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Yamaha MX775 Service Manual

Yamaha MX775
188 pages
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SERVICE MANUAL
MX775
MX800
MX825
7UD-F8197-E0LIT-19616-02-37
2016.12×1
!
7UD-F8197-E0_Cover.indd 1 2016/12/13 11:23:58

Table of Contents

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Yamaha MX775 Specifications

General IconGeneral
BrandYamaha
ModelMX775
CategoryEngine
LanguageEnglish

Summary

GENERAL INFORMATION

MACHINE IDENTIFICATION

Details about identifying the engine's serial number and model codes.

DIMENSIONS

Provides overall measurements of the engine in different views.

IMPORTANT INFORMATION

Covers crucial notes on preparation, service cautions, and parts handling.

BASIC SERVICE INFORMATION

Explains how to check bearings, oil seals, and electrical connections.

SPECIAL TOOLS AND TESTERS

Lists specialized tools required for service procedures.

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

Outlines the importance of preventive maintenance for reliability.

MAINTENANCE INTERVALS CHART

Table detailing maintenance tasks at specific operating intervals.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Specifies routine checks and lubrication procedures.

SPARK PLUGS

Instructions for checking, measuring gap, and replacing spark plugs.

MUFFLER

Procedures for removing, decarbonizing, and installing the muffler.

ENGINE OIL LEAKAGE

Guidance on checking for and addressing engine oil leaks.

ENGINE OIL LEVEL

Steps to check and maintain the correct engine oil level.

REPLACING THE ENGINE OIL

Detailed steps for draining and refilling the engine oil and filter.

FUEL LEAKAGE

Procedure for checking the fuel system for leaks.

FUEL FILTER

Instructions for removing, checking, and cleaning the fuel filter.

OIL COOLER

Guidance on checking and cleaning the oil cooler for damage or clogs.

AIR FILTER ELEMENT

Steps for removing, checking, and installing the air filter element.

ADJUSTING THE VALVE CLEARANCE

Detailed procedure for measuring and adjusting valve clearance.

ENGINE SPEED

Procedures for measuring and adjusting high and low engine speeds.

FITTINGS AND FASTENERS

Guidance on checking and tightening various fittings and fasteners.

ENGINE

ENGINE INSPECTION

Procedures for inspecting engine components, including compression.

MEASURING THE COMPRESSION PRESSURE

Detailed steps for measuring engine compression using a tester.

AIR FILTER

Exploded view and parts list for the air filter assembly.

MUFFLER

Exploded view and parts list for the muffler assembly.

OIL COOLER

Exploded view and parts list for the oil cooler system.

ECU, RECTIFIER/REGULATOR, AND FUSES

Exploded view and parts list for electrical control components.

IGNITION COILS

Exploded view and parts list for the ignition coil system.

CASE AND FAN

Exploded view and parts list for the engine's cooling fan and case.

FLYWHEEL AND STATOR COIL ASSEMBLY

Exploded view and parts list for the flywheel and stator coil.

CYLINDER HEAD COVERS, CYLINDER HEADS

Exploded views and parts lists for cylinder head components.

VALVES

Exploded view and parts list for the valve train components.

OIL PUMP

Exploded view and parts list for the oil pump assembly.

PISTONS, CAMSHAFT, CRANKCASE, AND CRANKSHAFT

Exploded views and parts lists for core engine rotating assembly.

FUEL

FUEL PUMPS

Exploded view and parts list for the fuel pump system.

THROTTLE BODY ASSEMBLY

Exploded view and parts list for the throttle body assembly.

FUEL INJECTORS AND INTAKE MANIFOLD

Exploded view and parts list for fuel injectors and intake manifold.

ELECTRICAL

CIRCUIT DIAGRAM

Schematic showing the electrical system layout and connections.

FUEL INJECTION SYSTEM

Instructions for using the FI Diagnostic Tool for system diagnosis.

ERROR CODE LIST

Comprehensive list of diagnostic error codes and their meanings.

DIAG CODE LIST

Details on diagnostic codes, items, and how to diagnose them.

FUEL INJECTION SYSTEM TROUBLESHOOTING

Step-by-step troubleshooting for common fuel injection system errors.

ELECTRICAL COMPONENTS

Identifies and illustrates various electrical components on the engine.

CHECKING THE SWITCH CONTINUITY

Procedure for testing switch continuity using a digital tester.

CHECKING THE FUSES

Steps for removing, checking, and replacing fuses.

CHECKING MANIFOLD ABSOLUTE PRESSURE SENSOR

Procedure for checking the MAP sensor using the FI Diagnostic Tool.

CHECKING THE THROTTLE POSITION SENSOR

Procedure for checking the throttle position sensor resistance.

CHECKING THE CRANKSHAFT POSITION SENSOR

Procedure for checking crankshaft position sensor resistance and gap.

CHECKING THE ENGINE TEMPERATURE SENSOR

Procedure for checking engine temperature sensor resistance.

CHECKING THE IGNITION COILS

Procedure for checking primary and secondary coil resistance.

CHECKING THE IGNITION SPARK GAP

Procedure for measuring the ignition spark gap.

CHECKING THE SPARK PLUG CAPS

Procedure for checking spark plug cap resistance.

CHECKING THE STATOR COIL ASSEMBLY

Procedure for checking stator coil resistance.

CHECKING THE RECTIFIER/REGULATOR

Procedure for checking rectifier/regulator output voltage.

CHECKING THE FUEL INJECTORS

Procedure for checking fuel injector resistance.

CHECKING THE STARTER MOTOR OPERATION

Procedure for testing the starter motor's operational status.

ELECTRIC STARTING SYSTEM

Exploded view and parts list for the electric starting system.

DISASSEMBLING THE STARTER MOTOR

Steps for disassembling the starter motor.

CHECKING THE ARMATURE COIL

Procedures for checking the armature coil's mica and continuity.

CHECKING THE BRUSH

Procedure for measuring brush length and checking brush springs.

CHECKING THE STARTER RELAY

Procedure for measuring starter relay coil resistance.

TROUBLESHOOTING

ENGINE DOES NOT START

Troubleshooting guide for ignition and starting system failures.

OTHER TROUBLES

Troubleshooting for engine starting issues and speed problems.

ENGINE STARTS BUT STALLS

Troubleshooting steps for an engine that starts but then stalls.

ENGINE SPEED DOES NOT INCREASE

Troubleshooting for issues where engine speed does not increase properly.

ENGINE SPEED IS UNEVEN

Troubleshooting steps for inconsistent engine speed.

THE BATTERY IS NOT CHARGED

Troubleshooting steps for a battery that is not charging.

GOVERNOR OPERATION

Checks and adjustments related to the governor system.

OIL PRESSURE SYSTEM

Troubleshooting steps for issues with the oil pressure system.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Key overall specifications for the engine and electrical system.

MAINTENANCE SPECIFICATIONS

Detailed specifications for engine components like pistons, rings, and valves.

TIGHTENING TORQUES

A comprehensive list of torque specifications for various fasteners.

LUBRICATION POINTS AND TYPE OF LUBRICANTS

Guide to lubrication points and recommended lubricant types.

WIRE ROUTING DIAGRAM

Diagrams illustrating the correct routing of electrical wires and hoses.

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