Yamaha MZ360 Service Manual
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Yamaha MZ360 Service Manual

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SERVICE MANUAL
MZ360
MX360
MZ400
7HC-F8197-E1

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Summary of Contents for Yamaha MZ360

  • Page 1 SERVICE MANUAL MZ360 MX360 MZ400 7HC-F8197-E1...
  • Page 3 MZ360/MX360/MZ400 SERVICE 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 This manual was produced by the Yamaha Motor Powered Products Co., Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha machines should have a basic understanding of mechanics and the techniques to repair these types of machines.
  • Page 5 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. •...
  • Page 6 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant 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...

  • Page 7: General Information

    INDEX GENERAL INFORMATION PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR ELECTRICAL TROUBLESHOOTING SPECIFICATIONS...

  • Page 8: Table Of Contents

    BASIC SERVICE INFORMATION .... 1-13 MEASURING THE COMPRESSION ELECTRICAL SYSTEM ...... 1-13 PRESSURE ...........3-1 SPECIAL TOOLS AND TESTERS... 1-17 AIR FILTER ..........3-3 MZ360/MZ400 ........3-3 MX360 ...........3-4 PERIODIC CHECKS AND FUEL TANK (Equipped models) ....3-5 ADJUSTMENTS EXCEPT FOR MX360C46A5 ....3-5 MX360C46A5 ........3-6 INTRODUCTION ........
  • Page 9 INSTALLING THE CYLINDER HEAD STARTER (MX360) ......3-15 ASSEMBLY ..........3-36 FLYWHEEL..........3-17 VALVE ............3-37 REMOVING THE VALVES AND  MZ360/MZ400 ........3-17 MX360 ..........3-18 VALVE SPRINGS.........3-38 CHECKING THE VALVES AND  REMOVING THE FLYWHEEL..... 3-19 INSTALLING THE FLYWHEEL.... 3-20 VALVE SPRINGS.........3-38...
  • Page 10 CHECKING THE STARTER MOTOR OPERATION (Equipped models) ..5-14 WIRE ROUTING DIAGRAM .....7-12 CHECKING THE WIRE HARNESS ..5-14 UPPER SIDE VIEW (MZ360) ....7-12 UPPER SIDE VIEW (MX360) ....7-14 ELECTRIC STARTING SYSTEM ..... 5-15 UPPER SIDE VIEW (MZ400) ....7-16 REMOVING THE STARTER MOTOR...
  • Page 11 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) .........
  • Page 12 MEMO...

  • Page 13: Machine Identification

    GENERAL INFORMATION MACHINE IDENTIFICATION SERIAL NUMBER The serial number is printed on the label “1” affixed to the position of the multi-purpose engine as shown in the illus- tration. • The first four digits identify the model, and the remaining digits indicates the production number.

  • Page 14: Dimensions

    DIMENSIONS DIMENSIONS DIMENSION CHART mm (in) TAPER 1/5 1.25 35.5 5/16 -24UNF-2B 29.5 46.8 58.7 TAPER 3/16...
  • Page 15 DIMENSIONS 5/16 -24UNF-2B 29.5 46.8 58.7 TAPER 3/16 +0.05 M8 1.25 +0.05 M10 1.25...

  • Page 16: Top

    DIMENSIONS 3/8 -24UNF-2B +0.058 88.5 6.31H10 60.3 72.2 *1: UNF: Unified fine thread (Unit: in) A: 7HCC (MZ360LHIDE, P.T.O. type L (Taper · millimeter)) B: 7HCB, 7HSB (MX360KA6D0 except for KOR, MZ400KH2P6, P.T.O. type K (Taper · inch)) C: 7HCB (MX360KA6D0 for KOR, P.T.O. type K (Taper · inch)) D: 7HC2 (MX360BA6A0, P.T.O.
  • Page 17 DIMENSIONS 445 (17.52) 163 (6.42) 282 (11.1) 300 (11.81) 162 (6.38) A: 7HCC (MZ360LHIDE) B: 7HCB (MX360KA6D0 except for KOR) C: 7HC2, 7HC3, 7HCJ, 7HCB (MX360BA6A0, MX360C46A5, MX360AA6A0, MX360AA6A5, MX360AA6A6, MX360KA6D0 for KOR)

  • Page 18: Mounting Base

    DIMENSIONS MOUNTING BASE mm (in) 16 (0.63) 37 (1.46) 65 (2.56) 16 (0.63) 37 (1.46) 65 (2.56)

  • Page 19: Left Side

    DIMENSIONS 16 (0.63) 37 (1.46) 65 (2.56) A: 7HCC (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)

  • Page 20: Front

    DIMENSIONS 462 (18.19) 163 (6.42)    5/16-24UNF-2B DEPTH18 103 (4.06) 3/8-16UNC2B    90.5 (3.56) DEPTH18 ( 9) 195.5 (7.7)    5/16-24UNF-2B DEPTH18 *1: UNF: Unified fine thread (Unit: in) *2: UNC: Unified coarse thread (Unit: in) *3: Inch screw identification mark of the mount face A: 7HCC (MZ360LHIDE) B: 7HC2, 7HC3, 7HCJ, 7HCB (MX360BA6A0, MX360C46A5, MX360AA6A0, MX360AA6A5, MX360AA6A6, MX360KA6D0 for KOR)
  • Page 21 DIMENSIONS 350 (13.78) 105.5 (4.15) 99 (3.9) 240 (9.45) (Slot hole) (Hole) 16 (0.63) 37 (1.46) 65 (2.56) 102 (4.02 ) 418 (16.46) 188 (7.4) 125 (4.92) 206.5 (8.13) 99 (3.9) (Hole) (Slot hole) 16 (0.63) 37 (1.46) 65 (2.56) 62 (2.44) 102 (4.02) *1: P.T.O.

  • Page 22: Right Side

    DIMENSIONS RIGHT SIDE mm (in) 462 (18.19) A: 7HC2, 7HC3, 7HCJ, 7HCB (MX360BA6A0, MX360C46A5, MX360AA6A0, MX360AA6A5, MX360AA6A6, MX360KA6D0 for KOR) 1-10...

  • Page 23: Important Information

    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.

  • Page 24: All Replacement Parts

    • 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.

  • Page 25: Bearings And Oil Seals

    BASIC SERVICE INFORMATION BEARINGS AND OIL SEALS Install the bearing(s) “1” and oil seal(s) “2” with their manu- facture’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s).
  • Page 26 BASIC SERVICE INFORMATION Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. Disconnect: • Lead • Coupler • Connector NOTICE • When disconnecting a coupler, release the coupler lock, hold both sections of the coupler securely, and then disconnect the coupler.
  • Page 27 BASIC SERVICE INFORMATION Check: • All connections Loose connection  Connect properly. • If the pin “1” on 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. Connect: •...
  • Page 28 BASIC SERVICE INFORMATION Check: • Continuity (with the digital circuit tester) Digital circuit tester (CD732): 90890-03243 Model 88 Multimeter with tachometer: YU-A1927 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4).

  • Page 29: Special Tools And Testers

    SPECIAL TOOLS AND TESTERS SPECIAL TOOLS AND TESTERS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. •...
  • Page 30 SPECIAL TOOLS AND TESTERS MEMO 1-18...

  • Page 31: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale.
  • Page 32 *1 ..The air filter and foam element need to be cleaned more frequently when using in unusually wet or dusty areas..Since these items require special tools, data and technical skills, have a Yamaha dealer per- form the service.

  • Page 33: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SPARK PLUG WARNING Check and adjust the areas around the cylinder head after the engine has cooled down completely. Remove: • Spark plug cap • Spark plug NOTICE Before removing the spark plug, use compressed air to clean the cylinder head cover to prevent dirt from falling into the engine.

  • Page 34: Fuel Leakage

    PERIODIC MAINTENANCE Install: • Spark plug Spark plug: 20 N·m (2.0 kgf·m, 15 lb·ft) To prevent threads from being damaged, temporally tighten “a” the spark plug before tightening it to the speci- fied torque “b”. FUEL LEAKAGE Check: • Leakage Check at fuel tank, fuel cock, fuel hose, and carbu- retor NOTICE...

  • Page 35: Replacing The Engine Oil

    PERIODIC MAINTENANCE Check: • Check that engine oil is at the specified level “a”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Oil level checking steps: a. Place the multi-purpose engine on a level surface. b. Warm up the engine for several minutes. c. Stop the engine. d.

  • Page 36: Air Filter Element (Mz360/Mz400)

    1.0 L (1.06 US qt, 0.88 Imp.qt) Check: • Engine oil level (Refer to “ENGINE OIL LEVEL” on page 2-4) AIR FILTER ELEMENT (MZ360/MZ400) NOTICE Be sure not to run the engine without air filter element. Otherwise this can result in excessive piston and/or cylinder wear.

  • Page 37: Air Filter Element (Mx360)

    PERIODIC MAINTENANCE Install: • Air filter element • Air filter cover • Air filter cover screw Air filter cover screw: 1.6 N·m (0.16 kgf·m, 1.2 lb·ft) AIR FILTER ELEMENT (MX360) NOTICE Be sure not to run the engine without air filter element. Otherwise this can result in excessive piston and/or cylinder wear.

  • Page 38: Muffler (Equipped Models)

    PERIODIC MAINTENANCE Check: • Air filter element Damage  Replace. Clogged  Wash the element with white kerosene, and then dry it thoroughly. Oil the element and squeeze out the excess oil. WARNING Do not wash the element with gasoline or with acidic, alkalic, or organic solvents.
  • Page 39 PERIODIC MAINTENANCE Remove: • Spark arrester “1” Use a flathead screw driver to pry the spark arrester out from the muffler. Remove: • Muffler (Refer to “MUFFLER” on page 3-7) 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.
  • Page 40 PERIODIC MAINTENANCE Install: • Muffler (Refer to “INSTALLING THE MUFFLER” on page 3-8) • Spark arrester • Spark arrester screw Spark arrester screw: 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Align the spark arrester lump “a” with the hole “b” in the muffler pipe.

  • Page 41: Fuel Tank Filter

    PERIODIC MAINTENANCE Check: • Fuel tank filter Damage  Replace. Dirt/clog  Clean. Clean the fuel tank filter with clean gasoline, and then dry it thoroughly. Install: • Fuel tank filter • Fuel tank cap WARNING Make sure that the fuel tank cap is tightened securely. FUEL COCK STRAINER WARNING Do not smoke, and keep away from open flames,...

  • Page 42: Breather Hose

    PERIODIC MAINTENANCE BREATHER HOSE Check: • Breather hose “1” Crack/damage  Replace. Poor connection  Connect. CYLINDER HEAD DECARBONIZATION Remove: • Cylinder head assembly (Refer to “CYLINDER HEAD COVER, CYLINDER HEAD” on page 3-33) Eliminate: • Carbon deposits (Refer to “CHECKING THE CYLINDER HEAD” on page 3-35) Install: •...
  • Page 43 PERIODIC MAINTENANCE Pull the recoil starter slowly, and then set the piston at TDC (top-dead-center) on the compression stroke. Check the piston position by inserting a screw driver into the spark plug hole. Measure: • Valve clearance (Between the rocker arm and valve stem end) Out of specification ...
  • Page 44 PERIODIC MAINTENANCE Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Adjustment steps: a. Loosen the locknut “1” and insert the 0.07 mm (0.0028 in) thickness gauge between the rocker arm and the valve tip. b. Using the tappet adjusting tool “2” turn the adjuster “3”...

  • Page 45: Engine Speed

    90890-06760, YU-39951-B Measure: • Engine speed (with no load) Out of specification  Adjust. Engine speed: 3110–3210 r/min (MZ360) 3700–3800 r/min (MX360/MZ400) ENGINE SPEED (Throttle lever equipped models) Warm up the engine for several minutes. Attach: • Digital tachometer “1”...

  • Page 46: Models)

    PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Measurement steps: a. Move the throttle lever “1” to the high engine speed position “a”. b. Check the high engine speed. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Measure: • Low engine speed (with no load) Out of specification  Adjust. Low engine speed: 1900–2100 r/min (MX360) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 47: Adjusting The Engine Speed

    Adjustment steps: a. Turn the throttle stop screw “1” (carburetor) in direc- tion “a” or “b” until the high engine speed is obtained. High engine speed: 3110–3210 r/min (MZ360) 3700–3800 r/min (MX360/MZ400) Direction “a” High engine speed is decreased. Direction “b”...

  • Page 48: Recoil Starter

    Low engine speed is increased. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ RECOIL STARTER 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) 2-18...

  • Page 49: Fittings And Fasteners

    PERIODIC MAINTENANCE FITTINGS AND FASTENERS Check: • All fittings and fasteners Looseness  Tighten. Rough movement  Replace the defective part(s). Damage/pitting  Replace. 2-19...
  • Page 50 PERIODIC MAINTENANCE MEMO 2-20...

  • Page 51: Engine

    ENGINE ENGINE INSPECTION MEASURING THE COMPRESSION PRESSURE Measure the compression pressure after checking and adjusting the valve clearance. Warm up the engine for several minutes. Remove: • Spark plug cap • Spark plug NOTICE Before removing the spark plug, use compressed air to clean the cylinder head cover to prevent dirt from falling into the engine.
  • Page 52 ENGINE INSPECTION ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Testing steps (below the minimum specification): a. Squirt a few drops of oil into the cylinder. b. Measure the compression again. Reading Diagnosis Higher than • Worn cylinder, piston, and piston ring(s) without oil • Defective piston, piston ring(s), valve(s), and Same as cylinder head gasket without oil...

  • Page 53: Air Filter

    AIR FILTER AIR FILTER MZ360/MZ400 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.6 N ・...

  • Page 54: Mx360

    AIR FILTER MX360 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 0.9 N ・ m (0.09 kgf ・ m, 0.66 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 55: Fuel Tank (Equipped Models)

    FUEL TANK (Equipped models) FUEL TANK (Equipped models) EXCEPT FOR MX360C46A5 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 lb ・ ft) 6 N ・...

  • Page 56: Mx360C46A5

    FUEL TANK (Equipped models) MX360C46A5 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 29 N ・ m (2.9 kgf ・ m, 21 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・...

  • Page 57: Muffler

    MUFFLER MUFFLER EQUIPPED MODELS 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 20 N ・...

  • Page 58: Installing The Muffler

    MUFFLER INSTALLING THE MUFFLER Install: • Gasket • Muffler assembly • Muffler nut “1” • Muffler nut “2” • Muffler bolt “3” Temporarily tighten the muffler nut “1”, muffler nut “2”, and muffler bolt “3” until just comes in contact with the surface. Tighten: •...

  • Page 59: Recoil Starter

    RECOIL STARTER RECOIL STARTER MZ360/MZ400 5.4 N ・ m (0.54 kgf ・ m, 4.0 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft)

  • Page 60: Disassembling The Recoil Starter (Mz360/Mz400)

    RECOIL STARTER DISASSEMBLING THE RECOIL STARTER (MZ360/ MZ400) Remove: • Starter handle “1” Before untying the knot “a” above the starter handle, make a knot “b” on the rope so that the rope is not pulled into the case. Remove: •...

  • Page 61: Assembling The Recoil Starter (Mz360/ Mz400)

    Check: • Drive pawls “1” • Drive plate “2” Wear/damage  Replace. • Springs “3” Cracks/damage  Replace. ASSEMBLING THE RECOIL STARTER (MZ360/ MZ400) Install: • Starter rope “1” • Starter spring “2” • Sheave drum “3” Engage the spring hook “a” with the drum slit, then wind the spring counterclockwise into the drum from the larger to the smaller diameter.
  • Page 62 RECOIL STARTER Install: • Starter handle • Drive plate screw “1” To set the spring preload, hook the starter rope into the sheave drum slot “a” and turn the sheave drum assembly counterclockwise four times, and then unhook the starter rope from the slot.

  • Page 63: Mx360

    RECOIL STARTER MX360 5.4 N ・ m (0.54 kgf ・ m, 4.0 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the recoil starter Remove the parts in the order listed. Recoil starter assembly Starter handle Drive plate...

  • Page 64: Disassembling The Recoil Starter (Mx360)

    RECOIL STARTER DISASSEMBLING THE RECOIL STARTER (MX360) Remove: • Starter handle “1” Before untying the knot “a” above the starter handle, make a knot “b” on the rope so that the rope is not pulled into the case. Remove: • Drive plate screw “1” •...

  • Page 65: Assembling The Recoil Starter (Mx360)

    RECOIL STARTER Check: • Drive pawls “1” • Drive plate “2” Wear/damage  Replace. • Springs “3” • Compression spring “4” Cracks/damage  Replace. ASSEMBLING THE RECOIL STARTER (MX360) Install: • Starter rope “1” • Starter spring “2” • Sheave drum “3” Engage the spring hook “a”...
  • Page 66 RECOIL STARTER Install: • Starter handle • Drive plate screw “1” To set the spring preload, hook the starter rope into the sheave drum slot “a” and turn the sheave drum assembly counterclockwise four times, and then unhook the starter rope from the slot.

  • Page 67: Flywheel

    FLYWHEEL FLYWHEEL MZ360/MZ400 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 120 N ・ m (12 kgf ・ m, 89 lb ・ ft) 7 N ・...

  • Page 68: Mx360

    FLYWHEEL MX360 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 120 N ・ m (12 kgf ・ m, 89 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・...

  • Page 69: Removing The Flywheel

    FLYWHEEL REMOVING THE FLYWHEEL Remove: • Flywheel cover • TCI unit Remove: • Flywheel nut “1” • Washer • Starter pulley Attach the sheave holder “2” to hold the flywheel. Sheave holder: 90890-01701 Primary clutch holder: YS-01880-A Remove: • Flywheel “1” •...

  • Page 70: Installing The Flywheel

    FLYWHEEL INSTALLING THE FLYWHEEL Install: • Woodruff key • Flywheel Install: • Starter pulley • Washer • Flywheel nut “1” Flywheel nut: 120 N·m (12 kgf·m, 89 lb·ft) Tighten the flywheel nut “1” using the sheave holder “2” to hold the flywheel. Sheave holder: 90890-01701 Primary clutch holder:...
  • Page 71 FLYWHEEL Measure: • TCI unit air gap Out of specification  Adjust. Thickness gauge: 90890-03268 Feeler gauge set: YU-26900-9 TCI unit air gap: 0.4–0.6 mm (0.0157–0.0236 in) Adjust: • TCI unit air gap ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Adjustment steps: a. Loosen the TCI unit bolts “1”. b.

  • Page 72: Governor

    GOVERNOR GOVERNOR THROTTLE LEVER ASSEMBLY (MX360BA6A0) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.1 N ・ m (0.11 kgf ・ m, 0.81 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 7 N ・...

  • Page 73: Throttle Lever Assembly (Mx360C46A5/Mx360Aa6A0/ Mx360Aa6A5/Mx360Aa6A6)

    GOVERNOR THROTTLE LEVER ASSEMBLY (MX360C46A5/MX360AA6A0/MX360AA6A5/ MX360AA6A6) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 74: Governor Arm Assembly (Mx360Ka6D0 For Kor)

    GOVERNOR GOVERNOR ARM ASSEMBLY (MX360KA6D0 for KOR) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the governor arm assembly Remove the parts in the order listed.

  • Page 75: Governor Arm Assembly (Mz360/Mz400/Mx360Ka6D0 Except For Kor)

    GOVERNOR GOVERNOR ARM ASSEMBLY (MZ360/MZ400/MX360KA6D0 except for KOR) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the governor arm assembly Remove the parts in the order listed.

  • Page 76: Flyweight Shaft Assembly (Mz360/Mz400)

    GOVERNOR FLYWEIGHT SHAFT ASSEMBLY (MZ360/MZ400) Order Job/Parts to remove Q’ty Remarks Removing the flyweight shaft assembly Remove the parts in the order listed. Refer to “ENGINE SWITCH AND OIL Engine switch and oil warning unit WARNING UNIT” on page 3-31.

  • Page 77: Flyweight Shaft Assembly (Mx360)

    GOVERNOR FLYWEIGHT SHAFT ASSEMBLY (MX360) Order Job/Parts to remove Q’ty Remarks Removing the flyweight shaft assembly Remove the parts in the order listed. Refer to “FUEL TANK (Equipped models)” on Fuel tank page 3-5. Refer to “FUEL TANK (Equipped models)” on Fuel tank stay page 3-5.

  • Page 78: Removing The Flyweight Shaft Assembly And Governor Fork

    GOVERNOR REMOVING THE FLYWEIGHT SHAFT ASSEMBLY AND GOVERNOR FORK Remove: • Crankcase cover • Governor assembly Remove: • Clip “1” • Governor fork “2” • Washers “3” Remove: • Flyweight shaft assembly “1” • Washer “2” Remove the flyweight shaft assembly by tapping the weight shaft from outside of the crankcase cover.

  • Page 79: Assembling The Flyweight Shaft Assembly

    GOVERNOR Check: • Weight • Flyweight shaft • Collar • Washer • Circlip • Weight shaft Wear/damage  Replace. ASSEMBLING THE FLYWEIGHT SHAFT ASSEMBLY Install: • Weight shaft “1” • Circlip “2” • Washer “3” • Collar “4” • Weights “5” •...

  • Page 80: Installing The Throttle Lever Assembly (Equipped Models)

    GOVERNOR Adjust: • Governor (Refer to “ADJUSTING THE GOVERNOR” on page 3-30) INSTALLING THE THROTTLE LEVER ASSEMBLY (Equipped models) Tighten: • Throttle lever assembly bolt ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Tighten the throttle lever assembly bolt “1” while pushing the hole “a” for installation of the throttle lever assembly against the crankcase “b”.

  • Page 81: Engine Switch And Oil Warning Unit

    ENGINE SWITCH AND OIL WARNING UNIT ENGINE SWITCH AND OIL WARNING UNIT 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the engine switch and oil...

  • Page 82: Engine Switch

    ENGINE SWITCH AND OIL WARNING UNIT ENGINE SWITCH 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the engine switch Remove the parts in the order listed. Refer to “FUEL TANK (Equipped models)” on Fuel tank page 3-5.

  • Page 83: Cylinder Head Cover, Cylinder Head

    CYLINDER HEAD COVER, CYLINDER HEAD CYLINDER HEAD COVER, CYLINDER HEAD 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) 7 N ・...
  • Page 84 CYLINDER HEAD COVER, CYLINDER HEAD 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 2.3 N ・...

  • Page 85: Checking The Rocker Arm

    CYLINDER HEAD COVER, CYLINDER HEAD CHECKING THE ROCKER ARM Check: • Rocker arm • Wear/damage/cracks  Replace. CHECKING THE PUSH ROD Check: • Push rod runout Runout limit: 0.15 mm (0.0059 in) Out of specifications  Replace. CHECKING THE CYLINDER HEAD Check: •...

  • Page 86: Installing The Cylinder Head Assembly

    CYLINDER HEAD COVER, CYLINDER HEAD INSTALLING THE CYLINDER HEAD ASSEMBLY Install: • Cylinder head • Cylinder head bolts “1” to “5”. Tighten the bolts to the specified torque in two steps and in order from “1” to “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) 3-36...

  • Page 87: Valve

    VALVE VALVE Order Job/Parts to remove Q’ty Remarks Removing the valve Remove the parts in the order listed. Refer to “CYLINDER HEAD COVER, CYLIN- Cylinder head assembly DER HEAD” on page 3-33. Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal Intake side only.

  • Page 88: Removing The Valves And Valve Springs

    VALVE REMOVING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves, valve springs and related components. Remove: • Valve cotter “1” • Valve spring retainer “2” • Valve spring “3” • Valve “4” • Valve stem seal (Intake side only) Remove the parts using the valve spring compres- sor “5”.
  • Page 89 VALVE Measure: • Valve stem diameter “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) Out of specifications  Replace. Measure: •...

  • Page 90: Checking The Valve Seats

    VALVE Measure: • Compressed valve spring force “a” Out of specification  Replace. 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) Installed length (Intake): 29.0 mm (1.1417 in) Installed length (Exhaust): 29.0 mm (1.1417 in)
  • Page 91 VALVE Insert the valve into the valve guide and use a valve lapper to contact the valve face with the valve seat. Do not rotate the valve while the valve face is contacting the valve seat. Measure: • Valve face contact width “a” Make sure that the contact width along the entire valve face is within specifications.

  • Page 92: Valve Lapping

    VALVE VALVE LAPPING Apply a coarse lapping compound evenly on the valve face. Lap the valve by tapping and rotating the valve lapper “1” clockwise and counterclockwise. Clean off all of the lapping compound from the valve face and valve seat. Apply fine lapping compound on the valve face and lap the valve as described in step Once the contacting surface of the valve face is pol- ished and becomes shiny, apply mechanic’s blue lay-...

  • Page 93: Installing The Valves And Valve Springs

    VALVE INSTALLING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves, valve springs and related components. Install: • Valve stem seal (Intake side only) • Valve “1” • Valve spring “2” • Valve spring retainer “3” •...

  • Page 94: Piston, Camshaft, Crankcase, And Crankshaft

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT MZ360/MZ400 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
  • Page 95 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Balancer shaft Camshaft Valve lifter Crankshaft shim Connecting rod cap Crankshaft Connecting rod Piston pin circlip Piston pin Piston Piston ring set 3-45...

  • Page 96: Mx360

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT MX360 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・...
  • Page 97 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Balancer shaft Camshaft Valve lifter Crankshaft shim Connecting rod cap Crankshaft Connecting rod Piston pin circlip Piston pin Piston Piston ring set 3-47...

  • Page 98: Removing The Balancer Shaft, Camshaft, And Valve Lifter

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT REMOVING THE BALANCER SHAFT, CAMSHAFT, AND VALVE LIFTER Remove: • Balancer shaft “1” Remove the balancer shaft “1” when the balancer shaft gear mark “a” and the crankshaft gear mark “b” are aligned. Remove: • Camshaft “2” Remove the camshaft “2”...
  • Page 99 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT Check: • Camshaft lobe dimensions “a” and “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”...

  • Page 100: Checking The Valve Lifter

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT CHECKING THE VALVE LIFTER Check: • Valve lifter Damage  Replace. INSTALLING THE VALVE LIFTER, BALANCER SHAFT, AND CAMSHAFT Install: • Intake valve lifter “1” • Exhaust valve lifter “2” Install: • Balancer shaft “1” NOTICE Be sure to align the balancer shaft “1”...

  • Page 101: Installing The Crankcase Cover

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT INSTALLING THE CRANKCASE COVER Install: • Crankcase cover • Crankcase cover bolts “1” to “8” Tighten the bolts to the specified torque in two steps and in order from “1” to “8”. Crankcase cover bolt: 1st: 12 N·m (1.2 kgf·m, 8.9 lb·ft) 2nd: 30 N·m (3.0 kgf·m, 22 lb·ft) CHECKING THE CYLINDER AND PISTON...
  • Page 102 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT Measure cylinder bore “C” by taking side-to-side and front- to-back measurements of the cylinder. Bore: 85.000–85.020 mm (3.3465–3.3472 in) Limit: 85.070 mm (3.3492 in) “C” = maximum of D b. If out of specification, replace the crankcase assembly, and replace the piston and piston rings as a set.

  • Page 103: Checking The Crankcase

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT CHECKING THE CRANKCASE Check: • Crankcase Damage  Replace. • Bearing Noise/wear/rotational failure  Replace. CHECKING THE PISTON PIN Check: • Piston pin Blue discoloration/grooves  Replace the piston pin and then check the lubrication system. Measure: •...

  • Page 104: Checking The Piston Rings

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT CHECKING THE PISTON RINGS The following procedure applies to all of the piston rings. Measure: • Piston ring side clearance Out of specification  Replace the piston and pis- ton rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and pis- ton rings.

  • Page 105: Checking The Crankshaft

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT 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) CHECKING THE CRANKSHAFT Check: •...

  • Page 106: Checking The Connecting Rod Oil Clearance

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT CHECKING THE CONNECTING ROD OIL CLEARANCE Measure the oil clearance if replacing the crankshaft or connecting rod. Place a piece of Plastigauge® “1” on the crank pin horizontally. Wipe off oil thoroughly from the crankshaft, connecting rod, and connecting rod cap.

  • Page 107: Installing The Piston And Piston Ring

    • Piston pin “2” • Piston pin circlips “3” • 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.
  • Page 108 • Piston with the connecting rod “1” position • 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. Install: •...

  • Page 109: Selecting The Crankshaft Shim

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT Install: • Connecting rod cap “1” • Connecting rod cap bolts “2” Connecting rod cap bolt: 20 N·m (2.0 kgf·m, 15 lb·ft) • Make sure that the “ ” mark “a” on the connecting rod is aligned with the “...
  • Page 110 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT Adjust: • Crankshaft free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Adjustment steps: a. Remove the crankcase cover “1”. (Refer to “PIS- TON, CAMSHAFT, CRANKCASE, AND CRANK- SHAFT” on page 3-44) b. Install or remove the shim “2” of the proper thick- ness.

  • Page 111: Removing The Carburetor

    CARBURETOR REMOVING THE CARBURETOR MZ360/MZ400 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. Gasket Carburetor assembly Gasket Joint Gasket *P-80®GRIP-IT When installing the fuel hose, use a brush to apply a small amount of P-80®GRIP-IT as an insertion...

  • Page 112: Mx360

    REMOVING THE CARBURETOR MX360 Order Job/Parts to remove Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Refer to “FUEL TANK (Equipped models)” on Fuel tank page 3-5. Air filter Refer to “AIR FILTER” on page 3-3. Gasket Carburetor assembly Gasket...

  • Page 113: Disassembling The Carburetor

    DISASSEMBLING THE CARBURETOR DISASSEMBLING THE CARBURETOR MZ360/MZ400 1.2 N ・ m (0.12 kgf ・ m, 0.88 lb ・ ft) 0.7 N ・ m (0.07 kgf ・ m, 0.52 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...

  • Page 114: Mx360

    DISASSEMBLING THE CARBURETOR MX360 1.2 N ・ m (0.12 kgf ・ m, 0.88 lb ・ ft) 0.7 N ・ m (0.07 kgf ・ m, 0.52 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...

  • Page 115: Checking The Carburetor

    DISASSEMBLING THE CARBURETOR CHECKING THE CARBURETOR Measure: • Float height “a” Out of specification  Replace. • Lift up the float so that the tip of the float valve lightly contacts the float arm, and then measure the float height “a”.

  • Page 116: Electrical

    ELECTRICAL CIRCUIT DIAGRAM WITH STARTER MOTOR, OIL WARNING UNIT, OIL WARNING LIGHT...
  • Page 117 CIRCUIT DIAGRAM 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) Color code Black Black/Red Blue Black/White Red/White Yellow Yellow/Red Brown...

  • Page 118: With Oil Warning Unit, Oil Warning Light

    CIRCUIT DIAGRAM WITH OIL WARNING UNIT, OIL WARNING LIGHT...
  • Page 119 CIRCUIT DIAGRAM 1. Engine switch 4. Oil warning light 2. Spark plug 5. Oil warning unit 3. TCI unit 6. Oil level switch Color code Black Yellow Blue Black/White...

  • Page 120: Without Oil Warning Unit, Oil Warning Light

    CIRCUIT DIAGRAM WITHOUT OIL WARNING UNIT, OIL WARNING LIGHT...
  • Page 121 CIRCUIT DIAGRAM 1. Engine switch 2. TCI unit Color code Black Black/White...

  • Page 122: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1. Spark plug 2. TCI unit 3. Oil warning unit 4. Engine switch 5. Oil level switch 6. Oil warning light...

  • Page 123: Checking The Switch Continuity

    ELECTRICAL COMPONENTS CHECKING THE SWITCH CONTINUITY Check each switch for continuity with the tester. If the con- tinuity reading is incorrect, check the wiring connections O.L” and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler termi- Ω”...
  • Page 124 ELECTRICAL COMPONENTS Check: • Fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester to the fuse and check the continuity. Set the digital circuit tester selector to “  ”. Digital circuit tester (CD732): 90890-03243 Model 88 Multimeter with tachometer: YU-A1927 b.

  • Page 125: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS CHECKING THE IGNITION SPARK GAP Check: • Engine oil level Insufficient  Add the engine oil. (Refer to “ENGINE OIL LEVEL” on page 2-4) Check: • Spark plug condition Wear/damage  Replace. (Refer to “SPARK PLUG” on page 2-3) Check: •...

  • Page 126: Checking The Spark Plug Cap Resistance

    ELECTRICAL COMPONENTS CHECKING THE SPARK PLUG CAP RESISTANCE Remove: • Spark plug cap Check: • Spark plug cap resistance Out of specification  Replace the spark plug cap. Spark plug cap resistance: 3.75–6.25 k ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the spark plug cap from the high tension cord.

  • Page 127: Checking The Ignition Coil  (Tci Unit, Secondary)  Resistance

    ELECTRICAL COMPONENTS Primary coil resistance: 0.64–0.96  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the ignition coil (TCI unit). b. Connect the digital circuit tester () to the primary terminal. Digital circuit tester (CD732): 90890-03243 Model 88 Multimeter with tachometer: YU-A1927 • Positive tester probe  Black/White “1”...

  • Page 128: Checking The Engine Switch

    ELECTRICAL COMPONENTS CHECKING THE ENGINE SWITCH Check: • Engine switch continuity Out of specification  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the engine switch connectors. b. Connect the digital circuit tester () to the engine switch connectors as shown. Digital circuit tester (CD732): 90890-03243 Model 88 Multimeter with tachometer: YU-A1927...

  • Page 129: Checking The Starter Motor Operation (Equipped Models)

    ELECTRICAL COMPONENTS b. Check the oil level switch continuity. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE STARTER MOTOR OPERATION (Equipped models) Check: • Starter motor operation Does not operate  Perform the electric starting system troubleshooting, starting with step 4. (Refer “ELECTRIC STARTING SYSTEM (Equipped models)”...
  • Page 130 ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR (Equipped models) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the starter motor...

  • Page 131: Electric Starting System

    ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR (Equipped models) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Disassembling the starter motor Disassemble the parts in the order listed.

  • Page 132: Checking The Armature Coil

    ELECTRIC STARTING SYSTEM CHECKING THE ARMATURE COIL Check: • Commutator (outer surface) Dirty  Clean it with #600 grit sandpaper. Measure: • Mica (insulation depth between the commutator segments) Out of specification  Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator.

  • Page 133: Checking The Brush

    ELECTRIC STARTING SYSTEM CHECKING THE BRUSH Measure: • Brush length (of each brush) “1” Out of specification  Replace. Brush wear limit length: 6.0 mm (0.2362 in) Check: • Brush spring “2” Fatigue/damage  Replace. CHECKING THE STARTER RELAY Measure: •...

  • Page 134: Charging System

    CHARGING SYSTEM CHARGING SYSTEM CHECKING THE CHARGING COIL (Equipped models) Remove: • Charging coil (Refer to “FLYWHEEL” on page 3-17) Check: • Charging coil resistance Out of specification  Replace. Charging coil resistance: 1.6  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester () to the charging coil as shown.

  • Page 135: Troubleshooting

    TROUBLESHOOTING ENGINE DOES NOT START Checking steps Possible remedy Check the engine oil level. Add the oil if it is insufficient. (Refer to “ENGINE OIL LEVEL” on page 2-4) Check the fuel level. Add the fuel if it is insufficient. Check if the fuel has deteriorated.

  • Page 136: Electric Starting System (Equipped Models)

    ELECTRIC STARTING SYSTEM (Equipped models) ELECTRIC STARTING SYSTEM (Equipped models) The starter motor fails to turn. Checking steps Possible remedy Check the fuse. (Refer to “CHECKING THE FUSE (Equipped models)” on Replace the fuse. page 5-8) • Clean the battery terminals. Check the battery (option).

  • Page 137: Engine Speed Does Not Increase

    ENGINE SPEED DOES NOT INCREASE ENGINE SPEED DOES NOT INCREASE Checking steps Possible remedy Check the spark plug for dirt and check the spark plug gap. Clean, adjust, or replace the spark plug. Check the air filter element for dirt. Clean.

  • Page 138: Engine Speed Is Uneven

    ENGINE SPEED IS UNEVEN ENGINE SPEED IS UNEVEN Checking steps Possible remedy Check the fuel level. Add the fuel if it is insufficient. Check if fuel has deteriorated. Replace the fuel. Check if the fuel cock is clogged. Clean. Check the spark plug for dirt and check the spark plug gap. Clean, adjust, or replace the spark plug. Check the carburetor pilot screw turn out and float height.

  • Page 139: Governor Operation

    GOVERNOR OPERATION GOVERNOR OPERATION Checking steps Possible remedy Check that the governor link operate smoothly. Adjust or replace. Check that the governor spring is stretched. Replace. Check the governor adjustment. Adjust. (Refer to “ADJUSTING THE GOVERNOR” on page 3-30) Check the governor weight and governor bushing function. (Refer to “CHECKING THE FLYWEIGHT SHAFT ASSEM- Adjust or replace.
  • Page 140 GOVERNOR OPERATION MEMO...

  • Page 141: Specifications

    Displacement 0.358 L (358 cm³) (MZ360/MX360) 0.402 L (402 cm³) (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/cm², 65.25–79.75 psi)
  • Page 142 Clockwise (from flywheel) Governor type Centrifugal weight system Electrical: Ignition system 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.

  • Page 143: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Piston: Piston-to-cylinder clearance 0.015–0.029 mm (0.0006–0.0011 in) Limit 0.150 mm (0.0059 in) Piston diameter 84.977–84.998 mm (3.3455–3.3464 in) Limit 84.9 mm (3.3425 in) Measuring point (from piston 19.5 mm (0.767 in) skirt bottom) Oversize 1st 85.25 mm (3.3563 in) 85.50 mm (3.3661 in) Piston pin hole inside diameter...
  • Page 144 MAINTENANCE SPECIFICATIONS Warpage limit 0.05 mm (0.002 in) Crankshaft: Big end side clearance 0.20–0.65 mm (0.008–0.026 in) Runout limit 0.02 mm (0.0008 in) Crank pin outside diameter 35.969–35.985 mm (1.4161–1.4167 in) Limit 35.9 mm (1.4134 in) Crankshaft free play 0–0.20 mm (0–0.0079 in) Connecting rod: Small end diameter 20.006–20.020 mm (0.7876–0.7882 in)
  • Page 145 (Intake) Installed compression spring 91.20–104.93 N (9.3–10.7 kgf, 20.50–23.59 lbf) force (Exhaust) Tilt limit 1.7 mm (0.0669 in) Carburetor: I.D. mark 7HC00 (MZ360) 7HC10 (MZ360) 7HC10 (MX360) 7HC21 (MX360) 7HSB0 (MZ400) Bore size ø26 (MZ360) ø30.4 (MX360/MZ400) Main jet #105 (MZ360)...
  • Page 146 Main nozzle 63C/65A (MZ360) Pilot jet #53.8 (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)

  • Page 147: Electrical

    Primary coil resistance Secondary coil resistance 9.36–14.04 k 3.75–6.25 k at 20 C (68 F) Spark plug cap resistance 26  ± 5 % (MZ360) Choke solenoid resistance TCI unit air gap 0.4–0.6 mm (0.0157–0.0236 in) Minimum ignition spark gap 6.0 mm (0.24 in)
  • Page 148 TIGHTENING TORQUES TIGHTENING TORQUES Item Thread size Tightening torque Air filter cover screw (MZ360/ M6  1.0 1.6 N·m (0.16 kgf·m, 1.2 lb·ft) MZ400) M6  1.0 Air filter cover nut (MX360) 1.6 N·m (0.16 kgf·m, 1.2 lb·ft) M6  1.0 Air filter element nut (MX360) 0.9 N·m (0.09 kgf·m, 0.66 lb·ft)
  • Page 149 TIGHTENING TORQUES Item Thread size Tightening torque Float 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 —...

  • Page 150: Tightening Torques

    GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifi- cations for special components or 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.

  • Page 151: Lubrication Points And Type Of Lubricants

    LUBRICATION POINTS AND TYPE OF LUBRICANTS LUBRICATION POINTS AND TYPE OF LUBRICANTS Part name Type of lubricant Oil seal lip Governor fork oil seal lip Bearing Connecting rod big end Crank pin Crankshaft journal Connecting rod cap bolt Piston pin Piston Balancer shaft journal Balancer shaft gear teeth...

  • Page 152: Wire Routing Diagram

    WIRE ROUTING DIAGRAM WIRE ROUTING DIAGRAM UPPER SIDE VIEW (MZ360) 7-12...
  • Page 153 WIRE ROUTING DIAGRAM 1. Spark plug cap 4. Charging coil lead 2. Oil level switch lead 5. Solenoid (equipped 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.

  • Page 154: Upper Side View (Mx360)

    WIRE ROUTING DIAGRAM UPPER SIDE VIEW (MX360) 7-14...
  • Page 155 WIRE ROUTING DIAGRAM 1. Spark plug cap 5. Ground terminal 2. Wire harness protector 6. Engine switch 3. Oil warning unit 7. Oil warning light 4. Engine switch lead (ground) 8. High tension cord A. The spark plug cap should face the direction indicated in the illustration. B.

  • Page 156: Upper Side View (Mz400)

    WIRE ROUTING DIAGRAM UPPER SIDE VIEW (MZ400) 7-16...
  • Page 157 WIRE ROUTING DIAGRAM 1. Spark 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.

  • Page 158: Engine Switch And Oil Warning Unit (With Oil Warning Light, Oil Warning Unit, Oil Level Switch)

    WIRE ROUTING DIAGRAM ENGINE SWITCH AND OIL WARNING UNIT (With oil warning light, oil warning unit, oil level switch) 7-18...
  • Page 159 WIRE ROUTING DIAGRAM 1. Oil warning light 4. Clamp 2. Engine 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.

  • Page 160: Engine Switch And Oil Warning Unit (With Oil Warning Unit, Oil Level Switch)

    WIRE ROUTING DIAGRAM ENGINE SWITCH AND OIL WARNING UNIT (With oil warning unit, oil level switch) 7-20...
  • Page 161 WIRE ROUTING DIAGRAM 1. Engine switch 3. Wire harness 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.

  • Page 162: Engine Switch And Oil Warning Unit (No Oil Level Switch)

    WIRE ROUTING DIAGRAM ENGINE SWITCH AND OIL WARNING UNIT (No oil level switch) 1. Engine switch A. Attach the projection of the engine switch to the hole of the bracket. Color code Black Black/White 7-22...

  • Page 163: Tci Unit (Mz360)

    WIRE ROUTING DIAGRAM TCI UNIT (MZ360) 1. Spark plug cap 5. Electric starter (equipped models) 2. High tension cord 6. Flywheel 3. Charging coil (equipped models) 7. TCI unit 4. Clamp A. Make sure that the high tension cord is not pinched when installing the flywheel cover.

  • Page 164: Tci Unit (Mx360)

    WIRE ROUTING DIAGRAM TCI UNIT (MX360) 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.

  • Page 165: Tci Unit (Mz400)

    WIRE ROUTING DIAGRAM TCI UNIT (MZ400) 1. High tension cord 4. Electric starter (equipped models) 2. Charging coil (equipped models) 5. Flywheel 3. Clamp 6. TCI unit A. Make sure that the high tension cord is not pinched when installing the flywheel cover. B.
  • Page 166 WIRE ROUTING DIAGRAM 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. 7-26...

  • Page 167: Oil Level Switch (Crankcase Cover, Mx360)

    WIRE ROUTING DIAGRAM 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. 7-27...
  • Page 168 WIRE ROUTING DIAGRAM 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. 7-28...
  • Page 169 WIRE ROUTING DIAGRAM MEMO 7-29...
  • Page 170 APPENDIX CIRCUIT DIAGRAM WITH STARTER MOTOR, OIL WARNING UNIT, OIL WARNING LIGHT...

  • Page 171: Oil Level Switch

    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) Color code Black Black/Red Blue Black/White Red/White Yellow Yellow/Red Brown...
  • Page 172 WITH OIL WARNING UNIT, OIL WARNING LIGHT...
  • Page 173 1. Engine switch 4. Oil warning light 2. Spark plug 5. Oil warning unit 3. TCI unit 6. Oil level switch Color code Black Yellow Blue Black/White...
  • Page 174 WITHOUT OIL WARNING UNIT, OIL WARNING LIGHT...
  • Page 175 1. Engine switch 2. TCI unit Color code Black Black/White...
  • Page 176 MEMO...
  • Page 178 2019.03×1 !

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