Yamaha MZ400 Supplementary Service Manual Download | Manualshive

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MZ400

MX400

SUPPLEMENTARY
SERVICE MANUAL

7HS-F8197-10

LIT-19616-02-36

2016_02×1

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7HS-F8197-10_cover.indd 1

2016/02/25 15:28:11

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Summary of Contents for MZ400

Page 1: ...MZ400 MX400 SUPPLEMENTARY SERVICE MANUAL 7HS F8197 10 LIT 19616 02 36 2016_02 1 7HS F8197 10_cover indd 1 2016 02 25 15 28 11 ...

Page 2: ...7HS F8197 10_cover indd 2 2016 02 25 15 28 11 ...

Page 3: ...owledge attempted repairs or service to this model may render it unfit for use and or unsafe Yamaha Motor Powered Products Co Ltd is continually striving to further improve all mod els manufactured by Yamaha Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will where applicable appear in future editions of this manual TIP ...

Page 4: ...otential personal injury haz ards Obey all safety messages that follow this symbol to avoid possible injury or death WARNING A WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the machine or other property TIP A TIP provides key information to make proce dures ea...

Page 5: ...G 3 20 CYLINDER HEAD COVER CYLINDER HEAD 6 5 4 3 2 7 8 9 7 8 11 Nm 1 1 m kgf 8 0 ft lbf 20 Nm 2 0 m kgf 14 ft lbf 2 3 Nm 0 23 m kgf 1 7 ft lbf 12 Nm 1 2 m kgf 8 7 ft lbf 50 Nm 5 0 m kgf 36 ft lbf 1st 2nd 7 Nm 0 7 m kgf 5 1 ft lbf 9 1 Order Job Parts to remove Q ty Remarks Removing the cylinder head cover cylinder head Remove the parts in the order listed Fuel tank Refer to FUEL TANK on 3 4 Muffler...

Page 6: ...ts Engine Carburetor Electrical Troubleshooting Specifications Filling fluid Lubricant Special tool T R Tightening torque Wear limit clearance Engine speed Electrical data Replace the part with a new one LS Lithium soap base grease M Molybdenum disulfide grease E Engine oil M Molybdenum disulfide oil LT Apply locking agent LOCTITE ...

Page 7: ...INDEX GENERAL INFORMATION GEN INFO SPECIFICATIONS SPEC 1 2 ...

Page 8: ...1 GENERAL INFORMATION MACHINE IDENTIFICATION 1 1 ENGINE SERIAL NUMBER 1 1 STARTING SERIAL NUMBER 1 1 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 ENGINE 2 3 ELECTRICAL 2 7 ...

Page 9: ... the position 2 of the multi purpose engine as shown in the illustration TIP The first four digits identify the model and the remaining digits indicates the production number STARTING SERIAL NUMBER Model Code Starting serial number MZ400KH2P6 7HSB 7HSB 1000101 MX400AA6L6 7HSJ 7HSJ 1000101 TIP Designs and specifications are subject to change without notice 1 ...

Page 10: ...0 Compression ratio 8 2 1 Standard compression pressure kPa kg cm2 psi 450 550 4 5 5 5 65 3 79 8 Net output kW PS r min 8 93 12 14 3600 Fuel Unleaded regular gasoline Fuel tank capacity L US gal Imp gal 6 1 1 61 1 34 Engine oil quantity L US qt Imp qt 1 1 1 16 0 97 Recommended engine oil A YAMALUBE 4 10W 40 SAE 10W 30 or 10W 40 B SAE 30 C SAE 20 D SAE 10W A YAMALUBE 4 10W 40 B SAE 30 C SAE 20 D SA...

Page 11: ... BPR4ES NGK Spark plug gap mm in 0 7 0 8 0 028 0 031 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 numerous factors including the operating speed of the engine environmental conditions and other variables 2 ...

Page 12: ...975 0 7864 Piston ring mm in Top ring Type Barrel Dimensions B T 1 2 3 1 0 0472 0 1220 End gap 0 20 0 35 0 0079 0 0138 Limit 0 6 0 0236 Side clearance 0 04 0 08 0 0016 0 0031 Limit 0 13 0 0051 2nd ring Type Taper Dimensions B T 1 2 3 2 0 0472 0 1260 End gap 0 30 0 45 0 0118 0 0177 Limit 0 8 0 0315 Side clearance 0 03 0 07 0 0012 0 0028 Limit 0 13 0 0051 Oil ring Type 3 piece type Dimensions B T 2 ...

Page 13: ...diameter A 20 006 20 020 0 7876 0 7882 Oil clearance 0 006 0 025 0 0002 0 0010 Big end diameter B 36 000 36 015 1 4173 1 4179 Big end oil clearance 0 016 0 046 0 0006 0 0018 Limit 0 09 0 0035 Camshaft mm in Camshaft outside diameter 113 4 113 7 4 465 4 476 Camshaft lobe dimensions A IN 32 5 32 6 1 2795 1 2835 Limit 32 3 1 2717 A EX 32 5 32 6 1 2795 1 2835 Limit 32 3 1 2717 B IN 26 0 26 1 1 0236 1 ...

Page 14: ...mit IN 1 6 0 063 EX 1 6 0 063 Valve seat contact width IN 0 7 0 9 0 0276 0 0354 EX 0 7 0 9 0 0276 0 0354 Limit IN 1 6 0 063 EX 1 6 0 063 Valve seat width IN 0 7 0 9 0 0276 0 0354 EX 0 7 0 9 0 0276 0 0354 Valve margin thickness IN 1 0 1 4 0 0394 0 0551 EX 1 0 1 4 0 0394 0 0551 Valve stem runout limit 0 01 0 0004 θ 90 Valve guide Guide inside diameter IN 6 000 6 012 0 2362 0 2367 EX 6 000 6 012 0 23...

Page 15: ... 49 20 50 23 59 Tilt limit mm in 1 7 0 0669 Carburetor mm in Type manufacture RUIXNG I D mark 7HP E4301 Bore size ø26 Main jet 1 23 0 050 1 27 0 050 Main air jet 1 4 0 055 Pilot air jet 1 2 0 045 Pilot outlet 1 0 0 039 Valve seat size 1 8 0 070 Pilot jet 0 54 0 02 0 55 0 02 Pilot screw 1 3 4 turns out Throttle valve 13 14 Float height H 14 9 0 59 Governor arm Tension spring attach hole 3 1 Engine ...

Page 16: ...sistance Ω 20 0 6 Secondary coil resistance kΩ 20 11 2 Spark plug cap resistance kΩ 3 75 6 25 at 20 C 68 F TCI unit air gap mm in 0 4 0 6 0 0157 0 0236 Minimum spark gap mm in 6 0 0 24 Electric starting system Depth of insulator mm in 0 4 0 8 0 0157 0 0315 Insulation resistance MΩ More than 10 Brush spring pressure N kgf lbf 13 1 Brush wear limit length mm in 6 0 0 24 ...

Page 17: ...7HS F8197 10_cover indd 2 2016 02 25 15 28 11 ...

Page 18: ...MZ400 MX400 SUPPLEMENTARY SERVICE MANUAL 7HS F8197 10 LIT 19616 02 36 2016_02 1 7HS F8197 10_cover indd 1 2016 02 25 15 28 11 ...

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