Yamaha MX825 - Page 3

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MX775, MX800, MX825

SERVICE MANUAL

©2016 by Yamaha Motor

Corporation, U.S.A.

1st Edition, December 2016

All rights reserved. Any reprinting or

unauthorized use without the written

permission of Yamaha Motor

Corporation, U.S.A.

is expressly prohibited.

LIT-19616-02-37

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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