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Yamaha EF3000iSE - Inverter Generator - 3000 Maximum AC Output, Service Manual

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Yamaha EF3000iSE - Inverter Generator - 3000 Maximum AC Output Service Manual Download Page 110

4-12

–

+

ELEC

ELECTRIC STARTING SYSTEM

C0NTINUITY

MOVES

3. Starter motor
•

Connect the jumper lead 

1

 to the starter

relay terminals on the battery end and the
starter motor end.

•

Check the starter motor operation.

*

SWL4060J

DOES NOT MOVE

Repair and/or replace the starter motor.

WARNING

• A wire that is used as a jumper lead must

have the equivalent capacity or more as
that of the battery lead, otherwise the
jumper lead may burn.

• This check is likely to produce sparks, so

be sure that no flammable gas or fluid is
in the vicinity.

CONTINUITY

4. Starter relay
•

Disconnect the starter relay from the cou-
pler.

•

Connect the jumper lead to the starter
relay and the battery terminals.

Battery positive terminal 

→

 pink 

1

 

Battery negative terminal 

→

 green 

2

 

Battery positive terminal 

→

 red/white 

3

 

Battery negative terminal 

→

 

green/yellow 

4

È

120 V-60 Hz

É

220 V-50 Hz, 230 V-50 Hz

•

Connect the pocket tester (

Ω

 

×

 1) to check

the starter relay terminals for continuity.

Tester positive probe 

→

 red 

5

 

Tester negative probe 

→

 red 

6

 

*

NO CONTINUITY

Replace the starter relay.

SWL4060T

È

SWL4070T

É

Summary of Contents for EF3000iSE - Inverter Generator - 3000 Maximum AC Output

Page 1: ...SERVICE MANUAL EF3000iSE 7WL 28197 E0 310140 ...

Page 2: ...afety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED 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 A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer M...

Page 3: ...bricant 8 Special tool 9 Tightening 0 Wear limit clearance A Engine speed B Ω V A Illustrated symbols C through K in the exploded diagram indicate the grades of lubri cant and the locations of the lubrication points C Apply engine oil D Apply gear oil E Apply molybdenum disulfide oil F Apply wheel bearing grease G Apply lightweight lithium soap base grease H Apply molybdenum disulfide grease I App...

Page 4: ...INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE ELECTRICAL SPECIFICATIONS ...

Page 5: ...SSURE 2 14 ENGINE SPEED NO LOAD 2 16 ECONOMY ENGINE SPEED 2 16 CHOKE CABLE 2 17 BREATHER HOSE 2 17 ELECTRICAL 2 18 SPARK PLUG 2 18 MAIN SWITCH 2 19 ECONOMY SWITCH 2 20 PILOT LIGHT 2 20 OVERLOAD WARNING LIGHT 2 20 DC CIRCUIT BREAKER 2 21 DC CIRCUIT BREAKER 120 V 60 Hz 2 21 RECEPTACLE 2 22 AC SWITCH NFB 120 V 60 Hz 23 5 A 2 22 AC SWITCH NFB 120 V 60 Hz 15 A 2 23 FUSES 2 23 BATTERY 2 25 BATTERY TERMI...

Page 6: ...IN INSPECTION 3 38 PISTON RING INSPECTION 3 40 CRANKSHAFT INSPECTION 3 41 CONNECTING ROD OIL CLEARANCE INSPECTION 3 42 PISTON RING AND PISTON ASSEMBLY 3 43 CRANKSHAFT ASSEMBLY 3 44 CARBURETOR 3 45 FLOAT HEIGHT INSPECTION 3 49 CHOKE CABLE INSTALLATION 3 50 THROTTLE CONTROL MOTOR 3 50 TROUBLESHOOTING 3 51 THROTTLE CONTROL SYSTEM 3 56 CHAPTER 4 ELECTRICAL ELECTRICAL COMPONENTS 4 1 120 V 60 Hz 4 1 220...

Page 7: ...E The first three characters of this number are for model identification the remaining digits are the unit production number 1 SWL1010T SWL1020J STARTING SERIAL NUMBER NOTE Designs and specifications are subject to change without notice Model Code Starting serial number 120 V 60 Hz 7WL2 7WL 220101 220 V 50 Hz 7WL3 7WL 330101 230 V 50 Hz 7WL3 7WL 300101 230 V 50 Hz 7WL3 7WL 350101 ...

Page 8: ...place the gaskets O rings cotter pins and circlips with new parts when servicing engine SVU1060 4 Tightening torque Be sure to follow torque specifications When tightening bolts nuts or screws start with the largest diameter fastener and work from an inner position to an outer position in a crisscross pattern SVU1070 5 Notes on disassembly and assembly a Parts should be cleaned in solvent and blow...

Page 9: ...l all mating parts and bearings during reassembly Apply grease to the oil seal lips BEARINGS AND OIL SEALS Install the bearing s 1 and oil seal s 2 with their manufacture s marks or numbers facing outward In other words the stamped let ters must be on the side exposed to view When installing oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bearings lib...

Page 10: ...ing an order NOTE For USA and Canada use part number starting with YM YU or YS For others use part number starting with 90890 1 Piston ring compressor P N YU 33294 90890 05158 This tool is used to compress the piston rings when installing the piston SVU1130 2 Valve spring compressor P N YM 01253 90890 01253 This tool is used to remove the valve springs SVU1140 3 Thickness gauge P N YU 26900 9 9089...

Page 11: ... Compression gauge 1 P N YU 33223 90890 03081 Adapter 2 P N YU 33223 3 90890 04082 This gauge is used for checking engine compression SVU1180 7 Dial gauge P N YU 03097 90890 03097 This instrument is used for checking crankshaft side clearance SVU1190 8 Piston pin puller P N YU 01304 90890 01304 This tool is used to remove the piston pin SVU1200 9 Sheave holder P N YS 01880 A 90890 01701 This tool ...

Page 12: ...20 2 12 Pocket tester P N YU 03112 C 90890 03112 This instrument is necessary for checking the electrical system SVU1230 13 Dynamic spark tester 1 P N YM 34487 Ignition checker 2 P N 90890 06754 This instrument is necessary for checking the ignition system components SVU1240 1 SVU1250 2 14 MF Battery charging Commercially available This instrument is necessary for charging the electrical system SW...

Page 13: ...icated as in the chart PERIODIC MAINTENANCE LUBRICATION INTERVALS Related to emission control system È É Ê Ë Ì Í Î Item Remarks Pre Opera tion check daily Initial 1 month or 20 Hr Every 3 months or 50 Hr Every 6 months or 100 Hr Every 12months or 300 Hr Ï Spark Plug Check condition Adjust gap and clean Replace if necessary Ð Valve Clearance Check and adjust when engine is cold Ñ Crankcasebreather ...

Page 14: ...on refer to PANELS AND COVERS in CHAPTER 3 1 Cover 1 7 0 Nm 0 7 m kg 5 1 ft lb 2 Panel 1 7 0 Nm 0 7 m kg 5 1 ft lb 3 Cover 2 7 0 Nm 0 7 m kg 5 1 ft lb 4 Cover 3 7 0 Nm 0 7 m kg 5 1 ft lb 5 Cap 1 6 Cap 2 7 Panel 2 8 Cover 4 7 0 Nm 0 7 m kg 5 1 ft lb 9 Cover 5 7 0 Nm 0 7 m kg 5 1 ft lb 0 Panel 3 7 0 Nm 0 7 m kg 5 1 ft lb A Battery bracket 7 0 Nm 0 7 m kg 5 1 ft lb B Panel 4 C Cover 6 7 0 Nm 0 7 m kg...

Page 15: ...T or set it to ON and pull the recoil starter to check that the oil level warn ing light 1 flashes Oil level warning light flashes Add oil Oil level warning light does not flash OK 2 Remove Panel 2 Refer to COVERS PANELS AND CAPS Oil filler cap 1 3 Check Check that the engine oil is at the spec ified level a Oil level checking steps Place the generator on a level surface Warm up the engine for sev...

Page 16: ...acle under the engine 5 Remove Oil drain bolt 1 6 Tilt the engine to drain the oil completely 7 Tighten Oil drain bolt T R Oil drain bolt 17 Nm 1 7 m kg 12 ft lb 1 SWL2050J 8 Remove Oil filler cap 1 9 Fill NOTE Recommended engine oil classification API Service SE or SF if not available SD Recommended oil È YAMALUBE 4 10W 30 or SAE 10W 30 type SE É SAE 30 Ê SAE 20 Ë SAE 10W Engine oil quantity 0 6 ...

Page 17: ... SAE 30 or 10W 30 or 10W 40 É SAE 20 or 10W 30 or 10W 40 Ê SAE 10W or 10W 30 or 10W 40 SAE 40 Above 35 C 95 F Engine oil quantity 0 6 L 0 53 Imp qt 0 63 US qt SVW2070T É FUEL LEAKAGE 1 Remove Cover 1 Cover 5 Cover 4 Refer to COVERS PANELS AND CAPS 2 Remove Fuel tank bolts Refer to FUEL TANK AND CONTROL BOX in CHAPTER 3 3 Slide the fuel tank to check for leakage CAUTION When sliding the fuel tank b...

Page 18: ...L2070J FUEL TANK FILTER WARNING Do not smoke and keep away from open flames sparks or any other source of fire when handling or in the vicinity of fuel 1 Remove Fuel tank cap 1 Fuel tank filter 2 2 Inspect Fuel tank filter Damage Replace 3 Clean Fuel tank filter NOTE Clean the fuel tank filter with solvent and then dry it thoroughly 4 Install Fuel tank filter Fuel tank cap WARNING Be sure the tank...

Page 19: ...Refer to FUEL TANK AND CONTROL BOX in CHAPTER 3 4 Remove Fuel hose fuel tank end Fuel pipe strainer 1 5 Inspect Fuel pipe strainer Damage Replace 6 Clean Fuel pipe strainer NOTE Clean the fuel pipe strainer with solvent and then dry it thoroughly 7 Install Fuel pipe strainer Fuel hose fuel tank end 8 Install Fuel tank Fuel hose fuel cock end Refer to FUEL TANK AND CONTROL BOX in CHAPTER 3 9 Instal...

Page 20: ... the excess kerosene out of the air filter element 1 6 Lubricate Air filter element 1 Soak the air filter element 1 in a 2 4 1 mixture of kerosene and engine oil NOTE Be sure to squeeze the excess kerosene and engine oil out of the air filter element 1 CAUTION Do not twist the air filter elements other wise they can tear Do not wash the air filter elements in gas oline or in acid alkaline or organ...

Page 21: ...sure that the air vent hose 5 and drain hose 6 are securely installed onto the frame 4 9 Install Cover 5 Panel 4 Refer to COVERS PANELS AND CAPS CAUTION The engine should never run without the air filter element installed otherwise exces sive piston and or cylinder wear may result 1 2 2 6 5 3 4 a b SWL2120J MUFFLER 1 Remove Engine assembly Refer to ENGINE ASSEMBLY in CHAPTER 3 2 Remove Muffler Ref...

Page 22: ... use a wire to clean the muffler oth erwise the noise damping material may come out and the damping effect may be reduced 5 Install Spark arrester Muffler screen Muffler cap Muffler band Muffler Refer to MUFFLER in CHAPTER 3 6 Install Engine assembly Refer to ENGINE ASSEMBLY in CHAPTER 3 SWL2410J VALVE CLEARANCE ADJUSTMENT 1 Remove Panel 4 Refer to COVERS PANELS AND CAPS 2 Remove Breather hose 1 S...

Page 23: ...the piston is at top dead center of the exhaust stroke turn the crankshaft one full turn 360 to set the piston at top dead center of the compression stroke SWL2140J 4 Measure Valve clearance Out of specification Adjust NOTE Valve clearance must be measured when the engine is cool to the touch Intake valve cold 0 18 0 22 mm 0 007 0 009 in Exhaust valve cold 0 18 0 22 mm 0 007 0 009 in Thickness gau...

Page 24: ...n the locknut 1 Adjuster Valve clearance Turn in Decrease Turn out Increase T R Locknut 10 Nm 1 0 m kg 7 2 ft lb 2 1 SWL2160J 1 2 SWL2170J 6 Install Spark plug 1 Cylinder head cover 2 Spark plug cap 3 Breather hose 4 7 Install Panel 4 Refer to COVERS PANELS AND CAPS T R Cylinder head cover bolt 10 Nm 1 0 m kg 7 2 ft lb Spark plug 18 Nm 1 8 m kg 13 ft lb 2 4 3 1 SWL2180J ...

Page 25: ...starter Flywheel magneto cover Refer to RECOIL STARTER AND FLY WHEEL MAGNETO in CHAPTER 3 2 Measure Air gap between TCI unit and flywheel magneto Use a thickness gauge 1 Out of specification Adjust 3 Adjust Air gap between TCI unit and flywheel magneto Adjustment steps Loosen the bolts 2 Adjust the air gap between the TCI unit and flywheel magneto by moving the TCI unit up or down Tighten the bolt...

Page 26: ... AND CONTROL UNIT and AIR FILTER ASSEMBLY CONTROL UNIT AND NOISE FILTER in CHAPTER 3 Fuel tank Refer to FUEL TANK AND CONTROL BOX in CHAPTER 3 COMPRESSION PRESSURE NOTE Measure the compression after checking and adjusting the valve clearance 1 Warm up the engine for several minutes 2 Remove Panel 4 Refer to COVERS PANELS AND CAPS 3 Remove Spark plug cap Spark plug 4 Connect Compression gauge 1 Ada...

Page 27: ... the cylinder Measure the compression pressure again Testing steps above maximum level Check the cylinder head valve surfaces and piston crown for carbon deposits 6 Install Spark plug Spark plug cap 7 Install Panel 4 Refer to COVERS PANELS AND CAPS Standard compression pressure 400 600 kPa 4 6 kg cm2 57 85 psi Reading Diagnosis If higher than without oil Worn cylinder piston and piston ring If the...

Page 28: ...he economy switch 1 to OFF a Measure the engine speed no load È 120 V 60 Hz 220 V 50 Hz É 230 V 50 Hz 4 Install Panel 4 Refer to COVERS PANELS AND CAPS ECONOMY ENGINE SPEED 1 Remove Panel 4 Refer to COVERS PANELS AND CAPS 2 Connect Inductive self powered tachometer or engine tachometer 1 Inductive self powered tachome ter YU 8036 B Engine tachometer 90890 03113 90793 80009 90793 80032 Engine speed...

Page 29: ...Hz 4 Install Panel 4 Refer to COVERS PANELS AND CAPS Economy engine speed no load 2 800 50 r min 1 a 1 a SWL2050T È É CHOKE CABLE 1 Inspect Choke knob pull the choke knob all the way out Choke knob automatically returns Adjust Adjustment steps Turn in the adjusting nut 1 until the choke knob does not automatically return BREATHER HOSE 1 Remove Panel 4 Refer to COVERS PANELS AND CAPS 2 Inspect Brea...

Page 30: ...e engine 1 Remove Panel 4 Refer to COVERS PANELS AND CAPS 2 Remove Spark plug cap Spark plug 3 Inspect Electrode 1 Wear damage Replace Insulator color 2 4 Measure Spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap If necessary clean the spark plug with a spark plug cleaner Before installing the spark plug clean the gas ket surface and plug surface Spark plug gap 0 7 0 ...

Page 31: ...0 MAIN SWITCH 1 Check Main switch Checking steps Set the main switch to ON and pull the recoil starter to start the engine Check that the engine stops when the main switch is set to STOP 1 Engine does not stop Refer to IGNI TION SYSTEM in CHAPTER 4 È 120 V 60 Hz 220 V 50 Hz É 230 V 50 Hz Check that the engine starts when the main switch is set to START Engine does not start Refer to ELEC TRIC STAR...

Page 32: ...OR SYSTEM in CHAPTER 4 1 a 1 a SWL2050T È É PILOT LIGHT 1 Check Pilot light 1 Checking steps Start the engine Check that the pilot light 1 turns on Refer to GENERATOR SYSTEM in CHAPTER 4 SWL2060T 1 OVERLOAD WARNING LIGHT 1 Check Overload warning light 1 2 Remove Control panel Overload warning light connector Refer to CONTROL PANEL in CHAP TER 3 Checking steps Connect three dry cell batteries 1 5 V...

Page 33: ... current not supplied Replace or refer to GENERATOR SYSTEM in CHAPTER 4 Pocket tester YU 03112 C 90890 03112 1 a b SWL2080T SWL2090T DC CIRCUIT BREAKER 120 V 60 Hz 1 Check DC circuit breaker Checking steps Set the DC circuit breaker 1 to the posi tion of ON a Connect the pocket tester DC 20 V Start the engine Set the economy switch to OFF Measure the DC voltage Set the DC circuit breaker 1 to OFF ...

Page 34: ...60 Hz 23 5 A 1 Set the AC switch NFB 1 to the ON a position 2 Connect the pocket tester AC 120 V to the AC receptacle 23 3 A and check the AC switch NFB for continuity No continuity Replace the AC switch NFB 3 Set the AC switch NFB 1 to the OFF b position 4 Connect the pocket tester AC 120 V to the AC receptacle 23 3 A and check the AC switch NFB for continuity Continuity Replace the AC switch NFB...

Page 35: ...r continuity Continuity Replace the AC switch NFB Pocket tester YU 03112 C 90890 03112 SWL2170T 15A ON AC SW OFF ON OFF ON ON SWL2150T FUSES CAUTION To avoid a short circuit always set the main switch to STOP when check ing or replacing a fuse 1 Remove Cover 5 Refer to COVERS PANELS AND CAPS 2 Remove Battery bracket 1 Battery band 2 Battery NOTE To check the fuses slide the battery out with the po...

Page 36: ...tch to ON and ver ify if the electrical circuit is operational If the fuse immediately blows again check the electrical circuit WARNING Never use a fuse with an amperage other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system and could possibly cause a fire 6 Install Fuse spare Fuse Starter relay 7 Install Battery Bat...

Page 37: ...tteries KEEP OUT OF REACH OF CHILDREN BATTERY TERMINAL 1 Remove Cover 5 Refer to COVERS PANELS AND CAPS 2 Remove Battery bracket 1 Battery band 2 Battery 3 CAUTION When removing the battery disconnect the negative lead first 3 Check Battery terminal Dirty terminal Clean with a wire brush Poor connection Correct NOTE After cleaning the terminals apply grease lightly to the terminals DANGER POISON K...

Page 38: ...ct as specified An incorrect electrolyte level has an adverse effect on battery performance The quantity of electrolyte varies with the type of the electrolyte container Use only the amount of electrolyte in the con tainer which comes with the battery Avoid using any electrolyte other than specified The specific gravity of the MF battery electrolyte is 1 320 20 C The specific gravity of the genera...

Page 39: ...use it will be used as battery plugs CAUTION Do not peel or pierce the sealed areas SWL2330J e Turn the electrolyte container upside down with the six sealed areas in line with the six filler ports of the battery f Push the container down strongly enough to break the seals The electrolyte will start to flow into the battery CAUTION Do not tilt the container as the electrolyte may stop flowing Neve...

Page 40: ...izontally with both hands CAUTION Never remove the strip of caps nor add any water or electrolyte WARNING Do not attempt boost charging under any circumstances Battery electrolyte is poisonous and dan gerous causing severe burns etc Con tains sulfuric acid Avoid contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk o...

Page 41: ...e If this is not done the life of the battery will be shortened drastically BATTERY CHARGING 1 Check Battery voltage Check the battery voltage using an MF battery tester commercially available Within green range Correct Within yellow or red range Charge the battery 2 Recharge the battery using an MF battery charger commercially available Charge the battery to the specified electric current and to ...

Page 42: ...al Remove the parts in the order listed below Fuel tank fuel hose Refer to FUEL TANK AND CONTROL BOX Starter handle Refer to RECOIL STARTER AND FLY WHEEL MAGNETO 1 Cover 1 1 2 Cover 5 1 3 Panel 1 1 4 Panel 3 1 5 Battery bracket 1 6 Cover 2 1 6 1 3 7 2 4 5 8 È È È È È È È È È È 7 0 Nm 0 7 m kg 5 1 ft lb È SWL3010 ...

Page 43: ... 6 1 8 Cover 3 1 NOTE To remove the control box disconnect the necessary couplers and leads It is not necessary to remove the cover 3 from the control box For installation reverse the removal procedure 6 1 3 7 2 4 5 8 È È È È È È È È È È 7 0 Nm 0 7 m kg 5 1 ft lb È SWL3010 ...

Page 44: ... 1 2 Wire harness 1 NOTE Disconnect all couplers and leads 3 Ground terminal 1 4 Engine speed limiter oil level warning unit 1 NOTE After installing all parts refer to WIRE ROUTING DIAGRAM in CHAPTER 5 to check the cable lead and hose routings For installation reverse the removal procedure 2 1 4 3 2 5 6 7 C B A 8 1 3 3 2 4 9 0 2 3 5 67 4 E D 1 9 2 3 5 67 4 D 1 9 F SWL3010T 120 V 60 Hz 220 V 50 Hz ...

Page 45: ...1 5 Oil level warning light 1 6 Pilot light 1 7 Overload warning light 1 8 DC receptacle 12 V 8 3 A 1 9 DC circuit breaker 1 0 AC switch NFB 15 A 1 A AC switch NFB 23 5 A 1 B AC receptacle 15 A 2 1 C AC receptacle 23 3 A 1 D DC receptacle 12 V 12 A 1 E AC receptacle 15 A 2 1 For assembly reverse the disassembly procedure F AC receptacle 16 A 2 1 2 1 4 3 2 5 6 7 C B A 8 1 3 3 2 4 9 0 2 3 5 67 4 E D...

Page 46: ...ed below Cover 1 cover 5 panel 4 panel 2 Refer to COVERS PANELS AND CAPS in CHAPTER 2 Fuel Drain Choke cable carburetor end Refer to CARBURETOR 1 Fuel hose 2 NOTE When removing the fuel tank disconnect only the fuel cock end of the fuel hose 2 Fuel tank cap 1 3 Cover 4 1 4 Fuel tank 1 5 Fuel pipe strainer 1 6 Fuel tank filter 1 7 0 Nm 0 7 m kg 5 1 ft lb È È È È 10 9 9 9 1 1 5 9 8 3 4 7 6 2 a SWL30...

Page 47: ...e control panel a 8 Ground lead 1 9 Wire harness 1 NOTE Disconnect all couplers leads and con nectors 10 Control box 1 NOTE After installing all parts refer to WIRE ROUTING DIAGRAM in CHAPTER 5 to check the cable lead and hose routings For installation reverse the removal procedure 7 0 Nm 0 7 m kg 5 1 ft lb È È È È 10 9 9 9 1 1 5 9 8 3 4 7 6 2 a SWL3020T ...

Page 48: ...fer to COVERS PANELS AND CAPS in CHAPTER 2 1 Air filter assembly 1 2 Breather hose 1 3 Air intake duct 1 4 Air filter element 2 NOTE Remove air filter element 1 and air filter element 2 as a set 5 Throttle control motor cover 1 6 Coupler connector 3 1 Disconnect 7 Control unit 1 8 Control unit cover 1 For installation reverse the removal procedure 4 0 Nm 0 4 m kg 2 9 ft lb È 7 0 Nm 0 7 m kg 5 1 ft...

Page 49: ...ver 2 cover 6 panel 3 Refer to COVERS PANELS AND CAPS in CHAPTER 2 1 Air filter assembly 1 2 Breather hose 1 3 Air intake duct 1 4 Air filter element 2 NOTE Remove air filter element 1 and air filter element 2 as a set 5 Throttle control motor cover 1 6 Coupler connector 3 1 Disconnect 7 Control unit 1 8 Coupler 1 Disconnect 9 Noise filter 1 For installation reverse the removal procedure 7 0 Nm 0 ...

Page 50: ...assembly control unit Refer to AIR FILTER ASSEMBLY AND CONTROL UNIT and AIR FILTER ASSEMBLY CONTROL UNIT AND NOISE FILTER Carburetor Refer to CARBURETOR Battery 1 Starter relay 1 2 Positive battery lead 1 WARNING Remove the battery before discon necting the positive battery lead and the starter motor lead 3 Starter motor lead 1 4 Rectifier 1 5 Starter handle 1 3 2 1 4 9 5 7 6 8 10 11 É È È È 13 14...

Page 51: ...arter pulley 1 11 TCI unit 1 12 Flywheel magneto 1 13 Woodruff key 1 14 Charging coil 1 NOTE After installing all parts refer to WIRE ROUTING DIAGRAM in CHAPTER 5 to check the cable lead and hose routings For installation reverse the removal procedure 3 2 1 4 9 5 7 6 8 10 11 É È È È 13 14 É 12 Ê È 7 0 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0 m kg 7 2 ft lb 65 Nm 6 5 m kg 47 ft lb È É Ê SWL3060 ...

Page 52: ...e Q ty Remarks Recoil starter disassembly Remove the parts in the order listed below 1 Starter handle 1 2 Bolt 1 3 Drive plate 1 4 Clip 1 5 Drive pawl 2 6 Spring 2 7 Sheave drum 1 8 Starter spring 1 9 Starter case 1 For assembly reverse the disassembly procedure SWL3070 ...

Page 53: ...OVAL 1 Remove Flywheel magneto nut 1 Washer Starter pulley NOTE Attach the sheave holder 2 to hold the fly wheel magneto Sheave holder YS 01880 A 90890 01701 Rotor assembly holder commercially available 1 2 SWL3470J 2 Remove Flywheel magneto 1 NOTE Remove the flywheel magneto using a bear ing puller commercially available 2 When removing the flywheel magneto be sure to hold it so that it does not ...

Page 54: ...eto 2 2 1 SWL3150J 2 Install Starter pulley Washer Flywheel magneto nut 1 NOTE Tighten the flywheel magneto nut 1 using the sheave holder 2 to hold the flywheel mag neto 3 Measure Air gap between TCI unit and flywheel magneto Refer to AIR GAP BETWEEN TCI UNIT AND FLYWHEEL MAGNETO in CHAPTER 2 T R Flywheel magneto nut 65 Nm 6 5 m kg 47 ft lb Sheave holder YS 01880 A 90890 01701 Rotor assembly holde...

Page 55: ...andle to the remove the starter handle 1 1 a b SWL3100J 2 Remove Drum sheave 1 CAUTION Be sure to press down on the drum sheave because the spring will spring out sud denly when it is removed from the sheave drum 1 SWL3110J 3 Remove Starter spring 1 1 SVU3330J RECOIL STARTER INSPECTION 1 Inspect Starter rope 1 2 Inspect Starter spring 2 Damage deterioration Replace 2 1 SVU3340J 3 Inspect Drive paw...

Page 56: ... Starter rope 2 Starter case 3 NOTE Wind the starter rope 2 clockwise two turns on the sheave drum 1 Engage the starter spring inner hook a with the strut b of the starter case 3 and then install the parts 1 2 b a SVU3360J 1 2 3 a b SWL3120J 3 Install Springs 1 Drive pawls 2 NOTE Install the springs 1 and drive pawls 2 at the R marks a 2 1 a SVU3380J 4 Install Clip 1 Drive plate 2 NOTE Align the g...

Page 57: ...fter tightening the bolt place the starter rope 2 in the cutout a in the sheave drum and wind it counterclock wise four turns NOTE Make a knot b at the end of the starter rope to prevent the rope from being retracted into the starter case 1 2 a SWL3130J b SWL3140J ...

Page 58: ...PTER 2 Air filter assembly control unit Refer to AIR FILTER ASSEMBLY AND CONTROL UNIT and AIR FILTER ASSEMBLY CONTROL UNIT AND NOISE FILTER Cover 3 Refer to PANELS AND COVERS NOTE Remove the cover 3 with the control box installed Recoil starter recoil starter cover Refer to RECOIL STARTER AND FLY WHEEL MAGNETO 1 Pipe frame 1 2 Engine assembly 1 For installation reverse the removal procedure É É É ...

Page 59: ...r removal Remove the parts in the order listed below Engine assembly Refer to ENGINE ASSEMBLY 1 Engine mount 4 2 Frame 1 3 Caster 1 1 4 Caster 2 1 5 Caster 3 2 For installation reverse the removal procedure É É É É 4 3 1 1 1 1 5 5 New New 2 É È 7 0 Nm 0 7 m kg 5 1 ft lb 16 Nm 1 6 m kg 11 ft lb È É SWL3490 ...

Page 60: ... 2 Muffler protector 1 3 Muffler 1 NOTE Remove the muffler nut then the muffler bolt 4 Gasket 1 5 Muffler band 1 6 Muffler cap 1 7 Muffler screen 1 8 Spark arrester 1 9 Generator cover 1 10 Exhaust pipe air shroud 2 1 For installation reverse the removal procedure 6 7 8 5 4 2 3 1 É É Ê É É 9 10 È É É É 7 0 Nm 0 7 m kg 5 1 ft lb 16 Nm 1 6 m kg 11 ft lb É Ê 3 5 Nm 0 35 m kg 2 5 ft lb È SWL3180 ...

Page 61: ...llustration SWL3200J 3 Install Muffler band NOTE Tighten the muffler band at the angle d shown in the illustration Make sure that the muffler band opening and muffler cap slit are not cov ering the hole b and that the muffler cap has not come out d 30 60 4 Install Muffler NOTE Finger tighten the muffler nut 1 and muffler bolt 2 and then tighten them to the specified torques respectively T R Muffle...

Page 62: ...FFLER 1 Fan 1 2 Generator 1 CAUTION The magnetic force of the magneto rotor is very strong Therefore be sure to remove the magneto rotor and sta tor coil assembly together as a set otherwise they may be damaged 3 Tube 2 4 Dowel pin 2 For installation reverse the removal procedure 4 4 3 2 3 É È Ê É 1 7 0 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0 m kg 7 2 ft lb 65 Nm 6 5 m kg 47 ft lb È É Ê SWL3230 ...

Page 63: ... 2 to hold the mag neto rotor Sheave holder YS 01880 A 90890 01701 Rotor assembly holder commercially available SWL3240J 2 Remove Stator coil assembly bolts 1 NOTE Turn the magneto rotor until the stator coil assembly bolts are visible through the holes in the rotor and then remove the bolts SWL3250J 3 Remove Stator coil assembly bolts 2 Tubes NOTE Turn the magneto rotor until the stator coil asse...

Page 64: ...rotor and stator coil assembly during or after removal oth erwise they may be damaged Rotor puller YU 33270 B 90890 01362 SWL3270J GENERATOR ASSEMBLY INSTALLATION CAUTION Be sure to remove any oil or grease from the tapered portion of the magneto rotor using a cloth dampened with thinner 1 Install Generator assembly 2 Install Stator coil assembly bolts 1 Tubes NOTE Turn the magneto rotor until the...

Page 65: ...oles in the rotor and then install the bolts 2 T R Stator coil assembly bolts 10 Nm 1 0 m kg 7 2 ft lb SWL3280J 4 Tighten Washer Magneto rotor nut 1 NOTE Tighten the magneto rotor nut 1 using the sheave holder 2 T R Magneto rotor nut 65 Nm 6 5 m kg 47 ft lb Sheave holder YS 01880 A 90890 01701 Rotor assembly holder commercially available SWL3240J ...

Page 66: ...y Refer to ENGINE ASSEMBLY Muffler Refer to MUFFLER Flywheel magneto Refer to RECOIL STARTER AND FLY WHEEL MAGNETO 1 Spark plug cap 1 2 Spark plug 1 3 Breather hose 1 4 Cylinder head cover 1 5 Gasket 1 6 Air shroud 1 7 Cylinder head assembly 1 8 Cylinder head gasket 1 9 Dowel pin 2 10 Push rod 2 For installation reverse the removal procedure SWL3320 CYLINDER HEAD COVER AND CYLINDER HEAD ...

Page 67: ... the crankshaft one full turn 360 to set the piston at top dead cen ter of the compression stroke Loosen the nuts in the proper sequence b a SWL3450 SWL3330J PUSH ROD INSPECTION 1 Measure Push rod runout Out of specification Replace Runout limit 0 5 mm 0 02 in SVU3100J CYLINDER HEAD INSPECTION 1 Inspect Cylinder head combustion chamber Check the combustion chamber for car bon deposits Carbon depos...

Page 68: ...0 05 mm 0 0020 in SVU3120J CYLINDER HEAD ASSEMBLY 1 Install Cylinder head bolts 1 to 4 NOTE Tighten the bolts to the specified torques in two steps and in order from 1 to 4 T R Cylinder head bolts 1st 12 Nm 1 2 m kg 8 7 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb SWL3340J BREATHER HOSE 1 Inspect Breather hose 1 NOTE Contact the end of the breather hose to the reed valve stopper a SVU3140J CYLINDER HEAD COVE...

Page 69: ...order listed below Cylinder head assembly Refer to CYLINDER HEAD COVER AND CYLINDER HEAD 1 Locknut 2 2 Adjuster 2 3 Locker arm 2 4 Valve cotter 2 5 Valve spring retainer 2 6 Valve spring 2 7 Valve intake 1 8 Valve exhaust 1 9 Valve stem seal 1 For installation reverse the removal procedure SWL3350 ...

Page 70: ...G INSPECTION 1 Measure Valve stem length a Valve face diameter b Out of specification Replace 2 Measure Valve stem diameter a Out of specification Replace Valve stem length Intake 65 9 mm 2 59 in Exhaust 66 2 mm 2 61 in Valve face diameter Intake 23 9 24 1 mm 0 9409 0 9488 in Exhaust 21 9 22 1 mm 0 8622 0 8701 in Valve stem diameter Intake 5 448 5 463 mm 0 2145 0 2151 in Exhaust 5 440 5 445 mm 0 2...

Page 71: ...a Out of specification Replace Valve spring free length Intake and exhaust 26 5 mm 1 04 in Limit 25 2 mm 0 99 in SVU3200J 5 Measure Valve spring tilt a Out of specification Replace Tilt limit 2 5 1 6 mm 0 06 in SVU3210J 6 Inspect Valve spring contact surface More than 2 3 of the contact surface does not contact Replace SVU3220J LOCKER ARM INSPECTION 1 Inspect Locker arm Wear damage cracks Replace ...

Page 72: ... seat 4 Measure 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 Valve face contact width intake and exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in SVU3240J 5 Measure Valve seat contact width a Make sure that the contact width along the entire valve seat is within specific...

Page 73: ...ALVE LAPPING 1 Apply a coarse lapping compound evenly on the valve face 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 Mecha...

Page 74: ...ter 4 Apply a small amount of molybdenum disulfide oil to the valve stem and use the valve spring compressor 5 to install the parts NOTE Install the chamfered side of the valve cotter facing down CAUTION Do not compress the valve spring more than necessary Valve spring compressor YM 01253 90890 01253 SVU3280J New ...

Page 75: ...gine assembly Refer to ENGINE ASSEMBLY Cylinder head assembly Refer to CYLINDER HEAD COVER AND CYLINDER HEAD Flywheel magneto Refer to RECOIL STARTER AND FLY WHEEL MAGNETO Generator assembly Refer to GENERATOR 1 Crankcase cover 1 2 Gasket 1 3 Rubber seal 2 4 Dowel pin 2 5 Bracket 1 6 Oil level switch 1 7 Camshaft 1 8 Valve lifter 2 For installation reverse the removal procedure SWL3360 ...

Page 76: ...ngth a and b Out of specifications Replace 3 Inspect Surface of camshaft gear teeth Decompressor Wear damage Replace Cam lobes length Intake a 26 9 0 05 mm 1 059 0 002 in b 22 0 0 05 mm 0 866 0 002 in Exhaust a 26 68 0 05 mm 1 050 0 002 in b 22 025 0 05 mm 0 867 0 002 in SVU3490J SVU3500J 4 Measure Camshaft diameter a Out of specification Replace Camshaft diameter 14 965 14 990 mm 0 5892 0 5902 in...

Page 77: ...ankshaft gear mark b SVU3530J CRANKCASE COVER INSPECTION 1 Inspect Crankcase cover 1 Damage Replace Bearing 2 Noise wear rotational failure Replace 1 2 SWL3380J CRANKCASE COVER INSTALLATION 1 Install Crankcase cover bolts 1 to 6 NOTE Tighten the bolts to the specified torques in two steps and in order from 1 to 6 T R Crankcase cover bolts 1st 12 Nm 1 2 m kg 8 7 ft lb 2nd 22 Nm 2 2 m kg 16 ft lb 1 ...

Page 78: ...e assembly Refer to ENGINE ASSEMBLY Cylinder head assembly Refer to CYLINDER HEAD COVER AND CYLINDER HEAD Flywheel magneto Refer to RECOIL STARTER AND FLY WHEEL MAGNETO Generator assembly Refer to GENERATOR Crankcase cover camshaft Refer to CRANKCASE COVER AND CAMSHAFT 1 Connecting rod cap 1 2 Crankshaft 1 3 Connecting rod 1 4 Piston pin circlip 2 5 Piston pin 1 6 Piston 1 7 Piston ring 3 For inst...

Page 79: ...ter 66 005 66 015 mm 2 5986 2 5990 in Cylinder inside diameter wear limit 66 020 mm 2 5992 in Cylinder taper limit 0 05 mm 0 0020 in SVU3590 2 Measure Cylinder warpage NOTE Measure the warpage on the contact surface of the cylinder head at six points using a straightedge and thickness gauge Out of specification Resurface or replace PISTON AND PISTON PIN INSPECTION 1 Measure Piston skirt diameter P...

Page 80: ...16 002 16 013 mm 0 6300 0 6304 in Wear limit 16 043 mm 0 6316 in SVU3600J 4 Measure Piston pin diameter Out of specification Replace Piston pin diameter 15 995 16 000 mm 0 6297 0 6299 in Wear limit 16 043 mm 0 6316 in SVU3610J 5 Inspect Check that the piston pin 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 protru...

Page 81: ...g 0 20 0 40 mm 0 0079 0 0157 in 0 65 mm 0 0256 in 2nd ring 0 20 0 40 mm 0 0079 0 0157 in 0 75 mm 0 0295 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in 0 9 mm 0 0354 in SVU3630J 2 Measure Piston ring side clearance Out of specification Replace Use a thickness gauge 1 NOTE Clean carbon deposits from the piston ring grooves and rings before measuring the side clearance Measure the side clearance at severa...

Page 82: ...f specification Replace Runout limit 0 02 mm 0 0008 in SWL3510J 2 Inspect Crankshaft gear 1 Wear damage Replace 1 SWL3520J 3 Measure Crankshaft pin outside diameter a Wear damage Replace Use a micrometer Out of specification Replace Crankshaft pin outside diameter 27 969 27 984 mm 1 1011 1 1017 in Wear limit 27 9 mm 1 0984 in SWL3530J ...

Page 83: ...ng rod 1 Connecting rod cap 2 NOTE Tighten the cap bolts so that the crankshaft does not move while the oil clearance is being measured 3 Remove Connecting rod cap Connecting rod 4 Measure Widest portion of the pressed Plasti gauge Out of specification Replace crank shaft or connecting rod and then mea sure the clearance again T R Connecting rod cap bolt 12 Nm 1 2 m kg 8 7 ft lb Connecting rod big...

Page 84: ... mark a faces towards the piston head Make sure that the piston rings move smoothly 2 Apply 4 stroke engine oil to the inside of the connecting rod small end SVW3770 3 Install Piston 1 Piston pin 2 Piston pin circlip 3 NOTE Make sure that the YAMAHA mark a on the connecting rod faces toward the crank case cover Make sure that the mark b on the pis ton head faces toward the push rod SVU3720J New ...

Page 85: ...OTE Make sure that the mark a on the pis ton head faces toward the push rod Make sure that the YAMAHA mark b on the connecting rod faces toward the crank case cover SVU3750J 4 Install Crankshaft 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 Camshaft Crankcase cover Refer to CRANKCASE COVER AND CAMSHAFT T R Connecting ro...

Page 86: ...COVERS PANELS AND CAPS in CHAPTER 2 Slide the fuel tank Refer to FUEL TANK AND CONTROL BOX Air filter assembly Refer to AIR FILTER ASSEMBLY AND CONTROL UNIT and AIR FILTER ASSEMBLY CONTROL UNIT AND NOISE FILTER 1 Choke cable 1 2 Choke knob 1 3 Fuel hose 1 4 Throttle control motor cover 1 5 Throttle control motor coupler 1 6 Carburetor 1 7 Gasket 1 SWL3400 ...

Page 87: ...3 46 ENG CARBURETOR Order Job name Part name Q ty Remarks 8 Carburetor joint 1 9 Gasket 1 For installation reverse the removal procedure SWL3400 ...

Page 88: ...Q ty Remarks Carburetor disassembly Remove the parts in the order listed below 1 Throttle control motor assembly 1 2 Throttle controller bracket 1 3 Bracket 1 4 Drain hose 1 5 Bolt 1 6 Gasket 1 7 Drain screw 1 8 Float chamber 1 9 Gasket 1 SWL3410 ...

Page 89: ...Job name Part name Q ty Remarks 0 Float pin 1 A Float 1 B Needle valve 1 C Main nozzle 1 D Main jet 1 E Air vent hose 1 F Throttle stop screw 1 G Pilot screw 1 H Pilot jet 1 For assembly reverse the disassembly procedure SWL3410 ...

Page 90: ...lve lightly contacts the float arm and then measure the float height a This mea surement should be made with the gasket removed Float height 16 0 mm 0 63 in SVU3790J SVU3800J 2 Clean Carburetor body Blow out all passages jets and carbu retor body with compressed air SVU3810J 3 Inspect Valve seat Wear damage Replace Dirt Clean 1 Wear at groove 2 Dirt SVU3820J ...

Page 91: ...in its fully open position a insert the tip of the inner cable into the drum hole 5 and then secure it in place with the screw 6 T R Screw 1 0 Nm 0 1 m kg 0 7 ft lb 4 a 5 3 2 6 1 SWL3420J THROTTLE CONTROL MOTOR 1 Inspect Throttle control motor 1 NOTE Install the shaft a of the throttle control motor by aligning it with the groove b of the throttle shaft Install the throttle valve and then make sur...

Page 92: ...ce Check fuel cock lever posi tion ON OFF Set to ON Check if fuel travels to fuel cock Clean fuel tank fuel cock and fuel pipe strainer GOOD NOT GOOD Check spark plug for dirt and check spark plug gap Check for voltage leakage due to faulty connection or broken insulation of the spark plug lead Check TCI unit coupler for corrosion or faulty connection Check the ignition system Refer to IGNITION SY...

Page 93: ...OOD WEAR Resurface or replace Check if the timing marks on the crankshaft and cam shaft 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 system Refer to THROTTLE CONTROL SYSTEM ...

Page 94: ... to a damaged carburetor joint or gas ket Tighten the carbu retor bolts securely Replace carbure tor joint or gasket with a new one GOOD NO GOOD Measure valve clearance GOOD OUT OF SPECIFICA TION Adjust Check compression using a compression gauge GOOD OUT OF SPECIFICA TION Improperly tight ened cylinder head Tighten securely Check if there are air gap between TCI unit and fly wheel magneto GOOD OU...

Page 95: ... clogged GOOD NO GOOD Disassemble or clean Check for air suction due to a damaged throttle shaft seal car buretor joint or gasket GOOD NO GOOD Disassemble or replace Check compression using com pression gauge GOOD TOO HIGH Decarbonize combustion chamber if there are carbon deposits TOO LOW Check if the timing marks on the crankshaft and camshaft are aligned GOOD NO GOOD Correct Check valve face an...

Page 96: ...knob approximately 1 3 to 1 2 way out and then check the engine operating condition STABLE UNSTABLE Check for air suction due to a damaged throttle shaft seal car buretor joint or gasket GOOD NO GOOD Disassemble or replace Check if slow or main passages such as the pilot jet and main jet in the carburetor are clogged GOOD NO GOOD Disassemble or clean Check valve face and valve seat for wear GOOD W...

Page 97: ...smoothly with slight resistance GOOD NO GOOD Replace the throttle control motor Measure the coil resistance between 3 1 3 2 3 4 and 3 5 of the throttle control motor Tester range Ω 100 250 Ω 7 25 C 77 F GOOD OUT OF SPECIFI CATION Replace the throttle control motor Check the connections of the wire har ness connectors and couplers and the wires for an open circuit or short circuit GOOD NO GOOD Corr...

Page 98: ...ONOMY CONTROL SWITCH IS SET TO ON Check AC output GOOD NO GOOD Refer to GENERATOR SYSTEM in CHAPTER 4 Check condition of the throttle con trol motor GOOD NO GOOD Replace throttle control motor Check economy switch GOOD NO GOOD Replace economy switch Check the connections of the wire harness connectors and couplers and the wires for an open circuit or short circuit GOOD NO GOOD Correct or replace D...

Page 99: ...rk plug B Throttle control motor C DC rectifier D Main switch E Economy switch F Engine speed limiter oil level warning unit G DC circuit breaker H DC receptacle 12 V 8 3 A I AC switch NFB 15 A J AC switch NFB 23 5 A K AC receptacle 15 A 2 L AC receptacle 23 3 A M Ground terminal N Overload warning light Red O Pilot light Green P Oil level warning light Red 3 2 1 SWL4090T C B A 0 9 8 7 6 5 4 SWL40...

Page 100: ...eto 0 TCI unit A Spark plug B Throttle control motor C DC rectifier D Main switch E Economy switch F Engine speed limiter oil level warning unit G DC receptacle 12 V 12 A H AC receptacle 15 A 2 I Ground terminal J Overload warning light Red K Pilot light Green L DC circuit breaker M Oil level warning light Red 3 2 1 SWL4090T C B A 0 9 8 7 6 5 4 SWL4080T H I J K M L D E F G SWL4020T ...

Page 101: ...er E Main switch F Economy switch G DC receptacle 12 V 12 A H AC receptacle 16 A 2 I Ground terminal J Overload warning light Red K Pilot light Green L DC circuit breaker M Oil level warning light Red N Engine speed limiter oil level warning unit O Noise filter 2 3 2 1 SWL4090T D C B A 9 8 7 6 5 4 0 SWL4030T B R BW Y L Y Y BW B W Br R R R Br Br R B B G Y G Y G Y G Y G Y BW Y Br B O N O EF G H I J ...

Page 102: ...ty If the continuity is faulty at any point replace the switch NOTE Set the pocket tester to 0 before starting a test When testing the switch for continuity the pocket tester should be set to the Ω 1 range When checking a switch turn it on and off a few times Pocket tester YU 03112 C 90890 03112 SWL4040 ...

Page 103: ...s before troubleshooting 1 Panel 4 2 Fuel tank 3 Control panel 4 Flywheel magneto 5 Crankcase cover Use the following special tool s for troubleshooting NO SPARK OR WEAK SPARK Pocket tester YU 03112 C 90890 03112 Dynamic spark tester YM 34487 Ignition checker 90890 06754 MEETS SPECIFICATION 1 Oil level Check the oil level Refer to OIL LEVEL CHECKING in CHAPTER 2 OUT OF SPECIFICATION Add oil GOOD 2...

Page 104: ...as shown Spark plug cap 1 Dynamic spark tester or ignition checker Dynamic tester lead or ignition checker lead Spark plug 4 È For USA and Canada É Except for USA and Canada SVU4055 SVU4060 OUT OF SPECIFICATION OR NO SPARK Crank the engine and measure the igni tion spark gap a Minimum spark gap 7 mm 0 28 in or more MEETS SPECIFICATION The ignition system is good È É ...

Page 105: ...k wise Install Turn the plug cap clockwise Inspect the spark plug lead for cracks or deterioration when installing the pug cap Cut 5 mm off the end of the spark plug lead and then connect it to the plug cap OUT OF SPECIFICATION Replace the spark plug cap MEETS SPECIFICATION 5 TCI unit coil resistance Remove the TCI unit 1 Primary coil resistance Connect the pocket tester Ω 1 to the primary termina...

Page 106: ...sistance 11 5 kΩ 20 at 20 C 68 F OUT OF SPECIFICATION Replace the TCI unit 2 1 SWL4050J 6 Main switch Disconnect the main switch coupler Connect the pocket tester Ω 1 to the main switch PWV0480 NO CONTINUITY Turn the main switch ON and check the main switch black and black white for continuity CONTINUITY Turn the main switch STOP and check the main switch black and black white for continuity CONTI...

Page 107: ...tinuity PWV0460J CONTINUITY NO CONTINUITY Replace the oil level switch PWV0450J GOOD 8 Air gap between TCI unit and flywheel magneto Measure the air gap between the magnet portion of the TCI unit and flywheel mag neto Refer to AIR GAP BETWEEN TCI UNIT AND FLYWHEEL MAGNETO in CHAP TER 2 Air gap between TCI unit and fly wheel magneto 0 5 0 1 mm 0 020 0 004 in OUT OF SPECIFICATION Adjust the air gap ...

Page 108: ...ignition system Check the terminal of the connector for contamination or rust and the connector for proper connection Replace the flywheel magneto Replace the TCI unit Replace the engine speed limiter oil level warning unit DISCONNECTED Correct or replace the connector ...

Page 109: ...DOES NOT OPERATE Pocket tester YU 03112 C 90890 03112 Inductive self powered tachome ter YU 8036 B Engine tachometer 90890 03113 90793 80009 90793 80032 CONTINUITY 1 Fuse Remove the fuse Connect the pocket tester Ω 1 to the fuse Check the fuse for continuity NO CONTINUITY Replace the fuse GOOD 2 Battery voltage Connect the pocket tester DC 20 V to the battery terminals Measure battery voltage Test...

Page 110: ...heck is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity CONTINUITY 4 Starter relay Disconnect the starter relay from the cou pler Connect the jumper lead to the starter relay and the battery terminals Battery positive terminal pink 1 Battery negative terminal green 2 Battery positive terminal red white 3 Battery negative terminal green yellow 4 È 120 V 60 Hz É...

Page 111: ...red 1 Tester negative probe brown 2 Turn the main switch to START and check the main switch for continuity NO CONTINUITY Replace the main switch OFF ON START Br Br R R B B B W B W 2 1 SWL4080 6 Wire harness electric starting system Check the terminal of the connector for contamination or rust and the connector for proper connection DISCONNECTED Correct or replace the connector ...

Page 112: ...in the order listed below Flywheel magneto Refer to RECOIL STARTER AND FLY WHEEL MAGNETO in CHAPTER 3 1 Stop ring 1 2 Spring holder spring 1 1 3 Overrun clutch 1 4 Front bracket gasket 1 1 5 Washer 1 6 Rear bracket gasket 1 1 7 Brush brush spring 2 2 8 Armature coil 1 9 Yoke 1 For assembly reverse the disassembly procedure SWL4090 ...

Page 113: ...rush spring force 5 5 8 3 N 550 830 gf 12 1 18 3 lb 1 SWL4100J 3 Measure Armature coil insulation continuity Defects Replace the starter motor a Continuity check b Insulation check 1 Armature coil Insulation resistance More than 1 MΩ at 20 C 68 F SVW4240 4 Inspect Commutator Dirt Clean it with 600 grit sandpa per 5 Measure Commutator diameter a Out of specification Replace the starter motor Commut...

Page 114: ... Scrape the mica to the proper measurement with a hack saw blade that has been grounded to fit the commutator NOTE The mica of the commutator must be undercut to ensure proper operation of the commutator Mica undercut 1 5 mm 0 06 in ELECTRIC STARTING SYSTEM ...

Page 115: ... Pocket tester YU 03112 C 90890 03112 Inductive self powered tachome ter YU 8036 B Engine tachometer 90890 03113 90793 80009 90793 80032 CONTINUITY 1 Fuse Remove the fuse Connect the pocket tester Ω 1 to the fuse Check the fuse for continuity NO CONTINUITY Replace the fuse GOOD 2 Battery voltage Connect the pocket tester DC 20 V to the battery terminals Measure battery voltage Tester positive lead...

Page 116: ...ive terminal 2 Charging voltage 12 16 V 1 2 MEETS SPECIFICATION Properly connect the charging system GOOD 4 Charging coil resistance Disconnect the charging coil connector Connect the pocket tester Ω 1 to the charging coil Tester positive lead White terminal 1 Tester negative lead Ground 2 Charging coil resistance White Ground 0 35 Ω 20 at 20 C 68 F 2 1 SWL4130J OUT OF SPECIFICATION Replace the ch...

Page 117: ...ity Normal Tester positive lead White 1 Tester negative lead Red 2 Continuity Tester positive lead Red 2 Tester negative lead White 1 No Continu ity 1 2 SWL4135 NO CONTINUITY Replace the rectifier 6 Wire harness charging system Check the terminal of the connector for contamination or rust and the connector for proper connection DISCONNECTED Correct or replace the connector ...

Page 118: ...e inspection Disconnect the subcoil coupler 1 Connect the Blue leads and then connect the Orange leads Disconnect the main coil coupler Start the engine Connect the tip of the probe of pocket tester to the Yel low leads Measure the voltage Tester range AC 300 V Main coil AC voltage 200 250 V 120 V 60 Hz 380 470 V 220 V 50 Hz 230 V 50 Hz GOOD TOO LOW DOES NOT GENERATE 1 L L O O L L L L O O O O SWL4...

Page 119: ...Measure the resistance between the Orange to Orange lead Tester range Ω 1 Subcoil resistance 0 17 Ω 20 at 20 C 68 F GOOD DISCONNECTED SHORT CIRCUIT Replace the generator assembly L L O L L O O O SWL4190 Economy switch continuity inspection Switch ON Continuity Switch OFF No Continuity GOOD DISCONNECTED Wire harness inspection Check the terminal of the connector for contami nation or rust and the c...

Page 120: ...HROTTLE CONTROL SYSTEM in CHAP TER 3 Subcoil AC voltage inspection Disconnect the subcoil coupler 1 Connect the Blue leads and then connect the Orange leads Start the engine Connect the tip of the probe of pocket tester to the Blue leads Measure the voltage Tester range AC 120 V Subcoil AC voltage 13 5 23 0 V GOOD TOO LOW DOES NOT GENERATE L L O O L L L L O O O O 1 SWL4200 L L L L O O O O L L O O ...

Page 121: ...erminal 4 White terminal 2 NO White terminal 2 Blue terminal 5 YES Blue terminal 5 White terminal 2 NO Black terminal 3 Blue terminal 4 NO Blue terminal 4 Black terminal 3 YES Black terminal 3 Blue terminal 5 NO Blue terminal 5 Black terminal 3 YES CONTINUITY NO CONTINUITY Wire harness inspection Check the terminal of the connector for contami nation or rust and the connector for proper con nectio...

Page 122: ... 50 0 2 60 1 97 Compression ratio 8 5 1 Standard compression pressure kPa kg cm2 psi 400 600 4 6 57 85 Rated output 50 Hz kW PS 3 800 r min 3 5 4 7 60 Hz kW PS 3 800 r min 3 5 4 7 Operating hours 50 Hz Hrs 1 4 load economy switch is on 20 5 Rated load economy switch is on 8 0 60 Hz Hrs 1 4 load economy switch is on 20 5 Rated load economy switch is on 8 0 Fuel Unleaded regular gasoline Fuel tank c...

Page 123: ...e V 120 120 V 60 Hz 220 220 V 50 Hz 230 230 V 50 Hz Frequency Hz 50 220 V 50 Hz 230 V 50 Hz 60 120 V 60 Hz Rated output kVA 2 8 Rated current A 23 3 120 V 60 Hz 12 7 220 V 50 Hz 12 2 230 V 50 Hz DC output Rated voltage V 12 Rated current A 8 3 120 V 60 Hz 12 220 V 50 Hz 230 V 50 Hz Safety device type AC Electronic no fuse breaker DC Circuit breaker No fuse breaker Engine speed no load r min 3 550 ...

Page 124: ...in coil Three phase DC output subcoil Single phase Insulation resistance MΩ Over 10 Insulation type B type Receptacle AC 15 A Duples 1 23 3 A 1 120 V 60 Hz 15 A 2 220 V 50 Hz 16 A 2 230 V 50 Hz DC 12 A 1 220 V 50 Hz 230 V 50 Hz 8 3 A 1 120 V 60 Hz Unit EF3000iSE ...

Page 125: ... 0 6297 0 6299 Limit 16 043 0 6316 Piston ring mm in Top ring Type Barrel face Dimensions B T 1 5 2 7 0 0591 0 1063 End gap 0 20 0 40 0 0079 0 0157 Limit 0 65 0 0256 Side clearance 0 04 0 08 0 0016 0 0031 Limit 0 13 0 0051 2nd ring Type Taper Dimensions B T 1 5 2 7 0 0591 0 1063 End gap 0 20 0 40 0 0079 0 0157 Limit 0 75 0 0295 Side clearance 0 02 0 06 0 0008 0 0024 Limit 0 12 0 0047 Oil ring Type...

Page 126: ...0 1 0 0039 Camshaft mm in Camshaft outside diameter Cam dimension IN EX A 26 9 0 05 1 059 0 002 26 68 0 05 1 050 0 002 B 22 0 0 05 0 866 0 002 22 025 0 05 0 867 0 002 Camshaft journal 14 965 14 990 0 5892 0 5902 Limit 14 950 0 5886 Valve mm in Valve Face diameter A IN 23 9 24 1 0 9409 0 9488 EX 21 9 22 1 0 8622 0 8701 Stem diameter B IN 5 448 5 463 0 2145 0 2151 EX 5 440 5 445 0 2142 0 2144 Limit ...

Page 127: ...ee length IN 26 5 1 04 EX 26 5 1 04 Limit IN 25 2 0 99 EX 25 2 0 99 Set length IN 21 6 0 85 EX 21 6 0 85 Set force IN N kg lb 41 9 46 3 4 2 4 6 92 4 102 1 EX N kg lb 41 9 46 3 4 2 4 6 92 4 102 1 Tilt limit Degree mm in 2 5 1 6 0 06 Carburetor mm in Type manufacturer BV20 15 MIKUNI I D mark 7WL 00 Bore size ø15 Main jet 101 3 Min air jet ø1 8 Pilot air jet ø1 1 Pilot outlet ø0 9 Valve seat size ø1 ...

Page 128: ...0 07 Blue Blue Electrical Ignition timing at 3 600 r min BTDC 23 3 TCI unit Primary coil resistance Ω 20 0 5 Secondary coil resistance Ω 20 11 5 Air gap between TCI unit and flywheel magneto mm in 0 5 0 1 0 020 0 004 Charge coil resistance Ω 20 0 35 white ground Spark plug cap resistance kΩ 3 8 6 3 Minimum spark gap mm in 7 0 28 or more Battery Type manufacturer YTX12 BS YUASA Charging amperage an...

Page 129: ...nkshaft pin E Crankshaft journals E Connecting rod bolts E Piston pin E Piston surface E Valve stems intake and exhaust E Valve stem ends intake and exhaust M Rocker arm shaft E Valve push rod ends E Valve push rod guides E Valve lifters E Camshaft lobes E Camshaft gear teeth E Decompressor pin E Camshaft journals E Crankcase ball bearing E Crankcase cover ball bearing E ...

Page 130: ... 7 5 1 16 1 6 11 Muffler protector M6 1 0 7 0 0 7 5 1 Muffler band M5 0 8 3 5 0 35 2 5 Exhaust pipe air shroud 1 M6 1 0 7 0 0 7 5 1 Exhaust pipe air shroud 2 M6 1 0 7 0 0 7 5 1 Recoil starter M6 1 0 7 0 0 7 5 1 Drive plate M6 1 0 5 4 0 54 3 9 Flywheel magneto cover M6 1 0 7 0 0 7 5 1 Flywheel magneto nut M14 1 5 65 6 5 47 Generator cover M6 1 0 7 0 0 7 5 1 TCI unit M6 1 0 10 1 0 7 2 Fan M6 1 0 7 0...

Page 131: ...4 0 7 0 07 0 5 Bracket M5 3 5 0 35 2 5 Bolt M7 7 0 0 7 5 1 Pilot jet M6 1 7 0 17 1 2 Pipe frame M6 1 0 7 0 0 7 5 1 Caster M8 1 25 16 1 6 11 Cover 1 M6 1 0 7 0 0 7 5 1 Cover 2 M6 1 0 7 0 0 7 5 1 Cover 3 M6 1 0 7 0 0 7 5 1 Cover 4 M6 1 0 7 0 0 7 5 1 Cover 5 M6 1 0 7 0 0 7 5 1 Cover 6 M6 1 0 7 0 0 7 5 1 Fuel tank M6 1 0 7 0 0 7 5 1 Panel 1 M6 1 0 7 0 0 7 5 1 Panel 3 M6 1 0 7 0 0 7 5 1 Battery bracket...

Page 132: ...reads Components should be at room temperature DEFINITION OF UNITS 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 Unit Read Definition Measure mm Millimeter 10 3 meter Length cm Centimeter 10 2 meter Length kg Kilogram 103 gram Weight N Newton 1 kg m sec2 Force Nm Newton meter N m Torque m kg Meter kilogram m...

Page 133: ...WL5020T SWL5030T BEHIND CONTROL BOX SWL5010T BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR È White tape for identifying position É Red tape for distin guishing leads Ê Yellow tape for identifying position Ë To control box Ì To DC rectifier Í To generator Î To starter relay and rectifier Ï To engine COLOR CODE B Black Br Brown L Blue G Green Gy Gray R Red W White Y Yellow B W Black White ...

Page 134: ... SWL5030T BEHIND CONTROL BOX SWL5040T BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR È White tape for identi fying position É Red tape for distin guishing leads Ê Yellow tape for iden tifying position Ë To control box Ì To DC rectifier Í To generator Î To starter relay and rectifier Ï To engine COLOR CODE B Black Br Brown L Blue R Red W White Y Yellow B W Black White G Y Green Yellow ...

Page 135: ...EHIND CONTROL BOX SWL5060T BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR È White tape for identi fying position É Red tape for distin guishing leads Ê Yellow tape for iden tifying position Ë To control box Ì To DC rectifier Í To noise filter Î To generator Ï To starter relay and rectifier Ð To engine COLOR CODE B Black Br Brown L Blue R Red W White Y Yellow B W Black White G Y Green Yellow ...

Page 136: ...EHIND CONTROL BOX SWL5060T BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR È White tape for identi fying position É Red tape for distin guishing leads Ê Yellow tape for iden tifying position Ë To control box Ì To DC rectifier Í To noise filter Î To generator Ï To starter relay and rectifier Ð To engine COLOR CODE B Black Br Brown L Blue R Red W White Y Yellow B W Black White G Y Green Yellow ...

Page 137: ...ead 6 Negative battery lead 7 DC rectifier 8 Rectifier 9 Starter relay È Route the TCI unit lead through the notch in the fan case É Route the oil level switch lead through the hole in the crankcase Ê Route the wire harnesses as shown in the illus tration 2P 3P 4P B L W L 6P 6P 2P 3P A B C A C B 7 8 9 6 5 4 3 2 1 Ï Ð Î Ñ Ò Ó Í Ì Ë Ê É È Ë SWL5040 WIRE ROUTING DIAGRAM ...

Page 138: ...he hole in the recoil starter cover Î Install vertically Ï To starter motor Ð To battery Ñ Connect the ground lead green yellow within the range indicated in the illustration Ò Connect the negative battery lead within the range indicated in the illustration Ó To DC rectifier 2P 3P 4P B L W L 6P 6P 2P 3P A B C A C B 7 8 9 6 5 4 3 2 1 Ï Ð Î Ñ Ò Ó Í Ì Ë Ê É È Ë SWL5040 WIRE ROUTING DIAGRAM ...

Page 139: ...ry lead 7 DC rectifier 8 Rectifier 9 Starter relay 0 Noise filter È Route the TCI unit lead through the notch in the fan case É Route the oil level switch lead through the hole in the crankcase Ê Route the wire harnesses as shown in the illus tration 2P 3P 3P 4P B L W L 6P 6P 3P A B C A C B 7 8 9 6 5 4 3 2 1 Ï Î Ñ Ò Ó Í Ì Ë Ê É È Ë Ð Ô Ë 0 2P 2P SWL5110T WIRE ROUTING DIAGRAM ...

Page 140: ...recoil starter cover Î Install vertically Ï To starter motor Ð To battery Ñ Connect the ground lead green yellow within the range indicated in the illustration Ò Connect the negative battery lead within the range indicated in the illustration Ó To DC rectifier Ô To noise filter 2P 3P 3P 4P B L W L 6P 6P 3P A B C A C B 7 8 9 6 5 4 3 2 1 Ï Î Ñ Ò Ó Í Ì Ë Ê É È Ë Ð Ô Ë 0 2P 2P SWL5110T WIRE ROUTING DI...

Page 141: ...arter motor lead È Install the spark plug cap as shown in the illus tration É Route the oil level switch as shown in the illus tration Ê Route the spark plug lead so that it is aligned with the air shroud Ë Route the TCI unit lead through the notch in the flywheel magneto cover A A B B È É Ê Ë Ì Í Î 9 8 1 3 4 5 6 7 2 1 SWL5050J WIRE ROUTING DIAGRAM ...

Page 142: ...lead as shown Í Securely install the charging coil grommet into the hole in the crankcase Î Connect the starter motor lead and then cover the terminal with the cover A A B B È É Ê Ë Ì Í Î 9 8 1 3 4 5 6 7 2 1 SWL5050J WIRE ROUTING DIAGRAM ...

Page 143: ...ke duct È Route the air vent hose over the fuel hose fuel cock to carburetor É Securely install the air intake duct so that it con tacts the bottom of the air filter assembly case Ê To hole a in the frame Ë To hole b in the frame Ì To hole a in the frame Í To hole b in the frame A A 1 2 4 3 5 6 4 8 3 7 3 3 7 Ì Ì Î Ï Ð Í Í É Ê Ë È Ñ 7 SWL5070J WIRE ROUTING DIAGRAM ...

Page 144: ... the air intake duct frame installation end to attach the flange to the frame Ï Face the cut end of the air vent hose downward Ð Position the air vent hose end and cylinder head breather hose end below horizontal Ñ 15 20 mm 0 6 0 8 in A A 1 2 4 3 5 6 4 8 3 7 3 3 7 Ì Ì Î Ï Ð Í Í É Ê Ë È Ñ 7 SWL5070J WIRE ROUTING DIAGRAM ...

Page 145: ...to carburetor 4 Fuel hose fuel tank to fuel cock È Install the fuel hose fuel cock to carburetor with the hose carburetor end bent to the angle shown in the illustration É 10 Ê 35 5 mm 1 4 0 2 in 4 2 3 2 3 3 2 1 1 3 È É Ê A B B A SWL5060J WIRE ROUTING DIAGRAM ...

Page 146: ...switch C Overload warning light D DC receptacle 12 V 8 3 A E DC circuit breaker F Ground terminal G Main switch H Oil level warning light I Engine speed limiter oil level warning unit J Oil level switch K Fuse 10 A L Starter relay M Starter motor N Battery O Rectifier P Charging coil Q TCI unit R Spark plug S Throttle control motor COLOR CODE B Black Br Brown G Green Gy Gray L Blue R Red W White Y...

Page 147: ... DC receptacle 12 V 12 A B DC circuit breaker C Ground terminal D Main switch E Oil level warning light F Engine speed limiter oil level warning unit G Oil level switch H Fuse 10 A I Starter relay J Starter motor K Battery L Rectifier M Charging coil N TCI unit O Spark plug P Throttle control motor COLOR CODE B Black Br Brown G Green Gy Gray L Blue R Red W White Y Yellow O Orange B W Black White G...

Page 148: ...d warning light C DC receptacle 12 V 12 A D DC circuit breaker E Ground terminal F Main switch G Oil level warning light H Engine speed limiter oil level warning unit I Oil level switch J Fuse 10 A K Starter relay L Starter motor M Battery N Rectifier O Charging coil P TCI unit Q Spark plug R Throttle control motor COLOR CODE B Black Br Brown G Green Gy Gray L Blue R Red W White Y Yellow O Orange ...

Page 149: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002 11 CR E YAMAHA MOTOR CO LTD ...

Page 150: ...Y Y Y Y Y Y Y Y Y R W R R R R R R B G Y R L O G Y Y Y Y Y Y R R R R P Br R B R R R R R L R W B B B B W W W R W B L L L L L O O O O Br B R O G Y R L O O O O O O O O O O B B B L O O O O L L L Gy Gy Gy Gy Gy Gy B W P B W G G P P G G O O O B W B W Gy Gy Br Br Br Br B Br Br R G G G G G G R Br R R ...

Page 151: ...Y R W R R R R R R B G Y R L O G Y Y Y Y Y Y R R Br R B R R R R R L R W B B B B W W W R W B L L L L L O O O O Br B R O G Y R L O O O O O O O O O O B B B L O O O O L L L B W B W B W B W G Y G Y B W B W R W B W R W B W G Y G Y G Y G Y G Y R W R W G Y G Y O O O B W B W B W Gy Br Br B R R Br Br G Y R Br R R ...

Page 152: ...W R R R R R B G Y R L O G Y Y Y Y Y Y R R Br R B R R R R R L R W B B B B B W W W R W B L L L L L O O O O Br B R O G Y R L O O O O O O O O O O B B B L O O O O L L L B W B W B W B W G Y G Y B W B W R W B W R W B W G Y G Y G Y G Y G Y R W R W G Y G Y O O O B W B W B W Gy Br B È R Br R R B B B B 7 G Y G Y R R Br Br Br G Y B 0 G Y R Br ...

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