agent LOCTITE T R New LS M E S LT ...

Page 7: ...GENERAL INFORMATION PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR ELECTRICAL TROUBLESHOOTING SPECIFICATIONS 1 2 3 4 5 6 7 8 9 10 INDEX ...

Page 8: ...LTER ELEMENT MZ360 MZ400 2 6 AIR FILTER ELEMENT MX360 2 7 MUFFLER Equipped models 2 8 FUEL TANK FILTER Equipped models 2 10 FUEL COCK STRAINER 2 11 BREATHER HOSE 2 12 CYLINDER HEAD DECARBONIZATION 2 12 ADJUSTING THE VALVE CLEARANCE 2 12 ENGINE SPEED No throttle lever models 2 15 ENGINE SPEED Throttle lever equipped models 2 15 ADJUSTING THE ENGINE SPEED No throttle lever models 2 16 ADJUSTING THE ...

Page 9: ... SWITCH AND OIL WARNING UNIT 3 31 ENGINE SWITCH 3 32 CYLINDER HEAD COVER CYLINDER HEAD 3 33 CHECKING THE ROCKER ARM 3 35 CHECKING THE PUSH ROD 3 35 CHECKING THE CYLINDER HEAD 3 35 INSTALLING THE CYLINDER HEAD ASSEMBLY 3 36 VALVE 3 37 REMOVING THE VALVES AND VALVE SPRINGS 3 38 CHECKING THE VALVES AND VALVE SPRINGS 3 38 CHECKING THE VALVE SEATS 3 40 VALVE LAPPING 3 42 INSTALLING THE VALVES AND VALVE...

Page 10: ... MOTOR OPERATION Equipped models 5 14 CHECKING THE WIRE HARNESS 5 14 ELECTRIC STARTING SYSTEM 5 15 REMOVING THE STARTER MOTOR Equipped models 5 15 DISASSEMBLING THE STARTER MOTOR Equipped models 5 16 CHECKING THE ARMATURE COIL 5 17 CHECKING THE BRUSH 5 18 CHECKING THE STARTER RELAY 5 18 ASSEMBLING THE STARTER MOTOR 5 18 CHARGING SYSTEM 5 19 CHECKING THE CHARGING COIL Equipped models 5 19 TROUBLESH...

Page 11: ...D OIL WARNING UNIT With oil warning unit oil level switch 7 20 ENGINE SWITCH AND OIL WARNING UNIT No oil level switch 7 22 TCI UNIT MZ360 7 23 TCI UNIT MX360 7 24 TCI UNIT MZ400 7 25 OIL LEVEL SWITCH CRANKCASE COVER MZ360 7 26 OIL LEVEL SWITCH CRANKCASE COVER MX360 7 27 OIL LEVEL SWITCH CRANKCASE COVER MZ400 7 28 ...

Page 12: ...MEMO ...

Page 13: ...model and the remaining digits indicates the production number Designs and specifications are subject to change without notice MODEL NAME AND CODE 1 1 Model Code MZ360LHIDE 7HCC N 010 MZ360LHIDE 7HCC N 020 MZ360LHIDE 7HCC N 030 MZ360LHIDE 7HCC N 040 MX360KA6D0 7HCB N 010 MX360KA6D0 7HCB N 030 MX360BA6A0 7HC2 N 010 MX360BA6A0 7HC2 N 020 MX360C46A5 7HC3 N 020 MX360AA6A0 7HCJ N 020 MX360AA6A5 7HCJ N ...

Page 14: ...GENERAL INFORMATION DIMENSIONS DIMENSION CHART mm in 110H8 0 0 054 35 5 26 4 5 3 5 5 146 08h7 0 040 0 30 TAPER 1 5 M10 1 25 76 29 5 18 5 16 24UNF 2B 146 08h7 0 040 0 110H8 0 0 054 58 7 46 8 5 4 5 25 4h7 0 021 0 22 161h7 0 021 0 TAPER 3 16 ...

Page 15: ... 0 110H8 0 0 054 58 7 46 8 5 4 5 25 4h7 0 021 0 22 161h7 0 021 0 TAPER 3 16 76 29 5 5 16 24UNF 2B 63 60 42 28 25h7 0 021 0 110H8 0 054 0 146 08h7 0 040 0 21 0 1 0 7 0 0 05 4 5 5 M8 1 25 63 60 42 28 30h7 0 021 0 110H8 0 054 0 146 08h7 0 040 0 26 0 1 0 7 0 0 05 4 5 5 M10 1 25 ...

Page 16: ...e K Taper inch C 7HCB MX360KA6D0 for KOR P T O type K Taper inch D 7HC2 MX360BA6A0 P T O type B Straight millimeter E 7HC3 MX360C46A5 P T O type C Straight millimeter F 7HCJ MX360AA6A0 MX360AA6A5 MX360AA6A6 P T O type A Straight inch TOP mm in 6 31H10 0 0 058 21 8 0 1 0 4 5 5 72 2 28 60 3 88 5 25 4h7 0 021 0 110H8 0 054 0 146 08h7 0 040 0 3 8 24UNF 2B 444 6 17 5 162 7 6 41 281 9 11 1 277 8 10 94 ...

Page 17: ... 6 7 8 9 10 GENERAL INFORMATION A 7HCC MZ360LHIDE B 7HCB MX360KA6D0 except for KOR C 7HC2 7HC3 7HCJ 7HCB MX360BA6A0 MX360C46A5 MX360AA6A0 MX360AA6A5 MX360AA6A6 MX360KA6D0 for KOR 445 17 52 163 6 42 282 11 1 300 11 81 162 6 38 ...

Page 18: ...DIMENSIONS 1 6 1 2 3 4 5 6 7 8 9 10 GENERAL INFORMATION MOUNTING BASE mm in 90 5 3 56 105 4 13 65 2 56 37 1 46 16 0 63 2 11 0 43 2 11 0 43 90 5 3 56 105 4 13 65 2 56 37 1 46 16 0 63 2 11 0 43 2 11 0 43 ...

Page 19: ...HCC MZ360LHIDE B 7HCB 7HSB MX360KA6D0 except for KOR MZ400KH2P6 C 7HC2 7HC3 7HCJ 7HCB MX360BA6A0 MX360C46A5 MX360AA6A0 MX360AA6A5 MX360AA6A6 MX360KA6D0 for KOR LEFT SIDE mm in 90 5 3 56 105 4 13 65 2 56 37 1 46 16 0 63 2 11 0 43 2 11 0 43 310 7 12 23 133 5 5 26 ...

Page 20: ...HCB MX360BA6A0 MX360C46A5 MX360AA6A0 MX360AA6A5 MX360AA6A6 MX360KA6D0 for KOR FRONT mm in 427 16 81 462 18 19 163 6 42 490 19 29 133 5 5 26 90 5 3 56 195 5 7 7 103 4 06 70 2 76 4 5 16 24UNF 2B DEPTH18 4 3 8 16UNC2B DEPTH18 1 6 5 1 6 0 5 9 2 5 16 24UNF 2B DEPTH18 127 5 110H8 0 054 0 146 08h7 0 04 0 421 2 16 58 170 6 69 138 5 43 239 5 9 43 2 11 0 43 Hole 65 2 56 37 1 46 16 0 63 102 4 02 2 11 0 43 27...

Page 21: ... C 7HC2 7HC3 7HCJ 7HCB MX360BA6A0 MX360C46A5 MX360AA6A0 MX360AA6A5 MX360AA6A6 MX360KA6D0 for KOR 350 13 78 99 3 9 105 5 4 15 240 9 45 65 2 56 37 1 46 16 0 63 102 4 02 2 11 0 43 Hole 2 11 0 43 27 1 06 Slot hole 99 3 9 418 16 46 188 7 4 125 4 92 206 5 8 13 16 0 63 62 2 44 102 4 02 37 1 46 65 2 56 2 11 0 43 Hole 2 11 0 43 27 1 06 Slot hole ...

Page 22: ...DIMENSIONS 1 10 1 2 3 4 5 6 7 8 9 10 GENERAL INFORMATION RIGHT SIDE A 7HC2 7HC3 7HCJ 7HCB MX360BA6A0 MX360C46A5 MX360AA6A0 MX360AA6A5 MX360AA6A6 MX360KA6D0 for KOR mm in 464 18 27 462 18 19 ...

Page 23: ...t tools Be sure to use the correct special tool for the job to guard against damage Oil grease and seals Be sure to use genuine Yamaha oils grease and sealers or the equivalents Expendable parts Always replace the gaskets O rings cotter pins and cir clips with new parts when servicing engine Fuel hose When installing the fuel hose use a brush to apply a small amount of P 80 GRIP IT as an insertion...

Page 24: ...isassembly Contact surfaces of moving parts should be oiled when reassembled Make sure that the parts move smoothly after each sec tion of the machine is assembled ALL REPLACEMENT PARTS We recommend the use of genuine Yamaha parts for all replacements Use oil and or grease recommended by Yamaha for assembly and adjustment GASKETS OIL SEALS AND O RINGS 1 All gaskets seals and O rings should be repl...

Page 25: ...hium base grease to the seal lip s Oil the bearings liberally when installing BASIC SERVICE INFORMATION ELECTRICAL SYSTEM Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V 1 2 Do not use compressed air to spin the bearings dry This causes damage to the bearing surfaces NOTICE a Never insert the tester probes into the couple...

Page 26: ...ir blower Rust stains Connect and disconnect several times When disconnecting a coupler release the coupler lock hold both sections of the coupler securely and then disconnect the coupler There are many types of coupler locks therefore be sure to check the type of coupler lock before discon necting the coupler NOTICE When disconnecting a connector do not pull the leads Hold both sections of the co...

Page 27: ... the terminal is flattened bend it up After disassembling and assembling a coupler pull on the leads to make sure that they are installed securely 4 Connect Lead Coupler Connector TIP When connecting a coupler or connector push both sec tions of the coupler or connector together until they are connected securely Make sure all connections are tight 1 ...

Page 28: ...r and coupler of the TCI unit CDI unit when replacing the TCI unit CDI unit As a quick remedy use a contact revitalizer available at most part stores Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 For waterproof couplers never insert the tester leads directly into the coupler When performing any checks using a waterproof coupler use the specified test har nes...

Page 29: ...r YU A1927 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 Six piece tappet set YM A5970 Tappet adjusting tool 90890 01311 Digital tachometer 90890 06760 YU 39951 B Compression gauge 90890 03081 Engine compression tes ter YU 33223 Compression gauge extension 73mm 90890 04082 YM 04082 Sheave holder 90890 01701 Primary clutch holder YS 01880 A Flywheel puller 90890 01362 Heavy duty puller YU...

Page 30: ...SPECIAL TOOLS AND TESTERS 1 18 1 2 3 4 5 6 7 8 9 10 GENERAL INFORMATION MEMO ...

Page 31: ...nction to ensure air filter but are also vital to proper engine operation and maximum performance PERIODIC MAINTENANCE LUBRICATION INTERVALS Item Routine Pre operation check Initial Every 1 month or 20 Hrs 3 months or 50 Hrs 6 months or 100 Hrs 12 months or 300 Hrs Spark plug Check condition Clean and replace if nec essary Fuel Check fuel level and leak age Fuel hose Check fuel hose for cracks or ...

Page 32: ...ms require special tools data and technical skills have a Yamaha dealer per form the service Idle speed Check and adjust idle speed Recoil starter Check recoil starter for damage Fittings fasten ers Check all fittings and fas teners Correct if necessary The point where abnormality was recognized by use Item Routine Pre operation check Initial Every 1 month or 20 Hrs 3 months or 50 Hrs 6 months or ...

Page 33: ... specification Regap If necessary clean the spark plug with a spark plug cleaner TIP Before installing the spark plug clean the gasket surface and plug surface Check and adjust the areas around the cylinder head after the engine has cooled down completely WARNING Before removing the spark plug use compressed air to clean the cylinder head cover to prevent dirt from falling into the engine NOTICE 1...

Page 34: ...NE OIL LEAKAGE 1 Place the multi purpose engine on a level surface 2 Check the areas outside of the engine for oil leakage Oil leakage Replace the gasket oil seal or O ring ENGINE OIL LEVEL 1 Remove Oil filler cap 1 TIP This engine is equipped with two oil filler caps Use whichever side is accessible The amount of engine oil should be checked by looking at the reference surface as opposed to using...

Page 35: ...d oil if necessary 3 Install Oil filler cap REPLACING THE ENGINE OIL 1 Warm up the engine for several minutes and then stop the engine 2 Remove Oil filler cap 1 Oil drain bolt 2 Oil drain bolt gasket 3 TIP This engine is equipped with two oil filler caps Use whichever side is accessible This engine is equipped with two oil drain bolts Use whichever side is accessible 3 Drain Engine oil Place the o...

Page 36: ...ith white kerosene and then dry it thoroughly Oil the element and squeeze out the excess oil 0 10 30 50 70 90 110130 F 20 10 0 10 20 30 40 50 C SAE 10W 40 SAE 10W 30 Recommended oil brand YAMALUBE Available oil grade API SE type or higher JASO MA or MB Available viscosity index 10W 30 or 10W 40 Engine oil quantity 1 0 L 1 06 US qt 0 88 Imp qt Be sure not to run the engine without air filter elemen...

Page 37: ...cover screw AIR FILTER ELEMENT MX360 1 Remove Air filter cover nut 1 Air filter cover 2 Air filter element nut 3 2 Remove Air filter element 4 Air filter cover screw 1 6 N m 0 16 kgf m 1 2 lb ft Be sure not to run the engine without air filter element Otherwise this can result in excessive piston and or cylinder wear T R NOTICE 1 2 3 4 ...

Page 38: ...ut MUFFLER Equipped models 1 Remove Spark arrester screw 1 Do not wash the element with gasoline or with acidic alkalic or organic solvents Do not wring out the element This could cause it to tear WARNING NOTICE Air filter element nut 0 9 N m 0 09 kgf m 0 66 lb ft Air filter cover nut 1 6 N m 0 16 kgf m 1 2 lb ft The engine and muffler will be very hot after the engine has been run Avoid touching ...

Page 39: ...on page 3 7 4 Decarbonize Muffler Tap on the muffler in the area shown in the illustra tion to loosen carbon buildup and then shake it out from the end of the muffler 5 Decarbonize Spark arrester 1 Do not use a wire to clean otherwise the noise damp ing material may come out and the damping effect may be reduced NOTICE When cleaning with a wire brush use it softly to avoid damage or scratch the sp...

Page 40: ...park arrester screw TIP Align the spark arrester lump a with the hole b in the muffler pipe FUEL TANK FILTER Equipped models 1 Remove Fuel tank cap 1 Fuel tank filter 2 a b Spark arrester screw 3 5 N m 0 35 kgf m 2 6 lb ft T R Do not smoke and keep away from open flames sparks or any other source of fire when handling or in the vicinity of fuel WARNING 1 2 ...

Page 41: ...ner cup 1 Gasket 2 Fuel cock strainer 3 3 Check Fuel cock strainer Damage Replace Dirt clog Clean TIP Clean the fuel cock strainer with clean gasoline and then dry it thoroughly 4 Install Fuel cock strainer Gasket Strainer cup Make sure that the fuel tank cap is tightened securely Do not smoke and keep away from open flames sparks or any other source of fire when handling or in the vicinity of fue...

Page 42: ...liminate Carbon deposits Refer to CHECKING THE CYLINDER HEAD on page 3 35 3 Install Cylinder head assembly Refer to INSTALLING THE CYLINDER HEAD ASSEMBLY on page 3 36 ADJUSTING THE VALVE CLEARANCE 1 Remove Spark plug cap 1 Spark plug 2 2 Remove Breather hose 3 Air filter case stay 4 MX360 Cylinder head cover 5 Cylinder head cover gasket 1 1 2 3 4 5 Before removing the spark plug use compressed air...

Page 43: ...ton position by inserting a screw driver into the spark plug hole 4 Measure Valve clearance Between the rocker arm and valve stem end Out of specification Adjust TIP Valve clearance must be measured when the engine has cooled down enough to be touched Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 Valve clearance cold Intake 0 05 0 09 mm 0 0020 0 0035 in Exhaust 0 05 0 09 mm 0 0020 0 0035...

Page 44: ...e thickness gauge up and down to check for the proper resistance c Tighten the locknut 1 6 Install Cylinder head cover gasket Cylinder head cover Breather hose Spark plug Spark plug cap 1 3 2 Tappet adjusting tool 90890 01311 Six piece tappet set YM A5970 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 Adjuster Valve clearance Turn clockwise Decrease Turn counterclockwise Increase Valve ad...

Page 45: ...ith no load Out of specification Adjust ENGINE SPEED Throttle lever equipped models 1 Warm up the engine for several minutes 2 Attach Digital tachometer 1 3 Measure High engine speed with no load Out of specification Adjust 1 Digital tachometer 90890 06760 YU 39951 B Engine speed 3110 3210 r min MZ360 3700 3800 r min MX360 MZ400 1 Digital tachometer 90890 06760 YU 39951 B High engine speed 3750 38...

Page 46: ... 4 Measure Low engine speed with no load Out of specification Adjust Measurement steps a Move the throttle lever 1 to the low engine speed position a b Check the low engine speed ADJUSTING THE ENGINE SPEED No throttle lever models 1 Warm up the engine for several minutes 2 Attach Digital tachometer 1 1 a Low engine speed 1900 2100 r min MX360 1 a 1 Digital tachometer 90890 06760 YU 39951 B ...

Page 47: ...peed is obtained ADJUSTING THE ENGINE SPEED Throttle lever equipped models 1 Warm up the engine for several minutes 2 Attach Digital tachometer 1 1 a b High engine speed 3110 3210 r min MZ360 3700 3800 r min MX360 MZ400 Direction a High engine speed is decreased Direction b High engine speed is increased 2 c d 2 c d Low engine speed 1900 2100 r min MX360 Direction c Low engine speed is decreased D...

Page 48: ...n the throttle stop screw 3 carburetor in direc tion c or d until the low engine speed is obtained RECOIL STARTER 1 Check Recoil starter operate smoothly Rough movement Replace the defective part s Refer to CHECKING THE RECOIL STARTER MZ360 MZ400 on page 3 10 and CHECKING THE RECOIL STARTER MX360 on page 3 14 1 2 a b High engine speed 3750 3850 r min MX360 Direction a High engine speed is decrease...

Page 49: ...AINTENANCE 2 19 1 2 3 4 5 6 7 8 9 10 PERIODIC CHECKS AND ADJUSTMENTS FITTINGS AND FASTENERS 1 Check All fittings and fasteners Looseness Tighten Rough movement Replace the defective part s Damage pitting Replace ...

Page 50: ...PERIODIC MAINTENANCE 2 20 1 2 3 4 5 6 7 8 9 10 PERIODIC CHECKS AND ADJUSTMENTS MEMO ...

Page 51: ...n pressure Crank the engine until the needle stop rising on the compression gauge Out of specification Refer to the testing steps Before removing the spark plug use compressed air to clean the cylinder head cover to prevent dirt from falling into the engine NOTICE 1 2 Compression gauge 90890 03081 Engine compression tester YU 33223 Compression gauge extension 73mm 90890 04082 YM 04082 Standard com...

Page 52: ...um specification a Check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate 5 Install Spark plug Spark plug cap Reading Diagnosis Higher than without oil Worn cylinder piston and piston ring s Same as without oil Defective piston piston ring s valve s and cylinder head gasket Improper valve timing and valve clearance Spark plug 20 N m 2 0 kgf m 15 lb ft...

Page 53: ...ving the air filter Remove the parts in the order listed 1 Air filter cover 1 2 Air filter element 1 3 Element fitting plate 1 4 Plate 1 5 Breather hose 1 6 Air filter case 1 7 Gasket 1 1 2 3 6 4 7 5 10 N m 1 0 kgf m 7 4 lb ft 1 6 N m 0 16 kgf m 1 2 lb ft 1 6 N m 0 16 kgf m 1 2 lb ft 9 N m 0 9 kgf m 6 6 lb ft ...

Page 54: ...in the order listed 1 Air filter cover nut 1 2 Air filter cover 1 3 Air filter element nut 1 4 Air filter element case 1 5 Air filter element 1 6 Air filter case 1 7 Breather hose 1 8 Duct 1 9 Gasket 1 1 2 3 4 5 6 7 8 9 15 N m 1 5 kgf m 11 lb ft 0 9 N m 0 09 kgf m 0 66 lb ft 1 6 N m 0 16 kgf m 1 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 55: ...tination pipe Order Job Parts to remove Q ty Remarks Removing the fuel tank Remove the parts in the order listed 1 Fuel hose 1 Turn the fuel cock lever to the OFF position 2 Fuel tank 1 3 Fuel tank stay 1 1 4 Fuel tank stay 2 1 5 Fuel tank cap 1 6 Fuel cock assembly 1 3 4 6 5 1 2 1 3 N m 0 13 kgf m 0 95 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 29 N m 2 ...

Page 56: ... Removing the fuel tank Remove the parts in the order listed 1 Fuel hose 1 1 Turn the fuel cock lever to the OFF position 2 Fuel hose 2 1 3 Fuel tank 1 4 Fuel tank stay 1 1 5 Fuel tank stay 2 1 6 Fuel tank cap 1 7 Fuel cock assembly 1 8 Fuel cock stay 1 1 2 3 4 5 6 7 8 1 3 N m 0 13 kgf m 0 95 lb ft 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 29 N m 2 9 kgf m 21 ...

Page 57: ...ng the muffler Remove the parts in the order listed Fuel tank Refer to FUEL TANK Equipped models on page 3 5 1 Muffler 1 2 Gasket 1 3 Muffler cover 1 4 Spark arrester 1 3 1 2 4 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 20 N m 2 0 kgf m 15 lb ft 20 N m 2 0 kgf m 15 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft ...

Page 58: ...muffler nut 1 muffler nut 2 and muffler bolt 3 until just comes in contact with the surface 2 Tighten Muffler nut 1 Muffler nut 2 Muffler bolt 3 TIP Tighten the muffler nuts and muffler bolt to the specified torque in order of muffler nut 1 muffler nut 2 and muf fler bolt 3 2 1 3 New Muffler nut 20 N m 2 0 kgf m 15 lb ft Muffler bolt 20 N m 2 0 kgf m 15 lb ft T R T R ...

Page 59: ... recoil starter Remove the parts in the order listed 1 Recoil starter assembly 1 2 Starter handle 1 3 Drive plate 1 4 Clip 1 5 Drive pawl 2 6 Spring 2 7 Sheave drum 1 8 Starter spring 1 9 Starter case 1 10 Starter rope 1 1 2 3 4 5 5 6 6 7 8 9 10 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 5 4 N m 0 54 kgf m 4 0 lb ft ...

Page 60: ...ng preload before removing the drive plate screw 1 Hook the rope into the sheave drum slot a and turn the sheave drum assembly clockwise 3 Remove Sheave drum assembly 1 Starter spring 2 Starter rope CHECKING THE RECOIL STARTER MZ360 MZ400 1 Check Starter rope Wear damage Replace Starter case Cracks damage Replace Starter spring Dirt Clean and apply grease Wear damage Replace 1 a b 1 a 1 2 Be sure ...

Page 61: ...rter spring 2 Sheave drum 3 TIP Engage the spring hook a with the drum slit then wind the spring counterclockwise into the drum from the larger to the smaller diameter 2 Install Sheave drum assembly TIP Engage the spring hook a with the starter case hook b 3 Install Springs 1 Drive pawls 2 TIP Set the ends of the springs 1 outside the drive pawls 2 4 Install Drive plate Clip 1 1 1 2 3 3 1 2 3 a a ...

Page 62: ...ave drum slot a and turn the sheave drum assembly counterclockwise four times and then unhook the starter rope from the slot 6 Check Starter handle TIP Pull the starter handle several times to check that the sheave drum turns smoothly and to check the starter rope for slack Repeat steps 1 5 if necessary 1 a Drive plate screw 5 4 N m 0 54 kgf m 4 0 lb ft T R ...

Page 63: ...arter Remove the parts in the order listed 1 Recoil starter assembly 1 2 Starter handle 1 3 Drive plate 1 4 Clip 1 5 Drive pawl 2 6 Spring 2 7 Compression spring 1 8 Sheave drum 1 9 Starter spring 1 10 Starter case 1 11 Starter rope 1 1 2 3 4 5 5 6 6 7 8 9 10 11 5 4 N m 0 54 kgf m 4 0 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 64: ...ng preload before removing the drive plate screw 1 Hook the rope into the sheave drum slot a and turn the sheave drum assembly clockwise 3 Remove Sheave drum assembly 1 Starter spring 2 Starter rope CHECKING THE RECOIL STARTER MX360 1 Check Starter rope Wear damage Replace Starter case Cracks damage Replace Starter spring Dirt Clean and apply grease Wear damage Replace a b 1 1 a 1 2 Be sure to pre...

Page 65: ...spring 2 Sheave drum 3 TIP Engage the spring hook a with the drum slit then wind the spring counterclockwise into the drum from the larger to the smaller diameter 2 Install Sheave drum assembly TIP Engage the spring hook a with the starter case hook b 3 Install Springs 1 Drive pawls 2 TIP Set the ends of the springs 1 outside the drive pawls 2 4 Install Compression spring 1 Drive plate Clip 2 3 1 ...

Page 66: ...ave drum slot a and turn the sheave drum assembly counterclockwise four times and then unhook the starter rope from the slot 6 Check Starter handle TIP Pull the starter handle several times to check that the sheave drum turns smoothly and to check the starter rope for slack Repeat steps 1 5 if necessary a 1 Drive plate screw 5 4 N m 0 54 kgf m 4 0 lb ft T R ...

Page 67: ...arburetor Refer to REMOVING THE CARBURETOR on page 4 1 Recoil starter assembly Refer to RECOIL STARTER on page 3 9 1 Flywheel cover 1 2 TCI unit 1 3 Starter pulley 1 4 Flywheel 1 5 Woodruff key 1 6 Clamp 1 Equipped models only 7 Charging coil 1 Equipped models only 1 2 3 4 5 6 7 4 10 N m 1 0 kgf m 7 4 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 120 N m 12 kg...

Page 68: ... FUEL TANK Equipped models on page 3 5 Carburetor Refer to REMOVING THE CARBURETOR on page 4 1 Recoil starter assembly Refer to RECOIL STARTER on page 3 9 1 Flywheel cover 1 2 TCI unit 1 3 Starter pulley 1 4 Flywheel 1 5 Woodruff key 1 6 Cylinder air shroud plate 1 1 2 3 4 6 5 10 N m 1 0 kgf m 7 4 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 120 N m 12 kgf m ...

Page 69: ...e flywheel 3 Remove Flywheel 1 Woodruff key TIP Remove the flywheel 1 using the flywheel puller 2 Fully tighten the tool holding bolts making sure the tool body is parallel with the flywheel If necessary one bolt may be backed out slightly to level the tool body 1 2 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 1 2 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B ...

Page 70: ...to hold the flywheel 3 Install TCI unit Refer to INSTALLING THE TCI UNIT on page 3 20 Flywheel cover INSTALLING THE TCI UNIT 1 Install TCI unit TCI unit bolts 1 2 Flywheel nut 120 N m 12 kgf m 89 lb ft Sheave holder 90890 01701 Primary clutch holder YS 01880 A T R TCI unit bolt 10 N m 1 0 kgf m 7 4 lb ft Flywheel cover bolt 7 N m 0 7 kgf m 5 2 lb ft T R T R TCI unit bolt 10 N m 1 0 kgf m 7 4 lb ft...

Page 71: ...ir gap Adjustment steps a Loosen the TCI unit bolts 1 b Adjust the TCI unit air gap c Tighten the TCI unit bolts 1 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 TCI unit air gap 0 4 0 6 mm 0 0157 0 0236 in 1 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 TCI unit bolt 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 72: ... tank Refer to FUEL TANK Equipped models on page 3 5 Fuel tank stay Refer to FUEL TANK Equipped models on page 3 5 Engine switch and oil warning unit Refer to ENGINE SWITCH AND OIL WARNING UNIT on page 3 31 1 Spring 1 2 Link rod 1 3 Spring 1 4 Governor arm 1 5 Throttle lever assembly 1 1 1 N m 0 11 kgf m 0 81 lb ft 8 N m 0 8 kgf m 5 9 lb ft 1 2 3 4 5 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 l...

Page 73: ...ts in the order listed Fuel tank Refer to FUEL TANK Equipped models on page 3 5 Fuel tank stay Refer to FUEL TANK Equipped models on page 3 5 Engine switch and oil warning unit Refer to ENGINE SWITCH AND OIL WARNING UNIT on page 3 31 1 Spring 1 2 Link rod 1 3 Spring 1 4 Governor arm 1 5 Throttle lever assembly 1 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 1 2 3 4 5 7 N m 0 7 kgf m 5 2 lb f...

Page 74: ...parts in the order listed Fuel tank Refer to FUEL TANK Equipped models on page 3 5 Fuel tank stay Refer to FUEL TANK Equipped models on page 3 5 Engine switch and oil warning unit Refer to ENGINE SWITCH AND OIL WARNING UNIT on page 3 31 1 Spring 1 2 Link rod 1 3 Spring 1 4 Governor arm 1 5 Adjusting plate 1 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 1 2 3 4 5 ...

Page 75: ...move the parts in the order listed Fuel tank Refer to FUEL TANK Equipped models on page 3 5 Fuel tank stay Refer to FUEL TANK Equipped models on page 3 5 Engine switch and oil warning unit Refer to ENGINE SWITCH AND OIL WARNING UNIT on page 3 31 1 Spring 1 2 Link rod 1 3 Spring 1 4 Governor arm 1 5 Adjusting plate 1 8 N m 0 8 kgf m 5 9 lb ft 1 2 3 4 5 7 N m 0 7 kgf m 5 2 lb ft ...

Page 76: ...marks Removing the flyweight shaft assembly Remove the parts in the order listed Engine switch and oil warning unit Refer to ENGINE SWITCH AND OIL WARNING UNIT on page 3 31 Crankcase cover Refer to PISTON CAMSHAFT CRANK CASE AND CRANKSHAFT on page 3 44 1 Clip 1 2 Governor fork 1 3 Flyweight shaft assembly 1 3 2 1 ...

Page 77: ... the order listed Fuel tank Refer to FUEL TANK Equipped models on page 3 5 Fuel tank stay Refer to FUEL TANK Equipped models on page 3 5 Engine switch and oil warning unit Refer to ENGINE SWITCH AND OIL WARNING UNIT on page 3 31 Crankcase cover Refer to PISTON CAMSHAFT CRANK CASE AND CRANKSHAFT on page 3 44 1 Clip 1 2 Governor fork 1 3 Flyweight shaft assembly 1 3 2 1 ...

Page 78: ...weight shaft assembly 1 Washer 2 TIP Remove the flyweight shaft assembly by tapping the weight shaft from outside of the crankcase cover DISASSEMBLING THE FLYWEIGHT SHAFT ASSEMBLY 1 Remove Flyweight shafts 1 Weights 2 Collar 3 Washer 4 Circlip 5 Weight shaft 6 CHECKING THE FLYWEIGHT SHAFT ASSEMBLY 1 Check Flyweight shaft assembly move smoothly Rough movement Replace 3 1 3 2 1 2 1 2 3 4 5 6 1 1 ...

Page 79: ...EMBLY 1 Install Weight shaft 1 Circlip 2 Washer 3 Collar 4 Weights 5 Flyweight shafts 6 INSTALLING THE FLYWEIGHT SHAFT ASSEMBLY AND GOVERNOR FORK 1 Install Washer 1 Flyweight shaft assembly 2 2 Install Washers 1 Governor fork 2 Clip 3 3 Install Governor assembly Crankcase cover Refer to INSTALLING THE CRANKCASE COVER on page 3 51 6 6 6 5 4 3 2 1 New 1 2 3 1 1 2 ...

Page 80: ...ver assembly against the crankcase b b Tighten the throttle lever assembly bolt 2 c Tighten the throttle lever assembly bolts 1 and 2 to the specified torque ADJUSTING THE GOVERNOR 1 Adjust Governor Adjustment steps a Loosen the governor arm bolt 1 b Turn the governor arm 2 clockwise until it stops c Turn the governor fork 3 clockwise until it stops d Tighten the governor arm bolt 1 1 2 a b Thrott...

Page 81: ...parts in the order listed Fuel tank Refer to FUEL TANK Equipped models on page 3 5 Fuel tank stay Refer to FUEL TANK Equipped models on page 3 5 1 Engine switch 1 2 Oil warning light 1 With oil warning model 3 Wire harness protector 1 With oil warning model 4 Oil warning unit 1 With oil warning model 5 Clamp 1 With oil warning model 4 5 N m 0 45 kgf m 3 3 lb ft 1 2 3 4 5 4 5 N m 0 45 kgf m 3 3 lb ...

Page 82: ...SWITCH Order Job Parts to remove Q ty Remarks Removing the engine switch Remove the parts in the order listed Fuel tank Refer to FUEL TANK Equipped models on page 3 5 Fuel tank stay Refer to FUEL TANK Equipped models on page 3 5 1 Engine switch 1 4 5 N m 0 45 kgf m 3 3 lb ft 1 ...

Page 83: ...Air filter Refer to AIR FILTER on page 3 3 Carburetor Refer to REMOVING THE CARBURETOR on page 4 1 Flywheel cover Refer to FLYWHEEL on page 3 17 1 Spark plug cap 1 2 Spark plug 1 3 Air filter case stay 1 MX360 only 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Cylinder air shroud 1 7 Locknut 2 8 Adjuster 2 9 Screw 2 6 5 4 3 2 7 8 9 7 8 9 1 7 N m 0 7 kgf m 5 2 lb ft 11 N m 1 1 kgf m 8 1 ...

Page 84: ...ker arm shaft 2 11 Rocker arm 2 12 Push rod 2 13 Cylinder head assembly 1 14 Cylinder head gasket 1 15 Dowel pin 2 10 11 12 12 11 13 10 15 15 14 7 N m 0 7 kgf m 5 2 lb ft 11 N m 1 1 kgf m 8 1 lb ft 20 N m 2 0 kgf m 15 lb ft 2 3 N m 0 23 kgf m 1 7 lb ft 50 N m 5 0 kgf m 37 lb ft 12 N m 1 2 kgf m 8 9 lb ft 1st 2nd ...

Page 85: ... Check the combustion chamber for carbon depos its Any carbon deposits Eliminate TIP Be sure not to damage the contact surface of the cylinder 2 Check Cylinder head Cracks damage around the hole of spark plug Replace 3 Measure Cylinder head warpage TIP Measure the warpage on the contact surface of the cylin der head at six points using the straight edge and thick ness gauge Out of specifications R...

Page 86: ...INSTALLING THE CYLINDER HEAD ASSEMBLY 1 Install Cylinder head Cylinder head bolts 1 to 5 TIP Tighten the bolts to the specified torque in two steps and in order from 1 to 5 1 2 3 4 5 5 Cylinder head bolt 1st 12 N m 1 2 kgf m 8 9 lb ft 2nd 50 N m 5 0 kgf m 37 lb ft T R ...

Page 87: ...Removing the valve Remove the parts in the order listed Cylinder head assembly Refer to CYLINDER HEAD COVER CYLIN DER HEAD on page 3 33 1 Valve cotter 2 2 Valve spring retainer 2 3 Valve spring 2 4 Exhaust valve 1 5 Intake valve 1 6 Valve stem seal 1 Intake side only 1 2 3 5 6 4 1 2 3 ...

Page 88: ...5 CHECKING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves valve springs and related components 1 Measure Valve stem length a Valve head diameter b Out of specifications Replace 1 2 3 4 5 Do not compress the valve spring more than neces sary Valve spring compressor 90890 01253 NOTICE b a Valve stem length Intake 88 1 mm 3 4685 in Valve stem length Exhaust 88 1 mm ...

Page 89: ...pring free length a Out of specifications Replace a Valve stem diameter Intake 5 948 5 963 mm 0 2342 0 2348 in Valve stem diameter Exhaust 5 940 5 955 mm 0 2339 0 2344 in Limit Intake 5 918 mm 0 2330 in Limit Exhaust 5 910 mm 0 2327 in Valve stem runout limit 0 01 mm 0 0004 in a Valve spring free length Intake 36 2 mm 1 4252 in Valve spring free length Exhaust 36 2 mm 1 4252 in Limit Intake 34 39 ...

Page 90: ...procedure applies to all of the valves and valve seats 1 Remove carbon deposits from the valve face and valve seat 2 Apply a small amount of coarse mechanic s blue lay out fluid to the valve face a b a b Installed length Installed compression spring force Intake 91 20 104 93 N 9 3 10 7 kgf 20 50 23 59 lbf Installed compression spring force Exhaust 91 20 104 93 N 9 3 10 7 kgf 20 50 23 59 lbf Instal...

Page 91: ... rough eccentric wear Replace 5 Measure Valve seat contact width a Make sure that the contact width along the entire valve seat is within specifications Out of specification rough eccentric wear Replace a Valve face contact width Intake 0 7 0 9 mm 0 0276 0 0354 in Valve face contact width Exhaust 0 7 0 9 mm 0 0276 0 0354 in Limit Intake 1 4 mm 0 0551 in Limit Exhaust 1 4 mm 0 0551 in a Valve seat ...

Page 92: ... Apply fine lapping compound on the valve face and lap the valve as described in step 1 3 Once the contacting surface of the valve face is pol ished and becomes shiny apply mechanic s blue lay out fluid to make sure that there are traces of even contact in the center of the valve face TIP After every lapping procedure clean off the compound from the valve face and valve seat 1 Do not let the lappi...

Page 93: ...en I or IN is stamped on the stamped portion d of the valve install the valve on the intake side of the cylin der head and when EX is stamped install the valve on the exhaust side of the cylinder head 1 2 3 4 5 E M Valve spring compressor 90890 01253 New New a b Do not compress the spring more than necessary Surface a with the rounded edges of the valve cot ter must face downward to the valve spri...

Page 94: ...rder listed Cylinder head assembly Refer to CYLINDER HEAD COVER CYLIN DER HEAD on page 3 33 Flywheel Refer to FLYWHEEL on page 3 17 1 Crankcase cover 1 2 Gasket 1 3 Dowel pin 2 4 Clamp 1 5 Oil level switch 1 6 Flyweight shaft assembly 1 7 Clip 1 8 Governor fork 1 1 2 3 3 4 5 6 7 8 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 27 N m 2 7 kgf m 20 lb ft 27 N m 2 7 kgf m 20 lb ft 30 N m 3 0 k...

Page 95: ...to remove Q ty Remarks 9 Balancer shaft 1 10 Camshaft 1 11 Valve lifter 2 12 Crankshaft shim 1 13 Connecting rod cap 1 14 Crankshaft 1 15 Connecting rod 1 16 Piston pin circlip 2 17 Piston pin 1 18 Piston 1 19 Piston ring set 1 11 13 14 15 16 17 18 19 16 11 12 10 9 20 N m 2 0 kgf m 15 lb ft ...

Page 96: ...d assembly Refer to CYLINDER HEAD COVER CYLIN DER HEAD on page 3 33 Flywheel Refer to FLYWHEEL on page 3 17 1 Crankcase cover 1 2 Gasket 1 3 Dowel pin 2 4 Clamp 1 5 Oil level switch 1 6 Flyweight shaft assembly 1 7 Clip 1 8 Governor fork 1 1 2 3 3 4 5 6 7 8 27 N m 2 7 kgf m 20 lb ft 27 N m 2 7 kgf m 20 lb ft 30 N m 3 0 kgf m 22 lb ft 12 N m 1 2 kgf m 8 9 lb ft 1st 2nd 10 N m 1 0 kgf m 7 4 lb ft 10...

Page 97: ...to remove Q ty Remarks 9 Balancer shaft 1 10 Camshaft 1 11 Valve lifter 2 12 Crankshaft shim 1 13 Connecting rod cap 1 14 Crankshaft 1 15 Connecting rod 1 16 Piston pin circlip 2 17 Piston pin 1 18 Piston 1 19 Piston ring set 1 11 13 14 15 16 17 18 19 16 11 12 10 9 20 N m 2 0 kgf m 15 lb ft ...

Page 98: ...shaft gear mark a and the crankshaft gear mark b are aligned 2 Remove Camshaft 2 TIP Remove the camshaft 2 when the camshaft gear mark c and the crankshaft gear mark d are aligned 3 Remove Intake valve lifter 1 Exhaust valve lifter 2 CHECKING THE BALANCER SHAFT 1 Check Balancer gear teeth Balancer shaft Wear damage Replace CHECKING THE CAMSHAFT 1 Check Camshaft Crack damage wear Replace 1 2 a b c ...

Page 99: ...eter a Out of specification Replace a b Camshaft lobe dimensions Lobe height a Intake 32 10 32 20 mm 1 264 1 268 in Limit 31 90 mm 1 256 in Lobe height a Exhaust 32 50 32 60 mm 1 280 1 284 in Limit 32 30 mm 1 272 in Base circle diameter b Intake 25 98 26 08 mm 1 023 1 027 in Limit 25 98 mm 1 023 in Base circle diameter b Exhaust 26 03 26 13 mm 1 025 1 029 in Limit 25 83 mm 1 017 in a a Camshaft jo...

Page 100: ...tall Intake valve lifter 1 Exhaust valve lifter 2 2 Install Balancer shaft 1 3 Install Camshaft 2 CHECKING THE CRANKCASE COVER 1 Check Crankcase cover Damage Replace Bearing Noise wear rotational failure Replace 1 2 1 2 a b c d Be sure to align the balancer shaft 1 gear mark a with the crankshaft gear mark b Be sure to align the camshaft 2 gear mark c with the crankshaft gear mark d NOTICE NOTICE ...

Page 101: ...ylinder and replace the piston and piston rings as a set 2 Measure Cylinder warpage TIP Measure the warpage on the contact surface of the cylin der head at six points using a straight edge and thickness gauge Out of specification Replace the crankcase assembly 3 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge 1 2 3 4 5 6 7 8 8 Crankcase cover bolt 1st 12...

Page 102: ...e d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula f If out of specification replace the crankcase assembly and replace the piston and piston rings as a set Bore 85 000 85 020 mm 3 3465 3 3472 in Limit 85 070 mm 3 3492 in C maximum of D1 D2 D3 D4 D5 D6 P a Piston diameter 84 977 84 998 mm 3 3455 3 3464 in...

Page 103: ...Out of specification Replace 3 Measure Piston pin diameter a Out of specification Replace 4 Check Check that the piston pin enters smoothly into the piston pin hole TIP If the piston pin fits too tight into the piston check the pis ton pin hole If there is any protrusion use a knife or scraper to gently remove it so that piston pin can be pushed in smoothly with your fingers a Piston pin hole insi...

Page 104: ...learance eliminate any carbon deposits from the piston ring grooves and pis ton rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston rings as a set Piston ring Top ring Side clearance 0 04 0 08 mm 0 0016 0 0031 in Limit 0 13 mm 0 0...

Page 105: ...pin outside diameter a Out of specification Replace Use a micrometer Top ring End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0177 in Limit 0 80 mm 0 0315 in Oil ring End gap installed 0 20 0 70 mm 0 0079 0 0276 in 1 Dial gauge 90890 03097 Dial indicator gauge YU A8428 Runout limit 0 02 mm 0 0008 in a Crank pin outside diamet...

Page 106: ...l Connecting rod 1 Connecting rod cap 2 TIP Tighten the cap bolts so that the crankshaft does not move while the oil clearance is being measured 3 Remove Connecting rod cap Connecting rod 4 Measure Connecting rod big end oil clearance Out of specification Replace crankshaft or con necting rod assembly and then measure the clear ance again TIP Measure the widest portion of the pressed Plastigauge 1...

Page 107: ...l Piston 1 Piston pin 2 Piston pin circlips 3 TIP Make sure that the YAMAHA mark a on the con necting rod faces toward the crankcase cover Make sure that the mark b on the piston head faces toward the push rod Install the piston pin circlips so that the clip ends are 45 c or more from the cutout in the piston INSTALLING THE CRANKSHAFT 1 Make sure that the end gap of each piston ring is positioned ...

Page 108: ...ton ring compressor to the piston and then insert the piston into the cylinder 4 Check Piston with the connecting rod 1 position TIP Make sure that the mark a on the piston head faces toward the push rod Make sure that the YAMAHA mark b on the connect ing rod faces toward the crankcase cover 5 Install Crankshaft 1 1 1 Piston ring compressor 90890 05158 YM 08037 a b 1 1 ...

Page 109: ...amshaft Refer to INSTALLING THE VALVE LIFTER BAL ANCER SHAFT AND CAMSHAFT on page 3 50 Crankcase cover Refer to INSTALLING THE CRANKCASE COVER on page 3 51 SELECTING THE CRANKSHAFT SHIM 1 Measure Crankshaft free play a Out of specification Adjust 2 Calculate Shim thickness TIP For example if the free play is 0 4 mm 0 016 in install a 0 3 mm 0 012 in shim on the crankshaft so that free play is 0 1 ...

Page 110: ...AMSHAFT CRANKCASE AND CRANK SHAFT on page 3 44 b Install or remove the shim 2 of the proper thick ness c Install the crankcase cover 1 Refer to INSTALL ING THE CRANKCASE COVER on page 3 51 d Measure the crankshaft free play again TIP Repeat these steps until the free play is within specifica tion Shim thickness table 1 2 Part number Shim thickness 7CT E1561 00 0 1 0 03 ...

Page 111: ...o apply a small amount of P 80 GRIP IT as an insertion auxiliary agent to the nipple of the installation destination pipe Order Job Parts to remove Q ty Remarks Removing the carburetor Remove the parts in the order listed Air filter Refer to AIR FILTER on page 3 3 1 Gasket 1 2 Carburetor assembly 1 3 Gasket 1 4 Joint 1 5 Gasket 1 1 2 3 4 5 ...

Page 112: ...T as an insertion auxiliary agent to the nipple of the installation destination pipe Order Job Parts to remove Q ty Remarks Removing the carburetor Remove the parts in the order listed Fuel tank Refer to FUEL TANK Equipped models on page 3 5 Air filter Refer to AIR FILTER on page 3 3 1 Gasket 1 2 Carburetor assembly 1 3 Gasket 1 4 Joint 1 5 Gasket 1 1 2 3 4 5 ...

Page 113: ... Float chamber bolt 1 3 Gasket 1 4 Float chamber 1 5 Gasket 1 6 Float pin 1 7 Float 1 8 Needle assembly 1 9 Main nozzle 1 10 Throttle valve 1 11 Throttle stop screw spring 1 1 12 Main jet 1 13 Pilot jet 1 14 Throttle shaft 1 15 Choke valve 1 16 Choke lever 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 7 N m 0 07 kgf m 0 52 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 1 2 N m 0 12 kgf...

Page 114: ...lt 1 3 Gasket 1 4 Float chamber 1 5 Gasket 1 6 Float pin 1 7 Float 1 8 Needle assembly 1 9 Main nozzle 1 10 Throttle valve 1 11 Throttle stop screw spring 1 1 12 Main jet 1 13 Pilot jet 1 14 Throttle shaft 1 15 Choke valve 1 16 Choke lever 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0 7 N m 0 07 kgf m 0 52 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 1 2 N m 0 12 kgf m 0 88 lb ft 0 7...

Page 115: ...ce TIP Lift up the float so that the tip of the float valve lightly contacts the float arm and then measure the float height a Do not adjust the float height 2 Check Jets Carburetor body Clogged Apply compressed air to clean the jet 3 Check Valve seat Wear damage Replace Dirt Clean a Float height 16 6 mm 0 65 in a b a Wear at groove b Dirt ...

Page 116: ...CAL ELECTRICAL CIRCUIT DIAGRAM WITH STARTER MOTOR OIL WARNING UNIT OIL WARNING LIGHT START OFF ON B R Br R B B B L Y Y B W B W B R B R B W B W B W R W B Y R R R Y R B B W R R M Y R R R W B B R W Br B W B W B B R R 1 2 3 4 5 6 7 8 9 0 ...

Page 117: ... code 1 Oil level switch 6 Fuse 2 Oil warning unit 7 Engine switch 3 Oil warning light 8 Solenoid valve 4 TCI unit 9 Starter motor 5 Rectifier 10 Battery option B Black B R Black Red L Blue B W Black White R Red R W Red White Y Yellow Y R Yellow Red Br Brown ...

Page 118: ...CIRCUIT DIAGRAM 5 3 1 2 3 4 5 6 7 8 9 10 ELECTRICAL WITH OIL WARNING UNIT OIL WARNING LIGHT B B B L Y Y B W B W R R B B W 1 2 3 4 5 6 ...

Page 119: ...RCUIT DIAGRAM 5 4 1 2 3 4 5 6 7 8 9 10 ELECTRICAL Color code 1 Engine switch 4 Oil warning light 2 Spark plug 5 Oil warning unit 3 TCI unit 6 Oil level switch B Black Y Yellow L Blue B W Black White R Red ...

Page 120: ...CIRCUIT DIAGRAM 5 5 1 2 3 4 5 6 7 8 9 10 ELECTRICAL WITHOUT OIL WARNING UNIT OIL WARNING LIGHT B W B B B 1 2 ...

Page 121: ...CIRCUIT DIAGRAM 5 6 1 2 3 4 5 6 7 8 9 10 ELECTRICAL Color code 1 Engine switch 2 TCI unit B Black B W Black White ...

Page 122: ...ELECTRICAL COMPONENTS 5 7 1 2 3 4 5 6 7 8 9 10 ELECTRICAL ELECTRICAL COMPONENTS 1 Spark plug 2 TCI unit 3 Oil warning unit 4 Engine switch 5 Oil level switch 6 Oil warning light 1 2 3 4 5 6 ...

Page 123: ...ge When checking for continuity switch back and forth between the switch positions a few times CHECKING THE FUSE Equipped models 1 Remove Fuse 1 Ω O L Never insert the tester probes into the coupler termi nal slots Always insert the probes from the opposite end of the coupler taking care not to loosen or dam age the leads Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer...

Page 124: ... a new fuse of the correct amperage c Set the engine switch to ON and verify if the elec trical circuit is operational d If the fuse immediately blows again check the elec trical circuit 4 Install Fuse Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Fuse amperage 10 A Never use a fuse with an amperage other than that specified Improvising or using a fuse with ...

Page 125: ...eshooting starting with step 8 Refer to ENGINE DOES NOT START on page 6 1 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Disconnect the spark plug cap 1 from the spark plug b Connect the ignition checker 2 as shown c Connect the ignition checker lead to spark plug 3 as shown d Set the engine switch to ON e Pull the recoil starter handle f ...

Page 126: ...ance CHECKING THE AIR GAP 1 Check Thickness between the magnet rotor and TCI unit Out of specification Perform the TCI unit adjust ment steps Refer to INSTALLING THE TCI UNIT on page 3 20 CHECKING THE IGNITION COIL TCI UNIT PRIMARY RESISTANCE 1 Check Primary coil resistance Out of specification Replace Spark plug cap resistance 3 75 6 25 k 1 2 Digital circuit tester CD732 90890 03243 Model 88 Mult...

Page 127: ...ignition coil TCI unit b Connect the digital circuit tester to the second ary terminal c Measure the secondary coil resistance Primary coil resistance 0 64 0 96 1 2 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Positive tester probe Black White 1 Negative tester probe Body ground 2 Secondary coil resistance 9 36 14 04 k 1 2 Digital circuit tester CD732 90890...

Page 128: ...from the bottom of the crankcase cover 2 Check Oil level switch continuity Out of specification Replace a Connect the digital circuit tester to the oil level switch as shown 1 2 a b Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Positive tester probe Black 1 Negative tester probe Black 2 Engine switch ON Continuity a Engine switch OFF No continuity b 1 1 2 2 ...

Page 129: ...nals on the battery side and the starter motor side b Check the starter motor operation c Disconnect the engine switch coupler d Connect the jumper lead 1 to the starter relay coupler e Check the starter motor operation CHECKING THE WIRE HARNESS 1 Check Terminal of the connector Contamination rust or disconnection Clean or replace the connector 1 A wire that is used as a jumper lead must have at l...

Page 130: ...RICAL ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Equipped models Order Job Parts to remove Q ty Remarks Removing the starter motor Remove the parts in the order listed 1 Starter motor assembly 1 1 16 N m 1 6 kgf m 12 lb ft 16 N m 1 6 kgf m 12 lb ft ...

Page 131: ... to remove Q ty Remarks Disassembling the starter motor Disassemble the parts in the order listed 1 Rear bracket 1 2 Insulator 1 3 Brush holder 1 4 Brush spring 4 5 Brush 4 6 Yoke 1 7 Armature 1 8 Starter relay 1 9 Starter drive lever 1 10 Starter case 1 1 2 3 4 5 6 7 8 9 10 8 N m 0 8 kgf m 5 9 lb ft 5 N m 0 5 kgf m 3 7 lb ft ...

Page 132: ...d to fit the commutator TIP The mica insulation of the commutator must be undercut to ensure proper operation of the commutator 3 Measure Armature coil insulation continuity Defects Replace the starter motor Connect the digital circuit tester to the armature coil a Depth of insulator a 0 4 0 8 mm 0 0157 0 0315 in Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927...

Page 133: ... 1 resistance Connect the digital circuit tester to the starter relay Out of specification Replace ASSEMBLING THE STARTER MOTOR 1 Install Armature and starter drive lever 2 Install Starter relay 1 1 2 Brush wear limit length 6 0 mm 0 2362 in 1 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 A B C Holding coil resistance A B 1 1 Pull in coil resistance A C 0 5 ...

Page 134: ... Check Charging coil resistance Out of specification Replace a Connect the digital circuit tester to the charging coil as shown b Measure the charging coil resistance Charging coil resistance 1 6 1 2 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Positive tester probe Charging coil connector 1 Negative tester probe Body ground 2 ...

Page 135: ...TANCE on page 5 11 Replace the ignition coil 9 Check the spark plug cap resistance Refer to CHECKING THE SPARK PLUG CAP RESIS TANCE on page 5 11 Replace the spark plug cap 10 Check the carburetor for clogged passages or fuel overflow Clean 11 Check the compression pressure Refer to MEASURING THE COMPRESSION PRES SURE on page 3 1 Too high Decarbonize the combustion chamber if there is carbon deposi...

Page 136: ...fer to CIRCUIT DIAGRAM on page 5 1 Properly connect or repair the starting system s wiring 7 The starting system circuit is OK No Checking steps Possible remedy 1 Check the fuel level Add the fuel if it is insufficient 2 Check if the fuel cock is clogged Clean 3 Check if the fuel hoses is clogged Clean 4 Check if there is air suction from the carburetor joint gas ket or throttle shaft Tighten the ...

Page 137: ... Adjust the valve clearance 5 Check the valve face and valve seat for wear Refer to VALVE on page 3 37 Resurface or replace the valve face and valve seat 6 Check if the marks on the crankshaft camshaft and bal ancer shaft are aligned Refer to INSTALLING THE VALVE LIFTER BALANCER SHAFT AND CAMSHAFT on page 3 50 Correct 7 Check if there is seizure wear or damage on the piston piston ring or cylinder...

Page 138: ...the carburetor are clogged Clean the parts 8 Check the valve clearance Refer to ADJUSTING THE VALVE CLEARANCE on page 2 12 Adjust the valve clearance 9 Check the valve face and valve seat for wear Refer to VALVE on page 3 37 Resurface or replace the valve face and valve seat 10 Check if there is seizure wear or damage on the piston piston ring or cylinder Refer to PISTON CAMSHAFT CRANKCASE AND CRA...

Page 139: ...the governor link operate smoothly Adjust or replace 2 Check that the governor spring is stretched Replace 3 Check the governor adjustment Refer to ADJUSTING THE GOVERNOR on page 3 30 Adjust 4 Check the governor weight and governor bushing function Refer to CHECKING THE FLYWEIGHT SHAFT ASSEM BLY on page 3 28 Adjust or replace ...

Page 140: ...GOVERNOR OPERATION 6 6 1 2 3 4 5 6 7 8 9 10 TROUBLESHOOTING MEMO ...

Page 141: ...in MX360 306 mm 12 05 in MZ400 Dry weight MZ360 33 kg 72 75 lb MX360 MZ400 Engine Engine type Air cooled 4 stroke gasoline OHV Cylinder arrangement Single cylinder Displacement 0 358 L 358 cm MZ360 MX360 0 402 L 402 cm MZ400 Bore Stroke 85 0 63 2 mm 3 35 2 49 in MZ360 MX360 85 0 71 0 mm 3 35 2 80 in MZ400 Compression ratio 8 2 1 Standard compression pressure 450 550 kPa 4 5 5 5 kg cm 65 25 79 75 p...

Page 142: ... Centrifugal weight system Electrical Ignition system TCI Ignition timing 3600 r min BTDC 20 3 MZ360 MX360 BTDC 15 3 MZ400 Spark plug type BPR4ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in The power rating of the engine indicated in the SPECIFICATIONS is the net power output tested on an engine model and measured at 3600 r min Actual power output for an installed engine will vary depending on nu...

Page 143: ...19 995 20 000 mm 0 7872 0 7874 in Limit 19 975 mm 0 7864 in Piston ring Top ring Type Barrel Dimensions 1 2 3 1 mm 0 0472 0 1220 in End gap installed 0 20 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in Side clearance 0 04 0 08 mm 0 0016 0 0031 in Limit 0 13 mm 0 0051 in 2nd ring Type Taper Dimensions 1 2 3 2 mm 0 0472 0 1260 in End gap installed 0 30 0 45 mm 0 0118 0 0177 in Limit 0 80 mm 0 0315...

Page 144: ...e circle diameter Intake 25 98 26 08 mm 1 023 1 027 in Limit 25 98 mm 1 023 in Base circle diameter Exhaust 26 03 26 13 mm 1 025 1 029 in Limit 25 83 mm 1 017 in Camshaft journal diameter 15 965 15 990 mm 0 6285 0 6295 in Limit 15 950 mm 0 628 in Valve Valve dimensions Valve head diameter Intake 31 9 32 1 mm 1 2559 1 2638 in Valve head diameter Exhaust 27 9 28 1 mm 1 0984 1 1063 in Valve stem diam...

Page 145: ...Valve clearance cold Intake 0 05 0 09 mm 0 0020 0 0035 in Exhaust 0 05 0 09 mm 0 0020 0 0035 in Push rod Runout limit 0 15 mm 0 0059 in Valve spring Valve spring free length Intake 36 2 mm 1 4252 in Valve spring free length Exhaust 36 2 mm 1 4252 in Limit Intake 34 39 mm 1 3539 in Limit Exhaust 34 39 mm 1 3539 in Installed length Intake 29 0 mm 1 1417 in Installed length Exhaust 29 0 mm 1 1417 in ...

Page 146: ... 8 MZ360 0 5 MX360 0 54 MZ400 Pilot screw 2 1 4 turns out 2 turns out MZ360 1 1 4 1 2 turns out MX360 1 3 4 1 2 turns out MZ400 Throttle valve 120 MZ360 13 MX360 Float height 16 6 mm 0 65 in Governor arm Tension spring attach hole 4 MZ360 3 2 MX360 3 MZ400 Engine speed High engine speed No throttle lever models 3110 3210 r min MZ360 3700 3800 r min MX360 MZ400 High engine speed Throttle lever equi...

Page 147: ...25 k at 20 C 68 F Choke solenoid resistance 26 5 MZ360 TCI unit air gap 0 4 0 6 mm 0 0157 0 0236 in Minimum ignition spark gap 6 0 mm 0 24 in Charging coil resistance 1 6 20 Electric starting system Equipped models Depth of insulator 0 4 0 8 mm 0 0157 0 0315 in Insulation resistance More than 1 0 M Brush spring pressure 11 73 15 35 N 1 196 1 565 kgf 2 637 3 451 lbf Brush wear limit length 6 0 mm 0...

Page 148: ... N m 0 7 kgf m 5 2 lb ft TCI unit bolt M6 1 0 10 N m 1 0 kgf m 7 4 lb ft Flywheel nut M18 1 5 120 N m 12 kgf m 89 lb ft Governor arm bolt M6 1 0 8 N m 0 8 kgf m 5 9 lb ft Throttle lever assembly bolt M6 1 0 7 N m 0 7 kgf m 5 2 lb ft Adjusting plate bolt M6 1 0 7 N m 0 7 kgf m 5 2 lb ft Throttle lever assembly plate screw MX360BA6A0 M5 0 8 1 1 N m 0 11 kgf m 0 81 lb ft Throttle lever assembly wire ...

Page 149: ... chamber bolt 7 N m 0 7 kgf m 5 2 lb ft Carburetor drain screw 1 3 N m 0 13 kgf m 0 95 lb ft Pilot jet 1 2 N m 0 12 kgf m 0 88 lb ft Throttle valve screw 0 7 N m 0 07 kgf m 0 52 lb ft Choke valve screw 0 7 N m 0 07 kgf m 0 52 lb ft Item Thread size Tightening torque ...

Page 150: ... assemblies are included in the applicable sections of this book To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specifications call for clean dry threads Components should be at room temperature Thread size Tightening torque N m kgf m lb ft M4 2 0 0 20 1 5 M5 3 0 0 30 2 2 M6 7 0 7 5 2 M7 10 1 0 7 4 M8 1...

Page 151: ...ting rod cap bolt Piston pin Piston Balancer shaft journal Balancer shaft gear teeth Crankshaft gear teeth Valve stem Valve stem end Valve rocker arm shaft Valve push rod end Valve lifter stem Camshaft lobe Camshaft gear teeth Decompressor pin Camshaft journal Governor collar internal surface Governor fork meet surface Governor weight moving point Fuel pipe nipple installation destination of fuel ...

Page 152: ...WIRE ROUTING DIAGRAM 7 12 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS WIRE ROUTING DIAGRAM UPPER SIDE VIEW MZ360 ...

Page 153: ...ed models 3 Clamp A The spark plug cap should face the direction indicated in the illustration B Pass the lead under the throttle stop screw When shipment from the factory C Route the lead as shown D Fold the clamp as shown E Pass the lead through the hole in the crankcase F Screw in the high tension cord until it touches the spark plug cap ...

Page 154: ...WIRE ROUTING DIAGRAM 7 14 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS UPPER SIDE VIEW MX360 ...

Page 155: ...tration B After passing through the lead wire pull it lightly in the direction of the arrow C Route the lead as shown D The lead is black and the protector is gray E Attach the projection of the oil warning unit to the hole of the bracket F Make sure that the gap between the end of the wire harness protector and end of the crankcase is 5 mm 0 19 in or more G Fasten the ground terminal and engine s...

Page 156: ...WIRE ROUTING DIAGRAM 7 16 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS UPPER SIDE VIEW MZ400 ...

Page 157: ... plug cap 3 Charging coil lead 2 Oil level switch lead 4 High tension cord A The spark plug cap should face the direction indicated in the illustration B Pass the lead through the hole in the crankcase C Screw in the high tension cord until it touches the spark plug cap ...

Page 158: ...WIRE ROUTING DIAGRAM 7 18 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS ENGINE SWITCH AND OIL WARNING UNIT With oil warning light oil warning unit oil level switch ...

Page 159: ...ne switch lead ground 5 Engine switch 3 Wire harness protector A Fasten the ground terminal and engine switch together B Clamp the connector part C The lead is black and the protector is gray D Attach the projection of the engine switch to the hole of the bracket B Black Y Yellow L Blue B W Black White R Red ...

Page 160: ...WIRE ROUTING DIAGRAM 7 20 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS ENGINE SWITCH AND OIL WARNING UNIT With oil warning unit oil level switch ...

Page 161: ...s protector 2 Engine switch lead ground 4 Clamp A Unused yellow and black white lead wires are stored in the wire harness protector and fixed with a clamp together with other lead wires B Clamp the connector part C The lead is black and the protector is gray B Black Y Yellow L Blue B W Black White R Red ...

Page 162: ...M 7 22 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS ENGINE SWITCH AND OIL WARNING UNIT No oil level switch Color code 1 Engine switch A Attach the projection of the engine switch to the hole of the bracket B Black B W Black White ...

Page 163: ...Clamp A Make sure that the high tension cord is not pinched when installing the flywheel cover B Make it to the TCI unit side so that the lead wire cover can be clamped C Clamp should be done with cover D Adjust the TCI unit air gap between 0 4 0 6 mm 0 0157 0 0236 in on both sides E Pass the lead through the hole in the crankcase F The lead wire must be attached so that there is no slack without ...

Page 164: ... 1 Spark plug cap 3 Flywheel 2 High tension cord 4 TCI unit A Make sure that the high tension cord is not pinched when installing the flywheel cover B Adjust the TCI unit air gap between 0 4 0 6 mm 0 0157 0 0236 in on both sides C Pass the lead through the hole in the crankcase ...

Page 165: ...Make sure that the high tension cord is not pinched when installing the flywheel cover B Make it to the TCI unit side so that the lead wire cover can be clamped C Clamp should be done with cover D Adjust the TCI unit air gap between 0 4 0 6 mm 0 0157 0 0236 in on both sides E Pass the lead through the hole in the crankcase F The lead wire must be attached so that there is no slack without biting ...

Page 166: ... ROUTING DIAGRAM 7 26 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS OIL LEVEL SWITCH CRANKCASE COVER MZ360 1 Clamp 2 Oil level switch A Touch the tube gray with the grommet B Route the oil level switch lead as shown ...

Page 167: ... ROUTING DIAGRAM 7 27 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS OIL LEVEL SWITCH CRANKCASE COVER MX360 1 Clamp 2 Oil level switch A Touch the tube gray with the grommet B Route the oil level switch lead as shown ...

Page 168: ... ROUTING DIAGRAM 7 28 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS OIL LEVEL SWITCH CRANKCASE COVER MZ400 1 Clamp 2 Oil level switch A Touch the tube gray with the grommet B Route the oil level switch lead as shown ...

Page 169: ...WIRE ROUTING DIAGRAM 7 29 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS MEMO ...

Page 170: ...PPENDIX CIRCUIT DIAGRAM WITH STARTER MOTOR OIL WARNING UNIT OIL WARNING LIGHT START OFF ON B R Br R B B B L Y Y B W B W B R B R B W B W B W R W B Y R R R Y R B B W R R M Y R R R W B B 1 2 3 4 5 6 7 8 9 0 ...

Page 171: ... Fuse 2 Oil warning unit 7 Engine switch 3 Oil warning light 8 Solenoid valve 4 TCI unit 9 Starter motor 5 Rectifier 10 Battery option B Black B R Black Red L Blue B W Black White R Red R W Red White Y Yellow Y R Yellow Red Br Brown ...

Page 172: ...WITH OIL WARNING UNIT OIL WARNING LIGHT B B B L Y Y B W B W R R B B W 1 2 3 4 5 6 ...

Page 173: ...Color code 1 Engine switch 4 Oil warning light 2 Spark plug 5 Oil warning unit 3 TCI unit 6 Oil level switch B Black Y Yellow L Blue B W Black White R Red ...

Page 174: ...WITHOUT OIL WARNING UNIT OIL WARNING LIGHT B W B B B 1 2 ...

Page 175: ...Color code 1 Engine switch 2 TCI unit B Black B W Black White ...

Page 176: ...MEMO ...

Page 177: ...7HC F8197 E1_cover indd 3 4 2019 03 13 10 20 44 ...

Page 178: ...SERVICE MANUAL MZ360 MX360 MZ400 7HC F8197 E1 2019 03 1 7HC F8197 E1_cover indd 1 2 2019 03 13 10 20 44 ...

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