background image

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. 
Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check 
procedures are laid out with the individual steps in sequential order.

9

 

The manual is divided into chapters and each chapter is divided into sections. The current sec-
tion title is shown at the top of each page 

1

.

9

 

Sub-section titles appear in smaller print than the section title 

2

.

9

 

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of 
each removal and disassembly section 

3

.

9

 

Numbers are given in the order of the jobs in the exploded diagram. A number indicates a dis-
assembly step 

4

.

9

 

Symbols indicate parts to be lubricated or replaced 

5

.

  Refer to “ILLUSTRATED SYMBOLS”.

9

 

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of 
parts, notes in jobs, etc. 

6

. This step explains removal procedure only. For installation, reverse 

the steps.

9

 

Jobs requiring more information (such as special tools and technical data) are described 
sequentially 

7

.

ENG

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

Refer to “MUFFLER” on 3-6.

Air filter

Refer to “AIR FILTER” on 3-3.

Carburetor

Refer to “CARBURETOR” on 4-1.

Flywheel cover

Refer to “FLYWHEEL” on 3-12.

1

Spark plug cap

1

2

Spark plug

1

3

Air filter case stay

1

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

CYLINDER HEAD COVER, CYLINDER HEAD

ENG

3-22

CYLINDER HEAD COVER, CYLINDER HEAD

CHECKING THE PUSH ROD

  1.  Check:

 

9

  Push rod runout

Runout limit:
   Refer  to  “SPECIFICATIONS”  in 

the  Supplementary  service 
manual.

    Out of specifications 

 Replace.

CHECKING THE CYLINDER HEAD

  1.  Check:

 

9

  Cylinder head combustion chamber

    Check the combustion chamber for car-

bon deposits.

    Any carbon deposits 

 Eliminate.

TIP

Be sure not to damage the contact surface of 
the cylinder.

  2.  Check:

 

9

  Cylinder head

    Cracks/damage  around  the  hole  of 

spark plug 

 Replace.

CHECKING THE ROCKER ARM

  1.  Check:

 

9

  Rocker arm

    Wear/damage/cracks 

 Replace.

1

4
3

6

7

2

5

Содержание MZ400

Страница 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 ...

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

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

Страница 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 ...

Отзывы: