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Yamaha MX360 Supplementary Service Manual
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Yamaha MX360 Supplementary Service Manual

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SUPPLEMENTARY
SERVICE MANUAL
MX360
LIT-19616-02-34
7HC-F8197-11

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Summary of Contents for Yamaha MX360

  • Page 1 SUPPLEMENTARY SERVICE MANUAL MX360 LIT-19616-02-34 7HC-F8197-11...
  • Page 3 7HC-F8197-10. LIT-19616-02-32 ards. Obey all safety messages that follow this symbol to avoid possible injury or This manual was written by the Yamaha Motor death. Powered Products Co., Ltd. primarily for use by Yamaha dealers and their qualified mechan- WARNING ics.
  • Page 4 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.
  • Page 5 ILLUSTRATED SYMBOLS (Refer to the illustration) SYMBOL DEFINITION SYMBOL DEFINITION Periodic checks and General information adjustments Engine Carburetor Electrical Troubleshooting Specifications 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 INDEX GENERAL INFORMATION INFO ENGINE ELECTRICAL ELEC SPECIFICATIONS SPEC...

  • Page 8: Table Of Contents

    CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION .....1-1 ENGINE SERIAL NUMBER ....1-1 STARTING SERIAL NUMBER ....1-1 DIMENSIONS ..........1-2 DIMENSION CHART ......1-2 TOP ............1-3 LEFT SIDE ..........1-3 FRONT ..........1-4 MOUNTING BASE ........1-4 CHAPTER 2. ENGINE GOVERNOR ..........2-1 ADJUSTING THE GOVERNOR ....2-2 CHAPTER 3. ELECTRICAL CIRCUIT DIAGRAM ........3-1 CHAPTER 4.

  • Page 9: Chapter 1. General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION ENGINE SERIAL NUMBER The serial number is printed on the label 1 affixed to the position 2 of the multi-purpose engine as shown in the illustration. The first four digits identify the model, and the remaining digits indicates the production number.

  • Page 10: Dimensions

    PTO shaft dimensions (Type) Mounting face dimensions 5/16-24UNF-2B DEPTH18    3/8 -24UNF-2B 88.5 +0.058 6.31 60.3 MX360 AA6A6 (7HCJ) 72.2 5/16-24UNF-2B DEPTH18    3/8-16UNC2B    DEPTH18 *1: UNF; Unified fine thread (Unit: in) *2: UNC; Unified coarse thread (Unit: in)

  • Page 11: Top

    DIMENSIONS INFO Unit: in (mm) 11.81 (300) 6.38 (162) LEFT SIDE 18.19 (462) Unit: in (mm) 6.42 (163) 4.06 (103) 3.56 (90.5) 7.7 (195.5)

  • Page 12: Front

    DIMENSIONS INFO FRONT Unit: in (mm) 16.46 (418) 7.4 (188) 4.92 (125) 8.13 (206.5) 3.9 (99) 0.43 (11) (HOLE) 0.63 (16) 2 0.43 (11) 1.06 (27) (SLOT HOLE) 1.46 2.56 (37) (65) 2.44 4.02 (62) (102) MOUNTING BASE Unit: in (mm) 0.63 (16) 2.56 1.46...

  • Page 13: Chapter 2. Engine

    GOVERNOR ENGINE GOVERNOR 8 Nm (0.8 m · kgf, 5.8 ft · lbf) 7 Nm (0.7 m · kgf, 5.1 ft · lbf) 1.1 Nm (0.11 m · kgf, 0.80 ft · lbf) 7 Nm (0.7 m · kgf, 5.1 ft · lbf) Order Job/Parts to remove Q’ty...

  • Page 14: Adjusting The Governor

    GOVERNOR ADJUSTING THE GOVERNOR 1. Remove: 9 Fuel tank (Refer to “FUEL TANK, CANISTER” in 7HC-F8197-10 chapter 3.) 2. Adjust: 9 Governor Adjustment steps: a. Loosen the governor arm bolt 1. b. Turn the governor arm 2 clockwise until it stops. c.

  • Page 15: Chapter 3. Electrical

    ELEC CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM...

  • Page 16: Chapter 4. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: MX360 Model code number: 7HCJ Dimensions: Overall length mm (in) 418 (16.46) Overall width mm (in) 462 (18.19) Overall height mm (in) 490 (19.29) Dry weight kg (lb) ** (**) Engine: Engine type...
  • Page 17 SPEC GENERAL SPECIFICATIONS Model name: MX360 Model code number: 7HCJ Electrical: Ignition system Ignition timing (** r/min) BTDC 20° ± 3° BPR4ES (NGK) Spark plug type 0.7–0.8 (0.028–0.031) Spark plug gap mm (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 18: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model name: MX360 Model code number: 7HCJ Piston: mm (in) Piston clearance 0.015–0.029 (0.0006–0.0011) <Limit> Piston skirt diameter “D” 84.977–84.998 (3.3455–3.3464) <Limit> Measuring point “H” Oversize 1st 85.25 (3.3563) 85.5 (3.3661) Piston pin hole inside diameter 20.004–20.015 (0.7876–0.7880)
  • Page 19 SPEC MAINTENANCE SPECIFICATIONS Model name: MX360 Model code number: 7HCJ Crankshaft: mm (in) Big end side clearance “A” 0.20–0.65 (0.008–0.026) <Limit> Runout “B” <Limit> 0.02 (0.0008) Crank pin outside diameter “C” 35.969–35.984 (1.4161–1.4167) <Limit> Crankshaft free play 0–0.2 (0.000–0.008) Connecting rod: mm (in) Small end diameter “A”...
  • Page 20 SPEC MAINTENANCE SPECIFICATIONS Model name: MX360 Model code number: 7HCJ Valve: mm (in) Head diameter “A” 31.9–32.1 (1.2559–1.2638) 27.9–28.1 (1.0984–1.1063) Stem diameter “B” 5.948–5.963 (0.2342–0.2348) 5.940–5.955 (0.2339–0.2344) <Limit> 5.918 (0.2330) 5.910 (0.2327) Stem length “C” 88.1 (3.4685) 88.1 (3.4685) Valve face contact width “D”...
  • Page 21 SPEC MAINTENANCE SPECIFICATIONS Model name: MX360 Model code number: 7HCJ Valve spring: mm (in) Free length 36.2 (1.4252) 36.2 (1.4252) <Limit> 34.39 (1.3539) 34.39 (1.3539) Installed length 29 (1.1417) 29 (1.1417) Installed compression spring force N (kgf, lbf) 91.20–104.93 (9.12–10.49, 20.50–23.59) N (kgf, lbf) 91.20–104.93 (9.12–10.49, 20.50–23.59)

  • Page 22: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model name: MX360 Model code number: 7HCJ Ignition system: Ignition timing at 3600 r/min BTDC 20° ± 3° Primary coil resistance (Ω ± 20 %) Secondary coil resistance (kΩ ± 20 %) Spark plug cap resistance kΩ...

  • Page 23: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES Tightening torque Item Thread size Nm (m·kgf, ft·lbf) Air filter cover nut M6 × 1.0 1.6 (0.16, 1.2) Air filter element nut M6 × 1.0 0.9 (0.09, 0.65) Duct bolt M6 × 1.0 7 (0.7, 5.1) Duct nut M8 ×...
  • Page 24 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Nm (m·kgf, ft·lbf) Oil drain bolt M12 × 1.5 27 (2.7, 20) Connecting rod cap bolt M8 × 1.25 20 (2.0, 14) Float chamber bolt — 7 (0.7, 5.1) Carburetor drain screw —...

  • Page 25: General Torque Specifications

    SPEC GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE Tightening torque Thread size SPECIFICATIONS m·kgf ft·lbf This chart specifies torque for standard fas- teners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tight- 11.1 en multi fastener assemblies in a crisscross 22.1...

  • Page 26: Lubrication Points And Type Of Lubricants

    SPEC LUBRICATION POINTS AND TYPE OF LUBRICANTS LUBRICATION POINTS AND TYPE OF LUBRICANTS Part name Type of lubricant Oil seal lip Governor shaft 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 27: Wire Routing Diagram

    SPEC WIRE ROUTING DIAGRAM WIRE ROUTING DIAGRAM UPPER SIDE VIEW 1 Spark plug cap B After passing the lead through, F Make sure that the gap 2 TCI unit lead lightly pull it in the direction of between the end of the wire 3 Oil level switch lead the arrow.

  • Page 28: Engine Switch And Oil Warning Unit

    SPEC WIRE ROUTING DIAGRAM ENGINE SWITCH AND OIL WARNING UNIT Color code 1 Oil warning light B Fasten the ground terminal 2 Wire harness protector and oil warning unit together. B ..Black 3 Oil warning unit lead (ground) C The lead is black and the pro- L..Blue 4 Oil warning unit tector is gray.

  • Page 29: Tci Unit

    SPEC WIRE ROUTING DIAGRAM TCI UNIT Color code 1 High tension cord 2 Flywheel B/W ..Black/White 3 TCI unit A Make sure that the high ten- sion cord is not pinched when installing the flywheel cover. B Adjust the TCI unit air gap between 0.4–0.6 mm (0.0157–...

  • Page 30: Oil Level Switch (Crankcase Cover)

    SPEC WIRE ROUTING DIAGRAM OIL LEVEL SWITCH (CRANKCASE COVER) Color code 1 Clamp 2 Oil level switch B ..Black Gy ..Gray A The lead is black and the pro- tector is gray. B Touch the tube (gray) with the grommet. C Route the oil level switch lead as shown.
  • Page 31 CIRCUIT DIAGRAM...
  • Page 32 2015_09×1 !

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