Yamaha MX360 - Introduction

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MZ360/MX360/MZ400

SERVICE MANUAL

Products Co., Ltd.

1st Edition, March 2019

unauthorized use without the written

permission of Yamaha Motor

Powered Products Co., Ltd.

is expressly prohibited.

Main Page

General Information7
Table of Contents8
Machine Identification13
Serial Number13
Model Name and Code13
Dimensions14
Dimension Chart14
Top16
Mounting Base18
Left Side19
Front20
Right Side22
Important Information23
Preparation for Removal  and Disassembly23
Caution on Service23
Notes on Service23
All Replacement Parts24
Gaskets, Oil Seals, and O-Rings24
Bearings and Oil Seals25
Basic Service Information25
Electrical System25
Special Tools and Testers29
Periodic Checks and Adjustments31
Introduction31
Maintenance Intervals Chart31
Periodic Maintenance/Lubrication Intervals31
Periodic Maintenance33
Spark Plug33
Fuel Leakage34
Engine Oil Leakage34
Engine Oil Level34
Replacing the Engine Oil35
Air Filter Element (Mz360/Mz400)36
Air Filter Element (Mx360)37
MUFFLER (Equipped Models)38
Fuel Tank Filter41
Fuel Cock Strainer41
Breather Hose42
Cylinder Head Decarbonization42
Adjusting the Valve Clearance42
Engine Speed45
Models)46
Adjusting the Engine Speed46
Adjusting the Engine Speed47
Recoil Starter48
Fittings and Fasteners49
Engine51
Engine Inspection51
Measuring the Compression Pressure51
Air Filter53
Mz360/Mz40053
Mx36054
FUEL TANK (Equipped Models)55
Except for Mx360C46A555
Mx360C46A556
Muffler57
Equipped Models57
Installing the Muffler58
Recoil Starter59
Mz360/Mz40059
Disassembling the Recoil Starter (Mz360/Mz400)60
Checking the Recoil Starter (Mz360/Mz400)60
Assembling the Recoil Starter (Mz360/ Mz400)61
Mx36063
Disassembling the Recoil Starter (Mx360)64
Checking the Recoil Starter (Mx360)64
Assembling the Recoil Starter (Mx360)65
Flywheel67
Mz360/Mz40067
Mx36068
Removing the Flywheel69
Installing the Flywheel70
Installing the Tci Unit70
Governor72
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 Fork78
Disassembling the Flyweight Shaft Assembly78
Checking the Flyweight Shaft Assembly78
Assembling the Flyweight Shaft Assembly79
Installing the Flyweight Shaft Assembly and Governor Fork79
INSTALLING the THROTTLE LEVER ASSEMBLY (Equipped Models)80
Adjusting the Governor80
Engine Switch and Oil Warning Unit81
Engine Switch82
Cylinder Head Cover, Cylinder Head83
Checking the Rocker Arm85
Checking the Push Rod85
Checking the Cylinder Head85
Installing the Cylinder Head Assembly86
Valve87
Removing the Valves and Valve Springs88
Checking the Valves and Valve Springs88
Checking the Valve Seats90
Valve Lapping92
Installing the Valves and Valve Springs93
Piston, Camshaft, Crankcase, and Crankshaft94
Mz360/Mz40094
Mx36096
Removing the Balancer Shaft, Camshaft, and Valve Lifter98
Checking the Balancer Shaft98
Checking the Camshaft98
Checking the Valve Lifter100
Installing the Valve Lifter, Balancer Shaft, and Camshaft100
Checking the Crankcase Cover100
Installing the Crankcase Cover101
Checking the Cylinder and Piston101
Checking the Crankcase103
Checking the Piston Pin103
Checking the Piston Rings104
Checking the Crankshaft105
Checking the Connecting Rod Oil Clearance106
Installing the Piston and Piston Ring107
Installing the Crankshaft107
Selecting the Crankshaft Shim109
Removing the Carburetor111
Mx360112
Disassembling the Carburetor113
Mz360/Mz400113
Mx360114
Checking the Carburetor115
Electrical116
Circuit Diagram116
With Starter Motor, Oil Warning Unit, Oil Warning Light116
With Oil Warning Unit, Oil Warning Light118
Without Oil Warning Unit, Oil Warning Light120
Electrical Components122
Checking the Switch Continuity123
CHECKING the FUSE (Equipped Models)123
Checking the Ignition Spark Gap125
Checking the Spark Plug Cap Resistance126
Checking the Air Gap126
Checking the Ignition Coil  (Tci Unit, Secondary)  Resistance127
Resistance127
Checking the Engine Switch128
Checking the Oil Level Switch128
CHECKING the STARTER MOTOR OPERATION (Equipped Models)129
Checking the Wire Harness129
Electric Starting System131
DISASSEMBLING the STARTER MOTOR (Equipped Models)131
Checking the Armature Coil132
Checking the Brush133
Checking the Starter Relay133
Assembling the Starter Motor133
Charging System134
Checking the Charging Coil134
Troubleshooting135
Engine Does Not Start135
ELECTRIC STARTING SYSTEM (Equipped Models)136
Engine Starts but Stalls136
Engine Speed Does Not Increase137
Engine Speed Is Uneven138
The Battery Is Not Charged138
Governor Operation139
Specifications141
General Specifications141
Maintenance Specifications143
Engine143
Electrical147
Tightening Torques150
General Torque Specifications150
Lubrication Points and Type of Lubricants151
Wire Routing Diagram152
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 Switch171

Yamaha MX360 - Introduction

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