YAMAHA EF3000i SERVICE MANUAL

SERVICE MANUAL

EF3000iSE

7WL-28197-E0

310140

FOREWORD

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.

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

HOW TO USE THIS MANUAL

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.

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

WARNING

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

CAUTION:

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

NOTE:

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

MANUAL FORMAT

The procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,

•Bearings

Pitting/damage → Replace.

EXPLODED DIAGRAM

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

1		2
GEN		INSP
INFO		ADJ
3		4
ENG		ELEC –		+
5
SPEC
6		7
8		9
			T
			.
			R
			.
0		A
B
C	D	E
E		G	M
F	G	H
B		LS	M
I	J	K
LT		4	New

ILLUSTRATED SYMBOLS (Refer to the illustration)

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

1 General information

2 Periodic inspections and adjustments

3Engine

4Electrical

5Specifications

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

6 Filling fluid

7Lubricant

8Special tool

9Tightening

0 Wear limit, clearance A Engine speed

B Ω, V, A

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

C Apply engine oil D Apply gear oil

E Apply molybdenum disulfide oil F Apply wheel bearing grease

GApply lightweight lithium-soap base grease

HApply molybdenum disulfide grease

IApply a locking agent (LOCTITE®)

JApply Yamaha bond

KUse a new one

INDEX

GENERAL

INFORMATION

PERIODIC INSPECTIONS AND ADJUSTMENTS

ENGINE

ELECTRICAL

SPECIFICATIONS

CHAPTER 1.

GENERAL INFORMATION

MACHINE IDENTIFICATION ....................	1-1
SERIAL NUMBER ...............................	1-1
STARTING SERIAL NUMBER ............	1-1
IMPORTANT INFORMATION ..................	1-2
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 ...........	1-4

CHAPTER 2.

PERIODIC INSPECTIONS

AND ADJUSTMENTS

INTRODUCTION .......................................	2-1
MAINTENANCE INTERVALS CHART
(For Canada) ............................................	2-1
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS ....................	2-1
COVERS, PANELS, AND CAPS ..............	2-2
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

ELECTRICAL .........................................	2-18
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

CHAPTER 3.

ENGINE

PANELS AND COVERS ..........................	3-1
CONTROL PANEL ...................................	3-3
FUEL TANK AND CONTROL BOX .........	3-5
AIR FILTER ASSEMBLY
AND CONTROL UNIT ..............................	3-7
120 V-60 Hz, 220 V-50 Hz ..................	3-7
AIR FILTER ASSEMBLY, CONTROL UNIT
AND NOISE FILTER ................................	3-8
230 V-50 Hz ........................................	3-8
RECOIL STARTER
AND FLYWHEEL MAGNETO ..................	3-9
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 .............................	3-17
CHASSIS AND CASTERS .....................	3-18
MUFFLER ..............................................	3-19
MUFFLER INSTALLATION ...............	3-20

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

		GEN
	MACHINE IDENTIFICATION INFO
		GENERAL INFORMATION
		MACHINE IDENTIFICATION
		SERIAL NUMBER
		The serial number is printed on a label 1
		which is affixed to the generator as shown.
		NOTE:
1		The first three characters of this number are
		for model identification, the remaining digits
	SWL1010T
		are the unit production number.

SWL1020J

STARTING SERIAL NUMBER

	Model	Code	Starting serial
			number
	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.

1-1

GEN

IMPORTANT INFORMATION INFO

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

CAUTION ON SERVICE

1.Fire prevention

When servicing the engine, always keep the engine and yourself

SVU1030

away from fire.

NOTES ON SERVICE

1.Correct tools

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

SVU1040

2.Oil, grease and seals

Be sure to use genuine Yamaha oils, grease and sealers, or the

equivalents.

SVU1050

3.Expendable parts

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

SVU1060

SVU1070

SVU1080

SVU1090

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 compressed air after disassembly.

b.Contact surfaces of moving parts should be oiled when reassembled.

c.Make sure that the parts move smoothly after each section of the machine is assembled.

SVU1100

1-2

		IMPORTANT INFORMATION			GEN
					INFO
		ALL REPLACEMENT PARTS
		We recommend the use of genuine Yamaha parts for all replace-
		ments. 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 O-
		rings 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 let-
		ters must be on the side exposed to view.) When installing oil
		seal(s), apply a light coating of light-weight lithium base grease to
SVU1110		the seal lip(s). Oil the bearings liberally when installing.
		CAUTION:
		Do not use compressed air to spin the bearings dry. This
		causes damage to the bearing surfaces.
SVU1120

1-3

GEN

SPECIAL TOOLS AND TESTERS INFO

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.

SVU1130

2.Valve spring compressor P/N. YM-01253, 90890-01253

This tool is used to remove the valve springs.

SVU1140

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.

SVU1150

4.Cylinder gauge Commercially available

This instrument is used for checking cylinder bore size and condition.

SVU1160

1-4

		SPECIAL TOOLS AND TESTERS		GEN
				INFO
		5. Inductive self-powered tachometer
1
		1 P/N. YU-8036-B
		Engine tachometer
		2 P/N. 90890-03113
		3 P/N. 90793-80009
	SWL1010	4 P/N. 90793-80032

		This instrument is used for reading engine r/min.
	2

SWL1020

3

SWL1040

4

SWL1050

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.

SVU1180

7.Dial gauge

P/N. YU-03097, 90890-03097

This instrument is used for checking crankshaft side clearance.

SVU1190

8.Piston pin puller

P/N. YU-01304, 90890-01304

This tool is used to remove the piston pin.

SVU1200

9.Sheave holder

P/N. YS-01880-A, 90890-01701

This tool is necessary for holding the flywheel or rotor.

SVU1205

1-5

		SPECIAL TOOLS AND TESTERS		GEN
				INFO
		10.Rotor assembly holder
		Commercially available
		This tool is necessary for holding the rotor.
	SWL1030
		11.Rotor puller
1
		1 P/N. YU-33270-B
		2 P/N. 90890-01362
		This tool is necessary for removing the flywheel.
	SVU1210

2

SVU1220

SVU1230

1

SVU1240

2

SVU1250

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.

14.MF Battery charging Commercially available

This instrument is necessary for charging the electrical system.

SWL1060

1-6

INTRODUCTION/MAINTENANCE INTERVALS CHART (For Canada)/

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INSP ADJ

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

	È		É	Ê	Ë	Ì	Í	Î
				Pre-Opera-	Initial	Every	Every	Every
	Item		Remarks	tion check	1 month	3 months	6 months	12 months
				(daily)	or 20 Hr	or 50 Hr	or 100 Hr	or 300 Hr
Ï *Spark Plug		Check condition. Adjust gap and clean.				●
		Replace if necessary.
Ð *Valve Clearance		Check and adjust when engine is cold.						●
Ñ	*Crankcase breather	Check breather hose for cracks or damage.						●
	system	Replace if necessary.
Ò *Idle speed		Check and adjust engine idle speed.						●
		Ô	Check for leakage.	●
Ó *Exhaust System			Retighten or replace gasket if necessary.
		Õ	Check muffler screen and spark arrester.					●
			Clean/replace if necessary.
Ö Engine Oil		× Check oil level.		●
		Ø Replace.			●		●
Ù *Air Filter		Clean.				●
		Replace if necessary.
Ú Fuel Filter		Clean fuel tank filter.					●
		Replace if necessary.
Û Fuel Line		Check fuel hose for crack or damage. Replace		●
		if necessary.
Ü *Choke knob		Check choke operation.		●
Ý Cooling System		Check for fan damage.						●
Þ Starting System		ß Check recoil starter operation.		●
		À Check electric starter operation.		●
Á *Decarbonization		More frequently if necessary.						●
+ Generation		Check the pilot light comes on.		●
, Fittings/Fasteners		Check all fittings and fasteners.					●
		Correct if necessary.

*: Related to emission control system.

2-1

INSP

COVERS, PANELS, AND CAPS ADJ

COVERS, PANELS, AND CAPS

Front right view			Rear left view
1			9
			8
7		2	0
			C
6	3		B
5			A
4
			SWL2180T

1 Cover 1	7.0 Nm (0.7 m · kg, 5.1 ft · lb)
2 Panel 1
	7.0 Nm (0.7 m · kg, 5.1 ft · lb)
3 Cover 2
	7.0 Nm (0.7 m · kg, 5.1 ft · lb)
4 Cover 3
	7.0 Nm (0.7 m · kg, 5.1 ft · lb)
5 Cap 1
6 Cap 2
7 Panel 2
8 Cover 4
	7.0 Nm (0.7 m · kg, 5.1 ft · lb)
9 Cover 5
	7.0 Nm (0.7 m · kg, 5.1 ft · lb)
0 Panel 3
	7.0 Nm (0.7 m · kg, 5.1 ft · lb)
A Battery bracket
	7.0 Nm (0.7 m · kg, 5.1 ft · lb)
B Panel 4
C 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

ENGINE OIL LEAKAGE CHECKING/
		INSP
OIL LEVEL CHECKING		ADJ

	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”.

		OIL LEVEL CHECKING
		1. Check:
	1	• 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 warn-
			ing light 1 flashes.
			Oil level warning light flashes → Add
		SWL2010T	oil.
			Oil level warning light does not flash		→
			OK
	1	2. Remove:
	a	•	Panel 2
			Refer to “COVERS, PANELS, AND
			CAPS”.
		• Oil filler cap 1
		3. Check:
		• Check that the engine oil is at the spec-
		SWL2040J	ified 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

OIL LEVEL CHECKING/ OIL REPLACEMENT

INSP ADJ

1

SWL2050J

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 1

6.Tilt the engine to drain the oil completely.

7.Tighten:

•Oil drain bolt

	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
	1	Ê SAE #20
		Ë SAE 10W
SWL2060J
		Engine oil quantity:
È		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

OIL REPLACEMENT/ FUEL LEAKAGE

INSP ADJ

É					Recommended oil:
					È SAE #30	or 10W-30
						or 10W-40
					É SAE #20	or 10W-30
						or 10W-40
					Ê SAE 10W	or 10W-30
						or 10W-40
					SAE #40: Above 35 °C (95 °F)
					Engine oil quantity:
SVW2070T					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”.
		È For Canada
		É 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

FUEL LEAKAGE/ FUEL TANK FILTER

INSP ADJ

		4. Check:
			•	Leakage
				Check at fuel tank, fuel cock, fuel
				hoses, and carburetor.
		CAUTION:
		Replace the fuel hoses every four years.
	5.		Install:
SWL2070J			•	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:
1		• Fuel tank cap 1
		• Fuel tank filter 2
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

FUEL PIPE STRAINER

FUEL PIPE STRAINER

INSP ADJ

	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.
4.	Remove:
1	•	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
SWL2080J		BOX” in CHAPTER 3.
9.	Install:
	•	Cover 4
	•	Cover 5
	•	Cover 1
		Refer to “COVERS, PANELS, AND
		CAPS”.

2-7

INSP

AIR FILTER ELEMENT ADJ

1
2
1
SWL2090J
2
1
SVU2100J
SWL2110

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.

2-8

AIR FILTER ELEMENT/ MUFFLER

INSP ADJ

SWL2120J
2		2
	1	4
a
b	6	3
		5

8.Install:

•Air filter element case 1

•Hooks 2

NOTE:

•Align the projection a of the air filter case 1 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

MUFFLER/ VALVE CLEARANCE ADJUSTMENT

INSP ADJ

SWL2410J

4	2
	1
3	SWL2130J

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 muffler.

CAUTION:

Do not use a wire to clean the muffler, otherwise the noise damping material may come out, and the damping effect may be reduced.

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.

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

VALVE CLEARANCE ADJUSTMENT ADJ

SWL2140J

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.

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):

SWL2150J 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

VALVE CLEARANCE ADJUSTMENT ADJ

2

1

SWL2160J

1

2
SWL2170J
1	3
	4
2	SWL2180J

5.Adjust:

• Valve clearance

Adjustment steps:

•Loosen the locknut 1.

•Turn the adjuster 2 in or out to obtain the proper clearance.

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	Spark plug:
R
.
	18 Nm (1.8 m · kg, 13 ft · lb)

7.Install:

•Panel 4

Refer to “COVERS, PANELS, AND CAPS”.

2-12

AIR GAP BETWEEN TCI UNIT AND FLYWHEEL MAGNETO

INSP ADJ

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.

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
SWL2420J	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.

T .

R .

Air gap between TCI unit and flywheel magneto:

0.5 ± 0.1 mm (0.020 ± 0.004 in)

TCI unit bolt:

10 Nm (1.0 m · kg, 7.2 ft · lb)

2-13

AIR GAP BETWEEN TCI UNIT AND FLYWHEEL MAGNETO/COMPRESSION PRESSURE

INSP ADJ

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.

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:
2	1	•	Compression gauge 1
		•	Adapter 2
			Compression gauge:
			YU-33223, 90890-03081
			Adapter:
			YU-33223-3, 90890-04082
	SWL2190J
		2-14

INSP

COMPRESSION PRESSURE ADJ

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 com-

pression gauge.

Standard compression pressure: 400 ~ 600 kPa

(4 ~ 6 kg/cm2, 57 ~ 85 psi)

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.

	Reading		Diagnosis
	If higher than	•	Worn cylinder, piston, and
	without oil		piston ring
		•	Defective piston, ring(s),
	If the same as		valve(s), and cylinder
			head gasket
	without oil
		• 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

T .

R .

Spark plug:

18 Nm (1.8 m · kg, 13 ft · lb)

7.Install:

•Panel 4

Refer to “COVERS, PANELS, AND CAPS”.

2-15

ENGINE SPEED (NO LOAD)/ ECONOMY ENGINE SPEED

INSP ADJ

	ENGINE SPEED (NO LOAD)
	1. Remove:
	•	Panel 4
		Refer to “COVERS, PANELS, AND
		CAPS”.
1	2. Connect:
	• Inductive self-powered		tachometer	or
		engine tachometer 1
	SWL2200J	Inductive self-powered tachome-
		ter:
		YU-8036-B
		Engine tachometer:
		90890-03113
		(90793-80009, 90793-80032)

ÈÉ

a

1 a

1

SWL2020T

1

SWL2200J

3.Inspect:

•Engine speed (no load) Specified engine speed → OK

Out of specification → Refer to “TROUBLESHOOTING” 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

É230 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

Inductive self-powered tachometer:

YU-8036-B Engine tachometer:

90890-03113

(90793-80009, 90793-80032)

2-16

ECONOMY ENGINE SPEED/ CHOKE CABLE/BREATHER HOSE

INSP ADJ

ÈÉ

a a

1 1

SWL2050T

1

SWL2430J

3.Inspect:

•Economy engine speed Specified engine speed → OK

Out of specification → Refer to “TROUBLE 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

É230 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.

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
1		Cracks/damage → Replace.
		Poor connection → Correct.
3.	Install:
	•	Panel 4
		Refer to “COVERS, PANELS, AND
SWL2220J		CAPS”.

2-17

SPARK PLUG

ELECTRICAL

SPARK PLUG

WARNING

INSP ADJ

SVU2240J

SVU2250J

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)

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