Yamaha MX800V - Fittings and Fasteners

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PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE

FITTINGS AND FASTENERS

1.

Check:

• All fittings and fasteners

Looseness  Tighten.

Rough movement  Replace the defective part(s).

Damage/pitting  Replace.

Table of Contents

Default Chapter5
- Default Chapter5
  - How to Use this Manual5
- General Information7
  - Table of Contents8
Machine Identification11
- Serial Number11
- Starting Serial Number11
Dimensions12
- Top12
- Mounting Base12
- Rear13
- REAR (for Models Equipped with a Muffler)13
- Right Side14
- RIGHT SIDE (for Models Equipped with a Muffler)14
Important Information15
- Preparation for Removal and Disassembly15
- Caution on Service15
- Notes on Service15
- All Replacement Parts16
- Gaskets, Oil Seals, and O-Rings16
- Bearings and Oil Seals17
Basic Service Information17
- Electrical System17
Special Tools and Testers20
- Periodic Checks and Adjustments21
Introduction21
Maintenance Intervals Chart21
Periodic Maintenance/Lubrication Intervals21
Periodic Maintenance22
- Spark Plugs22
- Muffler23
- (For Models Equipped with a Muffler)23
- Engine Oil Leakage24
- Engine Oil Level25
- Replacing the Engine Oil26
- Fuel Leakage28
- Fuel Filter28
- Oil Cooler29
- Air Filter Element29
- Adjusting the Valve Clearance29
- Cylinder Heads Decarbonization33
- Engine Speed34
- Adjusting the Engine Speed35
- LOW ENGINE SPEED (Replace the Carburetor Assembly)36
- Fittings and Fasteners37
- Engine39
Engine Inspection39
- Measuring the Compression Pressure39
Air Filter41
MUFFLER (for Models Equipped with a Muffler)42
Oil Cooler43
- Removing the Oil Cooler44
- Checking the Oil Cooler44
- Installing the Oil Cooler44
Rectifier/Regulator46
Case and Fan47
- Removing the Case and Fan48
- Checking the Case and Fan49
- Installing the Case and Fan49
Tci Units, Flywheel and Stator Coil Assembly51
- Tci Units51
- Flywheel and Stator Coil Assembly52
- Removing the Flywheel and Stator Coil Assembly53
- Checking the Flywheel and Stator Coil Assembly54
- Installing the Flywheel and Stator Coil Assembly54
- Installing the Tci Units56
Cylinder Head Covers, Cylinder Heads57
- Cylinder Head #157
- Cylinder Head #259
- Checking the Rocker Arms and Rocker Arm Shafts61
- Checking the Push Rods61
- Removing the Cylinder Heads61
- Checking the Cylinder Heads61
- Installing the Cylinder Head Assembly62
Valves64
- Removing the Valves and Valve Springs65
- Checking the Valves and Valve Springs65
- Checking the Valve Seats67
- Valve Lapping68
- Installing the Valves and Valve Springs69
Oil Pump70
- Disassembling the Oil Pump71
- Checking the Oil Pump71
- Checking the Relief Valve72
- Checking the Crankcase72
- Installing the Oil Pressure Switch72
- Assembling the Oil Pump73
- Installing the Crankcase Cover 274
Pistons, Camshaft, Crankcase, and Crankshaft75
- Crankcase75
- Pistons, Camshaft, and Crankshaft77
- 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
- Removing the Camshaft and Valve Lifters80
- Checking the Camshaft80
- Checking the Valve Lifters81
- Checking the Reed Valve82
- Installing the Valve Lifters and Camshaft82
- Installing the Cover 182
- Installing the Cover 283
- Checking the Crankcase Cover 183
- Installing the Crankcase Cover 184
- Checking the Cylinders and Pistons84
- Checking the Crankcase86
- Checking the Piston Pins86
- Checking the Piston Rings86
- Checking the Crankshaft88
- Checking the Connecting Rods Oil Clearance89
- Installing the Pistons and Piston Rings90
- Installing the Crankshaft91
Fuel Pump95
- Checking the Fuel Pump96
- Fuel95
Carburetor Assembly97
- Removing the Carburetor97
- Disassembling the Carburetor98
- Removing the Carburetor Assembly99
- Checking the Carburetor Assembly99
- Installing the Carburetor Assembly99
Intake Manifold101
- Removing the Intake Manifold102
- Checking the Intake Manifold102
- Installing the Intake Manifold102
Circuit Diagram104
- Electrical104
Electrical Components106
- Checking the Switch Continuity108
- Checking the Oil Pressure Switch108
- Checking the Tci Unit Resistance108
- Notice108
- Checking the Ignition Spark Gap109
- Checking the Spark Plug Caps110
- Checking the Stator Coil Assembly110
- Checking the Rectifier/Regulator111
- Checking the Starter Motor Operation111
Electric Starting System113
- Removing the Starter Motor113
- Disassembling the Starter Motor114
- Checking the Armature Coil115
- Checking the Brush116
- Checking the Starter Relay116
- Assembling the Starter Motor116
- Troubleshooting119
Engine Does Not Start119
- Ignition System119
- Electric Starting System120
Other Troubles121
- Engine Starts but Stalls121
- Engine Speed Does Not Increase122
- Engine Speed Is Uneven123
- The Battery Is Not Charged124
- Governor Operation125
Oil Pressure System126
- Specifications127
General Specifications127
Maintenance Specifications129
- Engine129
- Electrical133
Tightening Torques136
General Torque Specifications136
Lubrication Points and Type of Lubricants137
Wire Routing Diagram138
- Upper Side View138
- Left Side View142
- Right Side View144
- Rear Side View150

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