Yamaha MZ400 Manuals

Manuals and User Guides for Yamaha MZ400. We have 2 Yamaha MZ400 manuals available for free PDF download: Service Manual, Supplementary Service Manual

Yamaha MZ400 Service Manual (178 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 5.36 MB

General Information
7
Table of Contents
8
Machine Identification
13
Serial Number
13
Model Name and Code
13
Dimensions
14
Dimension Chart
14
Top
16
Mounting Base
18
Left Side
19
Front
20
Right Side
22
Important Information
23
Preparation for Removal  and Disassembly
23
Caution on Service
23
Notes on Service
23
All Replacement Parts
24
Gaskets, Oil Seals, and O-Rings
24
Bearings and Oil Seals
25
Basic Service Information
25
Electrical System
25
Special Tools and Testers
29
Periodic Checks and Adjustments
31
Introduction
31
Maintenance Intervals Chart
31
Periodic Maintenance/Lubrication Intervals
31
Periodic Maintenance
33
Spark Plug
33
Fuel Leakage
34
Engine Oil Leakage
34
Engine Oil Level
34
Replacing the Engine Oil
35
Air Filter Element (Mz360/Mz400)
36
Air Filter Element (Mx360)
37
MUFFLER (Equipped Models)
38
Fuel Tank Filter
41
Fuel Cock Strainer
41
Breather Hose
42
Cylinder Head Decarbonization
42
Adjusting the Valve Clearance
42
Engine Speed
45
Models)
46
Adjusting the Engine Speed
46
Adjusting the Engine Speed
47
Recoil Starter
48
Fittings and Fasteners
49
Engine
51
Engine Inspection
51
Measuring the Compression Pressure
51
Air Filter
53
Mz360/Mz400
53
Mx360
54
FUEL TANK (Equipped Models)
55
Except for Mx360C46A5
55
Mx360C46A5
56
Muffler
57
Equipped Models
57
Installing the Muffler
58
Recoil Starter
59
Mz360/Mz400
59
Disassembling the Recoil Starter (Mz360/Mz400)
60
Checking the Recoil Starter (Mz360/Mz400)
60
Assembling the Recoil Starter (Mz360/ Mz400)
61
Mx360
63
Disassembling the Recoil Starter (Mx360)
64
Checking the Recoil Starter (Mx360)
64
Assembling the Recoil Starter (Mx360)
65
Flywheel
67
Mz360/Mz400
67
Mx360
68
Removing the Flywheel
69
Installing the Flywheel
70
Installing the Tci Unit
70
Governor
72
Throttle Lever Assembly (Mx360Ba6A0)
72
Throttle Lever Assembly (Mx360C46A5/Mx360Aa6A0/ Mx360Aa6A5/Mx360Aa6A6)
73
GOVERNOR ARM ASSEMBLY (MX360KA6D0 for KOR)
74
GOVERNOR ARM ASSEMBLY (MZ360/MZ400/MX360KA6D0 Except for KOR)
75
Flyweight Shaft Assembly (Mz360/Mz400)
76
Flyweight Shaft Assembly (Mx360)
77
Removing the Flyweight Shaft Assembly and Governor Fork
78
Disassembling the Flyweight Shaft Assembly
78
Checking the Flyweight Shaft Assembly
78
Assembling the Flyweight Shaft Assembly
79
Installing the Flyweight Shaft Assembly and Governor Fork
79
INSTALLING the THROTTLE LEVER ASSEMBLY (Equipped Models)
80
Adjusting the Governor
80
Engine Switch and Oil Warning Unit
81
Engine Switch
82
Cylinder Head Cover, Cylinder Head
83
Checking the Rocker Arm
85
Checking the Push Rod
85
Checking the Cylinder Head
85
Installing the Cylinder Head Assembly
86
Valve
87
Removing the Valves and Valve Springs
88
Checking the Valves and Valve Springs
88
Checking the Valve Seats
90
Valve Lapping
92
Installing the Valves and Valve Springs
93
Piston, Camshaft, Crankcase, and Crankshaft
94
Mz360/Mz400
94
Mx360
96
Removing the Balancer Shaft, Camshaft, and Valve Lifter
98
Checking the Balancer Shaft
98
Checking the Camshaft
98
Checking the Valve Lifter
100
Installing the Valve Lifter, Balancer Shaft, and Camshaft
100
Checking the Crankcase Cover
100
Installing the Crankcase Cover
101
Checking the Cylinder and Piston
101
Checking the Crankcase
103
Checking the Piston Pin
103
Checking the Piston Rings
104
Checking the Crankshaft
105
Checking the Connecting Rod Oil Clearance
106
Installing the Piston and Piston Ring
107
Installing the Crankshaft
107
Selecting the Crankshaft Shim
109
Removing the Carburetor
111
Mx360
112
Disassembling the Carburetor
113
Mz360/Mz400
113
Mx360
114
Checking the Carburetor
115
Electrical
116
Circuit Diagram
116
With Starter Motor, Oil Warning Unit, Oil Warning Light
116
With Oil Warning Unit, Oil Warning Light
118
Without Oil Warning Unit, Oil Warning Light
120
Electrical Components
122
Checking the Switch Continuity
123
CHECKING the FUSE (Equipped Models)
123
Checking the Ignition Spark Gap
125
Checking the Spark Plug Cap Resistance
126
Checking the Air Gap
126
Checking the Ignition Coil  (Tci Unit, Secondary)  Resistance
127
Resistance
127
Checking the Engine Switch
128
Checking the Oil Level Switch
128
CHECKING the STARTER MOTOR OPERATION (Equipped Models)
129
Checking the Wire Harness
129
Electric Starting System
131
DISASSEMBLING the STARTER MOTOR (Equipped Models)
131
Checking the Armature Coil
132
Checking the Brush
133
Checking the Starter Relay
133
Assembling the Starter Motor
133
Charging System
134
Checking the Charging Coil
134
Troubleshooting
135
Engine Does Not Start
135
ELECTRIC STARTING SYSTEM (Equipped Models)
136
Engine Starts but Stalls
136
Engine Speed Does Not Increase
137
Engine Speed Is Uneven
138
The Battery Is Not Charged
138
Governor Operation
139
Specifications
141
General Specifications
141
Maintenance Specifications
143
Engine
143
Electrical
147
Tightening Torques
150
General Torque Specifications
150
Lubrication Points and Type of Lubricants
151
Wire Routing Diagram
152
Upper Side View (Mz360)
152
Upper Side View (Mx360)
154
Upper Side View (Mz400)
156
ENGINE SWITCH and OIL WARNING UNIT (with Oil Warning Light, Oil Warning Unit, Oil Level Switch)
158
ENGINE SWITCH and OIL WARNING UNIT (with Oil Warning Unit, Oil Level Switch)
160
ENGINE SWITCH and OIL WARNING UNIT (no Oil Level Switch)
162
Tci Unit (Mz360)
163
Tci Unit (Mx360)
164
Tci Unit (Mz400)
165
Oil Level Switch (Crankcase Cover, Mx360)
167
Oil Level Switch
171

Yamaha MZ400 Supplementary Service Manual (18 pages)

Brand: Yamaha | Category: Engine | Size: 1.87 MB

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