Yamaha MZ300, Service Manual

Page 1: ...MZ300 MZ360 SUPPLEMENTARY SERVICE MANUAL 7CR F8197 10 LIT 19616 01 81 7CR F8197 10_cover indd 1 2012 03 06 10 26 00 ...

Page 2: ...7CR F8197 10_cover indd 2 2012 03 06 10 26 00 ...

Page 3: ...ed use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in USA LIT 19616 01 81 MZ300 MZ300R MZ360 MZ360R SERVICE MANUAL 7RJ 28197 N0 310069 April 1996 HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION Particularly important information is distin guished in this manual by the following notations This is the safety alert symbol It is used to al...

Page 4: ...ce Periodic inspections and adjustments Engine speed Engine Electrical data Electrical M Molybdenum disulfide oil Specifications E Engine oil Special tool LS Lithium soap base grease Filling fluid LT Apply locking agent LOCTITE Lubricant Replace the part with a new one T R Tightening torque M Molybdenum disulfide grease ...

Page 5: ...INDEX GENERAL INFORMATION GEN INFO PERIODIC INSPECTIONS AND ADJUSTMENTS INSP ADJ SPECIFICATIONS SPEC 1 2 3 ...

Page 6: ...2 DIMENSION CHART 1 2 MOUNTING BASE 1 2 TOP 1 3 SIDE 1 3 FRONT 1 4 SPECIAL TOOLS AND TESTERS 1 5 CHAPTER 2 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION 2 1 PERIODIC MAINTENANCE LUBRICATION INTERVALS 2 1 CHAPTER 3 SPECIFICATIONS GENERAL SPECIFICATIONS 3 1 MAINTENANCE SPECIFICATIONS 3 2 ENGINE 3 2 ELECTRICAL 3 3 ...

Page 7: ...ngine as shown in the illustration TIP The first four digits identifies a model and the remaining digits indicates a production number STARTING SERIAL NUMBER Model Code Serial number A MZ300 A2 7CRJ 7CRJ 1000101 B MZ360 A2 7CTJ 7CTJ 1000101 TIP Designs and specifications are subject to change without notice 7CR 1 7CT 1 A B MACHINE IDENTIFICATION STARTING SERIAL NUMBER 1 ...

Page 8: ...146 08 21 8 110 72 2 28 60 3 88 5 6 31 5 4 5 0 0 021 0 0 1 0 0 040 0 0 054 0 0 058 3 8 24UNF 2B 4 3 8 16UNC 4 M8 1 25 110 127 1 4 6 0 8 1 6 5 1 30 30 45 45 0 0 0 4 0 0 0 054 2B DEPTH 18 MZ360 A2 7CTJ 1 UNF Unified fine thread Unit in 2 UNC Unified coarse thread Unit in MOUNTING BASE Unit mm 2 1 1 65 37 16 2 11 90 5 105 DIMENSIONS ...

Page 9: ...1 3 GEN INFO DIMENSIONS TOP Unit mm SIDE Unit mm 423 485 451 162 133 5 195 5 103 90 5 70 2 M8 1 25 DEPTH 18 284 ...

Page 10: ...1 4 GEN INFO DIMENSIONS FRONT Unit mm 425 188 204 99 118 37 102 62 16 65 2 11 HOLE 2 11 27 SLOT HOLE ...

Page 11: ...79 This gauge is used to adjust valve clearance piston clearance and piston ring end gap 2 Cylinder gauge Commercially obtainable This instrument is used for checking cylinder bore size and condition 3 Digital tachometer P N YU 39951 B 90890 06760 This tool is needed for observing engine r min 4 Engine compression tester P N YU 33223 Compression gauge P N 90890 03081 This tool is used for checking...

Page 12: ... 90890 01701 This tool is necessary for holding the magneto rotor 10 Six piece tappet set P N YM A5970 Tappet adjusting tool P N 90890 01311 This tool is used to adjust the valve clearances ø9 ø8 ø10 ø3 ø4 YM A5970 90890 01311 3mm 11 Heavy duty puller P N YU 33270 B Flywheel puller P N 90890 01362 This tool is necessary for removing the magneto rotor SVU1220 12 Valve spring compressor P N YM 01253...

Page 13: ... condition adjust gap and clean Replace if necessary 8 2 Valve clearance Check and adjust when engine is cold 8 3 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 8 4 Idle speed Check and adjust engine idle speed 8 5 Exhaust system Check for leakage Retighten or replace gasket if necessary 8 Check spark arrester Clean replace if necessary 8 6 Engine oil Check...

Page 14: ...ERVALS No Item Remarks Pre Opera tion check daily Initial Every 1 month or 20 hr 3 months or 50 hr 6 months or 100 hr 12 months or 300 hr 15 Decarbonization More frequency if necessary 8 16 Fittings fasteners Check all fittings and fasteners Correct if necessary 8 ...

Page 15: ...Engine Type Air cooled 4 stroke gasoline OHV Rated out put 6 8 9 2 3600 7 6 10 3 3600 kW PS r min Starting method Recoil starter Ignition timing BTDC 23 3 Fuel tank Fuel tank capacity 6 1 1 61 1 34 L US gal Imp gal Engine oil Engine oil quantity 1 1 1 16 0 97 L US qt Imp qt Recommended engine oil å YAMALUBE 4 10W 40 SAE 10W 30 or 10W 40 SAE 30 ç SAE 20 SAE 10W Recommended engine oil grade API serv...

Page 16: ... 0 142 End gap 0 20 0 35 0 008 0 014 Limit 0 9 0 0354 2nd ring Dimensions B T 1 50 3 40 0 059 0 134 1 50 3 60 0 059 0 142 End gap 0 30 0 45 0 012 0 018 0 20 0 35 0 008 0 014 Limit 0 9 0 0354 Oil ring Dimensions B T 2 50 2 80 0 098 0 110 3 0 3 0 0 118 0 118 Valve mm in Valve clearance cold IN 0 07 0 003 EX 0 07 0 003 Valve spring mm in Set length IN 29 0 1 1417 EX 29 0 1 1417 Set force IN 10 0 kg 2...

Page 17: ...t 100 112 5 Pilot jet 53 8 57 5 Pilot screw 1 1 2 1 3 4 Valve seat size mm ø1 8 Float height H mm in 14 9 0 59 MAINTENANCE SPECIFICATIONS ELECTRICAL Model name MZ300 MZ360 Model code number 7CRJ 7CTJ Ignition system Spark plug cap resistance 3 75 6 25 kΩ TCI Primary coil resistance 1 2 Ω Secondary coil resistance 11 7 kΩ ...

Page 18: ...3 4 SPEC ...

Page 19: ...7CR F8197 10_cover indd 3 2012 03 06 10 26 00 ...

Page 20: ...PRINTED IN USA E 7CR F8197 10_cover indd 4 2012 03 06 10 26 00 ...