YAMAHA EF3000i SERVICE MANUAL
SERVICE MANUAL
EF3000iSE
7WL-28197-E0
310140
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.
NOTE:
This Service Manual contains information
regarding periodic maintenance to the emission control system. Please read this material
carefully.
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.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EF3000iSE
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st Edition, October 2002
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
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
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION
SERIAL NUMBER ...............................1-1
STARTING SERIAL NUMBER ............ 1-1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
AND DISASSEMBLY
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
MAINTENANCE INTERVALS CHART
(For Canada)
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
COVERS, PANELS, AND CAPS
ENGINE
....................................................2-3
ENGINE OIL LEAKAGE CHECKING ..2-3
OIL LEVEL CHECKING ....................... 2-3
OIL REPLACEMENT ...........................2-4
FUEL LEAKAGE .................................. 2-5
FUEL TANK FILTER ...........................2-6
FUEL PIPE STRAINER ....................... 2-7
AIR FILTER ELEMENT .......................2-8
MUFFLER ............................................2-9
VALVE CLEARANCE
ADJUSTMENT ..................................2-10
AIR GAP BETWEEN TCI UNIT
AND FLYWHEEL MAGNETO ...........2-13
COMPRESSION PRESSURE ...........2-14
ENGINE SPEED (NO LOAD) ............ 2-16
ECONOMY ENGINE SPEED ............ 2-16
CHOKE CABLE ................................. 2-17
BREATHER HOSE ............................2-17
.......................................2-1
............................................2-1
....................2-1
..............2-2
ELECTRICAL
SPARK PLUG ................................... 2-18
MAIN SWITCH .................................. 2-19
ECONOMY SWITCH ........................ 2-20
PILOT LIGHT .................................... 2-20
OVERLOAD WARNING LIGHT ........ 2-20
DC CIRCUIT BREAKER ................... 2-21
DC CIRCUIT BREAKER
(120 V-60 Hz) .................................... 2-21
RECEPTACLE .................................. 2-22
AC SWITCH (NFB)
(120 V-60 Hz/23.5 A) ........................ 2-22
AC SWITCH (NFB)
(120 V-60 Hz/15 A) ........................... 2-23
FUSES .............................................. 2-23
BATTERY .......................................... 2-25
BATTERY TERMINAL ...................... 2-25
BATTERY ELECTROLYTE ............... 2-26
BATTERY CHARGING ..................... 2-29
......................................... 2-18
CHAPTER 3.
ENGINE
PANELS AND COVERS
CONTROL PANEL
FUEL TANK AND CONTROL BOX
AIR FILTER ASSEMBLY
AND CONTROL UNIT
120 V-60 Hz, 220 V-50 Hz .................. 3-7
AIR FILTER ASSEMBLY, CONTROL UNIT
AND NOISE FILTER
230 V-50 Hz ........................................ 3-8
RECOIL STARTER
AND FLYWHEEL MAGNETO
RECOIL STARTER REMOVAL ........ 3-12
FLYWHEEL MAGNETO
REMOVAL ......................................... 3-12
FLYWHEEL MAGNETO
INSTALLATION ................................. 3-13
RECOIL STARTER
DISASSEMBLY ................................. 3-14
RECOIL STARTER INSPECTION .... 3-14
RECOIL STARTER ASSEMBLY ....... 3-15
ENGINE ASSEMBLY
CHASSIS AND CASTERS
MUFFLER
MUFFLER INSTALLATION ............... 3-20
.............................................. 3-19
.......................... 3-1
................................... 3-3
......... 3-5
.............................. 3-7
................................ 3-8
.................. 3-9
............................. 3-17
..................... 3-18
GENERATOR .........................................3-21
GENERATOR ASSEMBLY
REMOVAL .........................................3-22
GENERATOR ASSEMBLY
INSTALLATION .................................3-23
CYLINDER HEAD COVER
AND CYLINDER HEAD ..........................3-25
CYLINDER HEAD REMOVAL ...........3-26
PUSH ROD INSPECTION ................. 3-26
CYLINDER HEAD INSPECTION ......3-26
CYLINDER HEAD ASSEMBLY ......... 3-27
BREATHER HOSE ............................3-27
VALVE ....................................................3-28
VALVE AND VALVE SPRING
REMOVAL .........................................3-29
VALVE AND VALVE SPRING
INSPECTION .....................................3-29
LOCKER ARM INSPECTION ............3-30
VALVE SEAT INSPECTION .............. 3-31
VALVE LAPPING ..............................3-32
VALVE AND VALVE SPRING
ASSEMBLY .......................................3-33
CRANKCASE COVER
AND CAMSHAFT ...................................3-34
CRANKCASE COVER REMOVAL ....3-35
CAMSHAFT INSPECTION ................3-35
VALVE LIFTER INSPECTION ........... 3-36
CAMSHAFT ASSEMBLY ..................3-36
CRANKCASE COVER
INSPECTION .....................................3-36
CRANKCASE COVER
INSTALLATION .................................3-36
PISTON, CONNECTING ROD,
CRANKSHAFT AND CRANKCASE ...... 3-37
CRANKCASE (CYLINDER)
INSPECTION .....................................3-38
PISTON AND PISTON PIN
INSPECTION .....................................3-38
PISTON RING INSPECTION ............ 3-40
CRANKSHAFT INSPECTION ........... 3-41
CONNECTING ROD OIL
CLEARANCE INSPECTION .............. 3-42
PISTON RING
AND PISTON ASSEMBLY ................3-43
CRANKSHAFT ASSEMBLY ..............3-44
CARBURETOR ...................................... 3-45
FLOAT HEIGHT INSPECTION ......... 3-49
CHOKE CABLE INSTALLATION ...... 3-50
THROTTLE CONTROL MOTOR ...... 3-50
TROUBLESHOOTING ........................... 3-51
THROTTLE CONTROL SYSTEM ..... 3-56
CHAPTER 4.
ELECTRICAL
ELECTRICAL COMPONENTS ................ 4-1
120 V-60 Hz ........................................ 4-1
220 V-50 Hz ........................................ 4-2
230 V-50 Hz ........................................ 4-3
SWITCHES ............................................... 4-4
CHECKING SWITCH CONTINUITY ... 4-4
IGNITION SYSTEM .................................. 4-5
TROUBLESHOOTING CHART ........... 4-5
ELECTRIC STARTING SYSTEM ........... 4-11
TROUBLESHOOTING CHART ......... 4-11
STARTER MOTOR ........................... 4-14
CHARGING SYSTEM ............................ 4-17
TROUBLESHOOTING CHART ......... 4-17
GENERATOR SYSTEM ......................... 4-20
TROUBLESHOOTING CHART ......... 4-20
CHAPTER 5.
SPECIFICATIONS
GENERAL SPECIFICATIONS ................. 5-1
MAINTENANCE SPECIFICATIONS ........ 5-4
ENGINE .............................................. 5-4
GENERATOR AND ELECTRICAL ...... 5-7
LUBRICATION POINTS
AND LUBRICANT TYPES ....................... 5-8
TIGHTENING TORQUE ........................... 5-9
GENERAL TORQUE
SPECIFICATIONS ................................. 5-11
DEFINITION OF UNITS ......................... 5-11
WIRE ROUTING DIAGRAM ................... 5-12
1
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
SWL1010T
for model identification, the remaining digits
are the unit production number.
GEN
INFO
1
SWL1020J
STARTING SERIAL NUMBER
Model Code
120 V-60 Hz 7WL2 7WL-220101~
220 V-50 Hz 7WL3 7WL-330101~
230 V-50 Hz 7WL3 7WL-300101~
230 V-50 Hz 7WL3 7WL-350101~
NOTE:
Designs and specifications are subject to
change without notice.
Starting serial
number
1-1
SVU1030
SVU1040
SVU1050
GEN
IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
CAUTION ON SERVICE
1. 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
SVU1060
SVU1070
SVU1080
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.
SVU1090
SVU1100
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
SVU1110
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
SVU1120
CAUTION:
Do not use compressed air to spin the bearings dry. This
causes damage to the bearing surfaces.
1-3
SVU1130
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. The shape and part number used for the special tool
differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
• For USA and Canada, use part number starting with “YM-”, “YU-”
or “YS-”.
• For others, use part number starting with “90890-”.
1. Piston ring compressor
P/N. YU-33294, 90890-05158
This tool is used to compress the piston rings when installing the
piston.
INFO
SVU1140
SVU1150
SVU1160
2. Valve spring compressor
P/N. YM-01253, 90890-01253
This tool is used to remove the valve springs.
3. Thickness gauge
P/N. YU-26900-9, 90890-03079
This gauge is used to adjust valve clearance, piston clearance
and piston ring end gap.
4. Cylinder gauge
Commercially available
This instrument is used for checking cylinder bore size and condition.
1-4
SPECIAL TOOLS AND TESTERS
GEN
INFO
1
2
3
4
SWL1010
SWL1020
SWL1040
5. Inductive self-powered tachometer
1
P/N. YU-8036-B
Engine tachometer
2
P/N. 90890-03113
3
P/N. 90793-80009
4
P/N. 90793-80032
This instrument is used for reading engine r/min.
SWL1050
SVU1180
SVU1190
SVU1200
6. Compression gauge 1
P/N. YU-33223, 90890-03081
Adapter 2
P/N. YU-33223-3, 90890-04082
This gauge is used for checking engine compression.
7. Dial gauge
P/N. YU-03097, 90890-03097
This instrument is used for checking crankshaft side clearance.
8. Piston pin puller
P/N. YU-01304, 90890-01304
This tool is used to remove the piston pin.
9. Sheave holder
P/N. YS-01880-A, 90890-01701
This tool is necessary for holding the flywheel or rotor.
SVU1205
1-5
SWL1030
SPECIAL TOOLS AND TESTERS
10.Rotor assembly holder
Commercially available
This tool is necessary for holding the rotor.
GEN
INFO
1
2
1
SVU1210
SVU1220
SVU1230
SVU1240
11.Rotor puller
1
P/N. YU-33270-B
2
P/N. 90890-01362
This tool is necessary for removing the flywheel.
12.Pocket tester
P/N. YU-03112-C, 90890-03112
This instrument is necessary for checking the electrical system.
13.Dynamic spark tester 1
P/N. YM-34487
Ignition checker 2
P/N. 90890-06754
This instrument is necessary for checking the ignition system
components.
2
SVU1250
14.MF Battery charging
Commercially available
This instrument is necessary for charging the electrical system.
SWL1060
1-6
INSP
ADJ
INTRODUCTION/MAINTENANCE INTERVALS CHART (For Canada)/
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.
MAINTENANCE INTERVALS CHART (For Canada)
Proper periodic maintenance is important. Especially important are the maintenance services
related to emissions control. These controls not only function to ensure cleaner air but are also vital
to proper engine operation and maximum performance. In the following maintenance tables, the
services related to emissions control are indicated as “*” in the chart.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ÈÉÊËÌÍ
Item Remarks
Ï
*Spark Plug
Ð
*Valve Clearance Check and adjust when engine is cold.
*Crankcase breather
Ñ
system
Ò
*Idle speed Check and adjust engine idle speed.
Ó
*Exhaust System
Ö
Engine Oil
Ù
*Air Filter
Ú
Fuel Filter
Û
Fuel Line
Ü
*Choke knob Check choke operation.
Ý
Cooling System Check for fan damage.
Þ
Starting System
Á
*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.
Ô
Retighten or replace gasket if necessary.
Check muffler screen and spark arrester.
Õ
Clean/replace if necessary.
×
Check oil level.
Ø
Replace.
Clean.
Replace if necessary.
Clean fuel tank filter.
Replace if necessary.
Check fuel hose for crack or damage. Replace
if necessary.
ß
Check recoil starter operation.
À
Check electric starter operation.
Check all fittings and fasteners.
Correct if necessary.
Pre-Opera-
tion check
(daily)
●
●
●
●
●
●
●
Î
Initial
1 month
or 20 Hr
●●
Every
3 months
or 50 Hr
●
●
Every
6 months
or 100 Hr
●
●
Every
12 months
or 300 Hr
●
●
●
●
●
●
*: Related to emission control system.
2-1
INSP
ADJ
COVERS, PANELS, AND CAPS
COVERS, PANELS, AND CAPS
7
Front right view
6
5
4
1
3
2
Rear left view
9
8
0
C
B
A
SWL2180T
1
Cover 1
2
Panel 1
3
Cover 2
4
Cover 3
5
Cap 1
6
Cap 2
7
Panel 2
8
Cover 4
9
Cover 5
0
Panel 3
A
Battery bracket
B
Panel 4
C
Cover 6
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
7.0 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• The EF3000iSE are equipped with soundproof covers and panels that cover the engine and
frame.
• To make periodic maintenance checks easy, remove the applicable cover or panel.
• For cover or panel removal and installation, refer to “PANELS AND COVERS” in CHAPTER 3.
2-2
INSP
ADJ
ENGINE OIL LEAKAGE CHECKING/
OIL LEVEL CHECKING
ENGINE
ENGINE OIL LEAKAGE CHECKING
1. Remove:
• Panel 2
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Check the areas outside of the engine for
SWL2020J
oil leakage.
Oil leakage → Replace the gasket, oil
seal, or O-ring.
3. Install:
• Panel 4
• Panel 2
Refer to “COVERS, PANELS, AND
CAPS”.
1
a
1
SWL2010T
SWL2040J
OIL LEVEL CHECKING
1. Check:
• Oil level with oil level warning light 1
• Set the main switch to “START” “”
or set it to “ON” “” and pull the recoil
starter to check that the oil level warning light 1 flashes.
Oil level warning light flashes → Add
oil.
Oil level warning light does not flash
OK
2. Remove:
• Panel 2
Refer to “COVERS, PANELS, AND
CAPS”.
• Oil filler cap 1
3. Check:
• Check that the engine oil is at the specified level a.
Oil level checking steps:
• Place the generator on a level surface.
• 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.
→
2-3
INSP
ADJ
OIL LEVEL CHECKING/
OIL REPLACEMENT
4. Install:
• Oil filler cap
• Panel 2
Refer to “COVERS, PANELS, AND
CAPS”.
NOTE:
Tighten the oil filler cap securely by hand.
OIL REPLACEMENT
1. Warm up the engine for several minutes.
2. Stop the engine.
3. Remove:
• Panel 2
• Cap 2
• Cap 1
Refer to “COVERS, PANELS, AND
CAPS”.
4. Place a receptacle under the engine.
5. Remove:
• Oil drain bolt
6. Tilt the engine to drain the oil completely.
7. Tighten:
• Oil drain bolt
1
SWL2060J
È
1
1
SWL2050J
Oil drain bolt:
17 Nm (1.7 m · kg, 12 ft · lb)
T
.
R
.
8. Remove:
• Oil filler cap 1
9. Fill:
Recommended oil:
È YAMALUBE 4 (10W-30) or SAE
10W-30 type SE
É SAE #30
Ê SAE #20
Ë SAE 10W
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”.
SVU2060
2-4
INSP
ADJ
OIL REPLACEMENT/
FUEL LEAKAGE
É
SVW2070T
Recommended oil:
SAE #30 or 10W-30
È
or 10W-40
SAE #20 or 10W-30
É
or 10W-40
SAE 10W or 10W-30
Ê
or 10W-40
SAE #40: Above 35 °C (95 °F)
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”.
For Canada
È
Except for Canada
É
10.Install:
• Oil filler cap
NOTE:
Tighten the oil filler cap securely by hand.
11.Install:
• Cap 1
• Cap 2
• Panel 2
Refer to “COVERS, PANELS, AND
CAPS”.
FUEL LEAKAGE
1. Remove:
• Cover 1
• Cover 5
• Cover 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Remove:
• Fuel tank bolts
Refer to “FUEL TANK AND CONTROL
BOX” in CHAPTER 3.
3. Slide the fuel tank to check for leakage.
CAUTION:
When sliding the fuel tank, be sure not to
extremely bend, twist, or pull the fuel
hoses.
2-5
INSP
ADJ
SWL2070J
FUEL LEAKAGE/
FUEL TANK FILTER
4. Check:
• Leakage
Check at fuel tank, fuel cock, fuel
hoses, and carburetor.
CAUTION:
Replace the fuel hoses every four years.
5. Install:
• Fuel tank
Refer to “FUEL TANK AND CONTROL
BOX” in CHAPTER 3.
6. Install:
• Cover 4
• Cover 5
• Cover 1
Refer to “COVERS, PANELS, AND
CAPS”.
1
2
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.
4. Install:
• Fuel tank filter
• Fuel tank cap
WARNING
Be sure the tank cap is tightened securely.
SVU2080J
2-6
INSP
ADJ
FUEL PIPE STRAINER
FUEL PIPE STRAINER
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. Drain the fuel.
2. Remove:
• Cover 1
• Cover 5
• Cover 4
Refer to “COVERS, PANELS, AND
CAPS”.
3. Remove:
• Fuel hose (fuel cock end)
• Fuel tank
Refer to “FUEL TANK AND CONTROL
BOX” in CHAPTER 3.
1
SWL2080J
4. Remove:
• Fuel hose (fuel tank end)
• Fuel pipe strainer 1
5. Inspect:
• Fuel pipe strainer
Damage → Replace.
6. Clean:
• Fuel pipe strainer
NOTE:
Clean the fuel pipe strainer with solvent, and
then dry it thoroughly.
7. Install:
• Fuel pipe strainer
• Fuel hose (fuel tank end)
8. Install:
• Fuel tank
• Fuel hose (fuel cock end)
Refer to “FUEL TANK AND CONTROL
BOX” in CHAPTER 3.
9. Install:
• Cover 4
• Cover 5
• Cover 1
Refer to “COVERS, PANELS, AND
CAPS”.
2-7
INSP
ADJ
AIR FILTER ELEMENT
2
1
1
1
2
SWL2090J
SVU2100J
AIR FILTER ELEMENT
1. Remove:
• Panel 4
• Cover 5
Refer to “COVERS, PANELS, AND
CAPS”.
2. Remove:
• Hooks 1
• Air filter element case 2
3. Remove:
• Air filter element 1 1
• Air filter element 2 2
NOTE:
Remove air filter element 1 and air filter element 2 as a set.
4. Inspect:
• Air filter elements
Damage → Replace.
5. Clean:
• Air filter element 1
Wash the air filter elements in kerosene.
NOTE:
Be sure to squeeze the excess kerosene out of
the air filter element 1.
6. Lubricate:
• Air filter element 1
Soak the air filter element 1 in a 2–4:1
mixture of kerosene and engine oil.
NOTE:
Be sure to squeeze the excess kerosene and
engine oil out of the air filter element 1.
CAUTION:
• Do not twist the air filter elements, otherwise they can tear.
• Do not wash the air filter elements in gasoline or in acid, alkaline, or organic solvents.
7. Install:
• Air filter element 1
• Air filter element 2
NOTE:
Insert air filter element 1 into air filter element
2, and then install them into the air filter case.
SWL2110
2-8
INSP
ADJ
AIR FILTER ELEMENT/
MUFFLER
SWL2120J
a
b
2
1
6
2
5
4
3
8. Install:
• Air filter element case 1
• Hooks 2
NOTE:
• Align the projection a of the air filter case
with the slot b in the air filter element
bracket, and then install the air filter case.
• Make sure that the air intake duct 3 is
securely installed onto the frame 4.
• Make sure that the air vent hose 5 and
drain hose 6 are securely installed onto the
frame 4.
9. Install:
• Cover 5
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
1
CAUTION:
The engine should never run without the air
filter element installed, otherwise excessive piston and/or cylinder wear may result.
MUFFLER
1. Remove:
• Engine assembly
Refer to “ENGINE ASSEMBLY” in
CHAPTER 3.
2. Remove:
• Muffler
Refer to “MUFFLER” in CHAPTER 3.
3. Remove:
• Muffler band 1
• Muffler cap 2
• Muffler screen 3
• Spark arrester 4
SWL2400J
2-9
INSP
ADJ
MUFFLER/
VALVE CLEARANCE ADJUSTMENT
4. Decarbonize:
• Exhaust pipe 1
• Muffler 2
• Muffler screen 3
• Spark arrester 4
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
SWL2410J
Do not use a wire to clean the muffler, otherwise the noise damping material may
come out, and the damping effect may be
reduced.
muffler.
CAUTION:
5. Install:
• Spark arrester
• Muffler screen
• Muffler cap
• Muffler band
• Muffler
Refer to “MUFFLER” in CHAPTER 3.
6. Install:
• Engine assembly
Refer to “ENGINE ASSEMBLY” in
CHAPTER 3.
4
3
2
1
SWL2130J
VALVE CLEARANCE ADJUSTMENT
1. Remove:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Remove:
• Breather hose 1
• Spark plug cap 2
• Cylinder head cover 3
• Spark plug 4
2-10
INSP
ADJ
SWL2140J
VALVE CLEARANCE ADJUSTMENT
3. Gently pull the recoil starter to bring the
piston to top dead center of its compression stroke (when the screwdriver
inserted into the spark plug hole reaches
the highest position).
NOTE:
If the piston is at top dead center of the
exhaust stroke, turn the crankshaft one full
turn (360°) to set the piston at top dead center
of the compression stroke.
SWL2150J
4. Measure:
• Valve clearance
Out of specification → Adjust.
NOTE:
Valve clearance must be measured when the
engine is cool to the touch.
Intake valve (cold):
0.18 ~ 0.22 mm (0.007 ~ 0.009 in)
Exhaust valve (cold):
0.18 ~ 0.22 mm (0.007 ~ 0.009 in)
Thickness gauge:
YU-26900-9, 90890-03079
2-11
INSP
ADJ
2
1
VALVE CLEARANCE ADJUSTMENT
5. Adjust:
• Valve clearance
Adjustment steps:
• Loosen the locknut 1.
• Turn the adjuster 2 in or out to obtain the
proper clearance.
SWL2160J
SWL2170J
1
1
2
2
3
4
SWL2180J
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
.
6. Install:
• Spark plug 1
• Cylinder head cover 2
• Spark plug cap
3
• Breather hose 4
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)
7. Install:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2-12
INSP
ADJ
AIR GAP BETWEEN TCI UNIT AND FLYWHEEL
MAGNETO
AIR GAP BETWEEN TCI UNIT AND FLYWHEEL MAGNETO
1. Remove:
• Fuel tank
Refer to “FUEL TANK AND CONTROL
BOX” in CHAPTER 3.
• Air filter element assembly
Refer to “AIR FILTER ASSEMBLY AND
CONTROL UNIT” and “AIR FILTER
ASSEMBLY, CONTROL UNIT AND
NOISE FILTER” in CHAPTER 3.
• Carburetor
Refer to “CARBURETOR” in CHAPTER
3.
• Recoil starter
• Flywheel magneto cover
Refer to “RECOIL STARTER AND FLYWHEEL MAGNETO” in CHAPTER 3.
SWL2420J
2. Measure:
• Air gap between TCI unit and flywheel
magneto
Use a thickness gauge 1.
Out of specification → Adjust.
Thickness gauge:
YU-26900-9, 90890-03079
3. Adjust:
• Air gap between TCI unit and flywheel
magneto
Adjustment steps:
• Loosen the bolts 2.
• Adjust the air gap between the TCI unit
and flywheel magneto by moving the TCI
unit up or down.
• Tighten the bolts 2.
Air gap between TCI unit and flywheel magneto:
0.5 ± 0.1 mm (0.020 ± 0.004 in)
2-13
TCI unit bolt:
10 Nm (1.0 m · kg, 7.2 ft · lb)
T
.
R
.
INSP
ADJ
AIR GAP BETWEEN TCI UNIT AND FLYWHEEL
MAGNETO/COMPRESSION PRESSURE
4. Install:
• Flywheel magneto cover
• Recoil starter
Refer to “RECOIL STARTER AND FLYWHEEL MAGNETO” in CHAPTER 3.
• Carburetor
Refer to “CARBURETOR” in CHAPTER
3.
• Air filter element assembly
Refer to “AIR FILTER ASSEMBLY AND
CONTROL UNIT” and “AIR FILTER
ASSEMBLY, CONTROL UNIT AND
NOISE FILTER” in CHAPTER 3.
• Fuel tank
Refer to “FUEL TANK AND CONTROL
BOX” in CHAPTER 3.
2
1
COMPRESSION PRESSURE
NOTE:
Measure the compression after checking and
adjusting the valve clearance.
1. Warm up the engine for several minutes.
2. Remove:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
3. Remove:
• Spark plug cap
• Spark plug
4. Connect:
• Compression gauge 1
• Adapter 2
Compression gauge:
YU-33223, 90890-03081
Adapter:
YU-33223-3, 90890-04082
SWL2190J
2-14
INSP
ADJ
COMPRESSION PRESSURE
5. Measure:
• Compression
To measure the compression, set the
main switch to “START” “” or set it
to “ON” “” and pull the recoil starter
until the needle stops rising on the compression gauge.
Standard compression pressure:
400 ~ 600 kPa
(4 ~ 6 kg/cm
WARNING
To prevent sparking when cranking the
engine, ground the spark plug lead.
Testing steps (below minimum level):
• Squirt a few drops of oil into the cylinder.
• Measure the compression pressure again.
2
, 57 ~ 85 psi)
Reading Diagnosis
If higher than
without oil
• Worn cylinder, piston, and
piston ring
• Defective piston, ring(s),
If the same as
without oil
valve(s), and cylinder
head gasket
• Improper valve timing and
valve clearance
Testing steps (above maximum level):
• Check the cylinder head, valve surfaces,
and piston crown for carbon deposits.
6. Install:
• Spark plug
• Spark plug cap
Spark plug:
18 Nm (1.8 m · kg, 13 ft · lb)
T
.
R
.
7. Install:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2-15
INSP
ADJ
1
ENGINE SPEED (NO LOAD)/
ECONOMY ENGINE SPEED
ENGINE SPEED (NO LOAD)
1. Remove:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Connect:
• Inductive self-powered tachometer or
engine tachometer
1
SWL2200J
ÈÉ
a
1
a
1
SWL2020T
Inductive self-powered tachometer:
YU-8036-B
Engine tachometer:
90890-03113
(90793-80009, 90793-80032)
3. Inspect:
• Engine speed (no load)
Specified engine speed → OK
Out of specification → Refer to “TROU-
BLESHOOTING” in CHAPTER 3.
Inspection steps:
• Operate the engine (no load).
• Turn the economy switch 1 to “OFF”
“” a.
• Measure the engine speed (no load).
Engine speed (no load):
3,550 r/min
È
120 V-60 Hz, 220 V-50 Hz
É
230 V-50 Hz
4. Install:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
ECONOMY ENGINE SPEED
1. Remove:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Connect:
• Inductive self-powered tachometer or
engine tachometer
1
1
Inductive self-powered tachometer:
YU-8036-B
Engine tachometer:
90890-03113
(90793-80009, 90793-80032)
SWL2200J
2-16
INSP
ADJ
ECONOMY ENGINE SPEED/
CHOKE CABLE/BREATHER HOSE
ÈÉ
a
1
a
1
SWL2050T
3. Inspect:
• Economy engine speed
Specified engine speed → OK
Out of specification → Refer to “TROU-
BLE SHOOTING” in CHAPTER 3.
Inspection steps:
• Turn the economy switch 1 to “ON”
“” a.
• Operate the engine (no load).
• Measure the economy engine speed.
Economy engine speed (no load):
2,800 ± 50 r/min
È
120 V-60 Hz, 220 V-50 Hz
É
230 V-50 Hz
4. Install:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
CHOKE CABLE
1. Inspect:
• Choke knob
(pull the choke knob all the way out)
Choke knob automatically returns
Adjust.
→
1
SWL2430J
1
SWL2220J
Adjustment steps:
• Turn in the adjusting nut 1 until the choke
knob does not automatically return.
BREATHER HOSE
1. Remove:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Inspect:
• Breather hose 1
Cracks/damage → Replace.
Poor connection → Correct.
3. Install:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2-17
INSP
ADJ
SVU2240J
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:
• Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Remove:
• Spark plug cap
• Spark plug
3. Inspect:
• Electrode 1
Wear/damage → Replace.
• Insulator color 2
4. 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)
SVU2250J
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.
2-18
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