Honda EU3000i Handi Manual Download Page 2

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CONTENTS

SPECIFICATIONS

SERVICE INFORMATION

MAINTENANCE

TROUBLESHOOTING

COVER

FUEL SYSTEM

GOVERNOR SYSTEM

GENERATOR/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

OTHER ELECTRICAL

MUFFLER

GENERATOR/ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD

CYLINDER BLOCK

TECHNICAL FEATURES

WIRING DIAGRAMS

INDEX

Summary of Contents for EU3000i Handi

Page 1: ...iate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields anytime you hammer drill grind or wo...

Page 2: ...ESHOOTING 4 COVER 5 FUEL SYSTEM 6 GOVERNOR SYSTEM 7 GENERATOR CHARGING SYSTEM 8 IGNITION SYSTEM 9 STARTING SYSTEM 10 OTHER ELECTRICAL 11 MUFFLER 12 GENERATOR ENGINE REMOVAL INSTALLATION 13 CYLINDER HEAD 14 CYLINDER BLOCK 15 TECHNICAL FEATURES 16 WIRING DIAGRAMS 17 INDEX ...

Page 3: ...t practical or possible to warn you about all the hazards associated with servicing these products You must use your own good judgement Honda Motor Co Ltd SERVICE PUBLICATION OFFICE Date of Issue May 2009 You will find important safety information in a variety of forms including Safety Labels on the product Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARN...

Page 4: ...s and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the unit SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it will be explained specifically in the text without the use of the symbols Replace the part s with new one s before assembl...

Page 5: ...ne Block Temperature ECT Engine Coolant Temperature ECM Engine Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground HO2S Heated Oxygen sensor IAB Intake Air Bypass IAC Idle Air Control IAT Intake Air Temperature I D Inside diameter IG or IGN Ignition IN Intake INJ Injection L Left MAP Manifold Absolute Pressure MIL Malfunction Indicator L...

Page 6: ...1 1 1 1 SPECIFICATIONS SERIAL NUMBER LOCATION 1 2 SPECIFICATIONS 1 2 PERFORMANCE CURVES 1 5 DIMENSIONAL DRAWINGS 1 8 ...

Page 7: ...l GX160K1 Description code GCAAK Type 4 stroke overhead valve single cylinder inclined by 25 Displacement 163 cm3 9 9 cu in Bore x stroke 68 0 x 45 0 mm 2 68 x 1 77 in Compression ratio 8 5 0 3 Ignition system Transistor magneto ignition Ignition timing B T D C 25 3000 min 1 rpm Spark plug BPR6ES NGK W20EPR U DENSO Lubrication system Forced spray Oil capacity 0 53 0 56 US qt 0 47 Imp qt Recommende...

Page 8: ...drip proof type Excitation Self excitation Voltage regulation system PWM Pulse width modulation Phase Single phase Rotating direction Clockwise Viewed from the generator Rated output AC 2 600 VA DC 100 W Rated frequency 50 Hz 60 Hz 50 Hz AC Rated voltage 230 V 220 V Rated current 11 3 A 11 8 A DC Rated voltage 12 V Rated current 8 3 A Power factor 1 0 Cosθ Model EU30i Type U L LT RH RG Description...

Page 9: ...ate Momentary 1 max Average 1 max Average time 1 sec max Frequency stability 0 1 Hz max Insulation resistance 10 MΩ min AC circuit protector 15 4 A 16 1 A DC circuit protector 10 A Insulation type Type F Fuel tank capacity 5 9 1 56 US gal 1 30 Imp gal Fuel consumption 1 68 0 444 US gal 0 370 Imp gal Hr Max operating hours at rated load 3 5 Hr Guaranteed sound power level LWA LWA 92 dB A LPA 74 dB ...

Page 10: ...re and humidity The output voltage will be higher than usual when the generator is still cold immediately after the engine starts AC EXTERNAL CHARACTERISTIC CURVES GW G G8 F IT RG RH TYPE S S8 SK R TYPE 2 OUTPUT VOLTAGE V AC 250 245 240 235 230 225 220 215 4 6 8 10 12 14 LOAD CURRENT A 16 2 OUTPUT VOLTAGE V AC 240 235 230 225 220 215 210 205 4 6 8 10 12 14 LOAD CURRENT A 16 ...

Page 11: ...FICATIONS 1 6 U TYPE C L LT TYPE 2 OUTPUT VOLTAGE V AC 255 250 245 240 235 230 225 220 4 6 8 10 12 14 LOAD CURRENT A 16 5 OUTPUT VOLTAGE V AC 135 130 125 120 115 110 105 100 10 15 20 25 30 35 LOAD CURRENT A ...

Page 12: ...NAL CHARACTERISTIC CURVE This DC output characteristic was measured with the condition that condensers 200 000 μF were parallel connected DC 30 28 26 24 22 20 18 16 14 12 10 OUTPUT VOLTAGE V LOAD CURRENT A 1 2 3 4 5 6 7 8 9 10 11 ...

Page 13: ...SPECIFICATIONS 1 8 DIMENSIONAL DRAWINGS Unit mm in 468 18 4 379 14 9 91 3 6 445 17 5 538 21 2 489 19 3 622 24 5 480 18 9 ...

Page 14: ...2 1 2 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 3 LUBRICATION SEAL POINT 2 4 TOOLS 2 5 CABLE HARNESS ROUTING 2 7 ...

Page 15: ...d I D 30 020 30 033 1 1819 1 1824 30 066 1 1837 Big end oil clearance 0 040 0 063 0 0016 0 0025 0 12 0 005 Big end side clearance 0 1 0 4 0 004 0 016 1 1 0 043 Crankshaft Crank pin O D 29 970 29 980 1 1799 1 1803 29 920 1 1780 Valves Valve clear ance IN 0 15 0 02 EX 0 20 0 02 Valve stem O D IN 5 468 5 480 0 2153 0 2157 5 318 0 2094 EX 5 425 5 440 0 2136 0 2142 5 275 0 2077 Guide to stem clearance ...

Page 16: ...1 0 2 3 0 23 1 7 Air cleaner connecting tube screw M4 x 0 7 0 7 0 07 0 5 Resonator cover screw 5 x 25 mm M5 Screw 1 4 0 14 1 Resonator cover screw 5 x 30 mm M5 Screw 2 8 0 28 2 Spark arrester screw M4 Screw 2 2 0 22 1 6 Muffler hex nut M8 x 1 25 24 2 4 18 Muffler bracket nut M6 x 1 0 8 3 0 85 6 1 Fan cover nut M6 x 1 0 8 3 0 85 6 1 Handle cover screw M6 x 1 0 4 4 0 45 3 3 Front cover screw M6 x 1 ...

Page 17: ...kgf m lbf ft Screw 3 mm 1 0 1 0 7 4 mm 2 0 2 1 5 5 mm 4 0 4 2 9 6 mm 9 0 9 6 6 Bolt and nut 5 mm 5 0 5 3 6 6 mm 10 1 0 7 8 mm 22 2 2 16 10 mm 34 3 5 25 12 mm 54 5 5 40 Flange bolt and nut 4 mm 3 4 0 35 2 5 5 mm 5 0 5 3 6 6 mm 11 1 1 8 8 mm 26 2 7 20 10 mm 39 4 0 29 SH Small head flange bolt 6 mm 9 0 9 6 6 CT Cutting threads flange bolt Retightening 5 mm 5 4 0 55 4 0 6 mm 10 1 0 7 Location Material...

Page 18: ...achment 37 40 07746 0010200 Bearing driver attachment 52 55 07746 0010400 Pilot 25 07746 0040600 Driver handle 15 135L 07749 0010000 Seat cutter 24 5 07780 0010100 Seat cutter 27 5 07780 0010200 Flat cutter 25 07780 0012000 Flat cutter 28 07780 0012100 Interior cutter 30 07780 0014000 Cutter holder 5 5 07781 0010101 ...

Page 19: ...SERVICE INFORMATION 2 6 Flywheel puller set 07935 8050004 Bearing remover shaft set 25 07936 ZV10100 Valve guide driver 5 0x9 4 07942 8920000 Valve guide reamer 5 510 07984 2000001 ...

Page 20: ... ECO THROTTLE SWITCH WHITE TAPE CABLE CLAMP F CABLE CLAMP F Push the indicator wire harness into the groove beside the ribs of the front cover INDICATOR WIRE HARNESS RIB CABLE TIE C Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray 1 G G8 GW F IT R RH S S8 SK RG and U types only 2 C L and LT types only Clamp the indicator wire harness as ...

Page 21: ... 3 Bu R W Terminal number Wire color 2 1 Gr O Bl R W R Terminal number Wire color 1 2 3 Br 1 R 2 W 13 12 11 4 5 10 Y G 1 G 2 Y G 1 G 2 12 GENERATOR WIRE HARNESS CONTROL WIRE HARNESS RECTIFIER HARNESS BAND CLIP COUPLER CLIP HARNESS BAND CLIP 4 5 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray 10 11 13 3 S and SK types only 1 G G8 GW F IT...

Page 22: ...Control wire harness side Bl R Terminal number Wire color 1 2 3 4 R W Bu Y 2 3 1 Control wire harness side Control wire harness side C1 Y G 1 G 2 Y G 1 G 2 Y G 1 G 2 GND1 CONTROL WIRE HARNESS GENERATOR WIRE HARNESS CONTROL WIRE HARNESS THROTTLE CONTROL MOTOR SUB HARNESS GND1 C1 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray 1 G G8 GW F...

Page 23: ...er Wire color 1 2 3 R Y G W Terminal number Wire color 1 2 Bl R Bl Terminal number Wire color 1 2 Bl R Bl 13 1 INVERTER UNIT 13 1 ENGINE STOP SWITCH CONTROL WIRE HARNESS 5 4 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray 10 11 ...

Page 24: ...ION PULSE GENARATOR GENERATOR WIRE HARNESS HIGH TENSION CORD IGNITION COIL CORD GROMMET FAN COVER SEAL CLAMP HARNESS BAND CLIP HARNESS BAND CLIP LOWER SHROUD CYLINDER HEAD COVER C3 C2 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray ...

Page 25: ... GENERATOR WIRE HARNESS HIGH TENSION CORD FAN COVER SEAL CLAMP IGNITION COIL SPARK PLUG CAP BREATHER TUBE OIL LEVEL SWITCH HARNESS BAND CLIP CRANKCASE COVER FRONT FRAME C4 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray ...

Page 26: ...AMP FUEL COCK TUBE FAN COVER GUIDE CLAMP CHOKE CABLE COCK CABLE FUEL TANK BRACKET CLAMP FRONT FRAME FAN COVER GUIDE AIR INTAKE JOINT BREATHER TUBE COCK CABLE FUEL COCK FUEL TANK TUBE FUEL TANK AIR VENT TUBE DRAIN TUBE CARBURETOR TUBE CLIP B12 TUBE CLIP B12 TUBE CLIP B10 ...

Page 27: ...R Y G 3 6 Ignition control module side 2 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray COUPLER CLIP AC CIRCUIT PROTECTOR 16A DC RECEPTACLE CABLE TIE AC RECEPTACLE 16A 250V PARALLEL OPERATION OUTLET WHITE TAPE WHITE TAPE WHITE TAPE TERMINAL CORD TERMINAL CORD WHITE TAPE CONTROL WIRE HARNESS AC CIRCUIT PROTECTOR 16A IGNITION CONTROL MOD...

Page 28: ...EPTACLE 16A 240V PARALLEL OPERATION OUTLET TERMINAL CORD WHITE TAPE CONTROL WIRE HARNESS Terminal number Wire coior 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y Y G Bu R Y G 3 6 Ignition control module side 2 IGNITION CONTROL MODULE GND2 T4 C7 GND3 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray 2 T2 T1 C10 C9 T5 T3 C8 ...

Page 29: ...Bl R Y Y G Bu R G 3 6 Ignition control module side 2 COUPLER CLIP AC RECEPTACLE 20A 125V DC RECEPTACLE CABLE TIE AC RECEPTACLE 30A 125V PARALLEL OPERATION OUTLET WHITE TAPE WHITE TAPE WHITE TAPE WHITE TAPE CONTROL WIRE HARNESS IGNITION CONTROL MODULE T7 GND2 T8 T4 T5 T3 C7 T6 T1 T2 GND3 C8 2 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gr...

Page 30: ...ERATION OUTLET 2 WHITE TAPE WHITE TAPE WHITE TAPE WHITE TAPE CONTROL WIRE HARNESS AC RECEPTACLE 20A 250V Terminal number Wire coior 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y Y G Bu R Y G 3 6 Ignition control module side 2 IGNITION CONTROL MODULE T7 GND2 T8 T4 T5 T3 C7 T6 T1 T2 GND3 C8 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W Wh...

Page 31: ... G Br W W R Bl R Br W Y G Br W Y G C7 C8 T1 T2 T3 T4 T5 T6 T7 T8 GND2 Terminal number Wire coior 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y Y G Bu R Y G 3 6 Ignition control module side 2 WHITE TAPE WHITE TAPE WHITE TAPE IGNITION CONTROL MODULE T7 GND2 T8 T4 T5 T3 C7 T6 T1 T2 GND3 C8 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W Whit...

Page 32: ... R Br W Y G Br W Y G C7 C8 T1 T2 T3 T4 T5 T6 T7 T8 GND2 AC RECEPTACLE 15A 250V Terminal number Wire coior 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y Y G Bu R Y G 3 6 Ignition control module side 2 WHITE TAPE WHITE TAPE IGNITION CONTROL MODULE T7 GND2 T8 T4 T5 T3 C7 T6 T1 T2 C8 GND3 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White ...

Page 33: ...30A 125V WHITE TAPE SUB CORD A SUB CORD A CONTROL WIRE HARNESS Terminal number Wire coior 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y G Bu R G 3 6 Ignition control module side 2 CABLE TIE C 2 BREATHER HEATER SUB CORD AC CIRCUIT PROTECTOR 20A AC RECEPTACLE 20A 125V IGNITION CONTROL MODULE C12 T7 C9 GND2 C10 T8 T4 T5 T3 C11 C7 T6 T1 T2 GND3 C8 T9 T10 Bl Black Br Brown Y Yellow O Orange...

Page 34: ...OTTLE CONTROL MOTOR SUB HARNESS THROTTLE CONTROL MOTOR HARNESS CLIP HARNESS CLIP AIR INTAKE JOINT CHOKE CABLE RESONATOR COVER CLAMP 14 HARNESS BAND CLIP Route the throttle control motor wire sub harness as shown THROTTLE CONTROL MOTOR SUB HARNESS Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray Page 2 9 ...

Page 35: ...ther heater sub cord side 3 Cut the band end as shown HARNESS BAND BREATHER HEATER BREATHER HEATER SUB CORD HARNESS CLIP HARNESS BAND CLIP 14 THROTTLE CONTOROL MOTOR 0 10 mm 0 0 4 in THROTTLE CONTOROL MOTOR SUB HARNESS Route the throttle control motor wire sub harness as shown THROTTLE CONTROL MOTOR SUB HARNESS 3 RESONATOR COVER CLAMP Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Gre...

Page 36: ...R HEATER BREATHER HEATER INSULATOR BREATHER TUBE B AIR INTAKE JOINT INSULATOR AIR INTAKE JOINT BREATHER TUBE INSULATOR B BREATHER TUBE A BREATHER TUBE INSULATOR BREATHER TUBE C BREATHER TUBE A BREATHER HEATER INSULATOR BREATHER TUBE C ...

Page 37: ...MEMO ...

Page 38: ...CK 3 3 ENGINE OIL CHANGE 3 3 AIR CLEANER CHECK CLEANING 3 4 SPARK PLUG CHECK ADJUSTMENT 3 5 SPARK PLUG REPLACEMENT 3 6 SPARK ARRESTER CLEANING 3 7 VALVE CLEARANCE CHECK ADJUSTMENT 3 7 COMBUSTION CHAMBER CLEANING 3 9 FUEL TANK FILTER CLEANING 3 9 FUEL TUBE CHECK 3 10 ...

Page 39: ...e oil level every 15 hours of operation and change the oil if it flows out from the oil filler neck REGULAR SERVICE PERI OD 3 Each use First month or 20 hrs Every 15 hrs Ctype only Every 3 months or 50 hrs Every 6 months or 100 hrs Every year or 300 hrs Refer to page Perform at every indicated month or operating hour in terval whichever comes first ITEM Engine oil Check level 3 3 Check Operation o...

Page 40: ... performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range Tighten the oil filler cap securely Reinstall the oil maintenance cover ENGINE OIL CHANGE Drain the engine oil while the engine is warm Warm oil drains quickly and com...

Page 41: ...air flow to the carburetor reducing engine performance If the engine is operated in dusty areas clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE Loosen the 6 x 16 mm special screw 1 and remove the air cleaner cover 2 Remove the air cleaner element 1 and outer filter element 2 from the air cleaner case 3 Operating the engine without an air filter element or with a damaged...

Page 42: ...ner case Clean the air cleaner cover seal 3 and the air cleaner case if necessary Make sure that the air cleaner cover seal is set in the groove of the air cleaner case Install the air cleaner cover 4 Set the air cleaner cover on the air cleaner case as shown and tighten the cover 6 x 16 mm special screw 5 to the specified torque SPARK PLUG CHECK ADJUSTMENT Loosen the 6 x 16 mm special screw 1 and...

Page 43: ...r cover and tighten the 6 x 16 mm special screw to the specified torque SPARK PLUG REPLACEMENT Remove the muffler protector cover and spark plug cap 1 page 3 5 Remove the spark plug 2 using a spark plug wrench 3 Install a new spark plug finger tight to seat the washer and then tighten 1 2 turn with a spark plug wrench A loose spark plug can become very hot and can damage the engine Overtightening ...

Page 44: ...LEARANCE CHECK ADJUSTMENT Valve clearance inspection and adjustment must be performed with the engine cold Remove the following parts Front cover page 5 3 Rear cover page 5 4 Left and right side cover page 5 7 Right shroud page 5 8 Inverter unit page 8 7 Control panel page 8 8 Disconnect the spark plug cap from the spark plug Disconnect the breather tube from the cylinder head cover Remove the fou...

Page 45: ...s follows Hold the rocker arm pivot 1 and loosen the rocker arm pivot lock nut 2 Turn the rocker arm pivot to obtain the specified clearance Hold the rocker arm pivot and retighten the rocker arm pivot lock nut to the specified torque Recheck the valve clearance and if necessary readjust the clearance Check the head cover packing for damage or deterioration and install it to the cylinder head cove...

Page 46: ...uel tube and fuel tank 1 page 6 5 Clean the fuel tank with non flammable solvent and allow drying thoroughly Clean the fuel strainer 2 and fuel tank with non flammable solvent and be sure that the fuel strainer is not damaged Install the fuel tank page 6 5 1 Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle f...

Page 47: ...rter 4 from the fuel tank tube Check the fuel tank tube and fuel cock tube for deterioration cracks or signs of leakage replace as necessary Install the rubber supporter to the fuel tank tube Install the fuel tank page 6 5 Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills imm...

Page 48: ...4 1 4 4 TROUBLESHOOTING HARD STARTING 4 2 ENGINE STARTS BUT THEN STALLS 4 4 ENGINE OIL LEVEL IS LOW BUT ENGINE DOES NOT STOP 4 6 ENGINE SPEED DOES NOT INCREASE OR STABILIZE 4 7 ...

Page 49: ... drain screw and check whether fuel is reaching the carburetor Is it reaching the carburetor Remove the spark plug and check for wet or fouled electrodes Check for clogging of carburetor port nozzle and main jet Go to page 4 3 Light comes on Light does not come on Pull the recoil starter grip and check the oil alert indicator light on the control panel No Yes Drain the fuel from fuel tank and carb...

Page 50: ...irmly and restart the engine CONTROL WIRE HARNESS Viewed from terminal side Normal compression Check the cylinder compression page 14 5 Check for carbon deposits in the combustion chamber page 14 3 Good spark Perform the spark test page 9 6 Perform No Spark at Spark Plug troubleshooting page 9 2 From page 4 2 High cylinder compression Low cylinder compression No spark or weak spark THROTTLE CONTRO...

Page 51: ...n Low cylinder compression No No No Yes Drain the fuel tank and carburetor and refill with fresh fuel Check for secondary air entering Is it normal Check the fuel Is it fresh Check the valve clearance page 3 7 Check that the cylinder head is correctly tightened page 14 3 Check for defective cylinder head gasket valves or valve seats page 14 3 4 5 and 6 Check for worn piston piston rings or cylinde...

Page 52: ...ion Replace or repair the control wire harness page 8 13 Abnormal Replace or repair the generator wire harness page 8 10 Abnormal Abnormal Replace the stator page 8 10 Check the harness connecting the inverter unit and generator for open or short and for proper connection Check the generator page 8 29 Replace the inverter unit page 8 7 Normal Check the inverter unit page 8 27 Normal Turn the ignit...

Page 53: ...and check the oil alert indicator light on Light does not come on Remove disconnect the inverter unit page 8 7 Disconnect the generator 10P connector from the control wire harness Check terminal No 10 Y of the 10P connector and the C4 of the connector for open or short and for proper connection Continuity Check the harness connecting the control wire harness 10P connector terminal No 10 and igniti...

Page 54: ...and adjust the spark plug gap page 3 5 Replace if necessary page 3 6 Check the main jet for blockage page 6 15 Disassemble and clean the carburetor page 6 15 and 21 Yes Normal Go to page 4 8 High cylinder compression Low cylinder compression Check the valve clearance page 3 7 Check that the cylinder head is correctly tightened page 14 3 Check for defective cylinder head gasket valves or valve seat...

Page 55: ...ir gap page 9 6 Normal Perform the throttle control system troubleshooting page 7 2 From page 4 7 Check the ignition pulse generator resistance page 9 7 Replace the ignition pulse generator page 9 5 Abnormal Normal Adjust the ignition pulse generator air gap page 9 6 ...

Page 56: ...ATION 5 8 FRONT FRAME CENTER FRAME HANDLE BASE REMOVAL INSTALLATION 5 9 WHEEL REMOVAL INSTALLATION 5 10 CARRY HANDLE HOLDER REMOVAL INSTALLATION 5 11 UNDER COVER REMOVAL INSTALLATION 5 12 FRONT COVER DISASSEMBLY ASSEMBLY 5 13 REAR COVER DISASSEMBLY ASSEMBLY 5 14 RIGHT SHROUD DISASSEMBLY ASSEMBLY 5 15 LEFT SHROUD CENTER FRAME DISASSEMBLY ASSEMBLY 5 16 FRONT FRAME DISASSEMBLY ASSEMBLY 5 17 ...

Page 57: ...CARRY HANDLE RIGHT CARRY HANDLE LOWER CARRY GRIP PAN SCREW 6 x 12 mm SOCKET BOLT 6 x 32 mm 2 PLAIN WASHER 2 9 N m 0 9 kgf m 6 5 lbf ft 9 N m 0 9 kgf m 6 5 lbf ft UPPER CARRY GRIP INSTALLATION Install the upper carry grip noting the direction as shown LEFT CARRY HANDLE SIDE RIGHT CARRY HANDLE SIDE NUT 2 ...

Page 58: ...m 1 7 lbf ft SPECIAL SCREW 6 x 15 mm 4 4 4 N m 0 45 kgf m 3 3 lbf ft INSTALLATION Install the knob cap to the engine stop switch knob KNOB CAP HANDLE COVER SEAL INSTALLATION After installing the front cover start the engine with the carry handle at the stationary position and check that the carry handle does not rattle during operation INSTALLATION Install the engine switch knob as shown ENGINE SW...

Page 59: ...JOINT MUFFLER PROTECTOR COVER SPECIAL SCREW 6 x 16 mm AIR CLEANER TUBE CLIP 2 WASHER 2 INSTALLATION Install the rear grip cover as shown UPPER SIDE LOWER SIDE INSTALLATION Install the rear carry grip as shown SPECIAL SCREW 6 x 15 mm 5 4 4 N m 0 45 kgf m 3 3 lbf ft UPPER SIDE LOWER SIDE slant TANK MOUNT RUBBER A 2 3 N m 0 23 kgf m 1 7 lbf ft REMOVAL INSTALLATION Page 5 5 ...

Page 60: ...ect the air cleaner connecting tube 2 from the air intake joint 3 Remove the five special screws 1 and rear cover assembly 2 as shown INSTALLATION Align the tab 1 of the rear cover assembly 2 with the rear under guard 3 as shown Install the rear cover and five special screws 4 and tighten to the specified torque 1 2 3 1 2 3 1 2 TORQUE 4 4 N m 0 45 kgf m 3 3 lbf ft 1 2 3 4 3 ...

Page 61: ...amp screw 3 to the specified torque Connect the bottom of the resonator tube 1 aligning the projection with the groove 2 of the under cover Install the top of the resonator tube by aligning the projection with the groove 3 of the rear cover assembly TORQUE 0 7 N m 0 07 kgf m 0 5 lbf ft 1 3 2 1 3 2 ...

Page 62: ... MOUNT RUBBER C FUEL FILTER OIL MAINTENANCE COVER SEAL SIDE COVER UPPER SEAL B SIDE COVER UPPER SEAL A 4 4 N m 0 45 kgf m 3 3 lbf ft 4 4 N m 0 45 kgf m 3 3 lbf ft SPECIAL SCREW 6 x 15 mm 10 LEFT SIDE UNDER PLATE LEFT SIDE COVER SIDE COVER LOWER SEAL SIDE COVER LOWER SEAL RIGHT SIDE UNDER PLATE RIGHT SIDE COVER SEAL OIL MAINTENANCE COVER RIGHT SIDE COVER SPRING NUT 6 mm 2 FUEL FILLER NECK SEAL FUEL...

Page 63: ...UD CASE CLAMP 5 To mating INSTALLATION Install the right shroud by aligning the tabs with the slots of the left shroud INSTALLATION After installing the right shroud install the case clamps to the grooves of the right left shroud as shown LEFT SHROUD RIGHT SHROUD GROOVE LEFT SHROUD RIGHT SHROUD Slot Tab Align ...

Page 64: ...TION Install the center frame by aligning the flange of the left shroud with the groove of the front frame INSTALLATION Install the generator wire harness and grommet to the front frame hole as shown LEFT SHROUD GROOVE INSTALLATION Install the center frame left shroud as shown BOLT 6 x 57 mm 2 CENTER FRAME REAR GUARD BRACKET FRONT FRAME GROMMET GENARATOR WIRE HARNESS GENARATOR WIRE HARNESS FAN COV...

Page 65: ...WASHER 14 2 mm 2 WHEEL FLANGE BOLT 8 x 16 mm 4 WHEEL SHAFT REMOVAL Insert a screwdriver or equivalent tool into the groove as shown and remove the wheel cap INSTALLATION Install the E ring to the wheel shaft noting the installation direction as shown GROOVE OUTSIDE ...

Page 66: ... 12 mm FRICTION SETTING WASHER B GROOVE TAB FRICTION WASHER 2 FRICTION SPRING 4 FRICTION SPRING FRICTION SPRING WASHER 12 mm 4 LEFT HANDLE HOLDER PLAIN WASHER 6 mm FLANGE NUT 6 mm 8 3 N m 0 85 kgf m 6 1 lbf ft INSTALLATION Align the tabs with groove of the handle base INSTALLATION After installing check that the carry handle moves up and down by specified load 10 20 N 1 0 2 0 kgf 2 2 4 4 lbf 5 15 ...

Page 67: ...UBBER OIL DRAIN PLUG SPRING NUT 6 mm 7 SPECIAL BOLT 6 mm 2 LOWER AIR GUIDE REAR UNDER GUARD STOPPER RUBBER HARNESS CLIP 2 DISCHARGE GUARD STOPPER LEFT REAR GRIP PLATE 8 N m 0 82 kgf m 5 9 lbf ft 9 3 N m 0 95 kgf m 6 8 lbf ft FLANGE BOLT 6 x 20 mm 2 INSTALLATION Install the bottom rubber to the under cover as shown UNDER COVER COLLAR A 4 COLLAR 2 FLANGE BOLT 6 x 14 mm 4 UNDER COVER SPECIAL NUT 6 mm...

Page 68: ...Y Install the front cover seals A B and C as shown CABLE CLAMP F CABLE CLAMP F CABLE TIE INDICATOR ASSY FRONT COVER FRONT COVER SEAL A FRONT COVER SEAL C FRONT COVER SEAL B FRONT COVER SEAL A FRONT COVER SEAL B FRONT COVER SEAL C TAPPING SCREW 5 x 12 mm HANDLE STOPPER 2 1 2 N m 0 12 kgf m 0 9 lbf ft TAPPING SCREW 5 x 12 mm 2 1 2 N m 0 12 kgf m 0 9 lbf ft C6 C5 INDICATOR WIRE HARNESS ...

Page 69: ...al rear cover lower seal and rear cover intake seal as shown REAR COVER UPPER SEAL REAR COVER SHROUD SEAL REAR COVER LOWER SEAL REAR COVER INTAKE SEAL ASSEMBLY Install the air cleaner connecting tube in the position shown AIR CLEANER CONNECTING TUBE AIR CLEANER CONNECTING TUBE 0 7 N m 0 07 kgf m 0 5 lbf ft 0 mm 0 in REAR COVER Align AIR CLEANER TUBE ASSEMBLY ASSEMBLY Install the air cleaner tube a...

Page 70: ... DISASSEMBLY ASSEMBLY ASSEMBLY Bend the insulator bind clip as shown RIGHT SHROUD INSULATOR BIND CLIP RIGHT SHROUD INSULATOR RIGHT SHROUD SEAL INSULATOR BIND CLIP 9 RIGHT SHROUD SEAL RIGHT SHROUD INSULATOR INSULATOR BIND CLIP ...

Page 71: ...SEAL LEFT SHROUD SEAL A STOPPER RUBBER LEFT SHROUD INSULATOR BIND CLIP BOSS TAB BOSS TAB LEFT SHROUD SEAL A LEFT SHROUD SEAL LEFT SHROUD INSULATOR INSULATOR BIND CLIP 7 SPECIAL BOLT 6 mm STOPPER BRACKET CENTER FRAME TAPE LEFT SHROUD INSULATOR ASSEMBLY Install the left shroud seal A left shroud insulator and left shroud seal as shown Bend the insulator bind clip as shown 2 3 5 1 LEFT SHROUD CENTER ...

Page 72: ...OMMET FRONT FRAME TAPE FRONT FRAME SEAL LEFT SHROUD FRONT FRAME CENTER MAT FRONT FRAME FRONT FRAME SEAL LEFT SHROUD FRONT FRAME CENTER MAT FRONT FRAME TAPE FRONT FRAME SEAL ASSEMBLY Install the front frame seal front frame seal left shroud front frame center mat and front frame tape as shown FRONT FRAME SEAL ...

Page 73: ...MEMO ...

Page 74: ... REMOVAL INSTALLATION 6 11 FUEL TANK CAP DISASSEMBLY ASSEMBLY 6 12 FUEL TANK DISASSEMBLY ASSEMBLY C TYPE ONLY 6 13 AIR INTAKE JOINT DISASSEMBLY ASSEMBLY 6 14 CARBURETOR DISASSEMBLY ASSEMBLY 6 15 ENGINE SWITCH CONTROL DISASSEMBLY ASSEMBLY 6 16 COCK CABLE ADJUSTMENT 6 19 CHOKE CABLE ADJUSTMENT 6 19 THROTTLE STOP SCREW ADJUSTMENT 6 20 CARBURETOR BODY CLEANING 6 21 CARBURETOR INSPECTION 6 21 PILOT SCR...

Page 75: ...FUEL SYSTEM 6 2 FUEL SYSTEM TOOLS Float level gauge 07401 0010000 ...

Page 76: ... 2P connector Measure the resistance between the terminals of the breather heater 2P connector of the heater side Is the resistance 560 1 200Ω when the temperature is 0 20 C 32 68 F YES Start the engine and measure the AC voltage at the breather heater 2P connector of the harness side Is there 120V AC Perform the Non or Low AC Output troubleshooting page 8 3 Start the engine and check for 120V AC ...

Page 77: ...PECIAL SCREW 6 x 16 mm AIR CLEANER COVER AIR CLEANER COVER SEAL A INSTALLATION Install the air cleaner cover seal A as shown AIR CLEANER COVER SEAL A REAR COVER INSTALLATION Install the air cleaner cover seal C as shown AIR CLEANER COVER SEAL C CLEANING page 3 4 CLEANING page 3 4 2 3 N m 0 23 kgf m 1 7 lbf ft ...

Page 78: ...ank projections into the tank mount rubber A and B securely PROJECTION TANK MOUNT RUBBER A FUEL COCK TUBE COCK CABLE SUPPORTER RUBBER FUEL TANK TUBE WIRE CLAMP PAN SCREW 6 x 12 mm 3 FUEL COCK FUEL TANK BRACKET BOLT 6 x 16 mm 2 COCK CABLE HOLDER FUEL STRAINER TANK MOUNT RUBBER B TANK MOUNT RUBBER B 2 TUBE CLIP B12 3 TANK MOUNT RUBBER A 9 N m 0 9 kgf m 6 5 lbf ft TUBE CLIP B10 Apply to the pivot HEX...

Page 79: ...n of a fuel tank and the tank mount rubber B to a fuel tank bracket TANK MOUNT RUBBER A FUEL COCK TUBE COCK CABLE SUPPORTER RUBBER FUEL TANK TUBE WIRE CLAMP 8 mm FUEL COCK FUEL TANK BRACKET FUEL STRAINER TANK COVER RUBBER B TANK MOUNT RUBBER A PROJECTION TUBE CLIP B10 TUBE CLIP B12 3 COCK CABLE HOLDER Apply to the pivot TANK COVER RUBBER B HEX NUT 6 mm PLAIN WASHER 6 mm CIR CLIP 5 mm FLANGE BOLT 6...

Page 80: ...page 6 19 BREATHER TUBE A BREATHER TUBE B BREATHER TUBE INSULATOR BREATHER HEATER BREATHER HEATER INSULATOR AIR INTAKE JOINT FLNGE NUT 6 mm 2 8 3 N m 0 85 kgf m 6 1 lbf ft CYLINDER HEAD COVER BREATHER HEATER SUB CORD BREATHER TUBE C BREATHER TUBE INSULATOR B AIR INTAKE JOINT INSULATOR HARNESS BAND 4 INTAKE JOINT COLLAR 2 INSPECTION Page 6 23 CHOKE CABLE ADJUSTMENT Page 6 19 ...

Page 81: ...hat the air intake joint insulator is installed correctly Install the air intake joint to the carburetor page 6 7 Install the breather heater 1 in the air intake joint 2 Insert the breather tube A 3 with breather tube insulator 4 installed into the breather heater so that the white marking of the breather tube A is hidden At this point also install the breather tube insulator so that it goes insid...

Page 82: ... DISASSEMBLY ASSEMBLY Page 6 15 CLEANING Page 6 21 ADJUSTMENT Page 6 20 THROTTLE CONTROL MOTOR SUB HARNESS 2 3 N m 0 23 kgf m 1 7 lbf ft FLNGE NUT 6 mm 2 AIR INTAKE JOINT CHOKE SPRING 8 3 N m 0 85 kgf m 6 1 lbf ft THROTTLE CONTROL MORTOR TUBE CLIP B10 FUEL COCK TUBE HOLE PIN CABLE HOLDER DRAIN TUBE AIR VENT TUBE AIR INTAKE JOINT PACKING INTAKE JOINT COLLAR 2 AIR INTAKE JOINT INSTALLATION Install t...

Page 83: ...le page 6 19 HEX NUT 6 mm BOLT 6 x 20 mm WIRE CLAMP 8 mm AIR INTAKE JOINT COCK CABLE HOLDER CHOKE CABLE HOLDER ENGINE SWITCH CONTROL 9 3 N m 0 95 kgf m 6 9 lbf ft PAN SCREW 4 x 6 mm 2 3 N m 0 23 kgf m 1 7 lbf ft PAN SCREW 4 x 6 mm 2 3 N m 0 23 kgf m 1 7 lbf ft CHOKE SPRING COCK CABLE CHOKE CABLE INSTALLATION After installation adjust the cock cable and choke cable page 6 19 4 7 N m 0 5 kgf m 3 6 l...

Page 84: ...rator engine page 13 2 RESONATOR COVER RESONATOR SEAL B TAPPING SCREW 5 x 25 mm RESONATOR CASE RESONATOR SEAL A 2 8 N m 0 28 kgf m 2 lbf ft 1 4 N m 0 14 kgf m 1 lbf ft BOSS HOLE INSTALLATION Align the holes with the bosses of the resonator case TAPPING SCREW 5 x 30 mm 3 ...

Page 85: ...BLY TANK CAP BREATHER VALVE O RING 13 8 x 2 4 mm FUEL CAP PACKING FUEL CAP BREATHER SPONGE FUEL CAP INNER FUEL CAP SPRING WASHER 6 mm LOCK PIN 6 mm INSTALLATION Clean the sponge with water and neutral detergent and allow it to dry before installation ...

Page 86: ...R B ASSEMBLY Install the tank mount rubber A to the tank cover rubber B as shown ASSEMBLY Insert the projection of the fuel tank into the tank mount rubber A and tank cover rubber B securely PROJECTION ASSEMBLY Install the tank mount rubber A and tank cover rubber B to the fuel tank joint as shown TANK COVER RUBBER B TANK MOUNT RUBBER A FUEL TANK ...

Page 87: ...ces the air intake joint as shown CHOKE CABLE HOLDER PAN SCREW 4 x 6 mm SPECIAL SCREW 6 x 12 mm CHOKE LEVER E RING 5 mm AIR INTAKE JOINT SPECIAL NUT 6 mm PLAIN WASHER 6 mm PLAIN WASHER 6 mm Intake joint side AIR INTAKE JOINT SPECIAL NUT 6 mm chamfer chamfer SPECIAL SCREW 6 x 12 mm PLAIN WASHAER CHOKE LEVER 1 5 N m 0 15 kgf m 1 7 lbf ft ...

Page 88: ... SEALING WASHER ASSEMBLY Before installing clean thoroughly with low pressure compressed air MAIN JET ASSEMBLY Before installing clean thoroughly with low pressure compressed air MAIN NOZZLE ASSEMBLY Before installing clean thoroughly with low pressure compressed air Lightly lubricate the O ring to ensure easy installation into the carburetor body PILOT JET O RING FLOAT PIN O RING PILOT SCREW O RI...

Page 89: ...ON PLATE CHOKE CABLE BRACKET ENGINE SWITCH CAM CHOKE ARM ENGINE SWITCH BASE COCK CABLE BRACKET 1 4 N m 0 14 kgf m 1 lbf ft 1 4 N m 0 14 kgf m 1 lbf ft TAPPING SCREW 5 x 25 mm 2 TAPPING SCREW 5 x 16 mm TAPPING SCREW 5 x 16 mm PLAIN WASHER 8 mm 2 TAPPING SCREW 3 x 10 mm 2 INSPECTIONT Page 11 3 ADJUSTMENT Page 6 19 ADJUSTMENT Page 6 19 0 18 N m 0 018 kgf m 0 13 lbf ft 0 8 N m 0 08 kgf m 0 59 lbf ft ...

Page 90: ... 5 x 16 mm tapping screws 6 Install the choke cable 1 and choke cable spring 2 to the choke arm 3 Install the choke arm to the engine switch base 4 Install the cable end 1 of the cock cable to the engine switch cam 2 Insert the engine switch cam 1 into the boss 2 of the engine switch base in the direction as shown TORQUE 1 4 N m 0 14 kgf m 1 lbf ft 6 5 2 1 4 3 4 1 3 2 2 1 LOWER SIDE UPPER SIDE 1 2...

Page 91: ... switch 1 to the engine switch base 2 with two 3 x 10 mm tapping screws 3 Install the two 8 mm washers 1 engine switch plate 2 and two 5 mm washers 3 in the order shown to the engine switch base and fasten with two 5 x 25 mm tapping screws 4 as shown 1 2 3 1 3 2 TORQUE 0 18 N m 0 018 kgf m 0 13 lbf ft 3 1 2 TORQUE 0 8 N m 0 08 kgf m 0 59 lbf ft 4 1 2 3 3 1 ...

Page 92: ... the stopper loosen the 4 x 6 mm pan screw 5 and adjust the position of the inner cable 6 After adjustment tighten the 4 x 6 mm pan screw to the specified torque CHOKE CABLE ADJUSTMENT Remove the following parts Fuel tank page 6 5 Control panel page 8 8 Install the engine switch knob 1 to the engine switch cam 2 Switch the engine switch knob to OFF Confirm that the engine switch knob is in the hor...

Page 93: ...fied torque again while pulling the inner end of the choke cable slightly so that the choke spring 5 of the choke arm is not compressed Check again that the choke lever is not loose by turning it counterclockwise THROTTLE STOP SCREW ADJUSTMENT Remove the throttle stop screw 1 only if necessary for carburetor repair or cleaning Install the throttle stop screw so that the throttle valve is at the fu...

Page 94: ...orts with low pressure compressed air Pilot screw hole 2 Pilot jet hole 3 Pilot air jet 4 Main air jet 5 Transition ports 6 Pilot outlet 7 Main nozzle holder 8 Vent port 9 CARBURETOR INSPECTION FLOAT LEVEL HEIGHT Place the carburetor in the position as shown and measure the distance between the float top 1 and carburetor body 2 when the float just contacts the float valve without compressing the v...

Page 95: ... carburetor Removal of the limiter cap requires breaking the pilot screw A new pilot screw and limiter cap must be installed When the limiter cap has been broken off remove the broken pilot screw Place the spring on the replacement pilot screw and install it on the carburetor Turn the pilot screw 1 in until it is lightly seated then turn the screw out the required number of turns 1 2 OK REPLACE CL...

Page 96: ...ng CHOKE SET REPLACEMENT Remove the carburetor page 6 9 Pull out the choke valve plate 1 Remove the choke shaft 2 and install a new choke shaft coil spring 3 and plain washer 4 Insert a new choke valve plate to the slit 5 of the choke shaft Be sure the choke shaft is in the position between the projections 6 of the choke valve plate BREATHER HEATER INSPECTION C TYPE ONLY Measure the resistance bet...

Page 97: ...MEMO ...

Page 98: ...7 1 7 7 GOVERNOR SYSTEM THROTTLE CONTROL SYSTEM TROUBLESHOOTING 7 2 THROTTLE CONTROL MOTOR REMOVAL INSTALLATION 7 5 ECO THROTTLE SWITCH INSPECTION 7 6 THROTTLE CONTROL MOTOR INSPECTION 7 6 ...

Page 99: ...8 3 Perform engine troubleshooting following the instruction of Engine Speed Does Not Increase or Stabilize troubleshooting page 4 7 Replace the throttle control motor page 7 5 Abnormal Replace or repair the throttle control motor sub harness Abnormal Replace or repair the control wire harness page 8 13 Check the throttle control motor page 7 6 Normal Replace the inverter unit page 8 7 Check the t...

Page 100: ...tput Check the throttle control motor page 7 6 Replace the ECO throttle switch page 5 13 Abnormal Replace the throttle control motor page 7 5 Abnormal Replace or repair the indicator wire harness page 5 13 and or control wire harness page 8 13 Abnormal Replace or repair the throttle control motor sub harness Check the ECO throttle switch page 7 6 Check the harness connecting the ECO throttle switc...

Page 101: ...2 5 Bu R Y W Abnormal Replace or repair the control wire harness page 8 13 From page 7 3 Normal Replace the inverter unit page 8 7 Check the harness connecting the throttle control motor sub harness and inverter unit for open or short circuit and for proper connection ...

Page 102: ...nd flame away Handle fuel only outdoors Wipe up spills immediately THROTTLE CONTROL MOTOR SCREW WASHER 3 x 8 mm 2 THROTTLE MOTOR BRACKET COMPRESSION COIL SPRING LINK LEVER CARBURETOR ASSEMBLY INSTALLATION After installing the throttle control motor to the carburetor fully open the throttle lever THROTTLE LEVER SCREW WASHER 4 x 10 mm 2 REMOVAL Take care not to lose the compression coil spring when ...

Page 103: ...MOTOR INSPECTION Remove the throttle control motor page 7 5 Measure the resistance between the terminals If the resistance is outside the specification replace the throttle control motor page 7 5 Switch position Terminal ON OFF C5 C6 No continuity Continuity ECO THROTTLE SWITCH ON OFF C5 C6 Terminal Standard resistance 1 3 50 70 Ω 2 4 50 70 Ω 1 2 3 4 ...

Page 104: ...MOVAL INSTALLATION 8 7 CONTROL PANEL REMOVAL INSTALLATION 8 8 GENERATOR REMOVAL INSTALLATION 8 10 CONTROL PANEL DISASSEMBLY ASSEMBLY 8 13 INVERTER UNIT INSPECTION 8 27 RECTIFIER INSPECTION 8 28 PARALLEL OPERATION OUTLET INSPECTION 8 28 AC CIRCUIT PROTECTOR INSPECTION 8 28 GENERATOR INSPECTION 8 29 ...

Page 105: ...GENERATOR CHARGING SYSTEM 8 2 GENERATOR CHARGING SYSTEM TOOLS Flywheel puller set 07935 8050004 ...

Page 106: ...ecified engine speed 3 600 100 rpm ECO throttle switch OFF Check the ECO throttle switch and if no problem can be found perform Throttle Control System troubleshooting page 7 2 and 3 Remove the inverter unit page 8 7 Measure the resistance between the terminals of the sub coil 2P connector Resistance 0 4 0 7Ω Check the harness connecting the inverter unit and generator for an open or short circuit...

Page 107: ...Replace the AC circuit protector page 8 13 Replace the AC receptacle page 8 13 Remove the inverter unit page 8 7 Measure the resistance between the terminals of the main coil 4P connector Resistance No 2 R No 3 W 0 6 1 1Ω No 3 W No 4 Bu 0 6 1 1Ω No 2 R No 4 Bu 0 6 1 1Ω Check the harness connecting the inverter unit and generator for an open or short circuit and for proper connection Replace the in...

Page 108: ...gine speed 3 600 100 rpm ECO throttle switch OFF Normal Replace or repair the generator wire harness and or control wire harness page 8 10 and 13 Check the ECO throttle switch and if no problem can be found perform Throttle Control System troubleshooting page 7 2 and 3 Check the harness connecting the rectifier and DC receptacle for open or short circuit and for proper connection Normal Measure th...

Page 109: ...iewed from terminal side 9 Br Br Abnormal Normal Check the harness connecting the generator and rectifier for an open or short circuit and for proper connection Replace or repair the generator wire harness page 8 10 Replace the stator page 8 10 From page 8 5 ...

Page 110: ...YSTEM 8 7 INVERTER UNIT REMOVAL INSTALLATION Remove the front cover page 5 3 INVERTER MOUNT RUBBER 2 INVERTER UNIT RUBBER INVERTER UNIT WASHER BOLT 6 x 25 mm 9 3 N m 0 95 kgf m 6 9 lbf ft INVERTER JONIT COLLAR 13 4 5 10 11 ...

Page 111: ... engine stop switch as shown ENGINE STOP SWITCH 2P CONNECTOR REMOVAL INSTALLATION Move the terminal as shown TAPPING SCREW 5 x 16 mm 2 CONTROL WIRE HARNESS TERMINAL ENGINE STOP SWITCH 2P CONNECTOR RECTIFIER GENERATOR WIRE HARNESS TERMINAL GENERATOR WIRE HARNESS TERMINAL CONTROL WIRE HARNESS TERMINAL BOLT 6 x 10 mm 2 1 4 N m 0 14 kgf m 1 lbf ft 9 3 N m 0 95 kgf m 6 9 lbf ft BOLT 6 x 14 mm BOLT 6 x ...

Page 112: ...TOP SWITCH 2P CONNECTOR REMOVAL INSTALLATION Move the terminal as shown TAPPING SCREW 5 x 16 mm 2 CONTROL WIRE HARNESS TERMINAL ENGINE STOP SWITCH 2P CONNECTOR RECTIFIER GENERATOR WIRE HARNESS TERMINAL GENERATOR WIRE HARNESS TERMINAL CONTROL WIRE HARNESS TERMINAL 1 4 N m 0 14 kgf m 1 lbf ft BOLT 6 x 14 mm BOLT 6 x 14 mm BOLT 6 x 57 mm 2 BOLT 6 x 10 mm 2 9 3 N m 0 95 kgf m 6 9 lbf ft 12 GND1 3 ...

Page 113: ...STATOR COLLAR SHORT STATOR COLLAR LONG GENERATOR WIRE HARNESS FLYWHEEL PULLER 07935 8050004 REMOVAL Remove the rotor using a special tool flywheel puller Do not remove the rotor by tapping it with a hammer SOCKET BOLT 6 x 57 mm 4 11 N m 1 1 kgf m 8 lbf ft REMOVAL Hold the rotor with a commercially available strap wrench to loosen and tighten the 14 mm special nut TORQUE 74 N m 7 5 kgf m 54 lbf ft ...

Page 114: ...3 Connect the generator wire harness connectors to the three terminal side 4 as shown Clean off oil or grease from the crankshaft taper and rotor tapered hole Install the woodruff key 1 on the crankshaft Install the stator 2 while placing the generator wire harness 3 as shown and tighten the four 6 x 57 mm socket bolts 4 1 2 7 8 9 3 4 TORQUE 11 N m 1 1 kgf m 8 lbf ft 1 2 3 4 ...

Page 115: ...f key 3 on the crankshaft 4 Apply oil to the threads and seating surface of the 14 mm special nut 5 Holding the rotor 1 with a commercially available strap wrench 2 tighten the 14 mm special nut 3 to the specified torque Note that the magnetic force of the rotor is very strong Take care not to pinch your fingers during installa tion 1 4 3 2 5 TORQUE 74 N m 7 5 kgf m 54 lbf ft 3 2 1 ...

Page 116: ...LLEL OPERATION OUTLET 2 FLAT SCREW 4 x 12 mm 8 PAN SCREW 5 x 8 mm PACKING AC RECEPTACLE 16A 250V 2 HARNESS BAND CLIP PANEL MARK AC CIRCUIT PROTECTOR 16A 2 COUPLER CLIP CONTROL WIRE HARNESS CABLE TIE ASSEMBLY Install the ground terminal as shown PAN SCREW 5 x 13 mm 2 PAN SCREW 5 x 8 mm PAN SCREW 5 x 16 mm NUT 2 IGNITION CONTROL MODULE TERMINAL CORD FLANGE NUT 4 mm 8 ...

Page 117: ...ition control module side 2 COUPLER CLIP AC CIRCUIT PROTECTOR 16A DC RECEPTACLE CABLE TIE AC RECEPTACLE 16A 250V PARALLEL OPERATION OUTLET WHITE TAPE WHITE TAPE WHITE TAPE TERMINAL CORD TERMINAL CORD WHITE TAPE CONTROL WIRE HARNESS AC CIRCUIT PROTECTOR 16A IGNITION CONTROL MODULE C12 T7 C9 GND2 C10 T8 T4 T5 T3 C11 C7 T6 T1 T2 GND3 C8 2 Clamp the taping position as shown Bl Black Br Brown Y Yellow ...

Page 118: ...OL PANEL DC RECEPTACLE PACKING AC RECEPTACLE 16A 240V HARNESS BAND CLIP CONSENT SET PLATE SCREW WASHER 5 x 16 mm 4 AC CIRCUIT PROTECTOR 16A CONTROL WIRE HARNESS CABLE TIE COUPLER CLIP PAN SCREW 5 x 8 mm PAN SCREW 5 x 16 mm PANEL MARK PAN SCREW 5 x 13 mm 2 PAN SCREW 5 x 8 mm NUT IGNITION CONTROL MODULE PARALLEL OPERATION OUTLET 2 TERMINAL CORD ...

Page 119: ...6A 240V PARALLEL OPERATION OUTLET TERMINAL CORD WHITE TAPE CONTROL WIRE HARNESS Terminal number Wire color 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y Y G Bu R Y G 3 6 Ignition control module side 2 IGNITION CONTROL MODULE Clamp the taping position as shown C9 GND2 T4 T5 T3 T1 T2 GND3 C10 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W ...

Page 120: ...l as shown SCREW 3 GROUND 2 HARNESS BAND CLIP DC RECEPTACLE CONTROL WIRE HARNESS CABLE TIE AC RECEPTACLE 30A 125V AC RECEPTACLE 20A 125V PAN SCREW 5 x 8 mm PAN SCREW 5 x 12 mm PAN SCREW 5 x 13 mm 2 PAN SCREW 5 x 8 mm SCREW 3 COUPLER CLIP IGNITION CONTROL MODULE PARALLEL OPERATION OUTLET 2 PANEL MARK FLANGE NUT 4 mm 2 FLANGE NUT 4 mm 2 ...

Page 121: ... Bu R G 3 6 Ignition control module side 2 COUPLER CLIP AC RECEPTACLE 20A 125V DC RECEPTACLE AC RECEPTACLE 30A 125V PARALLEL OPERATION OUTLET WHITE TAPE WHITE TAPE WHITE TAPE CONTROL WIRE HARNESS IGNITION CONTROL MODULE CABLE TIE WHITE TAPE Clamp the taping position as shown T7 GND2 T8 T4 T5 T3 C7 T6 T1 T2 GND3 C8 2 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R...

Page 122: ... DC RECEPTACLE ASSEMBLY Install the ground terminal as shown SCREW 6 CABLE TIE CONTROL WIRE HARNESS HARNESS BAND CLIP AC RECEPTACLE 20A 250V PAN SCREW 5 x 8 mm COUPLER CLIP PAN SCREW 5 x 13 mm 2 PAN SCREW 5 x 12 mm PAN SCREW 5 x 8 mm IGNITION CONTROL MODULE PARALLEL OPERATION OUTLET 2 PANEL MARK FLANGE NUT 4 mm 4 ...

Page 123: ...PE WHITE TAPE WHITE TAPE CONTROL WIRE HARNESS AC RECEPTACLE 20A 250V Terminal number Wire color 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y Y G Bu R Y G 3 6 Ignition control module side 2 CABLE TIE WHITE TAPE Clamp the taping position as shown 2 T7 GND2 T8 T4 T5 T3 C7 T6 T1 T2 C8 GND3 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W Whit...

Page 124: ...ROL PANEL DC RECEPTACLE PARALLEL OPERATION OUTLET 2 FLAT SCREW 4 x 12 mm 8 PACKING 2 AC RECEPTACLE 16A 250V 2 HARNESS BAND CLIP COUPLER CLIP CONTROLWIRE HARNESS CABLE TIE ASSEMBLY Install the ground terminal as shown PAN SCREW 5 x 8 mm FLANGE NUT 4 mm 8 PAN SCREW 5 x 12 mm PANEL MARK PAN SCREW 5 x 13 mm 2 PAN SCREW 5 x 8 mm ...

Page 125: ... C7 C8 T1 T2 T3 T4 T5 T6 T7 T8 GND2 Terminal number Wire color 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y Y G Bu R Y G 3 6 Ignition control module side 2 WHITE TAPE WHITE TAPE WHITE TAPE IGNITION CONTROL MODULE CABLE TIE WHITE TAPE Clamp the taping position as shown T7 GND2 T8 T4 T5 T3 C7 T1 T2 GND3 C8 2 T6 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light g...

Page 126: ...NTROL PANEL DC RECEPTACLE PARALLEL OPERATION OUTLET 2 FLAT SCREW 4 x 20 mm 8 AC RECEPTACLE 15A 250V 2 HARNESS BAND CLIP COUPLER CLIP CONTROLWIRE HARNESS CABLE TIE ASSEMBLY Install the ground terminal as shown PAN SCREW 5 x 8 mm FLANGE NUT 4 mm 8 PAN SCREW 5 x 12 mm PANEL MARK PAN SCREW 5 x 13 mm 2 PAN SCREW 5 x 8 mm ...

Page 127: ...G C7 C8 T1 T2 T3 T4 T5 T6 T7 T8 GND2 AC RECEPTACLE 15A 250V Terminal number Wire color 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y Y G Bu R Y G 3 6 Ignition control module side 2 WHITE TAPE IGNITION CONTROL MODULE CABLE TIE WHITE TAPE Clamp the taping position as shown T7 GND2 T8 T4 T5 T3 C7 T6 T1 T2 C8 GND3 Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light g...

Page 128: ... C HARNESS BAND CLIP AC CIRCUIT PROTECTOR 20A AC CIRCUIT PROTECTOR 30A AC RECEPTACLE 30A 125V AC RECEPTACLE 20A 125V ASSEMBLY Install the ground terminal as shown CABLE TIE C PAN SCREW 5 x 8 mm FLANGE NUT 4 mm 4 PAN SCREW 5 x 16 mm PANEL MARK PAN SCREW 5 x 13 mm 2 PAN SCREW 5 x 8 mm COUPLER CLIP SPRING WASHER 5 mm PLAIN WASHER 5 mm SUB CORD A BREATHER HEATER SUB CORD IGNITION CONTROL MODULE ...

Page 129: ...ITE TAPE SUB CORD A SUB CORD A CONTROL WIRE HARNESS Terminal number Wire coior 1 2 4 5 7 8 9 Control wire harness side 10 Bl Bu Bl R Y Y G Bu R G 3 6 Ignition control module side 2 CABLE TIE C SUB CORD AC CIRCUIT PROTECTOR 20A AC RECEPTACLE 20A 125V IGNITION CONTROL MODULE CABLE TIE WHITE TAPE Clamp the taping position as shown 2 C12 T7 C9 GND2 C10 T8 T4 T5 T3 C11 C7 T6 T1 T2 GND3 C8 T9 T10 Bl Bla...

Page 130: ...on each tester When there is no continuity the display shows the same as it does when the tester is not used for measurement OL OF etc Some testers have reverse polarity Unit V Unit V Unit V Tester probe Connec tor Tester probe Con nector Terminal 5 1 0 3 0 8 3 0 3 0 8 Tester probe Connec tor Tester probe Con nector Terminal 1 1 0 3 0 8 3 0 3 0 8 Tester probe Connec tor Tester probe Con nector Ter...

Page 131: ...ALLEL OPERATION OUTLET INSPECTION There must be continuity between the outlet and terminal AC CIRCUIT PROTECTOR INSPECTION There should be continuity between the terminals with the AC circuit protector in the ON position 2 1 3 4 12 Tester probe Connector Tester probe Connector Terminal 1 2 3 4 1 2 Continuity Continuity Continuity 3 Continuity 4 Continuity 12 12 ...

Page 132: ...pair the generator wire harness page 8 10 If the resistance is out of specification replace the stator page 8 10 Coil Con nector Termi nal number Resis tance Ω MAIN 2 3 0 6 1 1 3 4 0 6 1 1 2 4 0 6 1 1 SUB 1 2 0 4 0 7 DC 3 4 0 1 0 3 EXCITER 5 9 0 4 0 7 11 10 10 11 Viewed from terminal side 12 12 10 11 12 10 11 12 COIL Terminal Standard resis tance Ω MAIN U V 0 6 0 9 U W 0 6 0 9 V W 0 6 0 9 SUB SUB ...

Page 133: ...MEMO ...

Page 134: ... COIL IGNITION PULSE GENERATOR REMOVAL INSTALLATION 9 5 IGNITION PULSE GENERATOR AIR GAP ADJUSTMENT 9 6 SPARK TEST 9 6 IGNITION PULSE GENERATOR INSPECTION 9 7 IGNITION COIL INSPECTION 9 7 IGNITION CONTROL MODULE LINE INSPECTION 9 7 IGNITION CONTROL MODULE INSPECTION 9 8 ...

Page 135: ...bnormal Adjust the ignition pulse generator air gap page 9 6 Abnormal Replace the ignition pulse generator page 9 5 Abnormal Replace the ignition coil page 9 5 Abnormal Replace or repair the generator wire harness page 8 10 and or control wire harness page 8 13 Check the engine stop switch page 11 3 Check the ignition pulse generator air gap page 9 6 Check the ignition pulse generator page 9 7 Nor...

Page 136: ...harness page 8 13 Abnormal Replace or repair the generator wire harness page 8 10 and or control wire harness page 8 13 From page 9 2 Check the harness connecting the ignition coil and ignition control module for open or short circuit and for proper connection Normal Check the harness connecting the exciter coil inverter unit and ignition control module for open or short circuit and for proper con...

Page 137: ...resistance page 8 29 Abnormal Replace the ignition control module page 8 13 Check the ignition control module page 9 8 No spark Normal Good spark Replace the ignition coil page 9 5 Perform the spark test again using a new ignition coil page 9 6 Normal Replace the ignition control module page 8 13 ...

Page 138: ...r shroud as shown GENERATOR WIRE HARNESS CYLINDER HEAD COVER HOOK STICK OUT INSULATOR BIND CLIP 3 UPPER SHROUD INSULATOR FLANGE BOLT 6 x 14 mm LOWER SHROUD COLLAR A LOWER SHROUD COLLAR B 9 3 N m 0 95 kgf m 6 9 lbf ft IGNITION PULSE GENERATOR IGNITION PULSE GENERATOR BRACKET SOCKET BOLT 5 x 14 mm 2 GENERATOR WIRE HARNESS FLANGE BOLT 6 x 23 mm 2 LOWER SHROUD IGNITION COIL 6 N m 0 6 kgf m 4 3 lbf ft ...

Page 139: ...s 4 Remove the feeler gauge SPARK TEST Remove the muffler protector cover page 5 4 Disconnect the spark plug cap 1 from the spark plug Connect a known good spark plug 2 to the spark plug cap and ground the spark plug to the cylinder head cover 3 Turn the engine stop switch to the ON position Ground the negative electrode of the spark plug against the cylinder head cover and pull the recoil starter...

Page 140: ...wire harness according to the table below If it is normal check the ignition control module Unit Ω Resistance 294 359 Ω 20 C 68 F 1 2 Resistance 0 684 0 836 Ω 2 Terminals Circuit Test and result 2 GND Oil level switch Check for resistance to fan cover body There should be no continuity with correct engine oil level 5 GND Exciter coil Check for resistance to fan cover body Resistance 1 0 2 0 Ω 6 GN...

Page 141: ...ber 1 2 3 4 5 6 7 8 9 10 Terminal number 1 1k 50k 1k 50k 20k 500k 1k 50k 50k 500k 2 1k 50k 1k 50k 20k 500k 1k 50k 50k 500k 3 1k 50k 1k 50k 20k 500k 1k 50k 50k 500k 4 20k 500k 20k 500k 20k 500k 50k 500k 1k 50k 50k 500k 5 50k 500k 50k 500k 50k 500k 10k 200k 200k 1M 6 10k 200k 10k 200k 10k 200k 10k 200k 20k 500k 7 50k 500k 50k 500k 50k 500k 50k 500k 20k 500k 8 9 10 30k 500k 30k 500k 30k 500k 50k 500k...

Page 142: ...10 1 10 10 STARTING SYSTEM RECOIL STARTER FAN COVER REMOVAL INSTALLATION 10 2 RECOIL STARTER ROPE REPLACEMENT 10 3 RECOIL STARTER INSPECTION 10 4 ...

Page 143: ...SYSTEM 10 2 STARTING SYSTEM RECOIL STARTER FAN COVER REMOVAL INSTALLATION Remove the side cover page 5 7 TAPPING SCREW 5 x 16 mm 2 RECOIL STARTER BOLT 6 x 20 mm 3 1 2 N m 0 12 kgf m 0 9 lbf ft STARTER ROPE GUIDE ...

Page 144: ...d or equivalent material 3 as shown Untie the knots 4 of the starter rope 5 at the starter grip side and the starter reel side and remove the starter rope When the starter rope has broken or the starter reel has rewound align the rope hole in the starter case 1 with the rope hole in the starter reel 2 by turning the starter reel 3 7 turns in the direction of the arrows 1 2 3 4 5 4 Untie Hold 1 Unt...

Page 145: ...l the grip cover to the recoil starter grip Check the recoil starter operation RECOIL STARTER INSPECTION RECOIL STARTER OPERATION Remove the recoil starter page 10 2 Check the operation of the ratchets 1 by pulling the starter rope out several times STARTER PULLEY Remove the recoil starter page 10 2 Check the inner side of the starter pulley 1 for deformation and wear 1 2 3 4 5 6 Tie Tie 7 1 1 ...

Page 146: ...11 1 11 11 OTHER ELECTRICAL OIL LEVEL SWITCH REMOVAL INSTALLATION 11 2 OIL LEVEL SWITCH INSPECTION 11 3 ENGINE STOP SWITCH INSPECTION 11 3 ...

Page 147: ...CAL OIL LEVEL SWITCH REMOVAL INSTALLATION Remove the crankshaft page 15 4 O RING 14 mm OIL LEVEL SWITCH OIL LEVEL SWITCH JOINT NUT 10 mm BOLT 6 x 12 mm 2 10 N m 1 0 kgf m 7 lbf ft INSTALLATION Install firmly in the groove CYLINDER BARREL ...

Page 148: ...hould go from continuity to no continuity as the switch is lowered into the oil ENGINE STOP SWITCH INSPECTION Remove the control panel page 8 8 Disconnect the engine stop switch 2P connector Check continuity between the terminals according to the table below 1 LOW OIL LEVEL CONTINUITY NORMAL OIL LEVEL NO CONTINUITY C4 Switch position Terminal FREE ON PUSH OFF 1 2 Continuity No continuity ENGINE ST...

Page 149: ...MEMO ...

Page 150: ...12 1 12 12 MUFFLER MUFFLER REMOVAL INSTALLATION 12 2 ...

Page 151: ... after stopping the engine Be careful not to touch the muffler while it is hot Al low it to cool before proceeding MUFFLER HEX NUT 8 mm 2 24 N m 2 4 kgf m 18 lbf ft MUFFLER GASKET BOLT 6 x 47 mm NUT 6 mm 8 3 N m 0 85 kgf m 6 1 lbf ft TAPPING SCREW 4 x 6 mm Equipped type only SPARK ARRESTER Equipped type only 2 2 N m 0 22 kgf m 1 6 lbf ft CLEANING Page 3 7 ...

Page 152: ...13 1 13 13 GENERATOR ENGINE REMOVAL INSTALLATION GENERATOR ENGINE REMOVAL INSTALLATION 13 2 FAN COVER FAN COVER GUIDE REMOVAL INSTALLATION 13 3 FAN COVER GUIDE DISASSEMBLY ASSEMBLY 13 4 ...

Page 153: ...STALLATION After installing the washer install the right front mount rubber aligning the tab with the slot of the crankcase cover CRANKCASE COVER TAB SLOT INSTALLATION Install the center under guard aligning four tabs with slots of the under cover CENTER UNDER GUARD SLOT FLANGE NUT 8 mm 4 NUT 6 mm 4 8 3 N m 0 85 kgf m 6 1 lbf ft WASHER 2 24 N m 2 4 kgf m 18 lbf ft BOLT 6 x 10 mm 2 8 N m 0 82 kgf m...

Page 154: ...ng the end with the groove of the upper shroud GROOVE CUTOUT REMOVAL Remove the rubber grommet of the stator FAN COVER GUIDE ASSEMBLY INSTALLATION Install the fan cover guide assembly aligning the cutout with the groove of the rubber grommet CUTOUT TAB FAN COVER BRACKET INSTALLATION Install the fan cover bracket aligning the cutout with the tab of the fan cover guide assembly 8 3 N m 0 85 kgf m 6 ...

Page 155: ...GUIDE ASSEMBLY Be sure that the fan cover seal is set securely FAN COVER SEAL FAN COVER GUIDE ASSEMBLY Install the projection as far as it will go FAN COVER GUIDE FAN COVER SEAL PROJECTION FAN COVER SEAL ASSEMBLY Be sure that the fan cover seal is set securely FAN COVER GUIDE FAN COVER SEAL ...

Page 156: ...R HEAD TOOLS 14 2 CYLINDER HEAD REMOVAL INSTALLATION 14 3 CYLINDER HEAD DISASSEMBLY ASSEMBLY 14 4 CYLINDER HEAD VALVES INSPECTION 14 5 VALVE GUIDE REPLACEMENT 14 8 VALVE GUIDE REAMING 14 9 VALVE SEAT RECONDITIONING 14 9 ...

Page 157: ...24 5 07780 0010100 Seat cutter 27 5 07780 0010200 Flat cutter 25 07780 0012000 Flat cutter 28 07780 0012100 Interior cutter 30 07780 0014000 Cutter holder 5 5 07781 0010101 Valve guide driver 5 0x9 4 07942 8920000 Valve guide reamer 5 510 07984 2000001 ...

Page 158: ... HEAD COVER REMOVAL INSTALLATION Loosen and tighten the four 8 x 60 mm flange bolts in a crisscross pattern in 2 or 3 steps TORQUE 24 N m 2 4 kgf m 18 lbf ft DOWEL PIN 10 x 16 mm 2 REMOVAL INSTALLATION Before installing the cylinder head remove any carbon deposits from the combustion chamber and inspect the valve seats After installing the cylinder head measure the cylinder compression CYLINDER HE...

Page 159: ...valve only PUSH ROD EXHAUST VALVE GUIDE INTAKE VALVE ASSEMBLY Do not interchange with the exhaust valve The intake valve is bigger than the exhaust valve CYLINDER HEAD Apply to the tappet surface and pivot VALVE SPRING RETAINER VALVE ROCKER ARM 2 ASSEMBLY Before installing the valve rocker arm check the surfaces that contact the rocker arm pivot bolt the push rod intake valve stem and the valve ro...

Page 160: ...asurement is more than the service limit replace the cylinder head VALVE SEAT WIDTH Thoroughly clean the combustion chamber and valve seats to remove carbon deposits Inspect each valve face for irregularities If necessary replace the valve page 14 4 Apply a light coat of Prussian Blue or erasable felt tipped marker ink to the each valve seat Insert the valve and snap it using a valve lapper 1 clos...

Page 161: ...e limit replace the valve page 14 4 Inspect the valve guide I D with this inspection GUIDE TO STEM CLEARANCE Subtract each valve stem O D from the corresponding valve guide I D to obtain the stem to guide clearance If the calculated clearance is more than the service limit replace the valves page 14 4 and valve guide Recondition the valve seats whenever the valve guides are replaced page 14 8 TOOL...

Page 162: ...VE SPRING PERPENDICULARITY Measure the valve spring perpendicularity If the measured perpendicularity is more than the service limit replace the valve spring page 14 4 PUSH ROD RUNOUT Check both ends of the push rod 1 for wear Check the push rod for straightness If necessary replace the push rod page 14 4 STANDARD 30 5 mm 1 20 in SERVICE LIMIT 29 0 mm 1 14 in SERVICE LIMIT 1 5 1 ...

Page 163: ...from the refrigerator one at a time as needed Install the new valve guides from the valve spring side of the cylinder head Exhaust valve guide 2 Drive the exhaust valve guide until the valve guide clip 3 is fully seated as shown Intake valve guide 4 Drive the intake valve guide to the specified height measured from the top of the valve guide to the cylinder head as shown After installing the valve...

Page 164: ... remove any cutting residue Check the valve guide bore it should be straight round and centered in the valve guide Insert the valve and check operation If the valve does not operate smoothly the guide may have been bent during installation Replace the valve guide if it is bent or damaged Check the valve guide to stem clearance page 14 6 VALVE SEAT RECONDITIONING Check the valve width page 14 5 Use...

Page 165: ...into their seats using a commercially available valve lapper 1 and lapping compound After lapping wash all residual compound off the cylinder head and valve Do not push the valve against the seat with force during lapping Apply a light pass with the valve lapper Avoid lapping the valve in the same position as it causes uneven wear Lap the valve by turning the lapper slowly Take care not to allow t...

Page 166: ...SHAFT PISTON REMOVAL INSTALLATION 15 4 PISTON DISASSEMBLY ASSEMBLY 15 5 CRANKCASE COVER CYLINDER BARREL PISTON CONNECTING ROD CRANKSHAFT CAMSHAFT INSPECTION 15 6 CRANKSHAFT BEARING REPLACEMENT CRANKCASE COVER SIDE 15 12 CRANKSHAFT BEARING OIL SEAL REPLACEMENT CYLINDER BARREL SIDE 15 13 ...

Page 167: ... TOOLS Sliding hammer weight 07741 0010201 Bearing driver attachment 37 40 07746 0010200 Bearing driver attachment 52 55 07746 0010400 Pilot 25 07746 0040600 Driver handle 15 135L 07749 0010000 Bearing remover shaft set 25 07936 ZV10100 ...

Page 168: ...TION Remove the fan cover guide assembly page 13 3 CRANKCASE COVER PACKING DOWEL PIN 2 CRANKCASE COVER OIL FILLER CAP PACKING OIL FILLER CAP DRAIN PLUG WASHER 10 2 mm DRAIN PLUG BOLT BOLT 8 x 32 mm 6 24 N m 2 4 kgf m 18 lbf ft 18 N m 1 8 kgf m 13 lbf ft ...

Page 169: ... toward the push rod hole of the cylinder head CYLINDER BARREL Slipper surface and stem Cam and bearings CAMSHAFT INSTALLATION Set the connecting rod cap with the oil dipper toward the camshaft and align the ribs of the connecting rod cap and the connecting rod CONNECTING ROD CAP Threads and seating surface 12 N m 1 2 kgf m 9 lbf ft INSTALLATION Before installing the crankshaft check the oil seal ...

Page 170: ...SECOND RING OIL RING COMBINATION RING TOP RING SECOND RING OIL RING COMBINATION RING SIDE RAIL SPACER PISTON PIN PISTON PIN CLIP 2 ASSEMBLY Do not reuse Install by setting one end of the piston pin clip in the groove of the piston pin bore holding the other end with needle nose pliers and rotating the clip in Do not align the end gap of the piston pin clip with the cutout of the piston pin bore Bi...

Page 171: ...vice limit replace the cylinder barrel page 15 4 CYLINDER SLEEVE I D Measure and record the cylinder I D at three levels in both the X axis perpendicular to crankshaft and the Y axis parallel to crankshaft Take the maximum reading to determine cylinder wear and taper If the measurement is more than the service limit replace the cylinder barrel page 15 4 STANDARD 14 000 14 018 mm 0 5512 0 5519 in S...

Page 172: ...ce is more than the service limit replace the piston page 15 5 and recheck the clearance If the clearance is still more than the service limit with the new piston replace the cylinder barrel page 15 4 PISTON PIN BORE I D Measure and record the piston pin bore I D of the piston If the measurement is more than the service limit replace the piston page 15 5 STANDARD 67 965 67 985 mm 2 6758 2 6766 in ...

Page 173: ...ch piston ring and ring groove of the piston using feeler gauge If the calculated clearance is more than the service limit replace the piston ring page 15 5 and recheck the clearance If the clearance is still more than the service limit with the new piston ring replace the piston page 15 5 PISTON RING WIDTH Measure each piston ring width If any of the measurements is less than the service limit re...

Page 174: ...ecting rod page 15 5 and recheck the clearance If the clearance is still more than the service limit with the new connecting rod replace the crankshaft page 15 4 CONNECTING ROD SMALL END I D Measure the connecting rod small end I D If the measurement is more than the service limit replace the connecting rod page 15 5 Check the piston pin O D page 15 8 STANDARD Top 0 200 0 350 mm 0 0079 0 0138 in S...

Page 175: ...e service limit with the new connecting rod replace the crankshaft page 15 4 CONNECTING ROD BIG END I D Set the connecting rod cap to the connecting rod and tighten the two connecting rod bolts 1 to the specified torque Measure the connecting rod big end I D If the measurement is more than the service limit replace the connecting rod page 15 5 Check the crank pin O D page 15 10 CRANK PIN O D Measu...

Page 176: ...akened replace the spring Check that the decompressor weight moves smoothly If the decompressor weight does not move correctly replace the camshaft page 15 4 RADIAL BALL BEARING Clean the bearing with solvent and dry it thoroughly Turn the inner race of the radial ball bearing with your finger and check for play Replace the radial ball bearing if it is noisy or has excessive play STANDARD IN 27 60...

Page 177: ...ls Apply oil to the circumference of a new bearing 1 Drive the radial ball bearing until it is fully seated on the end using the special tools CRANKSHAFT BEARING 6205 TOOLS Bearing remover shaft set 25 2 07936 ZV10100 Sliding hammer weight 3 07741 0010201 3 2 1 TOOLS Driver handle 15x135L 2 07749 0010000 Bearing driver attachment 52x55 3 07746 0010400 Pilot 25 4 07746 0040600 1 Circumference 4 3 2...

Page 178: ...al tools CRANKSHAFT OIL SEAL 25 x 41 x 6 mm Remove the crankshaft page 15 4 Remove the crankshaft oil seal Apply grease to the lip of a new oil seal 1 Drive the oil seal in the position as shown using the special tools CRANKSHAFT BEARING 6205 CRANKSHAFT OIL SEAL 25 x 41 x 6 mm TOOLS Driver handle 15x135L 2 07749 0010000 Bearing driver attachment 52x55 3 07746 0010400 Pilot 25 4 07746 0040600 3 2 4...

Page 179: ...MEMO ...

Page 180: ...16 1 16 16 TECHNICAL FEATURES FRAME MADE OF MAGNESIUM 16 2 INDICATOR 16 3 ...

Page 181: ...e by taking advantages of the T shaped frame CONSTRUCTION A light but yet robust body which has a stiffened frame by a resin cover alongside having a simple T shaped frame structure COOLING ZONE GENERATOR FUEL TANK HOT ZONE ENGINE MUFFLER COOLING ZONE MAGNESIUM FRAME CENTER FRAME RESIN FRAME FRONT FRAME COOLIING AIR INVERTER UNIT CONTROL PANEL T SHAPEDE FRAME RESIN COVER LARGE SIZE WHEEL REAR CARR...

Page 182: ...e 1 Operating hour 100 hrs Blinks once at start Blinks twice 4 300hrs Operating hours 400 hrs 5 400 hrs Operating hours 500 hrs 6 500 hrs operating hours OFF OFF OFF OFF OFF OFF ON Blinks once ON ON 3 200hrs Operating hours 300hrs Blinks 3 times ON Blinks 4 times Blinks 5 times ON ON Engine start Generate start Output indicator No blinking at start 2 100 hrs Operating hours 200 hrs Blinks twice at...

Page 183: ...tor overload error detection Detecting error indicates that it is detecting either of the following SCR element temperature abnormality FET element temperature abnormality excess voltage or excess current INDICATOR Assy OUTPUT INDICATOR GREEN ON OFF Condition of generator OUTPUT INDICATOR GREEN Generating power ON Stop generating power OFF INDICATOR Assy OVERLOAD INDICATOR RED ON OFF Condition of ...

Page 184: ... be cut to stop the engine Also when engine oil level is insufficient at start it will not be able to start the engine Insufficient engine oil INDICATOR Assy OVERLOAD INDICATOR RED Blinking cycle ON OFF 250ms 250ms BLINK OFF Condition of generator OVERLOAD INDICATOR RED Detecting malfunctions Blinking Other than above OFF INDICATOR Assy OIL ALERT INDICATOR RED ON OFF Condition of generator OIL ALE...

Page 185: ...MEMO ...

Page 186: ...17 1 17 17 WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM RELATED INFORMATION 17 2 WIRING DIAGRAMS 17 4 ...

Page 187: ...he dedicated connectors The double frame connectors represent the male connectors and the single frame connectors represent the female connectors Both the male and female connectors are shown by viewing them from the terminal side FEMALE CONNECTOR MALE CONNECTOR LOCK VIEWING DIRECTION VIEWING DIRECTION FEMALE CONNECTOR DRAWING SINGLE FRAME Female connector viewed from the terminal side CONNECTOR N...

Page 188: ...R Red P Pink W White Gr Gray SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a male or female terminal TERMINAL No CONNECTOR TERMINAL No Every connector and terminal has a number to help the users find the location and shape of the connector and the terminal arrangement by referring to the Connector general layout drawing and or the Connector drawing All the connec...

Page 189: ...Br W W W B r Y G B r B r B r MAIN EX SUB DC M A I N U M A I N V S U B V S U V N M A I N W v d c A C 1 A C 2 V C C V C C N C N C R X D T X D V 2 E C O H Z P L P L B B A A E S E ES EX IC CPU PC E Reg LS IND IND VCC PL OL IND IND DC N DC W GND TERMINAL FRONT COVER BLOCK GENERATOR BLOCK ENGINE BLOCK INVERTER BLOCK INVERTER UNIT CONTROL PANEL BLOCK CONSENT BOX THROTTLE CONTROL MOTOR OIL LEVEL SWITCH SP...

Page 190: ... G Y G W Br B r W B r W Y G W B r Y G W B r MAIN EX SUB DC M A I N U M A I N V S U B V S U V N M A I N W v d c A C 1 A C 2 V C C V C C N C N C R X D T X D V 2 E C O H Z P L P L B B A A E S E ES EX IC CPU PC E Reg LS IND IND VCC PL OL IND IND DC N DC W GND TERMINAL FRONT COVER BLOCK GENERATOR BLOCK ENGINE BLOCK INVERTER BLOCK INVERTER UNIT CONTROL PANEL BLOCK CONSENT BOX THROTTLE CONTROL MOTOR OIL ...

Page 191: ... R R W Y G Y G R W W Bl Bl W B r B r Y G W B r Y G MAIN EX SUB DC M A I N U M A I N V S U B V S U V N M A I N W v d c A C 1 A C 2 V C C V C C N C N C R X D T X D V 2 E C O H Z P L P L B B A A E S E ES EX IC CPU PC E Reg LS IND IND VCC PL OL IND IND DC N DC W FRONT COVER BLOCK GENERATOR BLOCK ENGINE BLOCK INVERTER BLOCK INVERTER UNIT CONTROL PANEL BLOCK THROTTLE CONTROL MOTOR OIL LEVEL SWITCH SPARK...

Page 192: ...W MAIN EX SUB DC M A I N U M A I N V S U B V S U V N M A I N W v d c A C 1 A C 2 V C C V C C N C N C R X D T X D V 2 E C O H Z P L P L B B A A E S E ES EX IC CPU PC E Reg LS IND IND VCC PL OL IND IND DC N DC W GND TERMINAL FRONT COVER BLOCK GENERATOR BLOCK ENGINE BLOCK INVERTER BLOCK INVERTER UNIT CONTROL PANEL BLOCK CONSENT BOX THROTTLE CONTROL MOTOR BREATHER HEATER OIL LEVEL SWITCH SPARK PLUG IG...

Page 193: ...MEMO ...

Page 194: ...2 FUEL TANK DISASSEMBLY ASSEMBLY C TYPE ONLY 6 13 FUEL TANK REMOVAL INSTALLATION 6 5 FUEL TANK FUEL FILTER CLEANING 3 9 FUEL TUBE CHECK 3 10 G GENARATOR SYSTEM TROUBLESHOOTING 8 3 GENERATOR INSPECTION 8 29 GENERATOR REMOVAL INSTALLATION 8 10 GENERATOR ENGINE REMOVAL INSTALLATION 13 2 H HARD STARTING 4 2 HOW TO READ WIRING DIAGRAM RELATED INFORMATION 17 2 I IGNITION COIL INSPECTION 9 7 IGNITION COI...

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