Yamaha MX825V-EFI Service Manual Download

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Summary of Contents for MX825V-EFI

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Page 2: ...ap 3 Specification 4 Features Structures 5 17 FI Diagnostic Tool 18 Wiring Schematic 21 Equipment Information 22 Oil Pressure Switch 23 Valve Shim Adjustment Overview 24 Valve Adjustment Procedure 25 Fuel Pump Information 26 MX825 Owner s Manual 27 ...

Page 3: ...el cooling fan area Fan case cover good maintainability 75 degree V bank angle compact engine 30 degree phase shift Crankshaft reduced vibration Yamaha muffler high performance low noise Fuel injection system good fuel efficiency performance emission Shim type valve clearance adjustment long maintenance interval Forced Lubrication system reduced engine wear Donaldson cyclone type air cleaner ...

Page 4: ...3 33 27 SAE J1940 33 28 Measured Maximum Power SAE J1995 hp SAE Certified Power 33 8 Measured by 3rd party 32 25 Measured in house 28 Maximum Torque ft lbs 50 1 51 1 44 6 Bore mm in 80 3 15 86 3 39 83 8 3 30 84 5 3 33 Stroke mm in 82 3 23 71 2 79 73 4 2 89 76 2 99 Compression Ratio 9 1 1 8 9 1 8 4 1 8 2 1 Oil capacity including filter Not final na 2 1 qt 2 4 qt ENG configuration air cooled vertica...

Page 5: ... reduce vibration Crankshaft 1 30 degree phase shift design 2 Internal oil passageways 1 Reduce vibration 2 Increase reliability reduce wear 30 degree Phase shift 2 Crank Pin 1 Crank Pin Engine oil pumped from Crankcase through the Crankshaft Back to Oil Pan To Con rod Big end Compact engine design fits a wide variety of applications while allowing easy access to maintenance components Good reliab...

Page 6: ...ight short skirt design piston w thin Piston Rings Less power is lost to friction which means more power is available for work and increased fuel economy Reduce internal engine friction The 1st ring can be installed either direction the R mark can be up or down The RN mark on the 2nd ring indicates upper side R on 1st ring RN on 2nd ring The RN mark shows upper side for 2nd ring Thin piston rings ...

Page 7: ...t design High performance Long maintenance interval 1 High performance 2 Long maintenance interval Valve clearance IN 0 04 0 08mm EX 0 08 0 12mm Periodical Check 1 000 hr Shim increments 0 05mm 2 Intake Valves 1 Exhaust Valve Valve springs for intake are different from that for exhaust Shims for Valve clearance adjustment valve adjustment procedure outlined in the Service Tips section Click ...

Page 8: ...hatch under fan case cover Fan Case Cover Fan Case Cover consists of 2 parts Good maintainability Easy to remove grass clippings from cooling system Periodical Maintenance minimum 200 hr Clean cooling fan area as needed using compressed air Clean oil cooler and any grass that may be trapped on backside Fan Cover Fan Case Maintenance hatch to remove grass clippings ...

Page 9: ...ippings from entering the flywheel cooling fan area Debris Screen Adopt Debris Screen Good maintainability To reduce grass clippings from clogging and easy maintenance Debris screen Used compressed air to remove grass clippings and other debris when cooling system is clogged Periodical Maintenance Clean cooling area as needed minimum 200 hr ...

Page 10: ...ubrication Forced lubrication system Good reliability and reduced engine wear Superior engine lubrication reliability and reduced wear Pressurized oil goes to oil filter and oil cooler through this hole To Oil filter Oil cooler Oil is supplied to the Crankshaft Camshaft after passing thru the oil cooler Trochoid Oil Pump Trochoid Oil Pump Oil Strainer Relief Valve Periodical maintenance Change eng...

Page 11: ...5V EFI 11 Supplied to Crankshaft refer to crankshaft page Supplied to Camshaft Supplied to Camshaft Spray oil to cylinder head Oil spray goes into cylinder head through hole Continuation of previous page Oil supply Camshaft ...

Page 12: ...nkcase assy has integral oil catch tray to help catch dripped oil from the filter Oil filter Oil filter position Easy serviceability Easy serviceability and easy clean up if needed Oil Filter wrench 65 67mm 14 flutes Periodical maintenance Change engine oil 100hr Change oil filter 200hr Cap Filter Wrench 65 67mm 14 Flutes commonly available at auto parts stores and other retailers Oil catch tray ...

Page 13: ... available from many suppliers Donaldson Cyclone type Air Cleaner Assy Commonly used air cleaner element Nothing ruins an engine faster than dirt that s why Yamaha chose a commonly available 2 stage design to maximize engine protection Good availability reliability Periodical maintenance Replace outer element 250hr Check Inner element 250hr Replace Inner element 500hr Element Assy Inner Element As...

Page 14: ...rformance and reduced harmful exhaust emissions Good reliability and parts availability Easy operation no separate choke enrichner device to operate Reliable engine starting in a very wide range of conditions Best possible fuel efficiency performance emission reliability Fuel Injection system to balance fuel efficiency with performance and reduce harmful exhaust emissions Fuel pump MAP MAT Sensor ...

Page 15: ...uation of previous page FI system ENG Temp MAP MAT Injector 2 Injector 1 Throttle Body w Throttle Position Sensor Electric Fuel Pump Crank Position Ignition Coil 2 Ignition Coil 1 ECU O2 sensor Use inch tool 5 8 or 16mm For ENG temp sensor ...

Page 16: ...side of engine Cover Crankcase 1 Bearings for camshaft and crankshaft Effect engine power Good fuel efficiency Reduce internal engine friction Ball Bearings Bottom side of Crankshaft Camshaft Camshaft Crankshaft Cover Crankcase 1 internal view Cover Crankcase 2 Oil pan Crankcase Plain Bearing Upper side of Crankshaft Cover Crankcase 1 with Crankcase Bottom UP ...

Page 17: ...engine Compact size engine Compact size engine 75 degree There is arrow on the piston which indicates intake side 1 Cylinder 2 Cylinder 1 Cylinder 2 Cylinder PTO Exhaust Up Intake Pistons are installed with the arrow on the piston crown pointed to the intake side of the engine this differs from the standard Yamaha practice where the arrow points to the exhaust ...

Page 18: ...U software version and info Small easy to use tool which is very durable Inexpensive enough for every mechanic to have their own the target MSRP is 150 00 Mode button Choose Mode Decide Up button Select items Down button Select items Connector for Diag Tool is installed on ENG Diag Tool Diag Tool and connecting lead FI Diagnostic Tool will be available from Yamaha Parts and Accessories Division To...

Page 19: ...R UP DOWN UP DOWN UP DOWN DOWN DOWN UP PROPERTY UP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 S E L E C T 2 C U R R E N T Display of Diag Tool Selecting Mode Display has 2 lines Upper line shows which mode you choose now or what you re doing Lower line shows what you select currently Main 5 modes of Diag tool ...

Page 20: ...r temp Temp F ET Engine temp Temp F TPS Throttle position O2 O2 density Volt RPM ENG rpm rpm HOUR Total run time hours Continuation of previous page FI diagnostic Tool Sensor outputs FI Diagnostic Tool Display More information on the FI Diagnostic tool is provided in the MX825 EFI Seminar literature ...

Page 21: ...SERVICE TIP Model MX825V EFI 21 Wiring Schematic ...

Page 22: ...e harness TE Connectivity 350715 1 and terminals TE Connectivity 350547 1 Multi connector Key Wire color codes may vary by manufacturer 1 MIL Brown wire ground for the MIL lamp circuit 2 Engine Stop White ground ignition to stop engine 3 Not used 4 Starter Brown Green energizes the starter motor solenoid 5 Oil Pressure Warning ground for the Oil Pressure Warning light circuit 6 Ignition key on Red...

Page 23: ...re Warning light 1 when the engine is not running and the Main Switch is turned to the ON or START position and 2 if the oil pressure drops during operation Condition Engine running with normal oil pressure Engine not running Oil pressure less than 7 1 psi 49 kPA Switch contacts OPEN CLOSED CLOSED Oil Pressure warning light OFF ON ON ...

Page 24: ...aced with a thicker shim If there is insufficient clearance the shim is replaced with a thinner shim Refer to the appropriate service manual for the complete measurement valve adjustment shim selection and pad replacement procedures The valve adjustment shim is cupped shaped and fits onto the valve stem effectively changing the overall length of the valve Shims will be available in a range of thic...

Page 25: ...xt thicker shim and recheck the clearance ex installed 280 replace with a 285 If the 0 13mm slides in it may require a shim 2 or more sizes larger 4 To remove and install shims remove the rocker arm shaft retaining bolt 1 and slide the shaft 2 out of the cylinder head for the valve s that need adjustment NOTE the location and placement of the two push rods 3 5 Remove the rocker arm s 4 and replace...

Page 26: ...mp then provides pressurized fuel to the fuel injectors through the high pressure hose fitting 5 fuel pressure specification is listed in the 2016 MX825 EFI Seminar material Service Tips If excessive fuel accumulates in the crankcase sump the diaphragm assembly in the vacuum pump 1 may have failed allowing fuel to flow into the crankcase via hose 2 Fuel filter 3 should be replaced following the in...

Page 27: ...Read this manual carefully before operating this machine OWNER S MANUAL MX775 MX800 MX825 LIT 19626 02 37 7UD F8199 60 E0 ...

Page 28: ...Cover page 2 Read this manual carefully before operating this machine This manual should stay with this machine if it is sold ...

Page 29: ...be minor discrepancies between your machine and this manual If there is any question concerning this manual please consult a Yamaha dealer This manual should be considered a permanent part of this machine and should remain with this machine when resold Product and specifications are subject to change without notice PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPER ATING THE MACHINE WAR...

Page 30: ...onal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the machine or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP ...

Page 31: ...on 7 Engine oil 7 Pre operation check 8 Pre operation check 8 Operation 9 Precautions for use 9 Periodic maintenance 10 The importance of maintenance 10 Maintenance schedule 10 Maintenance chart 10 Spark plug inspection 12 Engine oil replacement 13 Air filter 15 Spark arrester For models equipped with a muffler 16 Storage 18 Add fuel stabilizer 18 Engine 18 Troubleshooting 20 Engine won t start 20...

Page 32: ...ous Using a multi purpose engine indoors CAN KILL YOU IN MINUTES Multi purpose engine exhaust contains carbon monoxide This is a poison you can not see or smell NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents Fuel is highly flammable and poison ous Always turn off the engine when refuelling Never refuel while smoking o...

Page 33: ...our eye s see your doctor immediately If any fuel spills on your skin or clothing immediately wash with soap and water and change your clothes When refueling do not place the fuel tank cap near the muffler When operating or transporting the machine be sure it is kept upright If it tilts fuel may leak from the engine When lifting the engine use the engine hangers to attach a winch or other suitable...

Page 34: ... not likely to touch the machine Avoid placing any flammable materials near the exhaust outlet during operation In order to prevent overheating ensure adequate air flow by keeping the machine at least 1 m 3 ft from objects or other equipment Do not operate the engine with a dust cover or other objects covering it ...

Page 35: ...ressure fluids High pressure fluid leaks are highly toxic and hazard ous High pressure punctures the skin Do not use your hand to check for high pressure hydraulic leaks Accidental engine start prevention To prevent the engine from accidentally starting be sure to stop the engine and remove the spark plug caps before doing any service Rotating parts Keep hands feet hair and clothing away from the ...

Page 36: ...rmation Location of important labels Please read the following labels carefully before operating this machine TIP Maintain or replace safety and instruction labels as necessary 1 2 CAN ICES 2 NMB 2 7CN H2377 00 1 2 ...

Page 37: ...General view 1 Spark plug 7 Fuel filter 2 Air filter case cover 8 Oil filter cartridge 3 Oil cooler 9 Oil drain bolt 4 Shroud 10 Muffler For models equipped with a muffler 5 Fuel pump 11 Fuse 6 Oil filler cap 1 10 2 6 3 8 9 9 11 1 4 5 7 4 ...

Page 38: ...ed with out engine oil Do not start the engine until you have filled it with the sufficient engine oil NOTICE 1 2 1 Oil filler cap 2 Engine oil dipstick 0 C SAE 5W 32 F 25 C 80 F YAMALUBE SAE 10W 30 Performance All Purpose Be sure no foreign material enters the crankcase Recommended engine oil A YAMALUBE SAE 10W 30 Performance All Purpose SAE 10W 30 or 10W 40 B SAE 5W 30 Recommended engine oil gra...

Page 39: ...cks should be made each time the multi purpose engine is used Pre operation check Fuel line Check fuel hose for crack or damage Replace if necessary Engine oil Check oil level in engine If necessary add recommended oil to specified level See page 7 for more details Check multi purpose engine for oil leakage The point where abnormality was recognized by use Check operation If necessary consult a Ya...

Page 40: ... area or it may cause unconsciousness and death within a short time Operate the engine in a well ventilated area The multi purpose engine has been shipped with out engine oil Do not start the engine until you have filled it with the sufficient engine oil WARNING NOTICE ...

Page 41: ... it for you Stop the engine before starting maintenance work Use only Yamaha specified genuine parts for replacement Ask an authorized Yamaha dealer for further information Daily 50 hrs 100 hrs 200 hrs 250 hrs 500 hrs 1000 hrs Check spark plug Check muffler and spark arrester 1 Check oil level Change engine oil Change oil filter cartridge Clean shrouds and cooling area Check and change fuel filter...

Page 42: ...iodic maintenance 1 For models equipped with a Yamaha muffler 2 Have a Yamaha dealer perform the service The point where abnormality was recognized by use Daily 50 hrs 100 hrs 200 hrs 250 hrs 500 hrs 1000 hrs ...

Page 43: ... spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specifi cation 4 Install the spark plugs and then tighten them TIP If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 5 Install the spa...

Page 44: ...il filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of clean engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated Avoid draining the engine oil immediately after stopping the engine The oil is hot and should be handled w...

Page 45: ... several minutes while checking for oil leaks 1 Torque wrench Oil filter cartridge tightening torque 14 N m 1 4 kgf m 10 lb ft Oil drain bolt tightening torque 27 N m 2 7 kgf m 20 lb ft 1 0 C SAE 5W 32 F 25 C 80 F YAMALUBE SAE 10W 30 Performance All Purpose 1 Oil filler hole Be sure no foreign material enters the crankcase Recommended engine oil A YAMALUBE SAE 10W 30 Performance All Purpose SAE 10...

Page 46: ...t level 13 Install and tighten the oil filler cap Air filter 1 Unhook the holding clips and then remove the air filter case cover from the air filter case 2 Pull the air filter element out 3 Replace the air filter element and check condition of inner element If inner element is damaged or dirty replace it 4 Install new element s into the air filter case 1 Minimum level mark 2 Maximum level mark 3 ...

Page 47: ...ean it and then install it Spark arrester For models equipped with a muffler 1 Remove the screw The engine should never run without the air filter element excessive piston and cylinder wear may result NOTICE The engine and muffler will be very hot after the engine has been run Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or...

Page 48: ...sing a wire brush 4 Check the spark arrester Replace it if damaged 5 Install the spark arrester TIP Align the spark arrester lump with the hole in the muf fler pipe 6 Install the screw and then tighten the screw 1 1 Spark arrester When cleaning use the wire brush lightly to avoid damaging or scratching of the spark arrester NOTICE 1 2 1 Hole 2 Spark arrester lump ...

Page 49: ... a teaspoonful of engine oil into each spark plug hole 4 Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit sparking during the next step 5 Turn the engine over several times with the starter This will coat the cylinder walls with oil 6 Remove the spark plug caps from the spark plugs and then inst...

Page 50: ...multi purpose engine and apply a rust inhibitor 8 Store the multi purpose engine in a dry well venti lated place with the cover placed over it 9 The multi purpose engine must remain in a vertical position when stored carried or operated ...

Page 51: ...ap and adjust it if it is incorrect c Replace the spark plug if it still does not spark To prevent FIRE HAZARDS be sure fuel is not present in the spark plug area To prevent FIRE HAZARDS be sure to place the spark plug as far away as possible from the spark plug hole area To prevent ELECTRIC SHOCK do not hold spark plug lead with hand while testing WARNING Spark plug gap 0 7 0 8 mm 0 028 0 031 in ...

Page 52: ...se immediately blows again consult a Yamaha dealer For the 30 A fuse there is identification red tape on the wire harness c Install the fuse holder to the original position Be sure to use specified fuse A wrong fuse will cause electrical system damage and A FIRE HAZ ARD To prevent accidental short circuiting be sure stop the engine before replacing the fuse WARNING NOTICE 1 Fuse holder 2 Fuse hold...

Page 53: ... V type 2 cylinder Displacement cmu 824 Bore u Stroke mm in 80 0 u 82 0 3 15 u 3 23 Starting method Starter motor Fuel Unleaded gasoline Gasohol E10 acceptable Fuel supply Fuel injection Engine oil quantity L US qt Imp qt 2 0 2 11 1 76 Ignition system ECU control battery ignition Spark plug type BPR6ES NGK Spark plug gap mm in 0 7 0 8 0 028 0 031 Maximum angle of oper ation 30q Low oil level PTO s...

Page 54: ...t production number SERIAL No Keep a record of these numbers for reference when ordering parts from a Yamaha dealer Identification number records Record your model type Primary I D and serial num bers in the spaces provided to assist you in ordering spare parts from a Yamaha dealer Also record and keep these I D numbers in a separate place in case your machine is stolen MODEL PRI I D CODE SERIAL N...

Page 55: ...s Terms and Definitions For Electrical Electronic System It is recommended that these items be serviced by a Yamaha dealer Item 9 Fuel Injection 9 Engine Control Unit 9 Throttle Position Sensor 9 Crank Position Sensor 9 Intake Manifold Air Pressure Sensor Intake Temp Sensor 9 O2 Sensor 9 Ignition Coil Spark Plug 9 Fuel Pump 9 Crankcase 9 Air Filter Assy 9 Engine Temp Sensor Muff Spark Arrester Opt...

Page 56: ...onous 1 F Fuel is highly flammable and poisonous 1 G General safety information 1 General view 6 H High pressure fluids 4 I Identification number records 23 L Location of important labels 5 M Machine identification 23 Maintenance chart 10 Maintenance schedule 10 MX775 MX800 MX825 specifications 22 P Precautions for use 9 Pre operation check 8 Preparation 7 R Rotating parts 4 S Spark arrester 16 Sp...

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Page 59: ...s that may be the trademarks service marks of their respective owners These company brand and product names are used herein for identification purposes only and references to any names marks products or services of third parties do not constitute or imply endorsement sponsorship or recommendation of the third party or the products or services 2016 Yamaha Motor Corporation U S A All rights reserved...

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