Yamaha MZ250 2012 Manual

MZ250

MZ300

SUPPLEMENTARY

SERVICE MANUAL

7VB-F8197-11LIT-19616-01-88

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cover.indd 2 2012/10/30 18:14:11

FOREWORD

This Supplementary Service Manual has been

prepared to introduce new service and new

data for the MZ250 and MZ300.

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

mechanics. It is not possible to put an entire

mechanic’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.

MZ250/MZ300

SUPPLEMENTARY SERVICE MANUAL

Corporation, U.S.A.

1st Edition, September 2012

unauthorized use without the written

permission of Yamaha Motor

Corporation, U.S.A.

is expressly prohibited.

LIT-19616-01-88

MZ250/MZ300

SERVICE MANUAL:

7VB-F8197-10. LIT-19616-01-80

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.

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

sequentially 7.

3-21

ENG

CYLINDER HEAD COVER, CYLINDER HEAD

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)

11 Nm (1.1m · kgf, 8.0 ft · lbf)

20 Nm (2.0 m · kgf, 14 ft · lbf)

2.3 Nm (0.23m · kgf, 1.7 ft · lbf)

Order Job/Parts to remove Q’ty Remarks

Removing the cylinder head cover

and cylinder head

Remove the parts in the order listed

below.

Fuel tank Refer to “FUEL TANK, CANISTER” on 3-5.

Muffler Refer to “MUFFLER” on 3-7.

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

Carburetor Refer to “CARBURETOR” on 4-1.

Flywheel cover Refer to “FLYWHEEL” on 3-13.

1 Spark plug cap 1

2 Spark plug 1

3 Breather hose 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 21 2012/09/14 10:45:52

3-23

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 23 2012/09/14 10:45:52

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®)

INDEX

GENERAL INFORMATION GEN

INFO

ENGINE ENG

ELECTRICAL

ELEC

SPECIFICATIONS SPEC

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 (MZ250A/MZ300A) .......................1-3

LEFT SIDE (MZ250A/MZ300A) ............1-3

RIGHT SIDE (MZ250A/MZ300A) ..........1-4

FRONT (MZ250A/MZ300A) ..................1-5

MOUNTING BASE

(MZ250A/MZ300A) ...............................1-5

TOP (MZ250K/MZ300K) .......................1-6

LEFT SIDE (MZ250K/MZ300K) ............1-6

RIGHT SIDE (MZ250K/MZ300K) ..........1-7

FRONT (MZ250K/MZ300K) ..................1-8

MOUNTING BASE

(MZ250K/MZ300K) ...............................1-8

CHAPTER 2.

ENGINE

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

MZ250A/MZ300A ..................................2-1

MZ250K ................................................2-2

MZ300K ................................................2-3

ADJUSTING THE GOVERNOR ............2-4

CHAPTER 3.

ELECTRICAL

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

MZ250/MZ300 .......................................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 AND CHARGING COIL ......4-14

OIL LEVEL SWITCH

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

UPPER SIDE VIEW

(MZ250KHID0/MZ300KHID3) .............4-16

UPPER SIDE VIEW

(MZ300KHIDM) ...................................4-17

CARBURETOR AND CHARGING

COIL (MZ300KHIDM) .........................4-18

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 three digits identify the model, and

the remaining digits indicates the production

number.

STARTING SERIAL NUMBER

Model Code Starting serial

number

MZ250AAIA0 7KBJ 7KBJ-1000101–

MZ250KHID0 7KBN 7KBN-1000101–

MZ300AAIA0 7VBJ 7VBJ-1000101–

MZ300KHID3 7VBN 7VBN-1000101–

MZ300KHIDM 7VBN 7VBN-2000101–

TIP

Designs and specifications are subject to

change without notice.

1-2

GEN

INFO

DIMENSIONS

DIMENSION CHART

Unit: mm

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

MZ250 AAIA0

(7KBJ)

94.5

7/16 -20UNF-2B

4.5

72.2

88.5

25.4 -0.021

110 +0.054

146.08 -0.040

21.8 -0.1

6.31

146.08

-0.040

165.1

127

110 +0.054

4 M8 1.25DEPTH18

43/8 -16UNC2BDEPTH18

MZ300 AAIA0

(7VBJ)

MZ250 KHID0

(7KBN)

94.5

110 +0.054

22.161 -0.021

25.4 -0.021

146.08 -0.040

46.8 58.7

4.5

29.5 76

5/16 -24UNF-2B

3/16

∫

4 M8 1.25DEPTH18

127

146.08

165.1

-0.040

3/8 -16UNC2BDEPTH18

110 +0.054

MZ300 KHID3

(7VBN)

MZ300 KHIDM

(7VBN)

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

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

A To Engine center

B Taper

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