Yamaha MZ400 Supplementary Service Manual
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Yamaha MZ400 Supplementary Service Manual

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SUPPLEMENTARY
SERVICE MANUAL
MZ400
MX400
LIT-19616-02-36
7HS-F8197-10

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Summary of Contents for Yamaha MZ400

  • Page 1 SUPPLEMENTARY SERVICE MANUAL MZ400 MX400 LIT-19616-02-36 7HS-F8197-10...
  • Page 3 7HC-F8197-10/LIT-19616-02-32 MX360 SUPPLEMENTARY SERVICE MANUAL: 7HC-F8197-11/LIT-19616-02-34 This manual was written by the Yamaha Motor Powered Products Co., Ltd. primarily for use by Yamaha dealers and their qualified mechan- ics. It is not possible to put an entire mechan- ic’s education into one manual, so it is...

  • Page 4: How To Use This Manual

    HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION Particularly important information is distin- guished in this manual by the following nota- tions. This is the safety alert symbol. It is used to alert you to potential personal injury haz- ards. Obey all safety messages that follow this symbol to avoid possible injury or death.
  • Page 5 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 9 The manual is divided into chapters and each chapter is divided into sections.
  • Page 6 ILLUSTRATED SYMBOLS (Refer to the illustration) SYMBOL DEFINITION SYMBOL DEFINITION Periodic checks and General information adjustments Engine Carburetor Electrical Troubleshooting Specifications Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data Replace the part with a new one. Lithium-soap base grease Molybdenum disulfide grease Engine oil...
  • Page 7 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC...
  • Page 8 CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION .....1-1 ENGINE SERIAL NUMBER ....1-1 STARTING SERIAL NUMBER ....1-1 CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ....2-1 MAINTENANCE SPECIFICATIONS ..2-3 ENGINE ..........2-3 ELECTRICAL ........2-7...

  • Page 9: Engine Serial Number

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION ENGINE SERIAL NUMBER The serial number is printed on the label 1 affixed to the position 2 of the multi-purpose engine as shown in the illustration. The first four digits identify the model, and the remaining digits indicates the production number.

  • Page 10: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: MZ400 MX400 Model code number: 7HSB 7HSJ Dimensions: Overall length mm (in) 456 (17.95) 392.5 (15.45) 418 (16.46) (PTO:B type) (PTO:A type) Overall width mm (in) 479 (18.86) 462 (18.19) 480 (18.90)
  • Page 11 SPEC GENERAL SPECIFICATIONS Model name: MZ400 MX400 Model code number: 7HSB 7HSJ Electrical: Ignition system Ignition timing (3600 r/min) BTDC 23° ± 3° Spark plug type BPR4ES (NGK) 0.7–0.8 (0.028–0.031) Spark plug gap mm (in) * The power rating of the engine indicated in the SPECIFICATIONS is the net power output tested on an engine model and measured at 3600 r/min.
  • Page 12 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model name: MZ400 MX400 Model code number: 7HSB 7HSJ Piston: mm (in) Piston clearance 0.015–0.029 (0.0006–0.0011) <Limit> 0.06 (0.0024) Piston skirt diameter “D” 84.977–84.998 (3.3455–3.3464) <Limit> 84.921 (3.3433) Measuring point “H” 10 (0.3937) Oversize 1st 85.25 (3.3563)

  • Page 13: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS Model name: MZ400 MX400 Model code number: 7HSB 7HSJ Crankshaft: mm (in) Big end side clearance “A” 0.20–0.65 (0.008–0.026) <Limit> 0.8 (0.0315) Runout “B” <Limit> 0.02 (0.0008) Crank pin outside diameter “C” 35.969–35.984 (1.4161–1.4167) <Limit> 35.90 (1.4134) Crankshaft free play 0–0.2 (0.000–0.008)
  • Page 14 SPEC MAINTENANCE SPECIFICATIONS Model name: MZ400 MX400 Model code number: 7HSB 7HSJ Valve: mm (in) Head diameter “A” 31.9–32.1 (1.2559–1.2638) 27.9–28.1 (1.0984–1.1063) Stem diameter “B” 5.948–5.963 (0.2342–0.2348) 5.940–5.955 (0.2339–0.2344) <Limit> 5.918 (0.2330) 5.910 (0.2327) Stem length “C” 88.1 (3.4685) 88.1 (3.4685) Valve face contact width “D”...
  • Page 15 SPEC MAINTENANCE SPECIFICATIONS Model name: MZ400 MX400 Model code number: 7HSB 7HSJ Valve spring: mm (in) Free length 36.2 (1.4252) 36.2 (1.4252) <Limit> 34.39 (1.3539) 34.39 (1.3539) Installed length 29 (1.1417) 29 (1.1417) Installed compression spring force N (kgf, lbf) 91.20–104.93 (9.12–10.49, 20.50–23.59)
  • Page 16 SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model name: MZ400 MX400 Model code number: 7HSB 7HSJ Ignition system: Ignition timing at 3600 r/min BTDC 23° ± 3° Primary coil resistance (Ω ± 20 %) Secondary coil resistance (kΩ ± 20 %) 11.2 Spark plug cap resistance kΩ...
  • Page 18 2016_02×1 !

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