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Yamaha MX800V Service Manual

Manual is about: Multi-Purpose Engines

Summary of MX800V

  • Page 1

    Service manual mx800v mx825v 7uc-f8197-e0 lit-19616-02-50 2017.10×1 ! 7uc-f8197-e0_hyoshi.Indd 1-2 2017/10/27 13:08:23.

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    7uc-f8197-e0_hyoshi.Indd 3-4 2017/10/27 13:08:23.

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    Mx800v, mx825v service manual ©2017 by yamaha motor corporation, u.S.A. 1st edition, october 2017 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Lit-19616-02-50

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    Important this manual was produced by the yamaha motor powered products co., ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on...

  • 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. • the manual is divided int...

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    Symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every machine. Symbol definition symbol definition filling fluid lubricant special tool tightening torque wear limit, clearance engine speed electrical data replace the part ...

  • Page 7

    General information periodic checks and adjustments engine fuel electrical troubleshooting specifications 1 2 3 4 5 6 7 8 9 10 index.

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    Table of contents general information machine identification ......................1-1 serial number .................................1-1 starting serial number...............1-1 dimensions .............................................1-2 top .......................................................1-...

  • Page 9

    Cylinder head #2 ..........................3-21 checking the rocker arms and rocker arm shafts.............3-23 checking the push rods ...........3-23 removing the cylinder heads ................................................3-23 checking the cylinder heads ...........................................

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    Electrical circuit diagram....................................5-1 electrical components...................5-3 checking the switch continuity.........................................5-5 checking the oil pressure switch ................................................5-5 checking the tci unit resistan...

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    1 2 3 4 5 6 7 8 9 10 gener a l in forma t ion 1-1 general information machine identification serial number the serial number is printed on the label “1” affixed to the position of the multi-purpose engine as shown in the illus- tration. Tip • the first four digits identify the model, and the remaini...

  • Page 12

    Dimensions 1-2 1 2 3 4 5 6 7 8 9 10 gen e ral i n for m a t ion dimensions top mounting base *1: unc: unified coarse thread (unit: in) *2: pcd: pitch circle diameter mm (in) mm (in) 499.2(19.65) 157.1(6.19) 35 ° 35 ° 45 ° 45 ° pcd 254 4 3/8-16unc.

  • Page 13

    1-3 1 2 3 4 5 6 7 8 9 10 gener a l in forma t ion dimensions rear rear (for models equipped with a muffler) mm (in) mm (in) 451.2(17.76) 235.1(9.26) 451.2(17.76) 445.4(17.54) 235.1(9.26).

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    Dimensions 1-4 1 2 3 4 5 6 7 8 9 10 gen e ral i n for m a t ion right side right side (for models equipped with a muffler) mm (in) mm (in) 416.2(16.39) 108.8(4.28) 639(25.16) 416.2(16.39) 116.7(4.59) 108.8(4.28) 639(25.16).

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    1-5 1 2 3 4 5 6 7 8 9 10 gener a l in forma t ion important information important information preparation for removal and disassembly caution on service fire prevention when servicing the engine, always keep the engine and yourself away from fire. Notes on service correct tools be sure to use the co...

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    Important information 1-6 1 2 3 4 5 6 7 8 9 10 gen e ral i n for m a t ion tightening torque be sure to follow torque specifications. When tightening bolts, nuts or screws, start with the largest-diameter fas- tener and work from an inner position to an outer position in a crisscross pattern. Notes ...

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    1-7 1 2 3 4 5 6 7 8 9 10 gener a l in forma t ion basic service information bearings and oil seals install the bearing(s) “1” and oil seal(s) “2” with their manu- facture’s marks or numbers facing outward. (in other words, the stamped letters must be on the side exposed to view.) when installing oil...

  • Page 18

    Basic service information 1-8 1 2 3 4 5 6 7 8 9 10 gen e ral i n for m a t ion checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture dry with an air blower. Rust/...

  • Page 19

    1-9 1 2 3 4 5 6 7 8 9 10 gener a l in forma t ion basic service information 3. Connect: • lead • coupler • connector tip • when connecting a coupler or connector, push both sec- tions of the coupler or connector together until they are connected securely. • make sure all connections are tight. 4. Ch...

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    Special tools and testers 1-10 1 2 3 4 5 6 7 8 9 10 gen e ral i n for m a t ion special tools and testers the proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised t...

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    1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s 2-1 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operati...

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    2-2 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance periodic maintenance spark plugs 1. Remove: • spark plug caps “1” • spark plugs 2. Check: • spark plug type not correct replace. • electrode “1” wear/damage replace. • insulator color “2” not normal replace. 3. Measure: ...

  • Page 23

    2-3 1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s periodic maintenance 4. Install: • spark plugs tip to prevent threads from being damaged, temporally tighten “a” the spark plug before tightening it to the speci- fied torque “b”. Muffler (for models equipped with a muffler) 1. Remove:...

  • Page 24

    2-4 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance 3. Remove: • muffler (refer to “muffler (for models equipped with a muffler)” on page 3-4) 4. Decarbonize: • muffler tap on the muffler in the area shown in the illustra- tion to loosen carbon buildup, and then shake it ...

  • Page 25

    2-5 1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s periodic maintenance 2. Check the areas outside of the engine for oil leakage. Oil leakage replace the gasket, oil seal, or o-ring. Engine oil level 1. Remove: • oil filler cap “1” 2. Check: • check that engine oil is at the specified ...

  • Page 26

    2-6 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance 3. Install: • oil filler cap tip check whether the oil warning light comes on by turning the main switch. Oil warning light comes on add oil. Oil warning light does not comes on ok. Replacing the engine oil 1. Warm up th...

  • Page 27

    2-7 1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s periodic maintenance b. Lubricate the o-ring “3” of the new oil filter with a thin coat of engine oil. C. Tighten the new oil filter to specification with an oil filter wrench. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • oi...

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    2-8 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance fuel leakage 1. Check: • leakage check at fuel pump, fuel hose, and carburetor assembly. Fuel filter 1. Remove: • fuel filter 2. Check: • fuel filter damage replace. Dirt/clog clean. Tip clean the fuel filter with clean ...

  • Page 29

    2-9 1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s periodic maintenance oil cooler 1. Check: • oil cooler damage replace. Dirt/clog clean. Air filter element 1. Remove: • dust cap “1” • air filter case cover “2” • air filter element “3” • inner element “4” 2. Check: • air filter elemen...

  • Page 30

    2-10 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance 2. Remove: • cylinder head cover “3” • cylinder head cover gasket 3. Remove: • fan case cover “1” (refer to “case and fan” on page 3-9) • grass screen “2” (refer to “case and fan” on page 3-9) 4. Turn the crankshaft clo...

  • Page 31

    2-11 1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s periodic maintenance 6. Adjust: • adjust to original set value tip • when adjust valve clearance, record the measured read- ing of current. • measure the valve clearance in the following sequence. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 32

    2-12 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance c. Check the thickness of the current adjusting pad. Tip the thickness of each adjusting pad is indicated in 1/100 mm units “a” and inscribed on the side. Example: if the adjusting pad is marked “180”, the pad thick- ne...

  • Page 33

    2-13 1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s periodic maintenance g. Install the rocker arm “5”. (refer to “cylinder head covers, cylinder heads” on page 3-19) tip • lubricate the rocker arm with engine oil. • turn the crankshaft clockwise several full turns to seat the parts. H...

  • Page 34

    2-14 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance engine speed 1. Warm up the engine for several minutes. 2. Attach: • digital tachometer “1” 3. Measure: • high engine speed (with no load) out of specification adjust. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Move t...

  • Page 35

    2-15 1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s periodic maintenance b. Check the low engine speed. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ adjusting the engine speed 1. Warm up the engine for several minutes. 2. Attach: • digital tachometer “1” 3. Adjust: • high engine speed ▼▼▼...

  • Page 36

    2-16 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Move the throttle lever “1” to the low engine speed position “a”. B. Turn the screw “2” in direction “b” or “c” until obtain adequet low engine speed. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 37

    2-17 1 2 3 4 5 6 7 8 9 10 period ic check s an d a d ju stmen t s periodic maintenance fittings and fasteners 1. Check: • all fittings and fasteners looseness tighten. Rough movement replace the defective part(s). Damage/pitting replace..

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    2-18 1 2 3 4 5 6 7 8 9 10 pe riodic che cks and adjustments periodic maintenance memo.

  • Page 39

    1 2 3 4 5 6 7 8 9 10 engine 3-1 engine engine inspection measuring the compression pressure the following procedure applies to all of the cylinders. Tip measure the compression pressure after checking and adjusting the valve clearance. 1. Warm up the engine for several minutes. 2. Remove: • spark pl...

  • Page 40

    3-2 1 2 3 4 5 6 7 8 9 10 engine engine inspection ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug hole and measure again. Refer to the following table. B. If the compression pressure is ...

  • Page 41

    3-3 1 2 3 4 5 6 7 8 9 10 engine air filter air filter order job/parts to remove q’ty remarks removing the air filter remove the parts in the order listed. 1 dust cap 1 2 air filter case cover 1 3 air filter element 1 4 inner element 1 5 air filter cover 1 1 6 air filter case stay 1 7 air filter case...

  • Page 42

    3-4 1 2 3 4 5 6 7 8 9 10 engine muffler (for models equipped with a muffler) muffler (for models equipped with a muffler) order job/parts to remove q’ty remarks removing the muffler remove the parts in the order listed. 1 muffler 1 2 spark arrester 1 3 gasket 2 1 2 3 3.5 n ・ m (0.35 kgf ・ m, 2.6 lb ...

  • Page 43

    3-5 1 2 3 4 5 6 7 8 9 10 engine oil cooler oil cooler order job/parts to remove q’ty remarks removing the oil cooler remove the parts in the order listed. Engine oil drain. Refer to “replacing the engine oil” on page 2-6. 1 oil cooler 1 2 oil hose 1 1 3 oil hose 2 1 4 oil filter 1 5 adapter union bo...

  • Page 44

    3-6 1 2 3 4 5 6 7 8 9 10 engine oil cooler removing the oil cooler 1. Remove: • hose clamp (clic-r) “1” tip • remove the hose clamp using the hose clamp pliers “2”. • when removing the hose clamp, make sure that the thick tip “a” of the hose clamp pliers is directed as shown in the illustration. 2. ...

  • Page 45

    3-7 1 2 3 4 5 6 7 8 9 10 engine oil cooler tip • make sure the oil seal is positioned properly. • align the projection “a” on the adapter with the hole “b” in the crankcase cover 2. 3. Install: • oil filter • oil hose 2 • oil hose 1 • hose clamp (clic-r) “1” tip • install the hose clamp using the ho...

  • Page 46

    3-8 1 2 3 4 5 6 7 8 9 10 engine rectifier/regulator rectifier/regulator order job/parts to remove q’ty remarks removing the rectifier/regulator remove the parts in the order listed. 1 earth terminal 1 2 engine hunger 1 for maintenance. 3 rectifier/regulator lead connector 2 disconnect. 4 rectifier/r...

  • Page 47

    3-9 1 2 3 4 5 6 7 8 9 10 engine case and fan case and fan order job/parts to remove q’ty remarks removing the case and fan remove the parts in the order listed. Air filter case refer to “air filter” on page 3-3. Rectifier/regulator refer to “rectifier/regulator” on page 3-8. Fuel pump refer to “fuel...

  • Page 48

    3-10 1 2 3 4 5 6 7 8 9 10 engine case and fan removing the case and fan 1. Remove: • air filter case (refer to “air filter” on page 3-3) 2. Remove: • rectifier/regulator (refer to “rectifier/regulator” on page 3-8) 3. Remove: • fuel pump (refer to “fuel pump” on page 4-1) 4. Remove: • oil cooler (re...

  • Page 49

    3-11 1 2 3 4 5 6 7 8 9 10 engine case and fan checking the case and fan 1. Check: • fan case cover “1” • grass screen “2” • fan case “3” • fan “4” damage replace. Dirt/clog clean. Installing the case and fan 1. Install: • fan “1” • fan bolts • fan case “2” • fan case bolts • grass screen “3” • grass...

  • Page 50

    3-12 1 2 3 4 5 6 7 8 9 10 engine case and fan tip insert the tab “a” of the fan case cover “4” into the hole “b” of the fan case “2” first and then install. 2. Install: • oil filler pipe • oil filler pipe bolt • oil filler cap 2 4 a b a b oil filler pipe bolt: 7 n·m (0.7 kgf·m, 5.2 lb·ft) t r . ..

  • Page 51

    3-13 1 2 3 4 5 6 7 8 9 10 engine tci units, flywheel and stator coil assembly tci units, flywheel and stator coil assembly tci units order job/parts to remove q’ty remarks removing the tci units remove the parts in the order listed. Air filter case refer to “air filter” on page 3-3. Rectifier/regula...

  • Page 52

    3-14 1 2 3 4 5 6 7 8 9 10 engine tci units, flywheel and stator coil assembly flywheel and stator coil assembly order job/parts to remove q’ty remarks removing the flywheel and stator coil assembly remove the parts in the order listed. Air filter case refer to “air filter” on page 3-3. Rectifier/reg...

  • Page 53

    3-15 1 2 3 4 5 6 7 8 9 10 engine tci units, flywheel and stator coil assembly removing the flywheel and stator coil assembly 1. Remove: • air filter case (refer to “air filter” on page 3-3) 2. Remove: • rectifier/regulator (refer to “rectifier/regulator” on page 3-8) 3. Remove: • fuel pump (refer to...

  • Page 54

    3-16 1 2 3 4 5 6 7 8 9 10 engine tci units, flywheel and stator coil assembly 8. Remove: • flywheel “1” • woodruff key tip • remove the flywheel “1” using the heavy duty puller “2”. • fully tighten the tool holding bolts, making sure the tool body is parallel with the flywheel. If necessary, one bol...

  • Page 55

    3-17 1 2 3 4 5 6 7 8 9 10 engine tci units, flywheel and stator coil assembly 3. Install: • washer “1” • flywheel nut “2” tip tighten the flywheel nut “2” using the primary clutch holder “3” to hold the flywheel. 4. Install: • tci units • tci unit bolts (refer to “installing the tci units” on page 3...

  • Page 56

    3-18 1 2 3 4 5 6 7 8 9 10 engine tci units, flywheel and stator coil assembly installing the tci units the following procedure applies to all of the tci units. 1. Install: • tci unit • tci unit bolts 2. Measure: • tci unit air gap out of specification adjust. 3. Adjust: • tci unit air gap ▼▼▼▼▼▼▼▼▼▼...

  • Page 57

    3-19 1 2 3 4 5 6 7 8 9 10 engine cylinder head covers, cylinder heads cylinder head covers, cylinder heads cylinder head #1 order job/parts to remove q’ty remarks removing the cylinder head covers, and cylinder heads remove the parts in the order listed. Air filter case refer to “air filter” on page...

  • Page 58

    3-20 1 2 3 4 5 6 7 8 9 10 engine cylinder head covers, cylinder heads order job/parts to remove q’ty remarks 1 cylinder air shroud 1 2 cylinder head cover 1 3 cylinder head cover gasket 1 4 rocker arm shaft 1 intake 5 rocker arm shaft 1 exhaust 6 rocker arm 1 intake 7 rocker arm 1 exhaust 8 adjustin...

  • Page 59

    3-21 1 2 3 4 5 6 7 8 9 10 engine cylinder head covers, cylinder heads cylinder head #2 order job/parts to remove q’ty remarks removing the cylinder head covers, and cylinder heads remove the parts in the order listed. Air filter case refer to “air filter” on page 3-3. Rectifier/regulator refer to “r...

  • Page 60

    3-22 1 2 3 4 5 6 7 8 9 10 engine cylinder head covers, cylinder heads order job/parts to remove q’ty remarks 1 engine hunger 1 for maintenance. 2 cylinder air shroud 1 3 cylinder head cover 1 4 cylinder head cover gasket 1 5 rocker arm shaft 1 intake 6 rocker arm shaft 1 exhaust 7 rocker arm 1 intak...

  • Page 61

    3-23 1 2 3 4 5 6 7 8 9 10 engine cylinder head covers, cylinder heads checking the rocker arms and rocker arm shafts the following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • rocker arm “1” • rocker arm shaft “2” wear/damage/cracks replace. Checking the push rods t...

  • Page 62

    3-24 1 2 3 4 5 6 7 8 9 10 engine cylinder head covers, cylinder heads 1. Check: • cylinder head combustion chamber check the combustion chamber for carbon depos- its. Any carbon deposits eliminate. Tip be sure not to damage the sealing surface of the cylinder head. 2. Check: • cylinder head cracks/d...

  • Page 63

    3-25 1 2 3 4 5 6 7 8 9 10 engine cylinder head covers, cylinder heads cylinder head bolt: 1st: 12 n·m (1.2 kgf·m, 8.9 lb·ft) 2nd: 50 n·m (5.0 kgf·m, 37 lb·ft) t r . ..

  • Page 64

    3-26 1 2 3 4 5 6 7 8 9 10 engine valves valves order job/parts to remove q’ty remarks removing the valves remove the parts in the order listed. The following procedure applies to both cylin- ders. Cylinder head assembly refer to “cylinder head covers, cyl- inder heads” on page 3-19. 1 valve cotter 3...

  • Page 65

    3-27 1 2 3 4 5 6 7 8 9 10 engine valves removing the valves and valve springs the following procedure applies to all of the valves, valve springs and related components. 1. Remove: • valve cotter “1” • valve spring retainer “2” • valve spring “3” • valve stem seal “4” • valve spring seat “5” • valve...

  • Page 66

    3-28 1 2 3 4 5 6 7 8 9 10 engine valves 2. Measure: • valve stem diameter “a” out of specifications replace. 3. Measure: • valve stem runout out of specifications replace. Tip the value is half of that indicated on the dial indicator gauge. 4. Measure: • valve spring free length “a” out of specifica...

  • Page 67

    3-29 1 2 3 4 5 6 7 8 9 10 engine valves 6. Measure: • valve spring tilt “a” out of specifications replace. 7. Check: • valve spring contact surface “a” more than 2/3 of the contact surface does not con- tact replace. Checking the valve seats the following procedure applies to all of the valves and v...

  • Page 68

    3-30 1 2 3 4 5 6 7 8 9 10 engine valves 4. Measure: • valve face contact width “a” make sure that the contact width along the entire valve face is within specifications. Out of specification/rough/eccentric wear replace. 5. Measure: • valve seat contact width “a” make sure that the contact width alo...

  • Page 69

    3-31 1 2 3 4 5 6 7 8 9 10 engine valves 3. Once the contacting surface of the valve face is pol- ished and becomes shiny, apply mechanic’s blue lay- out fluid to make sure that there are traces of even contact in the center of the valve face. Tip after every lapping procedure, clean off the compound...

  • Page 70

    3-32 1 2 3 4 5 6 7 8 9 10 engine oil pump oil pump order job/parts to remove q’ty remarks removing the oil pump remove the parts in the order listed. Cylinder head assembly refer to “cylinder head covers, cyl- inder heads” on page 3-19. 1 collar 1 2 crankcase cover 2 1 3 dowel pin 2 4 relief valve 1...

  • Page 71

    3-33 1 2 3 4 5 6 7 8 9 10 engine oil pump disassembling the oil pump 1. Remove: • crankcase cover 2 2. Remove: • relief valve “1” 3. Remove: • oil pump cover “1” 4. Remove: • oil strainer cover “1” • oil strainer “2” • inner rotor “3” • outer rotor “4” checking the oil pump 1. Check: • inner rotor “...

  • Page 72

    3-34 1 2 3 4 5 6 7 8 9 10 engine oil pump 3. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” and “b” out of specification replace the defective part(s). 4. Check: • oil pump operation rough movement replace the defective part(s). Checking the relief valve 1. Check: • relief valve damage/wear...

  • Page 73

    3-35 1 2 3 4 5 6 7 8 9 10 engine oil pump tip engage the two threads of the oil pressure switch screw with the crankcase cover 2, apply loctite®, and tighten to the specified torque. Assembling the oil pump 1. Lubricate: • inner rotor • outer rotor 2. Install: • outer rotor “1” • inner rotor “2” • o...

  • Page 74

    3-36 1 2 3 4 5 6 7 8 9 10 engine oil pump installing the crankcase cover 2 1. Clean: • mating surfaces of the crankcase and the crank- case cover 2 (with a cloth dampened with lacquer thinner) 2. Apply: • sealant (onto the crankcase cover 2 mating surfaces) 3. Install: • crankcase cover 2 tip align ...

  • Page 75

    3-37 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft pistons, camshaft, crankcase, and crankshaft crankcase order job/parts to remove q’ty remarks removing the crankcase remove the parts in the order listed. Cylinder head assembly refer to “cylinder head covers, cyl- inder h...

  • Page 76

    3-38 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft order job/parts to remove q’ty remarks 12 cover 1 1 13 dowel pin 2 14 reed valve 1 15 oil seal 1 12 13 14 15 (8) (5) (5) 9 n ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) 10 n ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 n ・ m (1.0 kgf ・ m, 7.4 lb ...

  • Page 77

    3-39 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft pistons, camshaft, and crankshaft order job/parts to remove q’ty remarks removing the pistons, camshaft, and crankshaft remove the parts in the order listed. 1 camshaft 1 2 valve lifter 4 3 connecting rod cap 2 4 crankshaf...

  • Page 78

    3-40 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft removing the flyweight shaft assembly and governor fork 1. Remove: • crankcase cover 1 • governor assembly 2. Remove: • clips “1” • governor fork “2” • washers “3” 3. Remove: • flyweight shaft assembly “1” • washer “2” tip...

  • Page 79

    3-41 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft 2. Check: • weight • flyweight shaft • collar • washer • weight shaft wear/damage replace. Assembling the flyweight shaft assembly 1. Install: • weight shaft “1” • circlip “2” • washer “3” • collar “4” • weights “5” • flyw...

  • Page 80

    3-42 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft 4. Adjust: • governor (refer to “installing the carburetor assembly” on page 4-5) removing the camshaft and valve lifters the following procedure applies to all of the camshaft and valve lifters. 1. Remove: • camshaft “1” ...

  • Page 81

    3-43 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft 2. Check: • camshaft lobe dimensions “a” and “b” out of specification replace. 3. Check: • surface of camshaft gear teeth crack/damage/wear replace. 4. Check: • camshaft journal diameter “a” out of specification replace. C...

  • Page 82

    3-44 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft 1. Check: • valve lifter damage replace. Checking the reed valve 1. Check: • reed valve damage replace. Installing the valve lifters and camshaft the following procedure applies to all of the camshaft and valve lifters. 1....

  • Page 83

    3-45 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft 2. Apply: • sealant (onto the crankcase mating surfaces) 3. Install: • cover 1 • cover 1 bolts “1” to “5” tip tighten the bolts to the specified torque in order from “1” to “5”. Installing the cover 2 1. Install: • gasket ...

  • Page 84

    3-46 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft installing the crankcase cover 1 1. Install: • crankcase cover 1 • crankcase cover 1 bolts “1” to “8” tip tighten the bolts to the specified torque in two steps and in order from “1” to “8”. Checking the cylinders and pist...

  • Page 85

    3-47 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft tip measure cylinder bore “c” by taking side-to-side and front- to-back measurements of the cylinder. B. If out of specification, replace the crankcase assembly, and replace the piston and piston rings as a set. C. Measure...

  • Page 86

    3-48 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft checking the crankcase 1. Check: • crankcase damage replace. • bearing noise/wear/rotational failure replace. Checking the piston pins the following procedure applies to all of the piston pins. 1. Check: • piston pin blue ...

  • Page 87

    3-49 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft 1. Measure: • piston ring side clearance out of specification replace the piston and pis- ton rings as a set. Tip before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves ...

  • Page 88

    3-50 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft checking the crankshaft 1. Check: • crankshaft sprocket “1” damage/wear replace the crankshaft. 2. Measure: • crankshaft runout limit out of specification replace. Use a dial indicator gauge. 3. Measure: • crank pin outsid...

  • Page 89

    3-51 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft checking the connecting rods oil clearance the following procedure applies to all of the connecting rods. Tip measure the oil clearance if replacing the crankshaft or connecting rod. 1. Place a piece of plastigauge® “1” on...

  • Page 90

    3-52 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft installing the pistons and piston rings the following procedure applies to all of the pistons, piston rings and related components. 1. Install: • top ring “1” • 2nd ring “2” • oil ring “3” tip • be sure to install the top ...

  • Page 91

    3-53 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft installing the crankshaft 1. Make sure that the end gap of each piston ring is positioned correctly, as shown in the illustration. 2. Install: • piston with the connecting rod “1” 3. Attach: • piston ring compressor “1” ti...

  • Page 92

    3-54 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft 5. Check: • piston #2 with the connecting rod #2 “1” position. Tip • make sure that the “ ” mark “a” on the piston #2 head faces toward the flywheel. • make sure that the “yamaha” mark “b” on the connect- ing rod #2 faces ...

  • Page 93

    3-55 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft 8. Install: • connecting rod cap #2 “1” • connecting rod cap #2 bolts “2” tip • make sure that the “ ” mark “a” on the connecting rod #2 is aligned with the “ ” mark “b” on the connecting rod cap #2. • tighten the connecti...

  • Page 94

    3-56 1 2 3 4 5 6 7 8 9 10 engine pistons, camshaft, crankcase, and crankshaft memo.

  • Page 95

    1 2 3 4 5 6 7 8 9 10 fuel 4-1 fuel fuel pump order job/parts to remove q’ty remarks removing the fuel pump remove the parts in the order listed. 1 fuel filter 1 2 fuel hose 1 3 fuel pump 1 4 fuel pump bracket 1 5 pulsar hose 1 6 fuel delivery hose 1 7 n ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1 2 3 6 5 4.

  • Page 96

    4-2 1 2 3 4 5 6 7 8 9 10 fu el fuel pump checking the fuel pump 1. Check: • fuel hose “1” • fuel delivery hose “2” • pulsar hose “3” • fuel pump “4” cracks/damage replace. 2. Check: • fuel pump operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the manual vacuum pump (pressure/vac- uum t...

  • Page 97

    4-3 1 2 3 4 5 6 7 8 9 10 fuel carburetor assembly carburetor assembly removing the carburetor order job/parts to remove q’ty remarks removing the carburetor remove the parts in the order listed. Air filter case refer to “air filter” on page 3-3. 1 governor spring 1 2 governor assembly 1 3 throttle l...

  • Page 98

    4-4 1 2 3 4 5 6 7 8 9 10 fu el carburetor assembly disassembling the carburetor order job/parts to remove q’ty remarks disassembling the carburetor disassemble the parts in the order listed. 1 drain screw/spring 1/1 2 float chamber 1 3 gasket 1 4 float pin 1 5 float 1 6 needle assembly 1 7 gasket 1 ...

  • Page 99

    4-5 1 2 3 4 5 6 7 8 9 10 fuel carburetor assembly removing the carburetor assembly 1. Remove: • governor spring • governor assembly • throttle lever comp • link rod/spring 2. Remove: • breather hose “1” • joint 1 “2” • carburetor assembly “3” • gaskets “4” checking the carburetor assembly 1. Check: ...

  • Page 100

    4-6 1 2 3 4 5 6 7 8 9 10 fu el carburetor assembly 2. Install: • link rod/spring • throttle lever comp • governor assembly • governor spring “1” tip • install the bending portion (short) “a” of the governor spring “1” into the hole “c” of the throttle lever comp while installing the bending portion ...

  • Page 101

    4-7 1 2 3 4 5 6 7 8 9 10 fuel intake manifold intake manifold order job/parts to remove q’ty remarks removing the intake manifold remove the parts in the order listed. Air filter case refer to “air filter” on page 3-3. Rectifier/regulator refer to “rectifier/regulator” on page 3-8. Fuel pump refer t...

  • Page 102

    4-8 1 2 3 4 5 6 7 8 9 10 fu el intake manifold removing the intake manifold 1. Remove: • intake manifold “1” • intake manifold joints “2” • gaskets “3” checking the intake manifold 1. Check: • intake manifold • intake manifold joints cracks/damage replace. Installing the intake manifold 1. Install: ...

  • Page 103

    4-9 1 2 3 4 5 6 7 8 9 10 fuel intake manifold memo.

  • Page 104

    5-1 1 2 3 4 5 6 7 8 9 10 electrical electrical circuit diagram g w w w b/w b/w b r r b w w r r/l br/g off on r b st ar t w r/l br/g g w br/g r/l 250Ω led 2 3 1 2 1 7 8 9 0 w e 4 5 6 q.

  • Page 105

    5-2 1 2 3 4 5 6 7 8 9 10 electrical circuit diagram color code 1. Spark plug 8. Mil light 2. Tci unit 9. Oil warning light 3. Tci magneto 10.Battery 4. Rectifier/regulator 11.Rollover switch 5. Starter relay 12.Fuel cut solenoid 6. Starter motor 13.Oil pressure switch 7. Main switch b black b/w blac...

  • Page 106

    5-3 1 2 3 4 5 6 7 8 9 10 electrical electrical components electrical components 1 3 4 5 2 2.

  • Page 107

    5-4 1 2 3 4 5 6 7 8 9 10 electrical electrical components 1. Oil pressure switch 2. Tci unit 3. Stator coil assembly 4. Rectifier/regulator 5. Starter motor.

  • Page 108

    5-5 1 2 3 4 5 6 7 8 9 10 electrical electrical components checking the switch continuity check each switch for continuity with the tester. If the con- tinuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Tip • before checking for continuity, set the digita...

  • Page 109

    5-6 1 2 3 4 5 6 7 8 9 10 electrical electrical components ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the tci unit. B. Connect the digital circuit tester ( ) to the terminal. C. Measure the coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ checking the ignition spark gap the followi...

  • Page 110

    5-7 1 2 3 4 5 6 7 8 9 10 electrical electrical components checking the spark plug caps the following procedure applies to all of the spark plug caps. 1. Remove: • spark plug cap 2. Check: • spark plug cap resistance out of specification replace the spark plug cap. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 111

    5-8 1 2 3 4 5 6 7 8 9 10 electrical electrical components b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ checking the rectifier/regulator 1. Check: • rectifier/regulator output voltage out of specification replace the rectifier/regula- tor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 112

    5-9 1 2 3 4 5 6 7 8 9 10 electrical electrical components ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the jumper lead “1” to the starter relay ter- minals on the battery side and the starter motor side. B. Check the starter motor operation. C. Disconnect the main switch coupler. D. Connect ...

  • Page 113

    5-10 1 2 3 4 5 6 7 8 9 10 electrical electric starting system electric starting system removing the starter motor order job/parts to remove q’ty remarks removing the starter motor remove the parts in the order listed. 1 starter relay terminals 1 disconnect. 2 earth terminal 1 disconnect. 3 starter m...

  • Page 114

    5-11 1 2 3 4 5 6 7 8 9 10 electrical electric starting system disassembling the starter motor order job/parts to remove q’ty remarks disassembling the starter motor disassemble the parts in the order listed. 1 rear bracket 1 2 insulator 1 3 brush spring 4 4 brush 4 5 yoke 1 6 armature 1 7 starter re...

  • Page 115

    5-12 1 2 3 4 5 6 7 8 9 10 electrical electric starting system checking the armature coil 1. Check: • commutator (outer surface) dirty clean it with #600 grit sandpaper. 2. Measure: • mica (insulation depth between the commutator segments) out of specification scrape the mica to the proper measuremen...

  • Page 116

    5-13 1 2 3 4 5 6 7 8 9 10 electrical electric starting system checking the brush 1. Measure: • brush length (of each brush) “1” out of specification replace. 2. Check: • brush spring “2” fatigue/damage replace. Checking the starter relay 1. Measure: • magnetic switch coil resistance connect the digi...

  • Page 117

    5-14 1 2 3 4 5 6 7 8 9 10 electrical electric starting system 2. Install: • armature and starter drive lever “1” 3. Install: • starter relay “1” 1 1 starter relay nut: 11 n·m (1.1 kgf·m, 8.1 lb·ft) t r . ..

  • Page 118

    5-15 1 2 3 4 5 6 7 8 9 10 electrical electric starting system memo.

  • Page 119

    1 2 3 4 5 6 7 8 9 10 tr oubl eshoo t ing 6-1 troubleshooting engine does not start ignition system the ignition system fails to operate (no spark or intermittent spark). No. Checking steps possible remedy 1 check the battery. • clean the battery terminals. • recharge or replace the battery. 2 check ...

  • Page 120

    6-2 1 2 3 4 5 6 7 8 9 10 tr oublesh oo tin g engine does not start electric starting system the starter motor fails to turn. No. Checking steps possible remedy 1 check the battery. • clean the battery terminals. • recharge or replace the battery. 2 check the starter motor operation. (refer to “check...

  • Page 121

    6-3 1 2 3 4 5 6 7 8 9 10 tr oubl eshoo t ing other troubles other troubles engine starts but stalls no. Checking steps possible remedy 1 check the fuel level. Add the fuel if it is insufficient. 2 check if the fuel filter is clogged. Clean or replace. 3 check if the fuel hoses is clogged. Clean. 4 c...

  • Page 122

    6-4 1 2 3 4 5 6 7 8 9 10 tr oublesh oo tin g other troubles engine speed does not increase no. Checking steps possible remedy 1 check the spark plugs for dirt and check the spark plug gap. Clean, adjust, or replace the spark plugs. 2 check the air filter element for dirt. Replace the air filter elem...

  • Page 123

    6-5 1 2 3 4 5 6 7 8 9 10 tr oubl eshoo t ing other troubles engine speed is uneven no. Checking steps possible remedy 1 check the fuel level. Add the fuel if it is insufficient. 2 check if fuel has deteriorated. Replace the fuel. 3 check the spark plugs for dirt and check the spark plug gap. Clean, ...

  • Page 124

    6-6 1 2 3 4 5 6 7 8 9 10 tr oublesh oo tin g other troubles the battery is not charged no. Checking steps possible remedy 1 check the battery. • clean the battery terminals. • recharge or replace the battery. 2 check the stator coil. (refer to “checking the stator coil assembly” on page 5-7) replace...

  • Page 125

    6-7 1 2 3 4 5 6 7 8 9 10 tr oubl eshoo t ing other troubles governor operation no. Checking steps possible remedy 1 check that the governor link operate smoothly. Adjust or replace. 2 check that the governor spring is stretched. Replace. 3 check the governor adjustment. (refer to “installing the car...

  • Page 126

    6-8 1 2 3 4 5 6 7 8 9 10 tr oublesh oo tin g oil pressure system oil pressure system if the oil pressure switch fails to operate. No. Checking steps possible remedy 1 check the battery. • clean the battery terminals. • recharge or replace the battery. 2 check the main switch. Replace the main switch...

  • Page 127

    1 2 3 4 5 6 7 8 9 10 s pecific a t io ns 7-1 specifications general specifications model: mx800v (7u3j) mx825v (7ucj) dimensions: overall length 499 mm (19.65 in) overall width 451 mm (17.76 in) overall height 639 mm (25.16 in) dry weight 60 kg (132 lb) engine: engine type air cooled 4-stroke gasoli...

  • Page 128

    7-2 1 2 3 4 5 6 7 8 9 10 specifica t ions general specifications use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts. Notice.

  • Page 129

    7-3 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns maintenance specifications maintenance specifications engine piston: piston-to-cylinder clearance 0.033–0.047 mm (0.0013–0.0019 in) limit 0.15 mm (0.0059 in) piston diameter 79.959–79.980 mm (3.1480–3.1488 in) limit 79.900 mm (3.1457 in) measuring point (...

  • Page 130

    7-4 1 2 3 4 5 6 7 8 9 10 specifica t ions maintenance specifications crankshaft: big end side clearance 0.20–0.65 mm (0.0079–0.0256 in) runout limit 0.03 mm (0.0012 in) crank pin outside diameter 40.950–41.050 mm (1.6122–1.6161 in) connecting rod: small end diameter 19.006–19.020 mm (0.7483–0.7488 i...

  • Page 131

    7-5 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns maintenance specifications limit (intake) 1.6 mm (0.063 in) limit (exhaust) 1.6 mm (0.063 in) valve stem runout limit 0.01 mm (0.0004 in) valve guide guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in) guide inside diameter (exhaust) 6.000–6....

  • Page 132

    7-6 1 2 3 4 5 6 7 8 9 10 specifica t ions maintenance specifications oil pump: inner-rotor-to-outer-rotor-tip clearance 0.19–0.35 mm (0.008–0.013 in) relief valve operating pressure 342–538 kpa (3.42–5.38 kgf/cm², 49.59–78.01 psi) carburetor: type 7uc-10 (mx800v) 7uc-00 (mx825v) i.D. Mark 7uc-e4101-...

  • Page 133

    7-7 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns maintenance specifications electrical ignition system: coil resistance (tci unit) 8.8–11.9 k spark plug cap resistance 3.75–6.25 k tci unit air gap 0.4–0.6 mm (0.0157–0.0236 in) minimum ignition spark gap 6.0 mm (0.236 in) charging system: standard output...

  • Page 134

    7-8 1 2 3 4 5 6 7 8 9 10 specifica t ions tightening torques tightening torques item thread size tightening torque spark plug m14s 1.25 20 n·m (2.0 kgf·m, 15 lb·ft) spark arrester screw — 3.5 n·m (0.35 kgf·m, 2.6 lb·ft) oil filter — 14 n·m (1.4 kgf·m, 10 lb·ft) oil drain bolt m12 1.5 27 n·m (2.7 kgf...

  • Page 135

    7-9 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns tightening torques governor assembly bolt m6 1.0 8 n·m (0.8 kgf·m, 5.9 lb·ft) intake manifold nut and bolt m6 1.0 1st: 3.0 n·m (0.30 kgf·m, 2.2 lb·ft) 2nd: 7 n·m (0.7 kgf·m, 5.2 lb·ft) starter motor assembly bolt m8 1.25 23 n·m (2.3 kgf·m, 17 lb·ft) earth...

  • Page 136

    7-10 1 2 3 4 5 6 7 8 9 10 specifica t ions general torque specifications general torque specifications this chart specifies torque for standard fasteners with standard i.S.O. Pitch threads. Torque specifi- cations for special components or assemblies are included in the applicable sections of this b...

  • Page 137

    7-11 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns lubrication points and type of lubricants lubrication points and type of lubricants part name type of lubricant oil seal lip oil hose 1, 2 governor fork oil seal lip bearing connecting rod big end crank pin crankshaft journal connecting rod cap bolt pist...

  • Page 138

    7-12 1 2 3 4 5 6 7 8 9 10 specifica t ions wire routing diagram wire routing diagram upper side view.

  • Page 139

    7-13 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns wire routing diagram 1. Fuel delivery hose 4. Hose clamp 2. Intake manifold 5. Stay 3. Carburetor assembly a. Install yellow painted portion in the direction shown in the illustration..

  • Page 140

    7-14 1 2 3 4 5 6 7 8 9 10 specifica t ions wire routing diagram.

  • Page 141

    7-15 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns wire routing diagram 1. Tci unit #1 lead 5. Tci unit #2 2. Tci unit #1 6. Tci unit #2 lead 3. Plastic locking tie 7. Wire harness 4. Intake manifold a. Direction of upper surface of the engine. B. Allowance 2.0 mm (0.08 in) or less c. Install the lock of...

  • Page 142

    7-16 1 2 3 4 5 6 7 8 9 10 specifica t ions wire routing diagram left side view.

  • Page 143

    7-17 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns wire routing diagram 1. Rectifier/regulator 6. Starter motor 2. Earth terminal 7. Rectifier/regulator lead (white) 3. Spark plug cap 8. Rectifier/regulator lead (red) 4. Starter motor lead 9. Rectifier/regulator lead (black) 5. Starter relay lead a. Tigh...

  • Page 144

    7-18 1 2 3 4 5 6 7 8 9 10 specifica t ions wire routing diagram right side view.

  • Page 145

    7-19 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns wire routing diagram 1. Hose clamp 5. Pulsar hose 2. Fuel pump 6. Plastic locking tie 3. Fuel hose 7. Oil pressure switch lead 4. Fuel filer a. • install the air filter case cover as shown in the illustration. • the locking claw should be fixed securely ...

  • Page 146

    7-20 1 2 3 4 5 6 7 8 9 10 specifica t ions wire routing diagram.

  • Page 147

    7-21 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns wire routing diagram 1. Oil hose 1 4. Oil hose 2 2. Oil cooler 5. Oil filter 3. Hose clamp a. Insert the oil hose all the way into the oil cooler. B. Face the projection inward. C. Install the white painted portion in the direction shown in the illustrat...

  • Page 148

    7-22 1 2 3 4 5 6 7 8 9 10 specifica t ions wire routing diagram.

  • Page 149

    7-23 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns wire routing diagram 1. Oil pressure switch lead 4. Oil pressure switch 2. Pulsar hose 5. Spark plug cap 3. Fuel hose a. Oil pressure switch lead routing direction. B. Direction of upper surface of the engine.

  • Page 150

    7-24 1 2 3 4 5 6 7 8 9 10 specifica t ions wire routing diagram rear side view.

  • Page 151

    7-25 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns wire routing diagram 1. Air filter case cover 1 4. Joint 2 2. Air filter case stay 5. Air filter case 3. Breather hose a. Install the air filter case stay into the groove in the air filter case. B. Insert the hose until it reaches the end as shown in the...

  • Page 152

    7-26 1 2 3 4 5 6 7 8 9 10 specifica t ions wire routing diagram.

  • Page 153

    7-27 1 2 3 4 5 6 7 8 9 10 s pecific a t io ns wire routing diagram 1. Fuel cut solenoid lead 4. Carburetor assembly lead (red) 2. Clamp 5. Carburetor assembly lead (green) 3. Fuel cut solenoid lead (red/blue) 6. Fuel cut solenoid lead (black) a. Main switch coupler b. Secure with a clamp so as not t...

  • Page 154

    Appendix circuit diagram g w w w b/w b/w b r r b w w r r/l br/g 250Ω led off on st ar t 2 3 1 2 1 7 8 9 0 w e 4 5 6 q.

  • Page 155

    Color code 1. Spark plug 8. Mil light 2. Tci unit 9. Oil warning light 3. Tci magneto 10.Battery 4. Rectifier/regulator 11.Rollover switch 5. Starter relay 12.Fuel cut solenoid 6. Starter motor 13.Oil pressure switch 7. Main switch b black b/w black/white g green br/g brown/green r red r/l red/blue ...

  • Page 156

    Memo.

  • Page 157

    7uc-f8197-e0_hyoshi.Indd 3-4 2017/10/27 13:08:23.

  • Page 158: Mx800V

    Service manual mx800v mx825v 7uc-f8197-e0 lit-19616-02-50 2017.10×1 ! 7uc-f8197-e0_hyoshi.Indd 1-2 2017/10/27 13:08:23.