Yamaha MX360 Manuel

MX360

SUPPLEMENTARY

SERVICE MANUAL

7HC-F8197-11LIT-19616-02-34

2015_09×1 !

7HC-F8197-11_cover-mihiraki.indd 1 2015/09/01 9:52:50

B/W

1 Sparkplug

2 TCIunit

3 Oilwarningunit

4 Oillevelswitch

5 Oilwarninglight

6 Engineswitch

Color code

B   Black

L   Blue

R   Red

Y   Yellow

B/W Black/White

CIRCUIT DIAGRAM

7HC-F8197-11_cover-mihiraki.indd 2 2015/09/01 9:52:50

FOREWORD

This Supplementary Service Manual has been

prepared to introduce new service and new

data for MX360.

For complete information on service proce-

dures, it is necessary to use this Supplementary

Service Manual together with following manual:

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

assumed that persons using this book to per-

form maintenance and repairs on Yamaha

Multi-Purpose Engine have a basic under-

standing of the mechanical precepts and pro-

cedures inherent to Multi-Purpose Engine

repair technology. Without such knowledge,

attempted repairs or service to this model may

render it unfit for use and/or unsafe.

Yamaha Motor Powered Products Co., Ltd. is

continually striving to further improve all mod-

els manufactured by Yamaha. Modifications

and significant changes in specifications or

procedures will be forwarded to all Authorized

Yamaha dealers and will, where applicable,

appear in future editions of 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.

WARNING

A WARNING indicates a hazardous situa-

tion which, if not avoided, could result in

death or serious injury.

NOTICE

A NOTICE indicates special precautions

that must be taken to avoid damage to the

machine or other property.

TIP

A TIP provides key information to make proce-

dures easier or clearer.

MX360

SUPPLEMENTARY SERVICE MANUAL

Corporation, U.S.A.

1st Edition, September 2015

unauthorized use without the written

permission of Yamaha Motor

Corporation, U.S.A.

is expressly prohibited.

LIT-19616-02-34

MX360

SERVICE MANUAL:

7HC-F8197-10. LIT-19616-02-32

7HC-F8197-11.indb 1 2015/09/01 14:08:17

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. The current sec-

tion title is shown at the top of each page 1.

9 Sub-section titles appear in smaller print than the section title 2.

9 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section 3.

9 Numbers are given in the order of the jobs in the exploded diagram. A number indicates a dis-

assembly step 4.

9 Symbols indicate parts to be lubricated or replaced 5.

Refer to “ILLUSTRATED SYMBOLS”.

9 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. 6. This step explains removal procedure only. For installation, reverse

the steps.

9 Jobs requiring more information (such as special tools and technical data) are described

sequentially 7.

3-20

ENG

CYLINDER HEAD COVER, CYLINDER HEAD

6543

11 Nm (1.1 m · kgf, 8.0 ft · lbf)

20 Nm (2.0 m · kgf, 14 ft · lbf)

2.3 Nm (0.23 m · kgf, 1.7 ft · lbf)

12 Nm (1.2 m · kgf, 8.7 ft · lbf)

50 Nm (5.0 m · kgf, 36 ft · lbf)

1st

2nd

7 Nm (0.7 m · kgf, 5.1 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the cylinder head cover,

cylinder head

Remove the parts in the order listed.

Fuel tank Refer to “FUEL TANK, CANISTER” on 3-4.

Muffler Refer to “MUFFLER” on 3-6.

Air filter Refer to “AIR FILTER” on 3-3.

Carburetor Refer to “CARBURETOR” on 4-1.

Flywheel cover Refer to “FLYWHEEL” on 3-12.

1 Spark plug cap 1

2 Spark plug 1

3 Air filter case stay 1

4 Cylinder head cover 1

5 Cylinder head cover gasket 1

6 Cylinder air shroud 1

7 Locknut 2

8 Adjuster 2

9 Screw 2

CYLINDER HEAD COVER, CYLINDER HEAD

chap03.indd 20 2015/09/01 13:14:45

3-22

ENG

CYLINDER HEAD COVER, CYLINDER HEAD

CHECKING THE PUSH ROD

 1. Check:

9 Pushrodrunout

Runout limit:

Refer to “SPECIFICATIONS” in

the Supplementary service

manual.

  Outofspecifications→Replace.

CHECKING THE CYLINDER HEAD

 1. Check:

9 Cylinderheadcombustionchamber

  Checkthecombustionchamberforcar-

bondeposits.

  Anycarbondeposits→Eliminate.

TIP

Besurenottodamagethecontactsurfaceof

thecylinder.

 2. Check:

9 Cylinderhead

  Cracks/damage around the hole of

sparkplug→Replace.

CHECKING THE ROCKER ARM

 1. Check:

9 Rockerarm

  Wear/damage/cracks→Replace.

chap03.indd 22 2015/09/01 13:15:18

7HC-F8197-11.indb 2 2015/09/01 14:08:17

ILLUSTRATED SYMBOLS

(Refer to the illustration)

SYMBOL DEFINITION SYMBOL DEFINITION

General information Periodic checks and

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. LS Lithium-soap base grease

MMolybdenum disulfide grease

Engine oil

Molybdenum disulfide oil LT Apply locking agent (LOCTITE®)

7HC-F8197-11.indb 3 2015/09/01 14:08:18

7HC-F8197-11.indb 4 2015/09/01 14:08:18

INDEX

GENERAL INFORMATION GEN

INFO

ENGINE ENG

ELECTRICAL

ELEC

SPECIFICATIONS SPEC

7HC-F8197-11.indb 5 2015/09/01 14:08:19

CHAPTER 1.

GENERAL INFORMATION

MACHINE IDENTIFICATION .....................1-1

ENGINE SERIAL NUMBER ..................1-1

STARTING SERIAL NUMBER ..............1-1

DIMENSIONS .............................................1-2

DIMENSION CHART ............................1-2

TOP .......................................................1-3

LEFT SIDE ............................................1-3

FRONT ..................................................1-4

MOUNTING BASE ................................1-4

CHAPTER 2.

ENGINE

GOVERNOR ...............................................2-1

ADJUSTING THE GOVERNOR ............2-2

CHAPTER 3.

ELECTRICAL

CIRCUIT DIAGRAM ...................................3-1

CHAPTER 4.

SPECIFICATIONS

GENERAL SPECIFICATIONS ...................4-1

MAINTENANCE SPECIFICATIONS ..........4-3

ENGINE ................................................4-3

ELECTRICAL ........................................4-7

TIGHTENING TORQUES ...........................4-8

GENERAL TORQUE

SPECIFICATIONS ....................................4-10

LUBRICATION POINTS AND TYPE

OF LUBRICANTS ....................................4-11

WIRE ROUTING DIAGRAM ....................4-12

UPPER SIDE VIEW ............................4-12

ENGINE SWITCH AND OIL

WARNING UNIT .................................4-13

TCI UNIT .............................................4-14

OIL LEVEL SWITCH

(CRANKCASE COVER) .....................4-15

7HC-F8197-11.indb 6 2015/09/01 14:08:19

1-1

GEN

INFO

MACHINE IDENTIFICATION

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.

TIP

The first four digits identify the model, and

the remaining digits indicates the production

number.

STARTING SERIAL NUMBER

MX360AA6A6: 7HCJ-3000101–

TIP

Designs and specifications are subject to

change without notice.

7HC-F8197-11.indb 1 2015/09/01 14:08:19

1-2

GEN

INFO

DIMENSIONS

DIMENSION CHART

Unit: mm

Model (Code) PTO shaft dimensions (Type) Mounting face dimensions

MX360 AA6A6

(7HCJ)

4.5

72.2

60.3

88.5

25.4 -0.021

110 +0.054

146.08 -0.040

21.8 -0.1

6.31 +0.058

3/8 -24UNF-2B

146.08

-0.040

165.1

127

110 +0.054

4 3/8-16UNC2B DEPTH18

4 5/16-24UNF-2B DEPTH18

2 5/16-24UNF-2B DEPTH18

*1: UNF; Unified fine thread (Unit: in)

*2: UNC; Unified coarse thread (Unit: in)

7HC-F8197-11.indb 2 2015/09/01 14:08:19

Autres manuels pour MX360

Ce manuel convient aux modèles suivants

Table des matières

Autres manuels Yamaha Moto

Yamaha

Yamaha TT-R110E(Y) Manuel utilisateur

Yamaha

Yamaha PW80(T) Guide d'application

Yamaha

Yamaha TZR250 1987 Manuel utilisateur

Yamaha

Yamaha PW50(X) Manuel utilisateur

Yamaha

Yamaha YZFR1Y(C) Manuel utilisateur

Yamaha

Yamaha 2009 YZF-R6Y Manuel utilisateur

Yamaha

Yamaha TT-R110E Manuel utilisateur

Yamaha

Yamaha 1995 XV250SG Manuel utilisateur

Yamaha

Yamaha DT125R Manuel utilisateur

Yamaha

Yamaha FJR1300APX Manuel utilisateur

Yamaha

Yamaha XMAX YP250RA Manuel utilisateur

Yamaha

Yamaha XSR125 2021 Manuel utilisateur

Yamaha

Yamaha YZF-R1 98 Manuel utilisateur

Yamaha

Yamaha YBR125ED Manuel utilisateur

Yamaha

Yamaha 135LC 2022 Manuel utilisateur

Yamaha

Yamaha FZR400 1988-1989 Manuel utilisateur

Yamaha

Yamaha YZ250F(T) Guide d'application

Yamaha

Yamaha 2005 Royal Star XVZ13CTT Manuel utilisateur

Yamaha

Yamaha 2001 YZ426F/LC Guide d'application

Yamaha

Yamaha MT07M Manuel utilisateur

Yamaha

Yamaha YZF R1 2020 Manuel utilisateur

Yamaha

Yamaha TRACER 700 2020 Manuel utilisateur

Yamaha

Yamaha FZS1000N Manuel utilisateur

Yamaha

Yamaha FJR1300AE 2020 Manuel utilisateur

Manuels Moto populaires d'autres marques

OHVALE

OHVALE GP-0 Manuel de la liste des pièces

KTM

KTM 350 XCF-W USA Manuel utilisateur

HYOSUNG

HYOSUNG ST7 Manuel utilisateur

Husqvarna

Husqvarna FC 250 2016 Manuel utilisateur

Ducati

Ducati SCRAMBLER 800 Manuel d'instructions

MOTO GUZZI

MOTO GUZZI QUOTA 1100 ES Manuel utilisateur

APRILIA

APRILIA ETV MILLE CAPONORD - PART1 02-2001 Manuel utilisateur

KTM

KTM Freeride E-XC 2021 Manuel utilisateur

Fantic

Fantic Enduro 125 Manuel utilisateur

Ducati

Ducati Supersport 750 desmodue Manuel utilisateur

MV Agusta

MV Agusta 2008 F4 312RR 1078 Manuel d'instructions

Ducati

Ducati 748 monoposto strada Manuel utilisateur

ATK

ATK 1988 250 Manuel utilisateur

Excelsior-HENDERSON

Excelsior-HENDERSON 1999 HCX Manuel utilisateur

Triumph

Triumph Thunderbird Manuel utilisateur

Ducati

Ducati 996 Manuel utilisateur

BMW

BMW MOTORRAD K 1200 R Sport Manuel d'installation et d'entretien

BMW Motorrad

BMW Motorrad G 650 GS 2007 Manuel d'installation et d'entretien