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Yamaha EF2400iS - Inverter Generator, Service Manual

The Yamaha EF2400iS - Inverter Generator offers reliable and efficient power for all your outdoor needs. With its compact design and advanced inverter technology, it ensures stable electricity for sensitive electronics. Enhance your experience today by downloading the free Service Manual from manualshive.com. Get instant access to detailed instructions and maintenance tips to maximize the longevity of your generator.

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3-30

VALVE

5

4

3

2

1

VALVE AND VALVE SPRING ASSEMBLY

1. Install:

9

Valve 

1

9

Valve spring 

2

9

Valve spring retainer 

3

9

Valve cotter 

4 

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

5

to

install the parts.

c

C

Do not compress the valve spring more
than necessary.

ENG

Valve spring compressor:

YM-01253, 90890-01253

 7CF7E0-03  05.7.3 15:14  Page 30

Summary of Contents for EF2400iS - Inverter Generator

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2005 06 x 1 E SERVICE MANUAL EF2400iS 7CF 28197 E0 331153 7CFE0Cover 05 7 23 16 16 Page 1 ...

Page 2: ......

Page 3: ... Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w 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 cC 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 ...

Page 4: ...luid 9 Lubricant 0 Special tool q Tightening w Wear limit clearance e Engine speed r W V A Illustrated symbols t through d in the exploded diagram indicate the grades of lubri cant and the locations of the lubrication points t Apply engine oil y Apply gear oil u Apply molybdenum disulfide oil i Apply wheel bearing grease o Apply lightweight lithium soap base grease p Apply molybdenum disulfide gre...

Page 5: ...INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE CARBURETOR ELECTRICAL TROUBLESHOOTING SPECIFICATIONS ...

Page 6: ...ED ENGINE SPEED 2 14 BREATHER HOSE 2 14 ELECTRICAL 2 15 SPARK PLUG 2 15 ENGINE SWITCH 2 16 RECEPTACLE 2 17 AC SWITCH NFB For CANADA 2 17 DC SWITCH NFB For CANADA 2 18 DC CIRCUIT BREAKER 2 20 CHAPTER 3 ENGINE CONTROL BOX 3 1 CONTROL BOX DISASSEMBLY 3 1 CONTROL BOX ASSEMBLY 3 3 ENGINE 3 4 RECOIL STARTER 3 5 RECOIL STARTER DISASSEMBLY 3 6 RECOIL STARTER DISASSEMBLY 3 7 RECOIL STARTER INSPECTION 3 7 R...

Page 7: ...LATION 3 40 CRANKSHAFT ASSEMBLY 3 41 CHAPTER 4 CARBURETOR CARBURETOR 4 1 CARBURETOR DISASSEMBLY 4 2 FLOAT HEIGHT INSPECTION 4 4 THROTTLE CONTROL MOTOR 4 5 CHAPTER 5 ELECTRICAL ELECTRICAL COMPONENTS 5 1 CIRCUIT DIAGRAM 5 2 SWITCHES 5 5 CHECKING SWITCH CONTINUITY 5 5 IGNITION SYSTEM 5 6 TROUBLESHOOTING CHART 5 6 GENERATOR SYSTEM 5 10 TROUBLESHOOTING CHART 5 10 CHAPTER 6 TROUBLESHOOTING ENGINE 6 1 TH...

Page 8: ...ator as shown NOTE The first three characters of this number are for model identification the remaining digits are the unit production number STARTING SERIAL NUMBER NOTE Designs and specifications are subject to change without notice 120V 60Hz 7CF2 7CF 260101 For Canada 230V 50Hz 7CF2 7CF 300101 For Germany 230V 50Hz 7CF3 7CF 310101 For Australia 220V 60Hz 7CF3 7CF 320101 For Korea ...

Page 9: ...d sealers or the equivalents 3 Expendable parts Always replace the gaskets O rings cotter pins and circlips with new parts when servicing engine 4 Tightening torque Be sure to follow torque specifications When tightening bolts nuts or screws start with the largest diameter fastener and work from an inner position to an outer position in a crisscross pat tern 5 Notes on disassembly and assembly a P...

Page 10: ...eaned 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 lightweight lithium base grease to the seal lip s Oi...

Page 11: ...ston ring end gap 2 Cylinder gauge Commercially obtainable This instrument is used for checking cylinder bore size and con dition 3 Inductive tachometer P N YU 8036 A Engine tachometer P N 90890 03113 This instrument is used for reading engine r min 4 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 5 Dial gauge P ...

Page 12: ...instrument is necessary for checking the electrical system 9 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 10 Valve spring compressor P N YM 01253 90890 01253 This tool is used to remove the valve springs 11 Piston ring compressor P N YU 33294 90890 05158 This tool is used to compress the piston rings...

Page 13: ......

Page 14: ... as in the chart PERIODIC MAINTENANCE LUBRICATION INTERVALS INTRODUCTION MAINTENANCE INTERVALS CHART PERIODIC MAINTENANCE LUBRICATION INTERVALS No å Item Remarks ç Pre Operation check daily Initial Every ƒ 1 month or 20 Hr 3 months or 50 Hr 6 months or 100 Hr ˆ 12 months or 300 Hr 1 Check condition Spark Plug Adjust gap and clean Replace if necessary 0 2 Check and adjust Valve Clearance when engin...

Page 15: ...em Remarks ç Pre Operation check daily Initial Every ƒ 1 month or 20 Hr 3 months or 50 Hr 6 months or 100 Hr ˆ 12 months or 300 Hr 13 Generation Check the pilot light comes on 0 14 Fittings Check all fittings and fasteners Fasteners Correct if necessary 0 1 2 3 4 5 ...

Page 16: ...4 Front cover 1 Disconnect the couplers and lead wires 5 Rear cover 1 6 Fuel tank cap 1 7 Top cover 1 8 Side cover left right 1 1 9 Fuel tank assembly 1 Disconnect the fuel hose from the fuel cock For installation reverse the removal procedure COVERS AND FUEL TANK COVERS AND FUEL TANK 6 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 1 3 Nm 0 13 m kg 1 0 ft lb 7 9 8 1 2 4 3 8 5 å 7CF3010E INSP ADJ...

Page 17: ...eck whether the oil warning light flashes by operating the recoil starter Oil warning light flashes Add oil Oil warning light does not flash OK 2 Open the oil filler cover 3 Remove 9 Oil filler cap 1 4 Check 9 Check that the engine oil is at the spec ified level a Oil level checking steps 9 Place the engine on a level surface 9 Warm up the engine for several minutes 9 Stop the engine 9 Check that ...

Page 18: ...engine and then to drain the oil completely 5 Tighten 9 Oil drain bolt 2 6 Remove 9 Oil filler cap 7 Fill NOTE Recommended engine oil classification API Service SE or SF if not available SD 8 Install 9 Oil filler cap 9 Rubber cover INSP ADJ Recommended oil å YAMALUBE 4 10W 30 or SAE 10W 30 type SE SAE 30 or 10W 30 10W 40 ç SAE 20 or 10W 30 10W 40 SAE 10W or 10W 30 10W 40 Engine oil quantity 0 6 L ...

Page 19: ...s FUEL TANK FILTER w Do not smoke and keep away form open flames sparks or any other source of fire when handling or in the vicinity of fuel 1 Remove 9 Fuel tank cap 1 9 Fuel tank filter 2 2 Inspect 9 Fuel tank filter Damage Replace 3 Clean 9 Fuel tank filter NOTE Clean the fuel tank filter with solvent and then dry it thoroughly 4 Install 9 Fuel tank filter 9 Fuel tank cap w Be sure the tank cap ...

Page 20: ...ND FUEL TANK 2 Drain the fuel from the fuel tank com pletely 3 Remove 9 Fuel tank 9 Fuel hose 9 Fuel cock 1 4 Inspect 9 Fuel tank strainer 1 Damage Replace the fuel cock 5 Clean 9 Fuel tank strainer Damage Replace the fuel cock NOTE Clean the fuel tank strainer with solvent and then dry it thoroughly 6 Install 9 Fuel cock 7 Install 9 Fuel hose 9 Fuel tank 9 Side cover left 9 Side cover right 9 Top...

Page 21: ...e cap 2 2 Remove 9 Air cleaner element 1 3 inspect 9 Air cleaner element Damage Replace Clogging Wash the element in a sol vent and then dry it thoroughly Oil the element and squeeze out the excess oil cC 8 Do not wring out the element this could cause it to tear 8 Do not wash the element in gasoline or in acidic alkalinic or organic solvents 4 Install 9 Air cleaner element 9 Air cleaner case cap ...

Page 22: ...cover left 1 Refer to COVERS AND FUEL TANK 9 Muffler Refer to MUFFLER AND AIR CLEAN ER in CHAPTER 3 9 Muffler band 2 9 Muffler cap 3 9 Muffler screen 4 9 Spark arrester 5 2 Decarbonize 9 Muffler Tap on the muffler in the area shown in the illustration to loosen carbon buildup and then shake it out of the end of the muffler cC Don t use a wire to clean otherwise the noise damping material may come ...

Page 23: ... use the wire brush lightly to avoid damaging or scratching of the muffler screen and spark arrester 4 Install 9 Spark arrester 9 Muffler screen 9 Muffler cap 9 Muffler band 9 Muffler Refer to MUFFLER AND AIR CLEAN ER in CHAPTER 3 9 Side cover left Refer to COVERS AND FUEL TANK INSP ADJ ...

Page 24: ...y operate the starter rope to bring the piston to the top dead center of its compression stroke when the screwdriv er inserted into the spark plug hole reach es the highest position 4 Measure 9 Valve clearance Out of specification Adjust NOTE Valve clearance must be measured when the engine is cool to the touch INSP ADJ Intake Valve cold 0 1 mm 0 004 in Exhaust Valve cold 0 1 mm 0 004 in Thickness...

Page 25: ...cover 9 Breather hose 9 Spark plug 9 Spark plug cap 9 Rear cover Refer to COVERS AND FUEL TANK COMPRESSION PRESSURE NOTE Measure the compression after checking and adjusting the valve clearance 1 Warm up the engine for several minutes 2 Remove 9 Spark plug 3 Remove 9 Rear cover Refer to COVERS AND FUEL TANK INSP ADJ Adjuster Valve clearance Turn in Decrease Turn out Increase Locknut 10 Nm 1 0 m kg...

Page 26: ...ession again Testing steps above maximum level 9 Check the cylinder head valve surfaces and piston crown for carbon deposits 6 Install 9 Spark plug 9 Rear cover Refer to COVERS AND FUEL TANK INSP ADJ Compression gauge YU 33223 90890 03081 Adapter YU 33223 3 90890 04082 Standard compression pressure 820 880 kPa 8 2 8 8 kg cm2 119 128 psi Reading Diagnosis If higher than without oil If the same as w...

Page 27: ...NG in CHAPTER 6 Inspection steps 9 Operate the engine with no load 9 Measure the engine speed 4 Install 9 Rear cover Refer to COVERS AND FUEL TANK BREATHER HOSE 1 Remove 9 Rear cover Refer to COVERS AND FUEL TANK 2 Inspect 9 Breather hose 1 Cracks damage Replace Poor connection Correct 3 Install 9 Rear cover Refer to COVERS AND FUEL TANK INSP ADJ Inductive tachometer YU 8036 A Engine tachometer 90...

Page 28: ... 1 Remove 9 Rear cover Refer to COVERS AND FUEL TANK 2 Remove 9 Spark plug cap 9 Spark plug 3 Inspect 9 Electrode 1 Wear damage Replace 9 Insulator color 2 4 Measure 9 Spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap If necessary clean the spark plug with a spark plug cleaner Before installing the spark plug clean the gasket surface and plug surface INSP ADJ Spark pl...

Page 29: ...g before tightening it to the specified torque b 6 Install 9 Rear cover Refer to COVERS AND FUEL TANK ENGINE SWITCH 1 Check 9 Engine switch 1 Checking steps 9 Set the engine switch 1 to ON a 9 Start the engine 9 Check that the engine stops when the switch is set to STOP b INSP ADJ Spark plug 18 Nm 1 8 m kg 13 ft lb 230 V 50 Hz 220 V 60 Hz ...

Page 30: ...eceptacles 1 9 DC receptacle 2 Cracks damage Replace Poor connection Correct 1 8 7 A 2 12 V 8 A For GERMANY 1 9 1 A 2 12 V 8 A For KOREA 1 16 7 A 2 12 V 6 5 A For CANADA 1 8 7 A 2 12 V 8 7 A For AUSTRALIA INSP ADJ 230 V 50 Hz 220V 60Hz 120 V 60 Hz 230 V 50 Hz ...

Page 31: ...eceptacle and check the AC switch NFB for continuity No continuity Replace the AC switch NFB 3 Set the AC switch NFB 1 to the OFF b position 4 Connect the pocket tester AC 120 V to the AC receptacle and check the AC switch NFB for continuity Continuity Replace the AC switch NFB INSP ADJ Pocket tester YU 03112 90890 03112 Digital circuit tester 90890 03174 ...

Page 32: ...r DC 20 V 9 Start the engine 9 Set the economy switch to OFF 9 Measure the DC voltage 9 Set the DC switch 1 to OFF b Voltage is zero OK NOTE If the DC switch to OFF again refer to GEN ERATOR SYSTEM in CHAPTER 5 INSP ADJ Pocket tester YU 03112 90890 03112 Digital circuit tester 90890 03174 DC voltage More than 12 V at 5 000 r min with no load at AC output cur rent ...

Page 33: ...DC 20 V 9 Start the engine 9 Measure the DC voltage 9 Set the reset button to OFF b Voltage is zero OK NOTE If the reset button pup out OFF again refer to GENERATOR SYSTEM in CHAPTER 5 INSP ADJ DC voltage More than 12 V at 2 600 r min with no load at AC output cur rent Pocket tester YU 03112 90890 03112 Digital circuit tester 90890 03174 230 V 50 Hz 220V 60Hz 230 V 50 Hz 220V 60Hz 230 V 50 Hz 230 ...

Page 34: ...d below Front cover and rear cover Refer to COVERS AND FUEL TANK section in CHAPTER 2 1 Tapping screw 6 2 Plate assembly 1 Disconnect 3 Engine switch 1 Disconnect 4 Oil warning light red 1 Disconnect 5 Pilot light green 1 Disconnect 6 Over load warning light red 1 Disconnect 7 Terminal 2 Except for CANADA 8 DC receptacle 1 Disconnect 9 AC receptacle 1 Disconnect 10 DC circuit breaker 1 Disconnect ...

Page 35: ... AC switch NFB 1 For CANADA 15 DC switch NFB 1 For CANADA For assembly reverse the disassembly procedure 1 2 3 4 5 7CF3021E 1 2 12 10 11 3 12 4 5 6 7 9 8 1 2 8 11 3 12 4 5 6 9 15 14 12 1 2 12 8 11 3 12 4 5 6 7 9 10 13 1 2 12 10 11 3 12 4 5 6 7 9 8 230 V 50 Hz For GERMANY 120 V 60 Hz For CANADA 230 V 50 Hz For AUSTRALIA 220 V 60 Hz For KOREA ...

Page 36: ...3 3 CONTROL BOX ENG 2 1 CONTROL BOX ASSEMBLY 1 Install 9 Control box 1 NOTE Insert the rid of control box to the frame 2 ...

Page 37: ... order listed below Front cover rear cover side covers and fuel tank Refer to COVERS AND FUEL TANK section in CHAPTER 2 1 Band 1 2 Control unit 1 3 Throttle control motor wire coupler 1 Disconnect 4 Generator lead wire couplers 1 Disconnect 5 Front frame 1 6 Handle 2 7 Rear frame 1 8 Engine assembly 1 9 Noise filter 1 For GERMANY For installation reverse the removal procedure å For GERMANY ...

Page 38: ...emarks Recoil starter removal Remove the parts in the order listed below Front cover rear cover and side covers Refer to COVERS AND FUEL TANK and fuel tank section in CHAPTER 2 Carburetor Refer to CARBURETOR section in CHAPTER 4 1 Recoil starter assembly 1 2 Fan case cover 1 For installation reverse the removal procedure ...

Page 39: ...4 5 5 Nm 0 5 m kg 3 6 ft lb Order Job name Q ty Remarks Recoil starter disassembly Remove the parts in the order listed below 1 Bolt 1 2 Drive plate 1 3 Clip 1 4 Drive pawl 2 5 Spring 2 6 Sheave drum 1 7 Starter spring 1 8 Starter case 1 For disassembly reverse the assembly procedure ...

Page 40: ...se Then undo the knot b at the starter handle to the remove starter handle 1 2 Remove 9 Drum sheave 1 cC Be sure to press down on the drum sheave because the spring will spring out sudden ly when it is removed from the sheave drum 3 Remove 9 Spiral spring 1 RECOIL STARTER INSPECTION 1 Inspect 9 Starter rope 1 Damage Replace 2 Inspect 9 Spiral spring 2 Deterioration crack damage Replace 3 Inspect 9...

Page 41: ...ockwise and place it on the sheave drum 2 2 Install 9 Sheave drum 1 9 Starter rope 2 9 Starter case 3 NOTE 9 Wind the starter rope 2 clockwise two turns on the sheave drum 1 9 Engage starter spring inner hook a with the strut b of the starter case 3 and install the parts 3 Install 9 Spring 1 9 Drive pawl 2 NOTE Install the spring 1 and drive pawl 2 to the R mark a 4 Install 9 Clip 1 9 Drive plate ...

Page 42: ... After tightening the bolt place starter rope 2 in the cut out a in the sheave drum and wind it counterclockwise four turns NOTE Make a knot b at the end of the starter rope to prevent the rope from being retracted into the recoil starter case ENG 5 Nm 0 5 m kg 3 6 ft lb ...

Page 43: ... m kg 5 1 ft lb 2 3 Order Job name Q ty Remarks Ignition coil and rotor removal Remove the parts in the order listed below Engine assembly Refer to ENGINE Spark plug cap Recoil starter fan case Refer to ENGINE 1 Ignition coil 1 2 Rotor 1 3 Woodruff key 1 For installation reverse the removal procedure ...

Page 44: ...to remove any oil grease from the tapered portion of the magneto rotor using a cloth dampened with thinner 1 Install 9 Woodruff key 9 Rotor 9 Rotor nut 1 use the sheave holder 2 NOTE When installing the rotor make sure the woodruff key is properly seated in the key way of the crankshaft ENG Sheave holder YS 01880 90890 01701 Sheave holder YS 01880 90890 01701 Rotor puller YU 33270 2 90890 03162 3 ...

Page 45: ...AND ROTOR 2 Install 9 Ignition coil 3 Inspection 9 Air gap inspect the clearance between the magneto on the rotor and ignition coil Out of specification Replace ENG Air gap 0 5 0 1 mm 0 02 0 004 in 10 Nm 1 0 m kg 7 2 ft lb ...

Page 46: ...r Job name Q ty Remarks Muffler and air cleaner removal Remove the parts in the order listed below Front cover rear cover side covers Refer to COVERS AND FUEL TANK and fuel tank section in CHAPTER 2 Front and rear flame Refer to ENGINE Carburetor Refer to CARBURETOR section in CHAPTER 4 1 Exhaust cover 1 2 Muffler assembly 1 3 Gasket 1 4 Air cleaner case cap 1 5 Element 1 6 Metal gasket 1 7 Plate ...

Page 47: ...b 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb 1 2 Nm 0 12 m kg 0 9 ft lb 1 7 8 4 5 6 3 2 12 11 10 4 Nm 0 4 m kg 2 9 ft lb Order Job name Q ty Remarks 9 Silencer band 1 10 Cap 1 11 Muffler screen 1 12 Spark arrester 1 For installation reverse the removal procedure ...

Page 48: ...r cap 3 9 Muffler band 4 NOTE 9 Align the protrusion a located outside the spark arrester with the upper hole in the tail pipe 9 Align the rim of the muffler cap 3 with the protrusion b of the tail pipe 9 Contact the protrusion against the rim of the muffler cap 3 without allowing it to enter the slit 2 Install 9 Muffler nuts 1 9 Muffler bolt 2 NOTE Tighten the nuts and bolts to the specified torq...

Page 49: ...moval Remove the parts in the order listed below Front cover rear cover side covers Refer to COVERS AND FUEL TANK and fuel tank section in CHAPTER 2 Front and rear flame Refer to ENGINE Carburetor Refer to CARBURETOR section in CHAPTER 4 Muffler Refer to MUFFLER AND AIR CLEANER section Engine assembly Refer to ENGINE section 1 Rear end cover 1 2 Generator fan 1 3 Generator rotor 1 4 Tube 2 5 Stato...

Page 50: ...6 7 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb 65 Nm 6 5 m kg 47 ft lb 1 2 Nm 0 12 m kg 0 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb Order Job name Q ty Remarks 6 Stator assembly coupler 2 7 Cover 1 For installation reverse the removal procedure ...

Page 51: ... rotor 1 NOTE 9 Remove the magneto rotor 1 together with the stator coil assembly using the magneto rotor puller 2 9 Fully tighten the tool holding bolts making sure the tool body is parallel with the mag neto rotor If necessary one screw may be backed out slightly to level the tool body cC The magnetic force of the magneto rotor is very strong Therefore do not change the position of the magneto r...

Page 52: ...ND STATOR COIL ASSEMBLY INSTALLATION 1 Install 9 Cover 1 NOTE Connect the stator coil couplers before install the cover 1 2 Install 9 Magneto rotor 9 Stator coil assembly 9 Washer 9 Magneto rotor nut cC Be sure to remove any oil or grease from the tapered portion of the magneto rotor using a cloth dampened with thinner ENG ...

Page 53: ... until the stator coil assembly bolts are visible though the holes in the rotor and then remove the bolts 1 4 Tighten 9 Washer 9 Magneto rotor nut 1 NOTE Tighten the magneto rotor nut 1 using the sheave holder 2 ENG 65 Nm 6 5 m kg 47 ft lb Sheave holder YS 01880 90890 01701 10 Nm 1 0 m kg 7 2 ft lb ...

Page 54: ...the parts in the order listed head removal below Front cover rear cover side covers Refer to COVERS AND FUEL TANK and fuel tank section in CHAPTER 2 Front and rear flame Refer to ENGINE Carburetor Refer to CARBURETOR section in CHAPTER 4 Muffler Refer to MUFFLER AND AIR CLEANER section Engine assembly Refer to ENGINE section Recoil starter Refer to RECOIL STARTER AND ROTOR section Generator Refer ...

Page 55: ... m kg 13 ft lb 20 Nm 2 0 m kg 14 ft lb 10 Nm 1 0 m kg 7 2 ft lb E E Order Job name Q ty Remarks 3 Breather hose 1 Disconnect 4 Cylinder head cover 1 5 Gasket 1 6 Cylinder air shroud 1 7 Cylinder head 1 8 Gasket 1 9 Dowel pin 2 10 Push rod 2 For installation reverse the removal procedure ...

Page 56: ...deposits Carbon deposits Remove NOTE Be sure not to damage the contact surface of the cylinder 2 Inspect 9 Cylinder head Cracks damage around the hole of spark plug Replace 3 Measure 9 Cylinder head warpage Measure the warpage on the contact surface of the cylinder head at six points using the straight edge and thickness gauge Out of specifications Resurface or replace ENG Runout limit 0 5 mm 0 02...

Page 57: ... ASSEMBLY 1 Inspect 9 Cylinder head bolts 1 to 4 NOTE Tighten the bolts to the specified torque in two steps and in order from 1 to 4 BREATHER HOSE ASSEMBLY 1 Inspect 9 Breather hose 1 NOTE Contact the end of the breather hose to the reed valve stopper a ENG 20 Nm 2 0 m kg 14 ft lb ...

Page 58: ... name Q ty Remarks Valve removal Remove the parts in the order listed below Cylinder head Refer to CYLINDER HEAD section 1 Lock nut 2 2 Adjuster 2 3 Rocker arm 2 4 Valve cotter 2 5 Spring retainer 2 6 Spring 2 7 Exhaust valve 1 8 Intake valve 1 9 Stem seal 1 For installation reverse the removal procedure ...

Page 59: ...LVE SPRING INSPECTION 1 Measure 9 Valve stem length a 9 Valve face diameter b Out of specifications Replace 2 Measure 9 Valve stem diameter a Out of specifications Replace ENG Valve spring compressor YM 01253 90890 01253 Valve stem length Intake 65 9 mm 2 59 in Exhaust 66 2 mm 2 61 in Valve face diameter Intake 24 0 mm 0 94 in Exhaust 22 0 mm 0 87 in Valve stem diameter Intake and exhaust 5 5mm 0 ...

Page 60: ... Replace 5 Measure 9 Valve spring free length a Out of specifications Replace 6 Inspect 9 Valve spring contact surface More than 2 3 of the contact surface does not contact Replace LOCKER ARM INSPECTION 1 Inspect 9 Locker arm Wear damage cracks Replace ENG Runout limit 0 01 mm 0 0004 in Tilt limit 1 6 mm 0 06 in Valve spring free length Intake and exhaust 26 5 mm 1 04 in Limit 25 0 mm 0 98 in ...

Page 61: ...ontacting the valve seat 4 Measure 9 Valve face contact width a Make sure that the contact width along the entire valve face is within specifica tions Out of specification rough eccentric wear Replace 5 Measure 9 Valve seat contact width a Make sure that the contact width along the entire valve seat is within specifica tions Out of specification rough eccentric wear Replace ENG Valve face contact ...

Page 62: ...ce Lap the valve by tap ping and rotating the valve lapper 1 clockwise and counterclockwise 2 Clean off all of the lapping compound from the valve face and valve seat Apply fine lapping compound on the valve face and lap the valve as in step 1 3 If the contact width on the valve face shines white along the entire face apply mechanic s blueing dye Dykem to make sure that there are traces of even co...

Page 63: ...spring 2 9 Valve spring retainer 3 9 Valve cotter 4 Apply a small amount of molybdenum disulfide oil to the valve stem and use the valve spring compressor 5 to install the parts cC Do not compress the valve spring more than necessary ENG Valve spring compressor YM 01253 90890 01253 ...

Page 64: ...y Remarks Crankcase cover and crankshaft Remove the parts in the order listed removal below Engine assembly Refer to ENGINE section Cylinder head Refer to CYLINDER HEAD COVER CYLINDER HEAD section Recoil starter Refer to RECOIL STARTER AND ROTOR section Generator Refer to GENERATOR REMOVAL section 1 Crankcase cover 1 2 Gasket 1 3 Dowel pin 2 4 Bracket 1 5 Oil level switch 1 6 Camshaft 1 ...

Page 65: ...ASE COVER AND CAMSHAFT 7CF30110E 1 5 4 3 2 6 7 E E E 10 Nm 1 0 m kg 7 2 ft lb 17 Nm 1 7 m kg 12 ft lb 22 Nm 2 2 m kg 16 ft lb Order Job name Q ty Remarks 7 Valve lifter 2 For installation reverse the removal procedure ...

Page 66: ...Inspect 9 Surface of camshaft gear teeth 9 Decompressor Crack damage wear Replace 4 Inspect 9 Camshaft diameter a Out of specification Replace ENG Cam lobes length Intake a 26 9 0 05 mm 1 06 0 002 in b 22 0 0 05 mm 0 87 0 002 in Exhaust a 26 68 0 05 mm 1 05 0 002 in b 22 03 0 05 mm 0 87 0 002 in Camshaft diameter 14 965 14 990 mm 0 5892 0 5902 in Wear limit 14 950 mm 0 59 in ...

Page 67: ...o align the hole a of camshaft gear with the crankshaft gear mark b CRANKCASE COVER INSPECTION 1 Inspect 9 Crankcase cover 1 Damage Replace 9 Bearing 2 Noise wear rotational failure Replace CRANKCASE COVER INSTALLATION 1 Install 9 Crankcase cover bolts 1 to 6 NOTE Tighten the bolts to the specified torque in two steps and in order from 1 to 6 ENG 22 Nm 2 2 m kg 16 ft lb ...

Page 68: ...he parts in the order listed and crankcase removal below Engine assembly Refer to ENGINE section Recoil starter Refer to RECOIL STARTER AND ROTOR section Generator Refer to GENERATOR REMOVAL section Rocker arm and camshaft Refer to ROCKER ARM AND CAMSHAFT section 1 Connecting rod cap 1 2 Crank shaft 1 3 Connecting rod 1 4 Piston pin circlip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For insta...

Page 69: ...the contact surface of the cylinder head at six points using a straight edge and thickness gauge Out of specification Replace PISTON AND PISTON PIN INSPECTION 1 Measure 9 Piston skirt diameter P a 10 mm 0 4 in from the piston bottom edge Out of specification Replace ENG Maximum wear Maximum A B C Cylinder taper Maximum A Minimum C Cylinder inside diameter 66 00 66 02 mm 2 5984 2 5990 in Cylinder i...

Page 70: ...enters smoothly into the piston pin hole If the piston pin fits tightly into the pis ton check the piston pin hole If there is any protrusion use a knife or scraper to gently remove it so that piston pin can be pushed in gently with your fingers ENG Piston clearance 0 015 0 040 mm 0 0006 0 00157 in Piston clearance Cylinder inside diameter Piston skirt diameter Piston pin hole inside diameter 16 0...

Page 71: ... piston ring as a set 2 Measure 9 Piston side clearance Out of specification Replace Use a thickness gauge 1 NOTE 9 Clean carbon deposits from the piston ring grooves and rings before measuring the side clearance 9 Measure the side clearance at several por tions ENG Top ring Wear limit Ring end gap 0 9 mm 0 0354 in 0 2 0 4 mm 0 008 0 016 in 2nd ring 0 9 mm 0 0354 in 0 2 0 4 mm 0 008 0 016 in Oil r...

Page 72: ...ation Replace CONNECTING ROD OIL CLEARANCE INSPECTION NOTE Measure the oil clearance if replacing the crankshaft or connecting rod 1 Place a piece of Plastigauge 1 on the crank pin horizontally NOTE Clean off oil from all parts thoroughly 2 Install 9 Connecting rod 1 9 Connecting rod cap 2 NOTE Tighten the cap bolts so that the crankshaft does not move while the oil clearance is being measured ENG...

Page 73: ...d ring 2 9 Oil ring 3 NOTE 9 Be sure to install the top ring and second ring so that the R mark a faces toward the piston head 9 Make sure that the piston rings move smoothly 2 Apply 4 stroke engine oil to the inside of the connecting rod small end 3 Install 9 Piston 1 9 Piston pin 2 9 Piston pin circlip 3 NOTE 9 Make sure that the YAMAHA mark a on the connecting rod faces toward the crank case co...

Page 74: ...1 9 Connecting rod 2 NOTE 9 Make sure that the mark a on the pis ton head faces toward the push rod 9 Make sure that the YAMAHA mark b on the connecting rod faces toward the crank case cover 4 Install 9 Crankshaft 9 Connecting rod cap NOTE Make sure that the mark a on the con necting rod is aligned with the mark b on the rod cap 5 Install 9 Camshaft 9 Crankcase cover Refer to CRANKCASE COVER AND C...

Page 75: ......

Page 76: ...parts in the order listed below Rear cover and right side cover Refer to COVERS section in CHAPTER 2 Air cleaner case 1 Choke knob 1 2 Choke cable 1 Disconnect 3 Fuel hose 1 4 Throttle control motor cover 1 5 Throttle control motor coupler 1 Disconnect 6 Carburetor assembly 1 7 Gasket 1 8 Carburetor joint 1 9 Gasket 1 For installation reverse the removal procedure 1 2 3 4 5 ...

Page 77: ...0 7 ft lb 2 Nm 0 2 m kg 1 4 ft lb y t r CARB Order Job name Q ty Remarks Carburetor disassembly Disassemble the parts in the order listed below 1 Throttle control motor 1 2 Motor bracket 1 3 Plate 1 4 Bolt 1 5 Gasket 1 6 Drain screw 1 7 Float chamber 1 8 Float chamber gasket 1 9 Float pin 1 0 Float 1 q Needle assembly 1 w Main jet 1 e Main nozzle 1 1 2 3 4 5 ...

Page 78: ...e w 2 Nm 0 2 m kg 1 4 ft lb 1 Nm 0 1 m kg 0 7 ft lb 2 Nm 0 2 m kg 1 4 ft lb 1 Nm 0 1 m kg 0 7 ft lb 2 Nm 0 2 m kg 1 4 ft lb y t r CARB Order Job name Q ty Remarks r Cap 1 t Pilot screw 1 y Pilot jet 1 For assemble reverse the disassembly procedure ...

Page 79: ... lightly contacts the float arm and then measure the float height a This mea surement should be made with the gasket removed 9 Do not adjustable the float height 2 Clean 9 Carburetor body Blow out all passages jets and carbu retor body with compressed air 3 Inspect 9 Valve seat Wear damage Replace Dirt Clean 1 Wear at groove 2 Dirt CARB Float height 16 0 mm 0 63 in ...

Page 80: ...e control motor 1 NOTE 9 Install the shaft a of the throttle control motor by aligning it with the groove b of the throttle shaft 9 Install the throttle valve and then make sure that is moves smoothly 9 When installing the engine fully open the throttle valve CARB ...

Page 81: ......

Page 82: ... AC receptacle 7 DC circuit breaker 8 DC receptacle 9 Ground terminal 0 TCI unit q Control unit assembly w Rectifier e Generator assembly r Oil level switch t Spark plug y Throttle control motor u Twin tech parallel running ter minal i Noise filter For GERMANY o AC switch NFB For CANADA p DC switch NFB For CANADA 1 3 4 6 7 8 9 2 5 u 0 q w i e r t y p o 120 V 60 Hz only ...

Page 83: ...8 5 0 d 1 AC coil 2 DC charge coil 3 Sub coil 4 Rectifier 5 Generator assembly 6 Control unit assembly 7 Pilot light Green 8 AC switch NFB 9 AC receptacle 16 7A 2 0 Control box q Ground terminal w Overload warning light Red e DC receptacle 12V 6 5A r DC switch NFB t Engine switch y Oil warning light Red u Speed limiter i Oil level switch o Magneto rotor p TCI unit a Spark plug s Throttle control m...

Page 84: ...Rectifier 5 Generator assembly 6 Control unit assembly 7 Noise filter 8 Pilot light Green 9 Twin tech parallel running termi nal 0 AC receptacle 8 7A 2 q Control box w Ground terminal e Overload warning light Red r DC receptacle 12V 8A t DC circuit breaker y Engine switch u Oil warning light Red i Speed limiter o Oil level switch p Magneto rotor a TCI unit s Spark plug d Throttle control motor f E...

Page 85: ...C coil 2 DC charge coil 3 Sub coil 4 Rectifier 5 Generator assembly 6 Control unit assembly 7 Pilot light Green 8 Twin tech parallel running termi nal 9 AC receptacle For AUSTRALIA 9 1A 2 For KOREA 8 7A 2 0 Control box q Ground terminal w Overload warning light Red e DC receptacle 12V 8A r DC circuit breaker t Engine switch y Oil warning light Red u Speed limiter i Oil level switch o Magneto rotor...

Page 86: ...ity If the continuity is faulty at any point replace the switch NOTE 9 Set the pocket tester to 0 before starting a test 9 When testing the switch for continuity the pocket tester should be set to the 1 Ω range 9 When checking the switch turn it on and off a few times Pocket tester YU 03112 90890 03112 ...

Page 87: ...for troubleshooting Dynamic spark tester YU 34487 Ignition checker 90890 06754 1 Spark plug 9 Check the spark plug condition Refer to SPARK PLUG in CHAPTER 2 Repair or replace the spark plug SVU4055 SVU4060 2 Ignition spark gap 9 Disconnect the spark plug cap 1 from the spark plug 9 Connect the dynamic spark tester 2 or igni tion checker 3 as shown Spark plug cap 1 Dynamic spark tester or ignition...

Page 88: ...ot pull out the plug cap from the high tension cord 9 Remove Turn the plug cap counterclock wise 9 Install Turn the plug cap clockwise 9 Inspect the high tension cord for cracks or deterioration when install the pug cap 9 Cut 5 mm off the end of the high tension cord and then connect it to the plug cap 2 1 w q Spark plug cap resistance 4 0 6 0 kΩ Ω at 20 C 68 F Primary coil resistance 1 35 Ω Ω 20 ...

Page 89: ...r and ignition coil Air gap 0 5 0 1 mm 0 02 0 004 in 6 Engine switch 9 Disconnect the engine switch coupler in the control box 9 Connect the pocket tester Ω 1k to the engine switch terminal Tester lead Black white terminal 1 Tester lead Black terminal 2 Switch ON Continuity Switch STOP No continuity B B W 1 2 Replace the ignition coil OUT OF SPECIFICATION MEETS SPECIFICATION Adjust the air gap OUT...

Page 90: ...ster to the oil level switch for continuity Tester lead Blue lead 1 Tester lead Ground 2 1 2 1 2 å å å Continuity Correct No continuity Correct 8 Wire harness 9 Check the terminal of the connector for con tamination rust or disconnection Replace the speed limiter Replace the TCI unit Replace the oil level switch NO CONTINUITY CONTINUITY Correct or replace the connector NO GOOD GOOD GOOD ...

Page 91: ...he pilot light Check the throttle control system Refer to THROTTLE CONTROL SYSTEM in CHAPTER 6 Main coil AC voltage inspection 9 Start the engine 9 Connect the pocket tester to the White leads 9 Measure the voltage Tester range AC 300 V GOOD TOO LOW DOES NOT GENERATE W W W Y Y Y Main coil AC voltage 175 225 V at 20 C 68 F Magnetic force is weak Replace the magneto rotor Main coil resistance measur...

Page 92: ...ENERATE W W W W Or Or L L 1 Sub coil AC voltage 13 0 18 0 V at 20 C 68 F Magnetic force is weak Replace the magneto rotor Sub coil resistance inspection 9 Stop the engine 9 Measure the resistance between the White Orange leads Tester range Ω 1 SPECIFICATION OUT OF SPECIFICATION W W W W 1 Sub coil resistance 0 19 Ω Ω 20 at 20 C 68 F Replace the stator coil assembly Replace the control unit ...

Page 93: ...ircuit breaker DC coil DC voltage inspection 9 Connect sub coil 2 White leads 9 Start the engine then measure the voltage Tester range DC 20V GOOD TOO LOW DOES NOT GENERATE W W W W Or Or L L 2 DC coil DC voltage 17 23 V at 20 C 68 F Replace the rectifier DC coil resistance inspection 9 Stop the engine 9 Measure the resistance between the White Tester range Ω 1 SPECIFICATION OUT OF SPECIFICATION W ...

Page 94: ...Replace oil warning light oil warning unit or oil level switch Add Add Replace Set to ON Clean or replace fuel cock Replace the fuel TCI unit Clean or replace Remove spark plug attach it to spark plug cap and then ground the spark plug to check for spark GOOD WEAK OR SPARK NO SPARK 9Check spark plug for dirt and check spark plug gap 9Check for voltage leakage due to faulty con nection or broken in...

Page 95: ...OF GOOD SPECIFICATION Check valve face and valve seat for wear GOOD WEAR Resurface or replace Check if the marks on the crankshaft and camshaft are aligned GOOD NO GOOD Correct or replace Check if there is seizure or wear on the piston piston ring or cylinder GOOD SEIZURE OR WEAR Rebore or replace Check the condition of the throttle control sys tem Refer to THROTTLE CONTROL SYS TEM 1 2 3 4 5 6 7 ...

Page 96: ... due to a dam aged carburetor joint or gasket GOOD NO GOOD 9 Tighten the carburetor bolts securely 9 R e p l a c e carburetor joint or gas ket with a new one Measure valve clear ance GOOD OUT OF SPECIFICATION Adjust Check compression using compression gauge GOOD OUT OF SPECIFICATION Check piston piston ring and cylinder GOOD NO GOOD Replace Check air gap GOOD NO GOOD Replace Check the condition of...

Page 97: ...GOOD NO GOOD Disassemble or clean Check for air suction due to a damaged throttle shaft seal carburetor joint or gasket GOOD NO GOOD Disassemble or replace Check compression using compression gauge GOOD TOO HIGH TOO LOW Decarbonize combustion chamber if there are carbon deposits Check valve face and valve seat for wear GOOD NO GOOD Resurface or replace Check if the marks on the crankshaft and cams...

Page 98: ...y out and then check the engine operating condition STABLE UNSTABLE Resurface or replace Check for air suction due to a damaged throttle shaft seal carburetor joint or gasket GOOD NO GOOD Disassemble or replace Check if slow or main passages such as the pilot jet and main jet in carburetor are clogged GOOD NO GOOD Disassemble or clean Check valve face and valve seat for wear GOOD NO GOOD Resurface...

Page 99: ...eck if it turns smoothly with slight resistance GOOD NO GOOD Replace the throttle control motor Replace the throttle control motor Replace the control motor Measure the coil resistance between 3 1 3 2 3 4 and 3 5 of the throttle control motor Tester range Ω 1 SPECIFICATION OUT OF SPECIFICATION Coil resistance 250 Ω Ω 20 at 20 C 68 F Check the connections of the wire harness connectors and couplers...

Page 100: ...tput 50 60 Hz kW PS 3 200 r min 2 5 3 4 π Rated engine speed r min 3 200 œ Operating hours 50 60 Hz Hrs 1 4 rated load 8 6 ß W rated load 5 0 Fuel Unleaded regular gasoline Fuel tank capacity L lmp gal US gal 6 0 1 32 1 59 Engine oil capacity L lmp qt US qt 0 6 0 53 0 63 Engine recommended oil 4 stroke engine oil API service classification SE or SF if not available SD Ω Electrical å Ignition syste...

Page 101: ...r CANADA For GERMANY For AUSTRALIA For KOREA Rated voltage V 12 Rated output W 52 96 Rated current A 6 5 8 Safety device type AC Ω Electronic no fuse braker å Electronic no fuse breaker and AC switch DC N F B ç DC Circuit breaker Rated engine speed r min 3 200 é Voltage regulation ƒ Voltage feed back system Voltage stability Within 1 î Frequency stability Hz Within 0 1 Rotating speed control Throt...

Page 102: ... 0 106 End gap 0 2 0 4 0 008 0 016 0 9 0 0354 Side clearance 0 02 0 06 0 0008 0 0024 0 1 0 0039 Oil ring Type Ω Solid å Dimensions B T 2 5 2 7 0 098 0 106 End gap 0 2 0 4 0 008 0 016 0 9 0 0354 ç Cylinder mm in Inside diameter D 66 00 66 02 2 5984 2 5990 66 020 2 5990 é Taper limit 0 05 0 002 ƒ Warpage limit 0 05 0 002 Crankshaft mm in Big end side clearance A 0 2 0 60 0 008 0 024 0 75 0 029 î Run...

Page 103: ... 2 2 61 µ Valve face contact width D IN 0 7 0 03 1 7 0 067 EX 0 7 0 03 1 7 0 067 Valve stem runout limit 0 01 0 0004 θ 90 ø Valve guide π Guide inside diameter IN 5 5 0 22 5 4 0 21 EX 5 5 0 22 5 4 0 21 œ Stem to guide clearance IN 0 04 0 06 0 0016 0 0020 EX 0 06 0 08 0 002 0 003 Valve clearance cold IN 0 1 0 004 EX 0 1 0 004 ß Push rod mm in Runout limit 0 5 0 02 Valve spring mm in Free length IN ...

Page 104: ...I ƒ I D mark 7CF 10 Bore size Ø 15 0 5906 Main jet 86 3 ˆ Main air jet Ø 1 8 0 0709 Pilot air jet Ø 1 1 0 0433 Pilot outlet Ø 0 9 0 0354 Valve seat size Ø 1 8 0 0709 µ Main nozzle 31B Pilot jet 35 ø Throttle valve 150 π Float height H 16 0 0 63 MAINTENANCE SPECIFICATIONS SPEC ...

Page 105: ...0 23 0 2 600 Coil resistance Main coil Ω 20 3 0 W W R S S T R T With coupler disconnected µ Sub coil Ω 20 0 19 W W R S S T R T With coupler disconnected ø DC coil W 20 0 12 π W W With 4P coupler disconnected œ Electrical Ignition system ß TCI Ignition timing BTDC 23 3 Ignition coil Primary coil resistance Ω 20 1 35 Secondary coil resistance kΩ 20 6 8 Spark plug cap resistance kΩ 4 0 6 0 Spark plug...

Page 106: ...y M8 1 25 16 1 6 1 1 Muffler band M6 1 0 4 0 4 2 9 ø Engine mount nut M6 1 0 7 0 7 5 1 π Engine mount bolt M8 1 25 16 1 6 1 1 œ Crankcase M8 1 25 22 2 2 16 Recoil starter M6 1 0 7 0 7 5 1 ß Fuel tank M6 1 0 7 0 7 5 1 Rectifier M5 0 8 2 5 0 3 1 8 Ignition coil M6 1 0 7 0 7 5 1 Magneto rotor M14 1 5 65 6 5 47 Stator coil assembly M6 1 0 10 1 0 7 2 Generator rotor M14 1 5 65 6 5 47 Cover M5 0 8 1 3 0...

Page 107: ...e specifications call for clean dry treads Components should be at room temperature DEFINITION OF UNITS å Tread size Tightening torque Nm m kg ft lb M4 2 0 2 1 4 M5 3 0 3 2 2 M6 7 0 7 5 1 M7 10 1 0 7 2 M8 15 1 5 11 M10 30 3 0 22 M12 60 6 0 43 ç Unit Read Definition ƒ Measure mm Milimeter 103 meter ˆ Length cm Centimeter 102 meter Length kg µ Kilogram 103 gram ø Weight N π Newton œ 1 kg x m sec2 Fo...

Page 108: ...g rod bolt Engine oil Piston pin Engine oil µ Piston Engine oil ø Crankshaft bearing π Engine oil œ Valve stem Engine oil ß Valve stem end Molybdenum disulfide oil Valve rocker arm shaft Engine oil Valve push rod Engine oil Push rod guide Ω Engine oil å Lifter stem Engine oil ç Camshaft gear Engine oil é Camshaft lobe ƒ Engine oil Decompressor cam Engine oil î Crankcase ball bearing Engine oil Cra...

Page 109: ... Green 5 Over load warning light Red 6 AC switch NFB 7 AC receptacle 16 7A x 2 8 Ground terminal 9 DC receptacle 12V 8A 0 Ground terminal lead q Oil warning light lead w Choke cable e Choke knob r Speed limiter å Clamp with white tape Be sure to fully pushed when install the choke cable to the carburetor COLOR CODE B Black Br Brown G Green L Blue Or Orange R Red W White Y Yellow B W Black White G ...

Page 110: ...8A 9 Ground terminal 0 Ground terminal lead q Oil warning light lead w Choke cable e Noise filter r Choke knob t Speed limiter y Noise filter å Clamp with white tape Be sure to fully pushed when install the choke cable to the carburetor ç To noise filter lead To pilot lamp and noise filter Tighten with each terminal as shown ƒ Back to back two terminals with tape and then tighten them COLOR CODE B...

Page 111: ...rning light Red 6 Twin tech terminal 7 AC receptacle 8 7A x 2 8 DC receptacle 12V 8A 9 Ground terminal 0 Ground terminal lead q Oil warning light lead w Choke cable e Choke knob r Speed limiter å Clamp with white tape Be sure to fully pushed when install the choke cable to the carburetor COLOR CODE B Black Br Brown G Green L Blue Or Orange R Red W White Y Yellow B W Black White G Y Green Yellow 23...

Page 112: ...ning light Red 6 AC receptacle 9 1A x 2 7 Twin tech terminal 8 DC receptacle 12V 8A 9 Ground terminal 0 Ground terminal lead q Oil warning light lead w Choke cable e Choke knob r Speed limiter å Clamp with white tape Be sure to fully pushed when install the choke cable to the carburetor COLOR CODE B Black Br Brown G Green L Blue Or Orange R Red W White Y Yellow B W Black White G Y Green Yellow 220...

Page 113: ...ENERATOR 1 Control unit 2 Throttle control motor lead 3 Throttle control motor 4 TCI unit lead 5 Stator coil lead 6 Control unit lead 7 Rectifier 8 Noise filter For GERMANY å Install the ground lead as shown in illustration 45 å 1 2 3 4 5 6 7 8 ...

Page 114: ...ad 5 Clamp 6 Control box lead 7 Control box 8 Noise filter For GERMANY 9 Noise filter lead For GERMANY å Pass through the throttle control motor lead under the Red and Brown lead To throttle control motor ç To rectifier To control box To generator ƒ To Pass through into the hole on the crankcase Clamp with TCI unit 2P coupler Put in completely the cable cap to the clamp ...

Page 115: ...nob 5 Starter handle 6 Control unit 7 Rectifier 8 Band 9 Noise filter For GERMANY å Put in completely the cable cap to the clamp Be sure to fully pushed position when install the choke cable to the carburetor ç Pass through the starter rope into the front cover and then tie knot the rope end Hook the mount latch ...

Page 116: ...t lead 4 Fan case 5 High tension cord 6 Ignition coil 7 Ground lead å Install the plug cap as shown Pass through the hole on the crankcase ç Through out the hole on the crank case Install the high tension cord through the cut por tion on the air shroud Install the lead into the slot on the crankcase ...

Page 117: ...cleaner case å Install the fuel hose visible the white paint on the fuel hose between the fan case and air cleaner Pass the air vent hose onto the fuel hose ç Align the white paint onto the fuel hose with clip Check that the clip position is mounted on the spool on the joint Install the clip to over the white paint ...

Page 118: ......

Page 119: ......

Page 120: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2005 06 x 1 E SERVICE MANUAL EF2400iS 7CF 28197 E0 331153 7CFE0Cover 05 7 23 16 16 Page 1 ...

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