YAMAHA EF2800i SERVICE MANUAL

SERVICE MANUAL

EF2800i

7VU-28197-E0

310124

FOREWORD

HOW TO USE THIS MANUAL

This manual was written by the Yamaha Motor
Company 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 perform maintenance and repairs
on Yamaha generators have a basic under­standing of the mechanical precepts and pro­cedures inherent to generator repair
technology. Without such knowledge,
attempted repairs or service to this model may
render it unfit for use and/or unsafe.

Yamaha Motor Company Ltd. is continually
striving to further improve all models 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.

PARTICULARLY IMPORTANT
INFORMATION

This material is distinguished by the following
notation.

The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!

WARNING

Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.

CAUTION:

A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.

EF2800i

SERVICE MANUAL

©2001 by Yamaha Motor Co., Ltd.

1st Edition, April 2001
All rights reserved. Any reprinting or
unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

NOTE:

A NOTE provides key information to make pro­cedures easier or clearer.

MANUAL FORMAT

The procedures in this manual are organized
in a sequential, step-by-step format. The infor­mation has been compiled to provide the
mechanic with an easy to read, handy refer­ence that contains comprehensive explana­tions of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty
component will precede an arrow symbol and
the course of action required will follow the
symbol, e.g.,

• Bearings
Pitting/damage → Replace.

EXPLODED DIAGRAM

Each chapter provides exploded diagrams
before each disassembly section for ease in
identifying the correct disassembly and
assembly procedures.

12

GEN

INFO

INSP

ADJ

34

ENG

ELEC

–+

5

SPEC

ILLUSTRATED SYMBOLS
(Refer to the illustration)

Illustrated symbols 1 through 5 are designed
as thumb tabs to indicate the chapter’s number
and content.

General information

1

Periodic inspections and adjustments

2

Engine

3

Electrical

4

Specifications

5

67

89

T

.

R

.

0A

B

CDE

E

G

M

FGH

B

LS

M

IJK

LT

4

New

Illustrated symbols 6 through B are used to
identify the specific tools and test equipment.

Filling fluid

6

Lubricant

7

Special tool

8

Tightening

9

Wear limit, clearance

0

Engine speed

A

, V, A

Ω

B

Illustrated symbols C through K in the
exploded diagram indicate the grades of lubri­cant and the locations of the lubrication points.

Apply engine oil

C

Apply gear oil

D

Apply molybdenum disulfide oil

E

Apply wheel bearing grease

F

Apply lightweight lithium-soap base grease

G

Apply molybdenum disulfide grease

H

Apply a locking agent (LOCTITE

I

Apply Yamaha bond

J

Use a new one

K

®

)

INDEX

GENERAL INFORMATION
PERIODIC INSPECTIONS

AND ADJUSTMENTS
ENGINE

ELECTRICAL

SPECIFICATIONS

GEN

INFO

INSP

ADJ

ENG

–+

ELEC

SPEC

1
2
3
4
5

CHAPTER 1.

GENERAL INFORMATION

PILOT LIGHT .....................................2-13

RECEPTACLE ...................................2-14

MACHINE IDENTIFICATION

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

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

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY ...................................1-2

CAUTION ON SERVICE .....................1-2

NOTES ON SERVICE .........................1-2

ALL REPLACEMENT PARTS ............. 1-3

GASKETS, OIL SEALS,

AND O-RINGS .................................... 1-3

BEARINGS AND OIL SEALS ..............1-3

SPECIAL TOOLS AND TESTERS

...................1-1

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

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

CHAPTER 2.

PERIODIC INSPECTIONS

AND ADJUSTMENTS

INTRODUCTION

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

CHAPTER 3.

ENGINE

CONTROL PANEL

CONTROL BOX COVER
AND FUEL TANK

MUFFLER AND AIR CLEANER

BREATHER HOSE INSTALLATION ...3-5

MUFFLER ASSEMBLY .......................3-5

CONTROL UNIT AND AC-CDI UNIT

ENGINE

CYLINDER HEAD COVER AND CYLINDER
HEAD

.....................................................3-7

........................................................3-8

PUSH ROD INSPECTION .................3-10

CYLINDER HEAD INSPECTION .......3-10

CYLINDER HEAD ASSEMBLY .........3-11

BREATHER HOSE ASSEMBLY ........3-11

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

.....................................3-3

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

.......3-6

PERIODIC MAINTENANCE/LUBRICATION
INTERVALS

ENGINE

ENGINE OIL LEAKAGE

CHECKING .........................................2-2

OIL LEVEL CHECKING ...................... 2-2

OIL REPLACEMENT ...........................2-3

FUEL LEAKAGE ................................. 2-4

FUEL COCK STRAINER

INSPECTION ......................................2-4

FUEL TANK FILTER ...........................2-5

AIR FILTER ELEMENT ....................... 2-6

MUFFLER ...........................................2-7

VALVE CLEARANCE

ADJUSTMENT .................................... 2-8

COMPRESSION PRESSURE ........... 2-10

RATED ENGINE SPEED ..................2-11

BREATHER HOSE ............................2-11

ELECTRICAL

SPARK PLUG ...................................2-12

ENGINE SWITCH .............................2-13

ECONOMY SWITCH .........................2-13

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

....................................................2-2

.........................................2-12

VALVE

RECOIL STARTER

GENERATOR

....................................................3-12

VALVE AND VALVE SPRING

REMOVAL .........................................3-13

VALVE AND VALVE SPRING

INSPECTION .....................................3-13

ROCKER ARM INSPECTION ...........3-14

VALVE SEAT INSPECTION ..............3-15

VALVE LAPPING ...............................3-16

VALVE AND VALVE SPRING

ASSEMBLY .......................................3-17

.................................3-18

RECOIL STARTER

DISASSEMBLY .................................3-20

RECOIL STARTER INSPECTION .....3-20

RECOIL STARTER ASSEMBLY .......3-21

.........................................3-23

MAGNETO ROTOR AND STATOR COIL

ASSEMBLY REMOVAL .....................3-25

MAGNETO ROTOR AND STATOR COIL

ASSEMBLY INSTALLATION .............3-26

CRANKCASE COVER

AND CAMSHAFT ...................................3-28

CAMSHAFT INSPECTION ................3-29

VALVE LIFTER INSPECTION ..........3-30

CAMSHAFT ASSEMBLY ..................3-30

CRANKCASE COVER

INSPECTION ....................................3-30

CRANKCASE COVER

INSTALLATION .................................3-30

PISTON, CONNECTING ROD, CRANK-

SHAFT AND CRANKCASE ...................3-31

CRANKCASE (CYLINDER)

INSPECTION ....................................3-32

PISTON AND PISTON

PIN INSPECTION .............................3-32

PISTON RING INSPECTION ............ 3-34

CRANKSHAFT INSPECTION ........... 3-34

CONNECTING ROD OIL

CLEARANCE INSPECTION .............3-35

PISTON RING

AND PISTON ASSEMBLY ................3-36

CRANKSHAFT ASSEMBLY ..............3-37

CHAPTER 5.

SPECIFICATIONS

GENERAL SPECIFICATIONS ..................5-1

MAINTENANCE SPECIFICATIONS .........5-3

ENGINE ...............................................5-3

GENERATOR AND ELECTRICAL ......5-6

TIGHTENING TORQUE ............................5-7

GENERAL TORQUE

SPECIFICATIONS ....................................5-8

DEFINITION OF UNITS ............................5-8

WIRE ROUTING DIAGRAM .....................5-9

CONTROL BOX PANEL AND BEHIND

CONTROL BOX ...................................5-9

ENGINE AND GENERATOR .............5-10

CARBURETOR ......................................3-38

FLOAT HEIGHT INSPECTION .........3-40

CHOKE CABLE INSTALLATION ......3-41

THROTTLE CONTROL MOTOR ......3-41

TROUBLESHOOTING ...........................3-42

ENGINE .............................................3-42

THROTTLE CONTROL SYSTEM .....3-48

CHAPTER 4.

ELECTRICAL

ELECTRICAL COMPONENTS ................4-1

CIRCUIT DIAGRAM .................................4-2

SWITCHES ............................................... 4-3

CHECKING SWITCH CONTINUITY ...4-3

IGNITION SYSTEM ..................................4-4

TROUBLESHOOTING CHART ...........4-4

GENERATOR SYSTEM ........................... 4-9

TROUBLESHOOTING CHART ...........4-9

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

SERIAL NUMBER

The serial number is printed on a label
which is affixed to the generator as shown.

NOTE:

The first three characters of this number are

SVU1010H

for model identification, the remaining digits
are the unit production number.

GEN

INFO

1

SVU1020H

STARTING SERIAL NUMBER

7VU-300101~

NOTE:

Designs and specifications are subject to
change without notice.

1-1

SVU1030H

SVU1040H

SVU1050H

GEN

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

1. Correct tools
Be sure to use the correct special tool for the job to guard
against damage.

2. Oil, grease and seals
Be sure to use genuine Yamaha oils, grease and sealers, or the
equivalents.

INFO

1

SVU1060H

SVU1070H

SVU1080H

3. Expendable parts
Always replace the gaskets, O-rings, cotter pins and circlips with
new parts when servicing engine.

4. Tightening torque
Be sure to follow torque specifications. When tightening bolts,
nuts or screws, start with the largest-diameter fastener and work
from an inner position to an outer position in a crisscross pattern.

5. Notes on disassembly and assembly

a. Parts should be cleaned in solvent and blown dry with com-

pressed air after disassembly.

SVU1090H

SVU1100H

b. Contact surfaces of moving parts should be oiled when reas-

sembled.

c. Make sure that the parts, move smoothly after each section of

the machine is assembled.

1-2

SVU1110H

GEN

IMPORTANT INFORMATION

ALL REPLACEMENT PARTS

We recommend the use of genuine Yamaha parts for all replace­ments. Use oil and/or grease, recommended by Yamaha, for
assembly and adjustment.

GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets, seals, and O-rings should be replaced when an
engine is overhauled. All gaskets surfaces, oil seal lips, and O­rings must be cleaned.

2. Properly oil all mating parts and bearings during reassembly.
Apply grease to the oil seal lips.

BEARINGS AND OIL SEALS

Install the bearing(s) 1 and oil seal(s) 2 with their manufacture’s
marks or numbers facing outward. (In other words, the stamped let­ters must be on the side exposed to view.) When installing oil
seal(s), apply a light coating of light-weight lithium base grease to
the seal lip(s). Oil the bearings liberally when installing.

INFO

SVU1120H

CAUTION:

Do not use compressed air to spin the bearings dry. This
causes damage to the bearing surfaces.

1-3

SVU1130H

SVU1140H

GEN

SPECIAL TOOLS AND TESTERS

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
techniques.

1. Piston ring compressor
P/N. 90890-05158
This tool is used to compress the piston rings when installing the
piston.

2. Valve spring compressor
P/N. 90890-01253
This tool is used to remove the valve springs.

INFO

SVU1150H

SVU1160H

SVU1170H

SVU1180H

3. Thickness gauge
P/N. 90890-03079
This gauge is used to adjust valve clearance, piston clearance
and piston ring end gap.

4. Cylinder gauge
Commercially obtainable
This instrument is used for checking cylinder bore size and con­dition.

5. Engine tachometer
P/N. 90890-03113
This instrument is used for reading engine r/min.

6. Compression gauge 1
P/N. 90890-03081
Adapter 2
P/N. 90890-04082
This gauge is used for checking engine compression.

SVU1190H

7. Dial gauge
P/N. 90890-03097
This instrument is used for checking crankshaft side clearance.

1-4

SVU1200H

SVU1210H

SVU1220H

SPECIAL TOOLS AND TESTERS

8. Piston pin puller
P/N. 90890-01304
This tool is used to remove the piston pin.

9. Sheave holder
P/N. 90890-01701
This tool is necessary for holding the flywheel.

10.Rotor puller
P/N. 90890-01362
This tool is necessary for removing the flywheel.

GEN

INFO

SVU1230H

SVU1240H

11.Pocket tester
P/N. 90890-03112
This instrument is necessary for checking the electrical system.

12.Ignition checker
P/N. 90890-06754
This instrument is necessary for checking the ignition system
components.

1-5

INSP

ADJ

INTRODUCTION/PERIODIC MAINTENANCE/

LUBRICATION INTERVALS

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjust­ments. These preventive maintenance procedures, if followed, will ensure more reliable machine
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to machines already in service as well as new machines that are being prepared
for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Item Remarks

Spark plug
Valve clearance Check and adjust when engine is cold.

Crankcase breather
system

Idle speed Check and adjust engine idle speed.

Exhaust system

Engine oil

Air filter Clean. Replace if necessary.
Fuel filter

Fuel line
Choke knob Check choke operation.

Cooling system Check for fan damage.
Starting system Check recoil starter operation.
Decarbonization More frequently if necessary.
Generation Check the pilot light comes on.

Fittings/fasteners

Check condition, adjust gap and clean.
Replace if necessary.

Check breather hose for cracks or damage.
Replace if necessary.

Check for leakage.
Retighten or replace gasket if necessary.

Check muffler screen and spark arrester.
Clean/replace if necessary.

Check oil level.
Replace.

Clean fuel cock and fuel tank filter.
Replace if necessary.

Check fuel hose for cracks or damage.
Replace if necessary.

Check all fittings and fasteners.
Correct if necessary.

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

●

●

●

●

●

●

2

2-1

INSP

ADJ

SVU2010H

ENGINE OIL LEAKAGE CHECKING/

OIL LEVEL CHECKING

ENGINE

ENGINE OIL LEAKAGE CHECKING

1. Check the areas outside of the engine for
oil leakage.

Oil leakage → Replace the gasket, oil
seal, or O-ring.

SVU2020H

ECON.

SW

OIL LEVEL CHECKING

1. Check:

• Oil level with oil warning light 1

Check whether the oil warning light
flashes by operating the recoil starter.
Oil warning light flashes → Add oil.

OVER

AC

LOAD

Oil warning light does not flash → OK

2. Remove:

• Oil filler cap

1

3. Check:

• Check that the engine oil is at the spec-

ified level a.

Oil level checking steps:

• Place the engine on a level surface.

SVU2030H

• Warm up the engine for several minutes.

• Stop the engine.

• Check that the engine oil is at the specified

level a. Add oil if necessary.

4. Install:

• Oil filler cap

2-2

INSP

ADJ

SVU2040H

OIL REPLACEMENT

OIL REPLACEMENT

1. Warm up the engine for several minutes.

2. Stop the engine.

3. Place a receptacle under the engine.

4. Remove:

• Oil drain bolt

5. Tilt the engine to drain the oil completely.

6. Tighten:

• Oil drain bolt

Oil drain bolt:

17 Nm (1.7 m · kg, 12 ft · lb)

T

.

R

.

1

1

SVU2050H

SVU2060H

7. Remove:

• Oil filler cap

1

8. Fill:

Recommended oil:

È SAE #30 or 10W-30
É SAE #20 or 10W-30
Ê SAE 10W or 10W-30

Engine oil quantity:

0.6 L (0.53 Imp qt, 0.63 US qt)

NOTE:

Recommended engine oil classification:
API Service “SE” or “SF”, if not available, “SD”.

9. Install:

• Oil filler cap

2-3

INSP

ADJ

FUEL LEAKAGE/

FUEL COCK STRAINER INSPECTION

FUEL LEAKAGE

1. Check:

• Leakage

Check at fuel tank, fuel cock, fuel hose,
and carburetor.

CAUTION:

Replace hose every four years.

SVU2070H

FUEL COCK STRAINER INSPECTION

1. Turn the fuel cock to the “OFF” a posi­tion, detach the strainer cup, and then
remove the debris from inside the cup.

2. Remove:

• Fuel cock cup 1

•Gasket 2

• Strainer 3

3. Inspect:

• Fuel cock cup

Dirt/debris → Clean.

•Gasket 2

Damage → Replace.

• Strainer 3

Dirt/debris→ Clean.

SVU2080H

NOTE:

Clean the cup with solvent, and then dry it
thoroughly.

4. Install:

• Strainer

•Gasket

• Fuel cock cup

Fuel cock cup:

1.3 Nm (0.13 m · kg, 0.94 ft · lb)

T

.

R

.

CAUTION:

Securely install the strainer cup to prevent
fuel leaks.

2-4

INSP

ADJ

FUEL TANK FILTER

FUEL TANK FILTER

WARNING

Do not smoke, and keep away from open
flames, sparks, or any other source of fire
when handling or in the vicinity of fuel.

1. Remove:

• Fuel tank cap 1

• Fuel tank filter 2

2. Inspect:

• Fuel tank filter

Damage → Replace.

3. Clean:

• Fuel tank filter

NOTE:

Clean the fuel tank filter with solvent, and then
dry it thoroughly.

SVU2090H

4. Install:

• Fuel tank filter

• Fuel tank cap

WARNING

Be sure the tank cap is tightened securely.

2-5

INSP

ADJ

SVU2100H

SVU2110H

AIR FILTER ELEMENT

AIR FILTER ELEMENT

1. Remove:

•Screws 1

• Air filter case cover 2

2. Remove:

• Air filter element 1

SVU2120H

3. Inspect:

• Element

Damage → Replace.
Clogging → Wash the element in a sol­vent, and then dry it thoroughly.
Oil the element and squeeze out the
excess oil.

CAUTION:

• Do not wring out the element: this could
cause it to tear.

• Do not wash the element in gasoline or in
acidic, alkalinic, or organic solvents.

4. Install:

• Air filter element

• Air filter case cover

•Screws

CAUTION:

The engine should never run without the
element, otherwise excessive piston and/or
cylinder wear may result.

2-6

INSP

ADJ

SVU2130H

SVU2140H

MUFFLER

MUFFLER

1. Remove:

• Muffler
Refer to “MUFFLER AND AIR
CLEANER” in CHAPTER 3.

• Muffler band 1

• Muffler cap 2

• Washer 3

• Muffler screen 4

2. Decarbonize:

• Muffler
Tap on the muffler in the area shown in
the illustration to loosen carbon buildup,
and then shake it out of the end of the
muffler.

CAUTION:

Don’t use a wire to clean, otherwise the
noise damping material may come out, and
the damping effect may be reduced.

SVU2150H

3. Decarbonize:

• Muffler screen

4. Install:

• Muffler screen

• Muffler cap

• Muffler band

• Muffler
Refer to “MUFFLER AND AIR
CLEANER” in CHAPTER 3.

2-7

INSP

ADJ

VALVE CLEARANCE ADJUSTMENT

VALVE CLEARANCE ADJUSTMENT

1. Remove:

• Breather hose 1

• Spark plug cap 2

• Cylinder head cover 3

• Spark plug 4

SVU2160H

SVU2170H

SVU2180H

2. Gently operate the starter rope to bring
the piston to the top-dead-center of its
compression stroke (when the screw­driver inserted into the spark plug hole
reaches the highest position).

3. Measure:

• Valve clearance

Out of specification → Adjust.

NOTE:

Valve clearance must be measured when the
engine is cool to the touch.

Intake valve (cold):

0.1 mm (0.004 in)

Exhaust valve (cold):

0.1 mm (0.004 in)

Thickness gauge:

90890-03079

2-8

INSP

ADJ

VALVE CLEARANCE ADJUSTMENT

4. Adjust:

• Valve clearance

Adjustment steps:

• Loosen the locknut 1.

• Turn the adjuster 2 in or out to obtain the

proper clearance.

SVU2190H

SVU2200H

Adjuster Valve clearance

Turn in Decrease

Turn out Increase

• Tighten the locknut 1.

Locknut:

10 Nm (1.0 m · kg, 7.2 ft · lb)

T

.

R

.

5. Install:

• Cylinder head cover

• Breather hose

• Spark plug

• Spark plug cap

Cylinder head cover bolt:

10 Nm (1.0 m · kg, 7.2 ft · lb)

T

.

R

.

Spark plug:

18 Nm (1.8 m · kg, 13 ft · lb)

2-9

INSP

ADJ

COMPRESSION PRESSURE

COMPRESSION PRESSURE
NOTE:

Measure the compression after checking and
adjusting the valve clearance.

1. Warm up the engine for several minutes.

2. Remove:

• Spark plug

3. Connect:

• Compression gauge 1

• Adapter 2

Compression gauge:

90890-03081

Adapter:

90890-04082

SVU2210H

4. Measure:

• Compression

To measure the compression, pull the
recoil starter until the needle stops ris­ing on the compression gauge.

Standard compression pressure:

400 ~ 600 kPa
(4 ~ 6 kg/cm

2

, 57 ~ 85 psi)

WARNING

To prevent sparking when cranking the
engine, ground the high-tension cord.

Testing steps (below minimum level):

• Squirt a few drops of oil into the cylinder.

• Measure the compression again.

Reading Diagnosis

If higher than
without oil

• Worn cylinder, piston, and
piston ring

If the same as
without oil

2-10

• Defective piston, ring(s),
valve(s), and cylinder
head gasket

• Improper valve timing and
valve clearance

INSP

ADJ

COMPRESSION PRESSURE/

RATED ENGINE SPEED/BREATHER HOSE

Testing steps (above maximum level):

• Check the cylinder head, valve surfaces,
and piston crown for carbon deposits.

5. Install:

• Spark plug

Spark plug:

18 Nm (1.8 m · kg, 13 ft · lb)

T

.

R

.

SVU2220H

SVU2230H

RATED ENGINE SPEED

1. Connect:

• Engine tachometer

1

Engine tachometer:

90890-03113

2. Inspect:

• Rated engine speed
Specified engine speed → OK
Out of specification → Refer to “TROU­BLESHOOTING” in CHAPTER 3.

Inspection steps:

• Operate the engine (with no load).

• Turn economy switch 1 to “OFF” a.

• Measure the rated engine speed.

SVU2240H

Rated engine speed:

3,550 r/min

BREATHER HOSE

1. Inspect:

• Breather hose 1
Cracks/damage → Replace.
Poor connection → Correct.

2-11

INSP

ADJ

SPARK PLUG

ELECTRICAL

SPARK PLUG

WARNING

Inspect and adjust the areas around the
cylinder head after the engine has cooled
down completely.

CAUTION:

Before removing the spark plug, use com­pressed air to clean the cylinder head
cover to prevent dirt from falling into the
engine.

1. Remove:

• Spark plug cap

• Spark plug

SVU2250H

2. Inspect:

•Electrode 1
Wear/damage → Replace.

• Insulator color 2

3. Measure:

• Spark plug gap a
Use a wire gauge or thickness gauge.
Out of specification → Regap.

Spark plug gap:

0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

If necessary, clean the spark plug with a spark
plug cleaner.

Standard spark plug (with resistor):

BPR4ES (NGK)

Before installing the spark plug, clean the gas­ket surface and plug surface.

SVU2260H

2-12

INSP

ADJ

SPARK PLUG/ENGINE SWITCH/

ECONOMY SWITCH/PILOT LIGHT

4. Tighten:

• Spark plug

Spark plug:

18 Nm (1.8 m · kg, 13 ft · lb)

T

.

R

.

NOTE:

To prevent thread damage, finger tighten

SVU2270H

SVU2280H

the spark plug before tightening it to the speci­fied torque b.

ENGINE SWITCH

1. Check:

• Engine switch 1

Checking steps:

• Set the engine switch 1 to “ON” a.

• Start the engine.

• Check that the engine stops when the
switch is set to “STOP” b.

a

ECON.

SW

SVU2290H

ECONOMY SWITCH

1. Check:

• Economy switch 1

Checking steps:

• Set the economy switch 1 to “ON” a.

• Start the engine.

• Turn the switch of the electric device con­nected to the AC outlet “ON” and “OFF” to
check whether the engine speed increases
and decreases.

PILOT LIGHT

1. Check:

• Pilot light 1

Checking steps:

• Start the engine.

OVER

AC

LOAD

SVU2300H

2-13

• Make sure that the pilot light 1 turns on.

INSP

ADJ

TO RESET AC
RESTART ENGINE

RECEPTACLE

RECEPTACLE

1. Check:

• AC receptacles (15 A) 1
Cracks/damage → Replace.
Poor connection → Correct.

AC~

SVU2310H

2-14

CONTROL PANEL

1

CONTROL PANEL

ENGINE

ENG

2

3

2

3

Order Job name/Part name Q’ty Remarks

Control panel assembly removal

1 Control panel assembly 1
2 Wire harness 1 Disconnect all couplers and lead wires.
3 Ground terminal 1

Remove the parts in the order listed
below.

For installation, reverse the removal pro­cedure.

3

SVU3010H

3-1

CONTROL PANEL

1

ENG

2

3

2

3

Order Job name/Part name Q’ty Remarks

1
2
3
4
5
6
7

Control panel disassembly

Control panel 1
Engine switch 1
Economy switch 1
Oil warning light 1
Pilot light 1
Over load warning light 1
AC receptacle (15 A) 2

Remove the parts in the order listed
below.

For assembly, reverse the disassembly
procedure.

SVU3010H

3-2

CONTROL BOX COVER AND FUEL TANK

CONTROL BOX COVER AND FUEL TANK

7 Nm (0.7 m · kg, 5.1 ft · lb)

4

ENG

5

1

2

Order Job name/Part name Q’ty Remarks

Control box cover and fuel tank
removal

Control panel assembly
1 Control box cover 1
2 Oil warning unit 1
3 Wire harness 1 Disconnect all couplers, lead wires and

4 Fuel hose 1 Set the fuel cock “OFF” position.
5 Fuel tank 1

3

3

Remove the parts in the order listed
below.

connections.

For installation, reverse the removal
procedure.

SVU3020H

3-3

MUFFLER AND AIR CLEANER

MUFFLER AND AIR CLEANER

2 Nm (0.2 m · kg, 1.4 ft · lb)
4 Nm (0.4 m · kg, 2.9 ft · lb)

7 Nm (0.7 m · kg, 5.1 ft · lb)
10 Nm (1.0 m · kg, 7.2 ft · lb)
16 Nm (1.6 m · kg, 11 ft · lb)

2

ENG

7

6

4

5

3

9

13

11

10

1

12

14

New

Order Job name/Part name Q’ty Remarks

Muffler and air cleaner removal

Remove the parts in the order listed

below.
1 Muffler protector 1 1
2 Muffler 1
3 Muffler protector 2 1
4 Muffler band 1
5 Muffler cap 1
6 Washer 1
7 Muffler screen 1
8 Air filter case cover 1
9 Air filter element 1

10 Metal gasket 1
11 Plate 1
12 Air filter case 1
13 Breather hose 1
14 Gasket 1

For installation, reverse the removal

procedure.

8

SVU3030H

3-4