YAMAHA EF3000i SERVICE MANUAL

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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

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.

GEN

INFO

INSP

ADJ

ENG

ELEC

–+

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

Periodic inspections and adjustments

Engine

Electrical

Specifications

CDE

FGH

IJK

New

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

Filling fluid

Lubricant

Special tool

Tightening

Wear limit, clearance

Engine speed

, V, A

Ω

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

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lightweight lithium-soap base grease

Apply molybdenum disulfide grease

Apply a locking agent (LOCTITE

Apply Yamaha bond

Use a new one

)

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

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

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

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

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

SWL1010

SWL1020

SWL1040

5. Inductive self-powered tachometer

P/N. YU-8036-B

Engine tachometer

P/N. 90890-03113

P/N. 90793-80009

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

SVU1210

SVU1220

SVU1230

SVU1240

11.Rotor puller

P/N. YU-33270-B

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.

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

*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

Fuel Filter

Fuel Line

*Choke knob Check choke operation.

Cooling System Check for fan damage.

Starting System

*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. Replace if necessary.

Clean fuel tank filter. Replace if necessary.

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

Check recoil starter operation.

Check electric starter operation.

Check all fittings and fasteners. Correct if necessary.

Pre-Opera-

tion check

(daily)

●

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

Front right view

Rear left view

SWL2180T

Cover 1

Panel 1

Cover 2

Cover 3

Cap 1

Cap 2

Panel 2

Cover 4

Cover 5

Panel 3

Battery bracket

Panel 4

Cover 6

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”.

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

SWL2060J

SWL2050J

Oil drain bolt:

17 Nm (1.7 m · kg, 12 ft · lb)

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

SVW2070T

Recommended oil:

SAE #30 or 10W-30

or 10W-40

SAE #20 or 10W-30

or 10W-40

SAE 10W or 10W-30

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

Except for Canada

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”.

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

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.

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

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

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”.

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.

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

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

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)

6. Install:

• Spark plug 1

• Cylinder head cover 2

• Spark plug cap

• Breather hose 4

Cylinder head cover bolt:

10 Nm (1.0 m · kg, 7.2 ft · lb)

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

• 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)

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

• 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.

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.

, 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)

7. Install:

• Panel 4 Refer to “COVERS, PANELS, AND CAPS”.

2-15

INSP

ADJ

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

SWL2200J

ÈÉ

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

120 V-60 Hz, 220 V-50 Hz

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

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

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

120 V-60 Hz, 220 V-50 Hz

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.

→

SWL2430J

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

INSP

ADJ

SVU2280

SPARK PLUG/

MAIN SWITCH

5. Tighten:

• Spark plug

Spark plug:

18 Nm (1.8 m · kg, 13 ft · lb)

NOTE:

To prevent thread damage, finger tighten the spark plug before tightening it to the specified torque b.

6. Install:

• Spark plug cap

7. Install:

• Panel 4 Refer to “COVERS, PANELS, AND CAPS”.

ÈÉ

SWL2030T

ÈÉ

SWL2040T

MAIN SWITCH

1. Check:

• Main switch

Checking steps:

• Set the main switch to “ON” “” and pull the recoil starter to start the engine.

• Check that the engine stops when the main switch is set to “STOP” “” 1. Engine does not stop → Refer to “IGNI- TION SYSTEM” in CHAPTER 4.

120 V-60 Hz, 220 V-50 Hz

230 V-50 Hz

• Check that the engine starts when the main switch is set to “START” “”. Engine does not start → Refer to “ELEC- TRIC STARTING SYSTEM” in CHAPTER

120 V-60 Hz, 220 V-50 Hz

230 V-50 Hz

2-19

INSP

ADJ

ECONOMY SWITCH/PILOT LIGHT/

OVERLOAD WARNING LIGHT

ÈÉ

SWL2050T

ECONOMY SWITCH

1. Check:

• Economy switch 1

120 V-60 Hz, 220 V-50 Hz

230 V-50 Hz

Checking steps:

• Set the economy switch 1 to “ON” “” a.

• Start the engine.

• Turn the switch of the electric device con-

nected to the AC outlet “ON” “” and “OFF” “” to check whether the engine speed increases and decreases. Does not change → Refer to “TROUBLE- SHOOTING” in CHAPTER 3 and “GENERATOR SYSTEM” in CHAPTER 4.

PILOT LIGHT

1. Check:

• Pilot light 1

SWL2060T

SWL2070T

Checking steps:

• Start the engine.

• Check that the pilot light 1 turns on.

Refer to “GENERATOR SYSTEM” in CHAPTER 4.

OVERLOAD WARNING LIGHT

1. Check:

• Overload warning light 1

2. Remove:

• Control panel

• Overload warning light connector

Refer to “CONTROL PANEL” in CHAPTER 3.

Checking steps:

• Connect three dry cell batteries (1.5 V) to the overload warning light lead.

• Check that the overload warning light turns on. Does not turn on → Replace.

3. Install:

• Overload warning light connector

• Control panel

Refer to “CONTROL PANEL” in CHAPTER 3.

2-20

INSP

ADJ

DC CIRCUIT BREAKER/

DC CIRCUIT BREAKER (120 V-60 Hz)

DC CIRCUIT BREAKER

1. Check:

• DC circuit breaker

Checking steps:

• Check if the DC circuit breaker knob 1 is

SWL2080T

SWL2090T

set to “RESET” “” a.

• If the knob 1 is set to “OFF” “” b, direct current cannot be supplied.

• Start the engine.

• Connect a pocket tester (DC 20 V) to the

DC receptacle and check if direct current is supplied.

Pocket tester:

YU-03112-C, 90890-03112

Direct current not supplied → Replace or refer to “GENERATOR SYSTEM” in CHAPTER 4.

ON OFF

SVU2330C

SWL2100T

DC CIRCUIT BREAKER (120 V-60 Hz)

1. Check:

• DC circuit breaker

Checking steps:

• Set the DC circuit breaker 1 to the posi- tion of “ON” a.

• Connect the pocket tester (DC 20 V).

Pocket tester:

YU-03112-C, 90890-03112

• Start the engine.

• Set the economy switch to “OFF”.

• Measure the DC voltage.

DC voltage:

More than 12 V at 3,550 r/min (no load at AC output current)

• Set the DC circuit breaker 1 to “OFF” b. Voltage is zero → OK

2-21

INSP

ADJ

RECEPTACLE/

AC SWITCH (NFB) (120 V-60 Hz/23.5 A)

SWL2110T

SWL2120T

RECEPTACLE

1. Check:

• DC receptacle (12 V, 8.3 A) 1

• DC receptacle (12 V, 12 A) 2

• AC receptacles (15 A) 3

• AC receptacle (23.3 A) 4

• AC receptacles (15 A) 5

• AC receptacles (16 A) 6

Cracks/damage → Replace. Poor connection → Correct.

120 V-60 Hz

220 V-50 Hz

230 V-50 Hz

AC SW

ON ON

OFF

15A

OFF

SWL2130T

SWL2160T

SWL2140T

AC SWITCH (NFB) (120 V-60 Hz/23.5 A)

1. Set the AC switch (NFB) 1 to the “ON”

position.

2. Connect the pocket tester (AC 120 V) to

the AC receptacle (23.3 A) and check the AC switch (NFB) for continuity.

No continuity → Replace the AC switch (NFB).

Pocket tester:

YU-03112-C, 90890-03112

3. Set the AC switch (NFB) 1 to the “OFF”

b position.

4. Connect the pocket tester (AC 120 V) to

the AC receptacle (23.3 A) and check the AC switch (NFB) for continuity.

Continuity → Replace the AC switch (NFB).

2-22

INSP

ADJ

AC SWITCH (NFB) (120 V-60 Hz/15 A)/

AC SWITCH (NFB) (120 V-60 Hz/15 A)

AC SW

ON ON

OFF

15A

OFF

SWL2170T

SWL2150T

1. Set the AC switch (NFB) 1 to the “ON”

position.

2. Connect the pocket tester (AC 120 V) to

the AC receptacle (15 A) and check the AC switch (NFB) for continuity.

No continuity → Replace the AC switch (NFB).

Pocket tester:

YU-03112-C, 90890-03112

3. Set the AC switch (NFB) 1 to the “OFF”

position.

4. Connect the pocket tester (AC 120 V) to

the AC receptacle (15 A) and check the AC switch (NFB) for continuity.

Continuity → Replace the AC switch (NFB).

FUSES

SWL2280J

FUSES

CAUTION:

To avoid a short circuit, always set the main switch to “STOP” “” when check- ing or replacing a fuse.

1. Remove:

• Cover 5 Refer to “COVERS, PANELS, AND CAPS”.

2. Remove:

• Battery bracket 1

• Battery band 2

• Battery

NOTE:

To check the fuses, slide the battery out with the positive battery lead and negative battery lead connected to the battery.

3. Remove:

• Starter relay 1

• Fuse 2

• Fuse (spare)

SWL2290J

2-23

INSP

ADJ

FUSES

4. Check:

• Fuses

Checking steps:

• Connect the pocket tester ( and check the continuity.

NOTE:

Set the pocket tester selector to “

Pocket tester:

YU-03112-C, 90890-03112

• If the pocket tester indicates “∞”, replace the fuse.

5. Replace:

• Blown fuse

Replacing steps:

• Set the main switch to “STOP” “”.

• Install a new fuse of the correct amperage.

• Set the main switch to “ON” “” and ver-

ify if the electrical circuit is operational.

• If the fuse immediately blows again, check the electrical circuit.

Ω ×

1) to a fuse

Ω ×

1”

Fuse amperage:

10 A

WARNING

Never use a fuse with an amperage other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system and could possibly cause a fire.

6. Install:

• Fuse (spare)

• Fuse

• Starter relay

7. Install:

• Battery

• Battery band

• Battery bracket

8. Install:

• Cover 5 Refer to “COVERS, PANELS, AND CAPS”.

2-24

INSP

ADJ

DANGER/POISON

EYES EXPLOSIVE

GASES CAN CAUSE BLINDNESS OR INJURY

IN U.S.A., YUASA BATTERY, INC, SERVICED BY : READING, PA. 19612

SHIELD

SPARKS FLAMES SMOKING

KEEP OUT OF REACH OF CHILDREN

SULFURIC ACID

CAN CAUSE BLINDNESS OR SEVERE BURNS

FLUSH EYES IMMEDIATELY WITH WATER GET MEDICAL HELP FAST

LEAD

AH17

RETURN

RECYCLE

SWL2450

BATTERY/

BATTERY TERMINAL

BATTERY

WARNING

Battery fluid is poisonous and dangerous, causes severe burns, etc. Contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL – Flush with water. INTERNAL – Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flames, cigarettes, etc. away. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

SWL2300J

SWL2310J

BATTERY TERMINAL

1. Remove:

• Cover 5 Refer to “COVERS, PANELS, AND CAPS”.

2. Remove:

• Battery bracket 1

• Battery band 2

• Battery 3

CAUTION:

When removing the battery, disconnect the negative lead first.

3. Check:

• Battery terminal Dirty terminal → Clean with a wire brush. Poor connection → Correct.

NOTE:

After cleaning the terminals, apply grease lightly to the terminals.

2-25

INSP

ADJ

BATTERY TERMINAL/

BATTERY ELECTROLYTE

4. Install:

• Battery

• Battery band

• Battery bracket

CAUTION:

Connect the positive lead to the battery terminal first.

5. Install:

• Cover 5 Refer to “COVERS, PANELS, AND CAPS”.

BATTERY ELECTROLYTE

1. Fill:

CAUTION:

• Never remove the sealing sheet (aluminium seal) from the battery until the battery is filled with electrolyte. If battery plates are exposed to air, they will oxidize. As a result, power will not be generated as specified.

• Add electrolyte so that its level is correct as specified. An incorrect electrolyte level has an adverse effect on battery performance. The quantity of electrolyte varies with the type of the electrolyte container. Use only the amount of electrolyte in the container which comes with the battery.

• Avoid using any electrolyte other than specified. The specific gravity of the MF battery electrolyte is 1.320 (20 °C). (The specific gravity of the general type battery electrolyte is 1.280.) If the electrolyte whose specific gravity is less than 1.320, the sulfuric acid will decrease and thus low battery performance will result. Should any electrolyte, whose specific gravity is 1.320 or more, be used, the battery plates will corrode and battery life will shorten.

2-26

INSP

ADJ

BATTERY ELECTROLYTE

a. Place the battery on a level surface. b. Remove the sealing sheet 1.

Filler port

SWL2320J

c. Take the electrolyte container out of the

vinyl bag.

d. Detach the strip of caps (used as battery

plugs) 1.

Six sealed areas of container

NOTE:

Do not lose the strip of caps because it will be used as battery plugs.

SWL2330J

CAUTION:

Do not peel or pierce the sealed areas.

SWL2340J

e. Turn the electrolyte container upside

down with the six sealed areas in line with the six filler ports of the battery.

f. Push the container down strongly enough

to break the seals. The electrolyte will start to flow into the battery.

CAUTION:

• Do not tilt the container as the electrolyte may stop flowing.

• Never remove the container from the battery until all electrolyte has drained from the container.

2-27

INSP

ADJ

BATTERY ELECTROLYTE

g. Leave the container in this position for

20 minutes or longer to allow proper chemical reaction.

NOTE:

• Make sure air bubbles are rising from all six filler ports.

• If air bubbles are not rising from a filler port, tap the top of the container a few times.

SWL2350J

SWL2360J

• Do not cut the connected parts.

h. Be certain that all the electrolyte has been

drained from the container.

i. Fit the strip of caps (battery plugs)

securely into the filler ports. Make sure the top of the strip is at the same level as the top of the battery.

Press down horizontally with both hands.

CAUTION:

Never remove the strip of caps, nor add any water or electrolyte.

WARNING

• Do not attempt boost charging under any circumstances.

• Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: External — Flush with water. Internal — Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., away. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

2-28

INSP

ADJ

BATTERY ELECTROLYTE/

BATTERY CHARGING

2. Check:

• Using a digital voltmeter, the state of a discharged MF battery can be checked by measuring open-circuit voltage (the voltage measured with the positive and negative terminals being disconnected).

CAUTION:

The battery must be charged after it is filled with electrolyte. If this is not done, the life of the battery will be shortened drastically.

SWL2380J

SWL2390J

BATTERY CHARGING

1. Check:

• Battery voltage Check the battery voltage using an MF battery tester (commercially available). Within green range → Correct Within yellow or red range → Charge the battery.

2. Recharge the battery using an MF battery charger (commercially available).

• Charge the battery to the specified

electric current and to the specified voltage.

Charging amperage and charging time:

1.2 A × 5 ~ 10 hr

Charging voltage:

12.8 V or more

2-29

PANELS AND COVERS

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

PANELS AND COVERS

ENGINE

ENG

Order Job name/Part name Q’ty Remarks

Panels and covers removal

Fuel tank/fuel hose Refer to “FUEL TANK AND CONTROL

Starter handle Refer to “RECOIL STARTER AND FLY-

1Cover 1 1 2Cover 5 1 3 Panel 1 1 4 Panel 3 1 5 Battery bracket 1 6Cover 2 1

Remove the parts in the order listed below.

BOX”.

WHEEL MAGNETO”.

SWL3010

3-1

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

PANELS AND COVERS

ENG

Order Job name/Part name Q’ty Remarks

7Cover 6 1 8Cover 3 1

NOTE:

To remove the control box, disconnect the necessary couplers and leads. It is not necessary to remove the cover 3 from the control box.

For installation, reverse the removal procedure.

SWL3010

3-2

CONTROL PANEL

ENG

120 V-60 Hz

220 V-50 Hz 230 V-50 Hz

Order Job name/Part name Q’ty Remarks

Control panel removal

Choke cable (carburetor end) Refer to “CARBURETOR”. 1 Control panel assembly 1 2 Wire harness 1

3 Ground terminal 1 4 Engine speed limiter/oil level warning

unit

Remove the parts in the order listed below.

NOTE:

Disconnect all couplers and leads.

NOTE:

After installing all parts, refer to “WIRE ROUTING DIAGRAM” in CHAPTER 5 to check the cable, lead, and hose routings.

For installation, reverse the removal procedure.

SWL3010T

3-3

CONTROL PANEL

ENG

120 V-60 Hz

220 V-50 Hz 230 V-50 Hz

Order Job name/Part name Q’ty Remarks

1 2 3

5 6 7 8 9

0 A

B C

D E F

Control panel disassembly

Main switch 1

Economy switch 1

Fuel cock knob 1

Choke knob 1

Oil level warning light 1

Pilot light 1

Overload warning light 1

DC receptacle (12 V, 8.3 A) 1

DC circuit breaker 1

AC switch (NFB) (15 A) 1

AC switch (NFB) (23.5 A) 1

AC receptacle (15 A × 2) 1

AC receptacle (23.3 A) 1

DC receptacle (12 V, 12 A) 1

AC receptacle (15 A × 2) 1 For assembly, reverse the disassembly

AC receptacle (16 A × 2) 1

Remove the parts in the order listed below.

NOTE:

After installing the fuel cock knob, check it for proper operation.

procedure.

SWL3010T

3-4

FUEL TANK AND CONTROL BOX

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

ENG

120 V-60 Hz, 220 V-50 Hz

230 V-50 Hz

Order Job name/Part name Q’ty Remarks

Fuel tank and control box removal

Remove the parts in the order listed below.

Cover 1/cover 5/panel 4/panel 2 Refer to “COVERS, PANELS, AND

CAPS” in CHAPTER 2. Fuel Drain. Choke cable (carburetor end) Refer to “CARBURETOR”.

1 Fuel hose 2

NOTE:

When removing the fuel tank, disconnect

only the fuel cock end of the fuel hose.

2 Fuel tank cap 1 3Cover 4 1 4 Fuel tank 1 5 Fuel pipe strainer 1 6 Fuel tank filter 1

SWL3020T

3-5

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

FUEL TANK AND CONTROL BOX

ENG

Order Job name/Part name Q’ty Remarks

7 Fuel level gauge 1

8 Ground lead 1 9 Wire harness 1

10 Control box 1

NOTE:

To install the fuel level gauge, face the

“E” mark toward the control panel a.

NOTE:

Disconnect all couplers, leads, and con-

nectors.

NOTE:

After installing all parts, refer to “WIRE

ROUTING DIAGRAM” in CHAPTER 5 to

check the cable, lead, and hose routings.

For installation, reverse the removal

procedure.

SWL3020T

3-6

AIR FILTER ASSEMBLY AND CONTROL UNIT

120 V-60 Hz, 220 V-50 Hz

4.0 Nm (0.4 m · kg, 2.9 ft · lb)

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

10 Nm (1.0 m · kg, 7.2 ft · lb)

New

ENG

120 V-60 Hz

Order Job name/Part name Q’ty Remarks

Air filter assembly and control unit removal

Remove the parts in the order listed

below. Cover 5/panel 3/panel 4 Refer to “COVERS, PANELS, AND

CAPS” in CHAPTER 2.

1 Air filter assembly 1 2 Breather hose 1 3 Air intake duct 1 4 Air filter element 2

NOTE:

Remove air filter element 1 and air filter

element 2 as a set.

SWL3030T

5 Throttle control motor cover 1 6 Coupler/connector 3/1 Disconnect. 7 Control unit 1 8 Control unit cover 1

For installation, reverse the removal

procedure.

3-7

AIR FILTER ASSEMBLY, CONTROL UNIT AND NOISE

FILTER

ENG

AIR FILTER ASSEMBLY, CONTROL UNIT AND NOISE FILTER

230 V-50 Hz

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

10 Nm (1.0 m · kg, 7.2 ft · lb)

New

Order Job name/Part name Q’ty Remarks

Air filter assembly, control unit, and noise filter removal

Cover 1/cover 5/cover 4/cover 2/ cover 6/panel 3

1 Air filter assembly 1 2 Breather hose 1 3 Air intake duct 1 4 Air filter element 2

5 Throttle control motor cover 1 6 Coupler/connector 3/1 Disconnect. 7 Control unit 1 8 Coupler 1 Disconnect. 9 Noise filter 1

Remove the parts in the order listed

below.

Refer to “COVERS, PANELS, AND

CAPS” in CHAPTER 2.

NOTE:

Remove air filter element 1 and air filter

element 2 as a set.

For installation, reverse the removal

procedure.

SWL3040T

3-8

RECOIL STARTER AND FLYWHEEL MAGNETO

WARNING

RECOIL STARTER AND FLYWHEEL MAGNETO

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

10 Nm (1.0 m · kg, 7.2 ft · lb)

65 Nm (6.5 m · kg, 47 ft · lb)

ENG

Order Job name/Part name Q’ty Remarks

Recoil starter and flywheel magneto removal

Fuel tank Refer to “FUEL TANK AND CONTROL

Cover 3 Refer to “PANELS AND COVERS”. Air filter assembly/control unit Refer to “AIR FILTER ASSEMBLY AND

Carburetor Refer to “CARBURETOR”. Battery

1 Starter relay 1 2 Positive battery lead 1

Remove the parts in the order listed

below.

BOX”.

CONTROL UNIT” and “AIR FILTER

ASSEMBLY, CONTROL UNIT AND

NOISE FILTER”.

SWL3060

Remove the battery before discon-

necting the positive battery lead and

the starter motor lead.

3 Starter motor lead 1 4Rectifier 1 5 Starter handle 1

3-9

RECOIL STARTER AND FLYWHEEL MAGNETO

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

10 Nm (1.0 m · kg, 7.2 ft · lb)

65 Nm (6.5 m · kg, 47 ft · lb)

ENG

Order Job name/Part name Q’ty Remarks

6 Recoil starter assembly 1 7 Recoil starter cover 1 8DC rectifier 1

9 Flywheel magneto cover 1 10 Starter pulley 1 11 TCI unit 1 12 Flywheel magneto 1 13 Woodruff key 1 14 Charging coil 1

NOTE:

After installing all parts, refer to “WIRE ROUTING DIAGRAM” in CHAPTER 5 to check the cable, lead, and hose routings.

SWL3060

3-10

For installation, reverse the removal procedure.

RECOIL STARTER AND FLYWHEEL MAGNETO

ENG

Order Job name/Part name Q’ty Remarks

1 2 3 4 5 6 7 8 9

Recoil starter disassembly

Starter handle 1 Bolt 1 Drive plate 1 Clip 1 Drive pawl 2 Spring 2 Sheave drum 1 Starter spring 1 Starter case 1

Remove the parts in the order listed below.

For assembly, reverse the disassembly procedure.

SWL3070

3-11

RECOIL STARTER AND FLYWHEEL MAGNETO

RECOIL STARTER REMOVAL

1. Remove:

• Starter handle 1

NOTE:

When removing the starter handle from the starter rope, be sure to wrap the starter rope around a screwdriver, etc., to prevent the rope from retracting into the starter case.

SWL3080J

ENG

FLYWHEEL MAGNETO REMOVAL

1. Remove:

• Flywheel magneto nut 1

• Washer

• Starter pulley

NOTE:

Attach the sheave holder 2 to hold the flywheel magneto.

SWL3470J

Sheave holder:

YS-01880-A, 90890-01701

Rotor assembly holder:

(commercially available)

2. Remove:

• Flywheel magneto 1

SWL3090J

NOTE:

• Remove the flywheel magneto using a bearing puller (commercially available) 2.

• When removing the flywheel magneto, be sure to hold it so that it does not turn.

CAUTION:

Do not hold the flywheel magneto by its fins, otherwise the fins can be damaged.

3-12

RECOIL STARTER AND FLYWHEEL MAGNETO

FLYWHEEL MAGNETO INSTALLATION

SWL3150J

1. Install:

• Woodruff key 1

• Flywheel magneto 2

CAUTION:

Be sure to remove any oil or grease from the tapered portion of the crankshaft using a cloth dampened with thinner.

NOTE:

Insert the woodruff key 1 into the groove in the flywheel magneto 2.

ENG

SWL3470J

2. Install:

• Starter pulley

• Washer

• Flywheel magneto nut 1

Flywheel magneto nut:

65 Nm (6.5 m · kg, 47 ft · lb)

NOTE:

Tighten the flywheel magneto nut 1 using the sheave holder 2 to hold the flywheel magneto.

Sheave holder:

YS-01880-A, 90890-01701

Rotor assembly holder:

(commercially available)

3. Measure:

• Air gap between TCI unit and flywheel magneto Refer to “AIR GAP BETWEEN TCI UNIT AND FLYWHEEL MAGNETO” in CHAPTER 2.

3-13

Air gap between TCI unit and flywheel magneto:

0.5 ± 0.1 mm (0.020 ± 0.004 in)

RECOIL STARTER AND FLYWHEEL MAGNETO

RECOIL STARTER DISASSEMBLY

1. Remove:

• Starter handle 1

NOTE:

Make a knot a at the end of the starter rope to prevent the rope from being retracted into the starter case. Then, undo the knot b at the starter handle to the remove the starter handle

2. Remove:

• Drum sheave 1

CAUTION:

Be sure to press down on the drum sheave, because the spring will spring out suddenly when it is removed from the sheave drum.

SWL3100J

SWL3110J

ENG

SVU3330J

SVU3340J

3. Remove:

• Starter spring 1

RECOIL STARTER INSPECTION

1. Inspect:

• Starter rope 1

2. Inspect:

• Starter spring

Damage/deterioration → Replace.

3. Inspect:

• Drive pawl 1

• Drive plate 2

Wear/damage → Replace.

SVU3350J

3-14

RECOIL STARTER AND FLYWHEEL MAGNETO

RECOIL STARTER ASSEMBLY

1. Install:

• Starter spring 1

• Sheave drum 2

ENG

SVU3360J

SWL3120J

NOTE:

Engage the starter spring outer hook a with the groove b marked “R” on the sheave drum

. Carefully wind the spring counterclockwise

and place it on the sheave drum 2.

2. Install:

• Sheave drum 1

• Starter rope 2

• Starter case 3

NOTE:

• Wind the starter rope 2 clockwise two turns on the sheave drum 1.

• Engage the starter spring inner hook a with the strut b of the starter case 3, and then install the parts.

SVU3380J

SVU3390J

3. Install:

• Springs 1

• Drive pawls 2

NOTE:

Install the springs 1 and drive pawls 2 at the “R” marks a.

4. Install:

• Clip 1

• Drive plate 2

NOTE:

Align the groove a of the drive plate 2 with the sheave drum strut b, and then install the parts.

3-15

RECOIL STARTER AND FLYWHEEL MAGNETO

ENG

SWL3130J

SWL3140J

5. Install:

• Bolt 1 After tightening the bolt, place the starter rope 2 in the cutout a in the sheave drum, and wind it counterclockwise four turns.

NOTE:

Make a knot b at the end of the starter rope to prevent the rope from being retracted into the starter case.

3-16

ENGINE ASSEMBLY

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

16 Nm (1.6 m · kg, 11 ft · lb)

ENGINE ASSEMBLY

ENG

SWL3290

Order Job name/Part name Q’ty Remarks

Engine removal

Engine oil Drain. Fuel tank Refer to “FUEL TANK AND CONTROL

Cover 6/panel 1/battery bracket Refer to “COVERS, PANELS, AND

Air filter assembly/control unit Refer to “AIR FILTER ASSEMBLY AND

Cover 3 Refer to “PANELS AND COVERS”.

Recoil starter/recoil starter cover Refer to “RECOIL STARTER AND FLY-

1 Pipe frame 1 2 Engine assembly 1

3-17

Remove the parts in the order listed below.

BOX”.

CAPS” in CHAPTER 2.

CONTROL UNIT” and “AIR FILTER ASSEMBLY, CONTROL UNIT AND NOISE FILTER”.

NOTE:

Remove the cover 3 with the control box installed.

WHEEL MAGNETO”.

For installation, reverse the removal procedure.

CHASSIS AND CASTERS

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

16 Nm (1.6 m · kg, 11 ft · lb)

CHASSIS AND CASTERS

ENG

New

SWL3490

Order Job name/Part name Q’ty Remarks

Chassis and caster removal

Engine assembly Refer to “ENGINE ASSEMBLY”. 1 Engine mount 4 2Frame 1 3Caster 1 1 4Caster 2 1 5Caster 3 2

Remove the parts in the order listed below.

For installation, reverse the removal procedure.

3-18

MUFFLER

ENG

3.5 Nm (0.35 m · kg, 2.5 ft · lb)

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

16 Nm (1.6 m · kg, 11 ft · lb)

Order Job name/Part name Q’ty Remarks

Muffler removal

Engine assembly Refer to “ENGINE ASSEMBLY”. 1 Exhaust pipe air shroud 1 1 2 Muffler protector 1 3 Muffler 1

4Gasket 1 5 Muffler band 1 6 Muffler cap 1 7 Muffler screen 1 8 Spark arrester 1 9 Generator cover 1

10 Exhaust pipe air shroud 2 1

Remove the parts in the order listed below.

NOTE:

Remove the muffler nut, then the muffler bolt.

For installation, reverse the removal procedure.

SWL3180

3-19

SWL3190J

SWL3200J

MUFFLER

ENG

MUFFLER INSTALLATION

1. Install:

• Spark arrester

NOTE:

To install the spark arrester, align the projection a on the spark arrester with the hole b in the muffler.

2. Install:

• Muffler cap 1

NOTE:

To install the muffler cap, align the slit in the muffler cap with the projection c on the muffler as shown in the illustration.

SWL3210J

3. Install:

• Muffler band

NOTE:

Tighten the muffler band at the angle d shown in the illustration. Make sure that the muffler band opening and muffler cap slit are not covering the hole b and that the muffler cap has not come out.

30 ~ 60°

Muffler band:

3.5 Nm (0.35 m · kg, 2.5 ft · lb)

4. Install:

• Muffler

NOTE:

Finger tighten the muffler nut 1 and muffler bolt 2, and then tighten them to the specified torques, respectively.

SWL3220J

3-20

Muffler nut:

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

Muffler bolt:

16 Nm (1.6 m · kg, 11 ft · lb)

GENERATOR

7.0 Nm (0.7 m · kg, 5.1 ft · lb)

10 Nm (1.0 m · kg, 7.2 ft · lb)

65 Nm (6.5 m · kg, 47 ft · lb)

GENERATOR

ENG

Order Job name/Part name Q’ty Remarks

Generator removal

Engine assembly Refer to “ENGINE ASSEMBLY”.

Muffler Refer to “MUFFLER”. 1Fan 1 2 Generator 1

Remove the parts in the order listed below.

CAUTION:

The magnetic force of the magneto rotor is very strong. Therefore, be sure to remove the magneto rotor and stator coil assembly together as a set, otherwise they may be damaged.

SWL3230

3 Tube 2 4 Dowel pin 2

3-21

For installation, reverse the removal procedure.

SWL3240J

GENERATOR

ENG

GENERATOR ASSEMBLY REMOVAL

CAUTION:

The magnetic force of the magneto rotor is very strong. Therefore, be sure to remove the magneto rotor and stator coil assembly together as a set, otherwise they may be damaged.

1. Remove:

• Magneto rotor nut 1

NOTE:

Attach the sheave holder 2 to hold the magneto rotor.

Sheave holder:

YS-01880-A, 90890-01701

Rotor assembly holder:

(commercially available)

SWL3250J

SWL3260J

2. Remove:

• Stator coil assembly bolts 1

NOTE:

Turn the magneto rotor until the stator coil assembly bolts are visible through the holes in the rotor, and then remove the bolts.

3. Remove:

• Stator coil assembly bolts 2

• Tubes

NOTE:

Turn the magneto rotor until the stator coil assembly bolts are visible through the holes in the rotor, and then remove the bolts.

3-22

SWL3270J

GENERATOR

ENG

4. Remove:

• Generator assembly 1

NOTE:

• Remove the magneto rotor together with the stator coil assembly using the rotor puller 2.

• Fully tighten the tool holding bolts, making sure that the tool body is parallel with the magneto rotor.

CAUTION:

The magnetic force of the magneto rotor is very strong. Therefore, do not change the position of the magneto rotor and stator coil assembly during or after removal, otherwise they may be damaged.

Rotor puller:

YU-33270-B, 90890-01362

SWL3480J

GENERATOR ASSEMBLY INSTALLATION

CAUTION:

Be sure to remove any oil or grease from the tapered portion of the magneto rotor using a cloth dampened with thinner.

1. Install:

• Generator assembly

2. Install:

• Stator coil assembly bolts 1

• Tubes

Stator coil assembly bolts:

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Turn the magneto rotor until the stator coil assembly bolts are visible though the holes in the rotor, and then install the bolts 1.

3-23

SWL3280J

GENERATOR

ENG

3. Install:

• Stator coil assembly bolts 2

Stator coil assembly bolts:

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Turn the magneto rotor until the stator coil assembly bolts are visible though the holes in the rotor, and then install the bolts 2.

SWL3240J

4. Tighten:

• Washer

• Magneto rotor nut 1

Magneto rotor nut:

65 Nm (6.5 m · kg, 47 ft · lb)

NOTE:

Tighten the magneto rotor nut 1 using the sheave holder 2.

Sheave holder:

YS-01880-A, 90890-01701

Rotor assembly holder:

(commercially available)

3-24

CYLINDER HEAD COVER AND CYLINDER HEAD

ENG

Order Job name/Part name Q’ty Remarks

Cylinder head cover and cylinder head removal

Engine assembly Refer to “ENGINE ASSEMBLY”. Muffler Refer to “MUFFLER”. Flywheel magneto Refer to “RECOIL STARTER AND FLY-

1 Spark plug cap 1 2 Spark plug 1 3 Breather hose 1 4 Cylinder head cover 1 5Gasket 1 6 Air shroud 1 7 Cylinder head assembly 1 8 Cylinder head gasket 1 9 Dowel pin 2

10 Push rod 2

Remove the parts in the order listed below.

WHEEL MAGNETO”.

For installation, reverse the removal procedure.

SWL3320

3-25

CYLINDER HEAD COVER AND CYLINDER HEAD

CYLINDER HEAD REMOVAL

1. Remove:

SWL3450

SWL3330J

• Cylinder head

NOTE:

• Rotate the crankshaft clockwise until the mark a on the flywheel magneto is parallel with the punch mark b. This is the condition in which the piston is at top dead center of the compression stroke.

• 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.

• Loosen the nuts in the proper sequence.

ENG

SVU3100J

SVU3110J

PUSH ROD INSPECTION

1. Measure:

• Push rod runout

Runout limit:

0.5 mm (0.02 in)

Out of specification → Replace.

CYLINDER HEAD INSPECTION

1. Inspect:

• Cylinder head combustion chamber Check the combustion chamber for carbon deposits Carbon deposits → Remove.

NOTE:

Be sure not to damage the contact surface of the cylinder.

2. Inspect:

• Cylinder head Cracks or damage around the spark plug hole → Replace.

3-26

CYLINDER HEAD COVER AND CYLINDER HEAD

3. Measure:

• Cylinder head warpage Measure the warpage on the contact surface of the cylinder head at six points using a straightedge and thickness gauge.

Warpage limit:

0.05 mm (0.0020 in)

SVU3120J

Out of specification → Resurface or replace.

ENG

SWL3340J

CYLINDER HEAD ASSEMBLY

1. Install:

• Cylinder head bolts 1 to 4.

NOTE:

Tighten the bolts to the specified torques in two steps and in order from 1 to 4.

Cylinder head bolts:

1st: 12 Nm (1.2 m · kg, 8.7 ft · lb)

2nd: 20 Nm (2.0 m · kg, 14 ft · lb)

BREATHER HOSE

1. Inspect:

• Breather hose 1

SVU3140J

NOTE:

Contact the end of the breather hose to the reed valve stopper a.

3-27

VALVE

ENG

Order Job name/Part name Q’ty Remarks

Valve removal

Cylinder head assembly Refer to “CYLINDER HEAD COVER AND

1 Locknut 2 2Adjuster 2 3 Locker arm 2 4 Valve cotter 2 5 Valve spring retainer 2 6 Valve spring 2 7 Valve (intake) 1 8 Valve (exhaust) 1 9 Valve stem seal 1

Remove the parts in the order listed below.

CYLINDER HEAD”.

For installation, reverse the removal procedure.

SWL3350

3-28

SVU3160J

VALVE

ENG

VALVE AND VALVE SPRING REMOVAL

1. Remove:

• Valve cotter 1

• Valve spring retainer 2

• Valve spring 3

• Valve 4

Remove the parts using the valve spring compressor 5.

CAUTION:

Do not compress the valve spring more than necessary.

Valve spring compressor:

YM-01253, 90890-01253

SVU3170J

VALVE AND VALVE SPRING INSPECTION

1. Measure:

• Valve stem length a

• Valve face diameter b

Valve stem length:

Intake: 65.9 mm (2.59 in) Exhaust: 66.2 mm (2.61 in)

Valve face diameter:

Intake: 23.9 ~ 24.1 mm

(0.9409 ~ 0.9488 in)

Exhaust: 21.9 ~ 22.1 mm

(0.8622 ~ 0.8701 in)

Out of specification → Replace.

2. Measure:

• Valve stem diameter

Valve stem diameter:

Intake: 5.448 ~ 5.463 mm

(0.2145 ~ 0.2151 in)

Exhaust: 5.440 ~ 5.445 mm

(0.2142 ~ 0.2144 in)

Wear limit:

Intake: 5.418 mm (0.2133 in) Exhaust: 5.410 mm (0.2130 in)

SVU3180J

Out of specification → Replace.

3-29

SVU3190J

SVU3200J

VALVE

ENG

3. Measure:

• Valve stem runout

Runout limit:

0.01 mm (0.0004 in)

Out of specification → Replace.

NOTE:

The value is half of that indicated on the dial gauge.

4. Measure:

• Valve spring free length a

Valve spring free length:

Intake and exhaust:

26.5 mm (1.04 in)

Limit: 25.2 mm (0.99 in)

Out of specification → Replace.

SVU3210J

SVU3220J

5. Measure:

• Valve spring tilt a

Tilt limit:

2.5°/1.6 mm (0.06 in)

Out of specification → Replace.

6. Inspect:

• Valve spring contact surface More than 2/3 of the contact surface does not contact → Replace.

LOCKER ARM INSPECTION

1. Inspect:

• Locker arm Wear/damage/cracks → Replace.

SVU3230J

3-30

VALVE

ENG

VALVE SEAT INSPECTION

1. Remove carbon deposits from the valve face and valve seat.

2. Apply a small amount of coarse Mechanic’s blueing dye (Dykem) to the valve face.

3. Insert the valve into the valve guide and use a valve lapper to contact the valve face with the valve seat.

NOTE:

Do not rotate the valve while the valve face is contacting the valve seat.

4. Measure:

• Valve face contact width

Make sure that the contact width along the entire valve face is within specifications.

SVU3240J

SVU3250J

Valve face contact width (intake and exhaust):

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) Limit: 1.6 mm (0.0630 in)

Out of specification/rough/eccentric wear → Replace.

5. Measure:

• Valve seat contact width

Make sure that the contact width along the entire valve seat is within specifications.

Valve seat contact width (intake and exhaust):

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) Limit: 1.6 mm (0.0630 in)

3-31

Out of specification/rough/eccentric wear → Replace.

SVU3270

VALVE

ENG

6. Remove the carbon deposits on the valve face a and valve seat.

• Valve face contact seat width b

• Valve margin thickness c

Apply a small amount of coarse Mechanic’s blueing dye (Dykem) to the valve seat. Press the valve through the valve guide and onto the valve seat to make a clear impression.

• Valve margin thickness

Out of specification → Replace.

• Valve face contact width

Out of specification → Replace.

Valve seat width:

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

Valve margin thickness:

0.3 mm (0.012 in)

SVU3270J

VALVE LAPPING

1. Apply a coarse lapping compound evenly on the valve face. Lap the valve by tapping and rotating the valve lapper

clockwise and counterclockwise.

2. Clean off all of the lapping compound from the valve face and valve seat. Apply fine lapping compound on the valve face and lap the valve as in step 1.

3. If the contact width on the valve face shines white along the entire face, apply Mechanic’s blueing dye (Dykem) to make sure that there are traces of even contact in the center of the valve face.

CAUTION:

Do not let the lapping compound enter the gap between the valve stem and the valve guide.

NOTE:

After every lapping procedure, clean off the compound from the valve face and valve seat.

3-32

SVU3280J

VALVE

VALVE AND VALVE SPRING ASSEMBLY

1. Install:

• Valve 1

• Valve spring 2

• Valve spring retainer 3

• Valve cotter 4

Apply a small amount of molybdenum disulfide oil to the valve stem and use the valve spring compressor 5 to install the parts.

Valve spring compressor:

YM-01253, 90890-01253

NOTE:

Install the chamfered side of the valve cotter facing down.

ENG

New

CAUTION:

Do not compress the valve spring more than necessary.

3-33

CRANKCASE COVER AND CAMSHAFT

ENG

Order Job name/Part name Q’ty Remarks

Crankcase cover and camshaft removal

Engine assembly Refer to “ENGINE ASSEMBLY”. Cylinder head assembly Refer to “CYLINDER HEAD COVER AND

Flywheel magneto Refer to “RECOIL STARTER AND FLY-

Generator assembly Refer to “GENERATOR”. 1 Crankcase cover 1 2Gasket 1 3 Rubber seal 2 4 Dowel pin 2 5Bracket 1 6 Oil level switch 1 7Camshaft 1 8 Valve lifter 2

Remove the parts in the order listed below.

CYLINDER HEAD”.

WHEEL MAGNETO”.

For installation, reverse the removal procedure.

SWL3360

3-34

CRANKCASE COVER AND CAMSHAFT

ENG

CRANKCASE COVER REMOVAL

1. Remove:

• Crankcase cover

NOTE:

Loosen the bolts in the proper sequence.

SWL3370J

CAMSHAFT INSPECTION

1. Inspect:

• Camshaft Damage → Replace.

SVU3480J

2. Measure:

• Cam lobes length a and b Out of specifications → Replace.

Cam lobes length:

Intake

: 26.9 ± 0.05 mm

(1.059 ± 0.002 in)

: 22.0 ± 0.05 mm

(0.866 ± 0.002 in)

SVU3490J

Exhausta: 26.68 ± 0.05 mm

(1.050 ± 0.002 in)

: 22.025 ± 0.05 mm

(0.867 ± 0.002 in)

SVU3500J

SVU3510J

3. Inspect:

• Surface of camshaft gear teeth

• Decompressor

Wear/damage → Replace.

4. Measure:

• Camshaft diameter a Out of specification → Replace.

Camshaft diameter:

14.965 ~ 14.990 mm (0.5892 ~ 0.5902 in)

Wear limit:

14.950 mm (0.5886 in)

3-35

CRANKCASE COVER AND CAMSHAFT

VALVE LIFTER INSPECTION

1. Inspect:

• Valve lifter Damage → Replace.

SVU3520J

CAMSHAFT ASSEMBLY

1. Install:

• Camshaft 1

CAUTION:

Be sure to align the hole a in the camshaft gear with the crankshaft gear mark b.

SVU3530J

ENG

CRANKCASE COVER INSPECTION

1. Inspect:

• Crankcase cover 1 Damage → Replace.

• Bearing 2 Noise/wear/rotational failure → Replace.

SWL3380J

CRANKCASE COVER INSTALLATION

1. Install:

• Crankcase cover bolts 1 to 6

NOTE:

Tighten the bolts to the specified torques in two steps and in order from 1 to 6.

Crankcase cover bolts:

SWL3390J

1st: 12 Nm (1.2 m · kg, 8.7 ft · lb)

2nd: 22 Nm (2.2 m · kg, 16 ft · lb)

3-36

PISTON, CONNECTING ROD, CRANKSHAFT AND

CRANKCASE

ENG

PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE

Order Job name/Part name Q’ty Remarks

Piston, connecting rod, crankshaft and crankcase removal

Engine assembly Refer to “ENGINE ASSEMBLY”. Cylinder head assembly Refer to “CYLINDER HEAD COVER AND

Flywheel magneto Refer to “RECOIL STARTER AND FLY-

Generator assembly Refer to “GENERATOR”. Crankcase cover/camshaft Refer to “CRANKCASE COVER AND

1 Connecting rod cap 1 2 Crankshaft 1 3 Connecting rod 1 4 Piston pin circlip 2 5 Piston pin 1 6Piston 1 7 Piston ring 3

Remove the parts in the order listed below.

CYLINDER HEAD”.

WHEEL MAGNETO”.

CAMSHAFT”.

For installation, reverse the removal procedure.

SWL3500

3-37

PISTON, CONNECTING ROD, CRANKSHAFT AND

CRANKCASE

CRANKCASE (CYLINDER) INSPECTION

1. Measure:

• Cylinder inside diameter

NOTE:

Take side to side a and front to back b measurements at each of the three locations A, B, and C (total of six measurements), and then find the average of the measurements.

Maximum wear = Maximum A, B, C Cylinder taper = Maximum A – Minimum C Out of specification → Replace.

Cylinder inside diameter:

66.005 ~ 66.015 mm

(2.5986 ~ 2.5990 in) Cylinder inside diameter wear limit:

66.020 mm (2.5992 in)

Cylinder taper limit:

SVU3590

0.05 mm (0.0020 in)

ENG

SVU3580J

2. Measure:

• Cylinder warpage

NOTE:

Measure the warpage on the contact surface of the cylinder head at six points using a straightedge and thickness gauge.

Out of specification → Resurface or replace.

Warpage limit:

0.05 mm (0.0020 in)

PISTON AND PISTON PIN INSPECTION

1. Measure:

• Piston skirt diameter P

= 10 mm (0.4 in) from the piston bottom edge

Out of specification → Replace.

SVU3590J

Piston skirt diameter:

65.975 ~ 65.990 mm

(2.5974 ~ 2.5980 in) Wear limit:

65.9 mm (2.5945 in)

3-38

PISTON, CONNECTING ROD, CRANKSHAFT AND

CRANKCASE

2. Measure:

• Piston clearance Out of specification → Rebore or replace cylinder and replace piston and piston rings.

Piston clearance:

0.015 ~ 0.040 mm (0.00059 ~ 0.00157 in)

Wear limit:

0.15 mm (0.00591 in)

Piston clearance =

Cylinder inside diameter – Piston skirt diameter

ENG

SVU3600J

SVU3610J

SVU3620J

3. Measure:

• Piston pin hole inside diameter Out of specification → Replace.

Piston pin hole inside diameter:

16.002 ~ 16.013 mm (0.6300 ~ 0.6304 in)

Wear limit:

16.043 mm (0.6316 in)

4. Measure:

• Piston pin diameter Out of specification → Replace.

Piston pin diameter:

15.995 ~ 16.000 mm (0.6297 ~ 0.6299 in)

Wear limit:

16.043 mm (0.6316 in)

5. Inspect:

• Check that the piston pin enters smoothly into the piston pin hole. If the piston pin fits tightly into the piston, check the piston pin hole. If there is any protrusion, use a knife or scraper to gently remove it so that the piston pin can be pushed in gently with your fingers.

3-39

PISTON, CONNECTING ROD, CRANKSHAFT AND

CRANKCASE

PISTON RING INSPECTION

1. Measure:

• Piston ring end gap Out of specification → Replace.

NOTE:

Insert the piston ring 1 into the cylinder, and push it approximately 5 mm (0.2 in) into the cylinder. Push in the ring with the piston crown so that

SVU3630J

the ring is at right angles to the cylinder bore.

Ring end gap Wear limit

ENG

SVU3640J

Top ring

2nd ring

Oil ring

2. Measure:

• Piston ring side clearance Out of specification → Replace. Use a thickness gauge 1.

Top ring

2nd ring

0.20 ~ 0.40 mm

(0.0079 ~ 0.0157 in)

0.20 ~ 0.40 mm

(0.0079 ~ 0.0157 in)

0.20 ~ 0.70 mm

(0.0079 ~ 0.0276 in)

Piston ring side

clearance

0.04 ~ 0.08 mm (0.0016 ~

0.0031 in)

0.02 ~ 0.06 mm (0.0008 ~

0.0024 in)

0.65 mm

(0.0256 in)

0.75 mm

(0.0295 in)

0.9 mm

(0.0354 in)

Wear limit

0.13 mm

(0.0051 in)

0.12 mm

(0.0047 in)

NOTE:

• Clean carbon deposits from the piston ring grooves and rings before measuring the side clearance.

• Measure the side clearance at several portions.

3-40

PISTON, CONNECTING ROD, CRANKSHAFT AND

CRANKCASE

CRANKSHAFT INSPECTION

1. Measure:

• Crankshaft runout limit Use a dial gauge. Out of specification → Replace.

Runout limit:

0.02 mm (0.0008 in)

SWL3510J

2. Inspect:

• Crankshaft gear 1 Wear/damage → Replace.

ENG

SWL3520J

SWL3530J

3. Measure:

• Crankshaft pin outside diameter Wear/damage → Replace. Use a micrometer. Out of specification → Replace.

Crankshaft pin outside diameter:

27.969 ~ 27.984 mm (1.1011 ~ 1.1017 in)

Wear limit:

27.9 mm (1.0984 in)

3-41

PISTON, CONNECTING ROD, CRANKSHAFT AND

CRANKCASE

CONNECTING ROD OIL CLEARANCE INSPECTION

NOTE:

Measure the oil clearance if replacing the crankshaft or connecting rod.

1. Place a piece of Plastigauge 1 on the crankshaft pin horizontally.

ENG

SVU3680J

SVU3690J

SVU3700J

NOTE:

Clean off oil from all parts thoroughly.

2. Install:

• Connecting rod 1

• Connecting rod cap 2

NOTE:

Tighten the cap bolts so that the crankshaft does not move while the oil clearance is being measured.

Connecting rod cap bolt:

12 Nm (1.2 m · kg, 8.7 ft · lb)

3. Remove:

• Connecting rod cap

• Connecting rod

4. Measure:

• Widest portion of the pressed Plasti-

gauge Out of specification → Replace crankshaft or connecting rod, and then measure the clearance again.

3-42

Connecting rod big end oil clearance:

0.015 ~ 0.040 mm (0.0006 ~ 0.0016 in)

Wear limit:

0.1 mm (0.0039 in)

PISTON, CONNECTING ROD, CRANKSHAFT AND

CRANKCASE

PISTON RING AND PISTON ASSEMBLY

1. Install:

• Top ring 1

• 2nd ring 2

• Oil ring 3

NOTE:

• Be sure to install the second ring so that the manufactures mark a faces towards the piston head.

• Make sure that the piston rings move smoothly.

2. Apply 4-stroke engine oil to the inside of the connecting rod small end.

ENG

SVW3770

SVU3720J

3. Install:

• Piston 1

• Piston pin 2

• Piston pin circlip 3

New

NOTE:

• Make sure that the “YAMAHA” mark a on the connecting rod faces toward the crankcase cover.

• Make sure that the “” mark b on the pis- ton head faces toward the push rod.

3-43

PISTON, CONNECTING ROD, CRANKSHAFT AND

CRANKCASE

CRANKSHAFT ASSEMBLY

1. Make sure that the end gap of each piston ring is positioned, as shown in the illustration.

Top ring a

2nd ring b

ENG

SVU3750J

SVU3730J

SVU3740J

Oil ring c

2. Install:

• Piston ring compressor 1

Piston ring compressor:

YU-33294, 90890-05158

3. Install:

• Connecting rod 1

• Piston 2

NOTE:

• Make sure that the “” mark a on the pis- ton head faces toward the push rod.

• Make sure that the “YAMAHA” mark b on the connecting rod faces toward the crankcase cover.

SVU3760J

4. Install:

• Crankshaft

• Connecting rod cap

NOTE:

Make sure that the “” mark a on the connecting rod is aligned with the “” mark b on the rod cap.

Connecting rod cap bolt:

12 Nm (1.2 m · kg, 8.7 ft · lb)

5. Install:

• Camshaft

• Crankcase cover

Refer to “CRANKCASE COVER AND CAMSHAFT”.

3-44

CARBURETOR

ENG

Order Job name/Part name Q’ty Remarks

Carburetor removal

Panel 4/cover 5 Refer to “COVERS, PANELS, AND

Slide the fuel tank Refer to “FUEL TANK AND CONTROL

Air filter assembly Refer to “AIR FILTER ASSEMBLY AND

1 Choke cable 1 2 Choke knob 1 3 Fuel hose 1 4 Throttle control motor cover 1 5 Throttle control motor coupler 1 6 Carburetor 1 7Gasket 1

Remove the parts in the order listed below.

CAPS” in CHAPTER 2.

BOX”.

CONTROL UNIT” and “AIR FILTER ASSEMBLY, CONTROL UNIT AND NOISE FILTER”.

SWL3400

3-45

CARBURETOR

ENG

Order Job name/Part name Q’ty Remarks

8 Carburetor joint 1 9Gasket 1

For installation, reverse the removal procedure.

SWL3400

3-46

CARBURETOR

ENG

Order Job name/Part name Q’ty Remarks

1 2 3 4 5 6 7 8 9

Carburetor disassembly

Throttle control motor assembly 1 Throttle controller bracket 1 Bracket 1 Drain hose 1 Bolt 1 Gasket 1 Drain screw 1 Float chamber 1 Gasket 1

3-47

Remove the parts in the order listed below.

SWL3410

CARBURETOR

ENG

Order Job name/Part name Q’ty Remarks

0 A B C D E F G H

Float pin 1 Float 1 Needle valve 1 Main nozzle 1 Main jet 1 Air vent hose 1 Throttle stop screw 1 Pilot screw 1 Pilot jet 1

For assembly, reverse the disassembly procedure.

3-48

SWL3410

SVU3790J

SVU3800J

CARBURETOR

ENG

FLOAT HEIGHT INSPECTION

1. Measure:

• Float height Out of specification → Replace.

NOTE:

Lift up the float height so that the tip of the needle valve lightly contacts the float arm, and then measure the float height a. (This measurement should be made with the gasket removed.)

Float height:

16.0 mm (0.63 in)

SVU3810J

SVU3820J

2. Clean:

• Carburetor body Blow out all passages, jets, and carburetor body with compressed air.

3. Inspect:

• Valve seat Wear/damage → Replace. Dirt → Clean.

Wear at groove

Dirt

3-49

CARBURETOR

ENG

CHOKE CABLE INSTALLATION

1. Inspect:

• Choke knob 1

NOTE:

Push the choke knob 1 entirely in before installing it to the frame.

2. Install:

• Casing cap (choke cable) 2

NOTE:

Place the choke knob casing cap against the stay 3.

3. Install:

• Inner cable 4

NOTE:

Place the carburetor choke valve in its fully open position a, insert the tip of the inner cable into the drum hole 5, and then secure it in place with the screw 6.

Screw:

1.0 Nm (0.1 m · kg, 0.7 ft · lb)

SWL3420J

SVU3840J

THROTTLE CONTROL MOTOR

1. Inspect:

• Throttle control motor 1

NOTE:

• Install the shaft a of the throttle control motor by aligning it with the groove

b of the

throttle shaft.

• Install the throttle valve, and then make sure that is moves smoothly.

• When installing the engine, fully open the throttle valve.

3-50

TROUBLESHOOTING

ENGINE DOES NOT START

TROUBLESHOOTING

ENG

Check that the oil level warning light turns on by pulling the starter rope.

LIGHT ON

Check engine oil level.

SUFFICIENT

Check fuel level.

SUFFICIENT

Check if fuel is deteriorated.

GOOD NOT GOOD Replace.

Check fuel cock lever position.

“ON”“OFF” Set to “ON”.

Check if fuel travels to fuel cock.

GOOD NOT GOOD

Remove spark plug, attach it to spark plug cap, and then ground the spark plug to check for spark.

GOOD

SPARK

DOSE NOT

TURN ON

INSUFFI-

CIENT

INSUFFI-

CIENT

WEAK OR

NO SPARK

Check connections between engine speed limiter/oil level warning unit and oil level switch.

GOOD NOT GOOD

• Check spark plug for dirt and check spark plug gap.

• Check for voltage leakage due to faulty connection or broken insulation of the spark plug lead.

• Check TCI unit coupler for corrosion or faulty connection.

• Check the ignition system. Refer to “IGNITION SYSTEM” in CHAPTER 4.

GOOD NO GOOD

Replace oil level warning light, engine speed limiter/oil level warning unit, or oil level switch.

Add.

Clean fuel tank, fuel cock, and fuel pipe strainer.

Clean. Correct. Replace.

Check carburetor for clogged passages or fuel overflow.

GOOD NO GOOD Clean.

Check compression using compression gauge.

OUT OF

SPECIFICA-

TION

GOOD

3-51

TROUBLESHOOTING

ENG

Measure valve clearance.

OUT OF

GOOD

Check valve face and valve seat for wear.

GOOD WEAR

Check if the timing marks on the crankshaft and camshaft are aligned.

GOOD NO GOOD Correct or replace.

Check if there is seizure or wear on the piston, piston ring, or cylinder.

GOOD

SPECIFICA-

TION

SEIZURE

OR WEAR

Adjust.

Resurface or replace.

Rebore or replace.

Check the condition of the throttle control system. Refer to “THROTTLE CONTROL SYSTEM”.

3-52

TROUBLESHOOTING

ENG

ENGINE STARTS BUT STALLS

Check fuel level.

SUFFICIENT

Check if fuel cock is clogged.

GOOD NO GOOD Clean.

Check if fuel pipe, fuel hose and fuel pipe strainer are clogged.

GOOD NO GOOD Clean.

INSUFFI-

CIENT

Add.

• Check if carburetor retaining nuts are loose.

• Check if there is air suction due to a damaged carburetor joint or gasket.

GOOD NO GOOD

Measure valve clearance.

OUT OF

GOOD

Check compression using a compression gauge.

GOOD

Check if there are air gap between TCI unit and flywheel magneto.

GOOD

SPECIFICA-

TION

OUT OF

SPECIFICA-

TION

OUT OF

SPECIFICA-

TION

Improperly tightened cylinder head

• Tighten the carburetor bolts securely.

• Replace carburetor joint or gasket with a new one.

Adjust.

Tighten securely.

Adjust.

Check the condition of the throttle control system. Refer to “THROTTLE CONTROL SYSTEM”.

3-53

TROUBLESHOOTING

ENG

ENGINE SPEED DOES NOT INCREASE

Check if the electric equipment consumes too much wattage for this generator.

GOOD TOO MUCH Use a generator with a larger capacity.

Check air filter element for dirt.

GOOD NOT GOOD Clean.

Check spark plug for dirt and check spark plug gap.

GOOD NOT GOOD Clean or adjust.

Check valve clearance.

GOOD

Check if main passages such as, the main jet, in the carburetor are clogged.

GOOD NO GOOD Disassemble or clean.

OUT OF SPECI-

FICATION

Adjust.

Check for air suction due to a damaged throttle shaft seal, carburetor joint, or gasket.

GOOD NO GOOD Disassemble or replace.

Check compression using compression gauge.

GOOD

Check if the timing marks on the crankshaft and camshaft are aligned.

GOOD NO GOOD Correct.

Check valve face and valve seat for wear.

GOOD WEAR Resurface or replace.

Check if there is seizure or wear on piston, piston ring, or cylinder.

GOOD

TOO HIGH Decarbonize combustion chamber if there are

TOO LOW

SEIZURE OR

WEAR

carbon deposits.

Rebore or replace.

Check the condition of the throttle

control system. Refer to “THROT- TLE CONTROL SYSTEM”.

3-54

TROUBLESHOOTING

ENGINE SPEED IS UNEVEN

Check fuel level.

SUFFICIENT INSUFFICIENT Add.

Check if fuel is deteriorated.

GOOD NO GOOD Replace.

Check if fuel cock, fuel pipe, fuel hose and fuel pipe strainer are clogged.

GOOD NO GOOD Clean.

Check spark plug for dirt and check spark plug gap.

GOOD NO GOOD Clean or adjust.

Measure valve clearance.

GOOD

OUT OF SPECI-

FICATION

Adjust.

ENG

While the engine is operating, pull the choke knob approximately 1/3 to 1/2 way out, and then check the engine operating condition.

STABLE UNSTABLE

Check for air suction due to a damaged throttle shaft seal, carburetor joint, or gasket.

GOOD NO GOOD Disassemble or replace.

Check if slow or main passages such as, the pilot jet and main jet, in the carburetor are clogged.

GOOD NO GOOD Disassemble or clean.

Check valve face and valve seat

for wear.

GOOD WEAR Resurface or replace.

Check if there is seizure or wear on the piston, piston ring, or cylinder.

GOOD

SEIZURE OR

WEAR

Rebore or replace.

Check the condition of the throttle control system. Refer to “THROT- TLE CONTROL SYSTEM”.

3-55

TROUBLESHOOTING

ENG

THROTTLE CONTROL SYSTEM

ENGINE DOES NOT START, ENGINE STARTS BUT STALLS, ENGINE SPEED DOES NOT INCREASE, OR ENGINE SPEED IS UNEVEN.

Check AC output.

GOOD NO GOOD Refer to “GENERATOR SYSTEM” in CHAPTER 4.

Rotate the shaft of the throttle control motor to check if it turns smoothly with slight resistance.

GOOD NO GOOD Replace the throttle control motor.

Measure the coil resistance between 3-1, 3-2, 3-4, and 3-5 of the throttle control motor. (Tester range: Ω × 100) 250 Ω ± 7% /25 °C (77 °F)

54321

GOOD

Check the connections of the wire harness connectors and couplers, and the wires for an open circuit or short circuit.

GOOD NO GOOD Correct or replace.

Defective control unit. Replace the control unit.

OUT OF SPECIFI-

CATION

SVU3850J

Replace the throttle control motor.

3-56

TROUBLESHOOTING

ENG

WITH NO LOAD, ENGINE SPEED DOES NOT INCREASE WHEN ECONOMY CONTROL SWITCH IS SET TO “OFF” “”. WITH NO LOAD, ENGINE SPEED DOES NOT DECREASE WHEN ECONOMY CONTROL SWITCH IS SET TO “ON” “”. WITH LOAD, ENGINE SPEED DOES NOT INCREASE WHEN ECONOMY CONTROL SWITCH IS SET TO “ON” “”.

Check AC output.

GOOD NO GOOD Refer to “GENERATOR SYSTEM” in CHAPTER 4.

Check condition of the throttle control motor.

GOOD NO GOOD Replace throttle control motor.

Check economy switch.

GOOD NO GOOD Replace economy switch.

Check the connections of the wire harness connectors and couplers, and the wires for an open circuit or short circuit.

GOOD NO GOOD Correct or replace.

Defective control unit. Replace the control unit.

3-57

B A

ELECTRICAL COMPONENTS

ELECTRICAL

ELECTRICAL COMPONENTS

120 V-60 Hz

Generator assembly

Oil level switch

Starter motor

Control unit

Charging coil

Starter relay

Rectifier

Battery

Flywheel magneto

TCI unit

Spark plug

Throttle control motor

DC rectifier

Main switch

Economy switch

Engine speed limiter/oil level warning unit

DC circuit breaker

DC receptacle (12 V, 8.3 A)

AC switch (NFB) (15 A)

AC switch (NFB) (23.5 A)

AC receptacle (15 A × 2)

AC receptacle (23.3 A)

Ground terminal

Overload warning light (Red)

Pilot light (Green)

Oil level warning light (Red)

SWL4090T

SWL4080T

ELEC

– +

SWL4010T

4-1

B A

ELECTRICAL COMPONENTS

220 V-50 Hz

Generator assembly

Oil level switch

Starter motor

Control unit

Charging coil

Starter relay

Rectifier

Battery

Flywheel magneto

TCI unit

Spark plug

Throttle control motor

DC rectifier

Main switch

Economy switch

Engine speed limiter/oil level warning unit

DC receptacle (12 V, 12 A)

AC receptacle (15 A × 2)

Ground terminal

Overload warning light (Red)

Pilot light (Green)

DC circuit breaker

Oil level warning light (Red)

SWL4090T

SWL4080T

ELEC

– +

SWL4020T

4-2

YAMAHA EF3000i SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual