Yamaha MX825 Service Manual

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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

Default Chapter5
- Default Chapter5
  - How to Use this Manual5
  - Table of Contents9
- General Information13
Machine Identification13
- Serial Number13
- Starting Serial Number13
Dimensions14
- Top14
- Mounting Base14
- Rear15
- REAR (for Models Equipped with a Muffler)15
- Right Side16
- RIGHT SIDE (for Models Equipped with a Muffler)16
Important Information17
- Preparation for Removal and Disassembly17
- Caution on Service17
- Notes on Service17
- All Replacement Parts18
- Gaskets, Oil Seals, and O-Rings18
- Bearings and Oil Seals19
Basic Service Information19
- Electrical System19
Special Tools and Testers23
- Periodic Checks and Adjustments25
Introduction25
Maintenance Intervals Chart25
Periodic Maintenance/Lubrication Intervals25
Periodic Maintenance26
- Spark Plugs26
- Muffler27
- (For Models Equipped with a Muffler)27
- Engine Oil Leakage28
- Engine Oil Level29
- Replacing the Engine Oil30
- Fuel Leakage32
- Fuel Filter32
- Oil Cooler33
- Air Filter Element33
- Adjusting the Valve Clearance33
- Cylinder Heads Decarbonization37
- Engine Speed38
- Adjusting the Engine Speed39
- LOW ENGINE SPEED (Replace the Throttle Body)39
- Fittings and Fasteners40
- Engine41
Engine Inspection41
- Measuring the Compression Pressure41
- Fuel41
Air Filter43
MUFFLER (for Models Equipped with a Muffler)44
Oil Cooler45
- Removing the Oil Cooler46
- Checking the Oil Cooler46
- Installing the Oil Cooler46
Ecu, Rectifier/Regulator, and Fuses48
- Installing the Fuses49
Ignition Coils50
Case and Fan51
- Removing the Case and Fan52
- Checking the Case and Fan53
- Installing the Case and Fan53
Flywheel and Stator Coil Assembly55
- Removing the Flywheel and Stator Coil Assembly56
- Checking the Flywheel and Stator Coil Assembly57
- Installing the Flywheel and Stator Coil Assembly57
- Installing the Crankshaft Position Sensor59
Cylinder Head Covers, Cylinder Heads60
- Cylinder Head #160
- Cylinder Head #262
- Checking the Rocker Arms and Rocker Arm Shafts64
- Checking the Push Rods64
- Removing the Cylinder Heads64
- Checking the Cylinder Heads64
- Installing the Cylinder Head Assembly65
Valves67
- Removing the Valves and Valve Springs68
- Checking the Valves and Valve Springs68
- Checking the Valve Seats70
- Valve Lapping71
- Installing the Valves and Valve Springs72
Oil Pump73
- Disassembling the Oil Pump74
- Checking the Oil Pump74
- Checking the Relief Valve75
- Checking the Crankcase Cover 275
- Installing the Oil Pressure Switch75
- Assembling the Oil Pump76
- Installing the Crankcase Cover 277
Pistons, Camshaft, Crankcase, and Crankshaft78
- Crankcase78
- Pistons, Camshaft, and Crankshaft80
- Removing the Flyweight Shaft Assembly and Governor Fork81
- Disassembling the Flyweight Shaft Assembly81
- Checking the Flyweight Shaft Assembly81
- Assembling the Flyweight Shaft Assembly82
- Installing the Flyweight Shaft Assembly and Governor Fork82
- Removing the Camshaft and Valve Lifters83
- Checking the Camshaft83
- Checking the Valve Lifters84
- Checking the Reed Valve85
- Installing the Valve Lifters and Camshaft85
- Installing the Cover 185
- Installing the Cover 286
- Checking the Crankcase Cover 186
- Installing the Crankcase Cover 187
- Checking the Cylinders and Pistons87
- Checking the Crankcase89
- Checking the Piston Pins89
- Checking the Piston Rings89
- Checking the Crankshaft91
- Checking the Connecting Rods Oil Clearance92
- Installing the Pistons and Piston Rings92
- Installing the Crankshaft94
Fuel Pumps97
- Removing the High-Pressure Fuel Pump98
- Checking the Low-Pressure Fuel Pump99
- Checking the High-Pressure Fuel Pump99
- Installing the High-Pressure Fuel Pump100
- Fuel97
Throttle Body Assembly102
- Removing the Throttle Body Assembly103
- Checking the Throttle Body Assembly103
- Installing the Throttle Body Assembly103
Fuel Injectors and Intake Manifold105
- Removing the Fuel Injectors107
- Installing the Fuel Injectors108
- Removing the Manifold Absolute Pressure Sensor110
- Installing the Manifold Absolute Pressure Sensor110
- Removing the Intake Manifold110
- Checking the Intake Manifold111
- Installing the Intake Manifold111
- Electrical112
Circuit Diagram112
Fuel Injection System114
- Fi Diag Tool Instructions114
- Fuel Injection Diagram120
- Error Code List121
- Diag Code List122
- Fuel Injection System Troubleshooting123
Electrical Components136
- Checking the Switch Continuity138
- Checking the Fuses138
- Checking the Oil Pressure Switch139
- Checking Manifold Absolute Pressure Sensor140
- Checking the Throttle Position Sensor140
- Checking the Crankshaft Position Sensor141
- Checking the Engine Temperature Sensor142
- Checking the Ignition Coils143
- Checking the Ignition Spark Gap144
- Checking the Spark Plug Caps144
- Checking the Stator Coil Assembly145
- Checking the Rectifier/Regulator146
- Checking the Fuel Injectors146
- Checking the Starter Motor Operation147
Electric Starting System148
- Removing the Starter Motor148
- Disassembling the Starter Motor149
- Checking the Armature Coil150
- Checking the Brush151
- Checking the Starter Relay151
- Assembling the Starter Motor151
- Troubleshooting153
Engine Does Not Start153
- Ignition System153
- Electric Starting System154
- Fuel Injection System154
- Fuel Pump System154
Other Troubles155
- Engine Starts but Stalls155
- Engine Speed Does Not Increase156
- Engine Speed Is Uneven157
- The Battery Is Not Charged157
- Governor Operation158
Oil Pressure System158
- Specifications159
General Specifications159
Maintenance Specifications161
- Engine161
- Electrical165
General Torque Specifications168
Tightening Torques168
Lubrication Points and Type of Lubricants169
Wire Routing Diagram170
- Upper Side View170
- Left Side View174
- Right Side View176
- Rear Side View180

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Yamaha MX825 Specifications

General

Brand	Yamaha
Model	MX825
Category	Engine
Language	English

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