Yamaha EF3000iSE - Inverter Generator - 3000 Maximum AC... Service Manual Download Page 11 | Manualshive

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GENERATOR

......................................... 3-21

GENERATOR ASSEMBLY
REMOVAL ......................................... 3-22
GENERATOR ASSEMBLY
INSTALLATION ................................. 3-23

CYLINDER HEAD COVER
AND CYLINDER HEAD

.......................... 3-25

CYLINDER HEAD REMOVAL  ........... 3-26
PUSH ROD INSPECTION ................. 3-26
CYLINDER HEAD INSPECTION  ...... 3-26
CYLINDER HEAD ASSEMBLY  ......... 3-27
BREATHER HOSE  ............................ 3-27

VALVE

.................................................... 3-28

VALVE AND VALVE SPRING
REMOVAL ......................................... 3-29
VALVE AND VALVE SPRING
INSPECTION ..................................... 3-29
LOCKER ARM INSPECTION ............ 3-30
VALVE SEAT INSPECTION .............. 3-31
VALVE LAPPING .............................. 3-32
VALVE AND VALVE SPRING
ASSEMBLY ....................................... 3-33

CRANKCASE COVER
AND CAMSHAFT

................................... 3-34

CRANKCASE COVER REMOVAL  .... 3-35
CAMSHAFT INSPECTION  ................ 3-35
VALVE LIFTER INSPECTION ........... 3-36
CAMSHAFT ASSEMBLY  .................. 3-36
CRANKCASE COVER
INSPECTION ..................................... 3-36
CRANKCASE COVER
INSTALLATION ................................. 3-36

PISTON, CONNECTING ROD,
CRANKSHAFT AND CRANKCASE

...... 3-37

CRANKCASE (CYLINDER)
INSPECTION ..................................... 3-38
PISTON AND PISTON PIN
INSPECTION ..................................... 3-38
PISTON RING INSPECTION  ............ 3-40
CRANKSHAFT INSPECTION  ........... 3-41
CONNECTING ROD OIL
CLEARANCE INSPECTION .............. 3-42
PISTON RING
AND PISTON ASSEMBLY  ................ 3-43
CRANKSHAFT ASSEMBLY  .............. 3-44

CARBURETOR

...................................... 3-45

FLOAT HEIGHT INSPECTION  ......... 3-49
CHOKE CABLE INSTALLATION  ...... 3-50
THROTTLE CONTROL MOTOR  ...... 3-50

TROUBLESHOOTING

........................... 3-51

THROTTLE CONTROL SYSTEM ..... 3-56

CHAPTER 4.

ELECTRICAL

ELECTRICAL COMPONENTS

................ 4-1

120 V-60 Hz  ........................................ 4-1
220 V-50 Hz  ........................................ 4-2
230 V-50 Hz  ........................................ 4-3

SWITCHES

............................................... 4-4

CHECKING SWITCH CONTINUITY ... 4-4

IGNITION SYSTEM

.................................. 4-5

TROUBLESHOOTING CHART ........... 4-5

ELECTRIC STARTING SYSTEM

........... 4-11

TROUBLESHOOTING CHART ......... 4-11
STARTER MOTOR ........................... 4-14

CHARGING SYSTEM

............................ 4-17

TROUBLESHOOTING CHART ......... 4-17

GENERATOR SYSTEM

......................... 4-20

TROUBLESHOOTING CHART ......... 4-20

CHAPTER 5.

SPECIFICATIONS

GENERAL SPECIFICATIONS

................. 5-1

MAINTENANCE SPECIFICATIONS

........ 5-4

ENGINE .............................................. 5-4
GENERATOR AND ELECTRICAL ...... 5-7

LUBRICATION POINTS
AND LUBRICANT TYPES

....................... 5-8

TIGHTENING TORQUE

........................... 5-9

GENERAL TORQUE
SPECIFICATIONS

................................. 5-11

DEFINITION OF UNITS

......................... 5-11

WIRE ROUTING DIAGRAM

................... 5-12

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

Page 1: ...SERVICE MANUAL MANUEL D ATELIER MANUAL DE SERVICIO EF3000iSE 7WL 28197 40 310134...

Page 2: ......

Page 3: ...fety 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 ins...

Page 4: ...culi rement importantes sont rep r es par les notations suivantes Le symbole d alerte signifie ATTENTION SOYEZ VIGILANT VOTRE SECURITE EST EN JEU Le non respect des instructions AVERTISSEMENT peut ent...

Page 5: ...ntes El s mbolo de alerta de seguridad significa ATENCI N EST ATENTO EST EN JUEGO SU SEGURIDAD PERSONAL El incumplimiento de las instrucciones de ADVERTENCIA puede causar graves lesio nes e incluso la...

Page 6: ...bricant 8 Special tool 9 Tightening 0 Wear limit clearance A Engine speed B V A Illustrated symbols C through K in the exploded diagram indicate the grades of lubri cant and the locations of the lubri...

Page 7: ...olybd ne I Appliquer de l agent de blocage LOCTITE J Appliquer du fixant Yamaha K Utiliser une pi ce neuve S MBOLOS ILUSTRADOS Consulte la ilustraci n Los s mbolos ilustrados 1 a 5 est n dise a dos pa...

Page 8: ...INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE ELECTRICAL SPECIFICATIONS...

Page 9: ...LES INSPECTIONS ET R GLAGES P RIODIQUES MOTEUR CIRCUIT LECTRIQUE CARACT RISTI QUES NDICE INFORMACI N GENERAL 1 INSPECCI N Y AJUSTES PERI DICOS 2 MOTOR ENG 3 SISTEMA EL CTRICO ELEC 4 ESPECIFICACIO NES...

Page 10: ...SURE 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...

Page 11: ...N 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 FLOA...

Page 12: ...U ENTRE LE BLOC TCI ET LE VOLANT 2 13 PRESSION DE COMPRESSION 2 14 R GIME MOTEUR SANS CHARGE 2 16 R GIME MOTEUR CONOMIQUE 2 16 C BLE DE STARTER 2 17 RENIFLARD 2 17 CIRCUIT LECTRIQUE 2 18 BOUGIE 2 18 C...

Page 13: ...3 38 INSPECTION DU PISTON ET DU SEGMENT DE PISTON 3 38 INSPECTION DE L AXE DE PISTON 3 40 INSPECTION DU VILEBREQUIN 3 41 V RIFICATION DE L ESPACE DE GRAISSAGE DE LA BIELLE 3 42 SEGMENT DE PISTON ET E...

Page 14: ...LOCIDAD DEL MOTOR EN AHORRO DE ENERG A 2 16 CABLE DEL ESTRANGULADOR 2 17 MANGUERA DEL RESPIRADERO 2 17 SISTEMA EL CTRICO 2 18 BUJ A 2 18 INTERRUPTOR PRINCIPAL 2 19 INTERRUPTOR DE AHORRO DE ENERG A 2 2...

Page 15: ...ILLOS DE PIST N 3 40 INSPECCI N DEL CIG E AL 3 41 INSPECCI N DE LA HOLGURA DE ACEITE DE LA BIELA 3 42 ANILLOS DE PIST N Y CONJUNTO DEL PIST N 3 43 CONJUNTO DEL CIG E AL 3 44 CARBURADOR 3 45 INSPECCI N...

Page 16: ...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 a...

Page 17: ...ro de s rie de d part 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 INFORMACI N GENERAL IDENTIFICACI N DE LA M QUINA N MERO DE SERIE E...

Page 18: ...lace 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 wi...

Page 19: ...tage c V rifier que les l ments mobiles se d placent librement apr s remontage de chaque section de la machine INFORMACI N IMPORTANTE PREPARACI N PARA LA EXTRACCI N Y EL DESMONTAJE PRECAUCI N EN EL SE...

Page 20: ...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 outw...

Page 21: ...damment les roulements lors de leur mise en place ATTENTION Ne pas s cher les roulements l air comprim Cela peut endommager leur surface PIEZAS DE RECAMBIO En todas las sustituciones recomendamos uti...

Page 22: ...ng 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 comp...

Page 23: ...piston 4 Calibre positif Disponible dans le commerce Cet instrument est utilis pour contr ler la taille et l tat d un al sage HERRAMIENTAS Y EQUIPOS DE PRUEBA ESPECIALES Para poder realizar el montaje...

Page 24: ...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 us...

Page 25: ...Cet outil est utilis pour retirer l axe du piston 9 Cl sangle R f YS 01880 A 90890 01701 Cet outil est n cessaire pour maintenir le volant 5 Tac metro autom tico inductivo 1 P N YU 8036 B Tac metro de...

Page 26: ...0 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 i...

Page 27: ...st me d allumage 14 Chargeur de batterie sans entretien MF Disponible dans le commerce Cet outil est n cessaire pour charger le syst me lectrique 10 Soporte del conjunto del rotor Disponible en el mer...

Page 28: ...missions control are indicated as in the chart PERIODIC MAINTENANCE LUBRICATION INTERVALS Related to emission control system Item Remarks Pre Opera tion check daily Initial 1 month or 20 Hr Every 3 mo...

Page 29: ...tionnement de la veilleuse Fixations Attaches V rifier le serrage de tous les raccords Ajuster si n cessaire Associ au syst me de contr le des missions INSPECCIONES Y AJUSTES PERI DICOS INTRODUCCI N E...

Page 30: ...n 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...

Page 31: ...m kg 5 1 ft lb 7 0 Nm 0 7 m kg 5 1 ft lb 7 0 Nm 0 7 m kg 5 1 ft lb CUBIERTAS PANELES Y TAPAS Vista frontal derecha Vista trasera izquierda 1 Cubierta 1 2 Panel 1 3 Cubierta 2 4 Cubierta 3 5 Tapa 1 6 T...

Page 32: ...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 Ref...

Page 33: ...er le moteur pendant plusieurs minutes Arr ter le moteur V rifier que l huile moteur est au niveau sp ci fi a Ajouter de l huile si n cessaire MOTOR COMPROBACI N DE FUGAS DE ACEITE DEL MOTOR 1 Extraig...

Page 34: ...ceptacle 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...

Page 35: ...E 10W Quantit d huile moteur 0 6 l 0 53 Imp qt 0 63 US qt CONTR LE DU NIVEAU D HUILE VIDANGE DE L HUILE COMPROBACI N DEL NIVEL DE ACEITE CAMBIO DE ACEITE 4 Instale Tap n de relleno de aceite Panel 2 C...

Page 36: ...SAE 30 or 10W 30 or 10W 40 SAE 20 or 10W 30 or 10W 40 SAE 10W or 10W 30 or 10W 40 SAE 40 Above 35 C 95 F Engine oil quantity 0 6 L 0 53 Imp qt 0 63 US qt SVW2070T FUEL LEAKAGE 1 Remove Cover 1 Cover 5...

Page 37: ...ou tirer exag r ment les flexibles de carburant VIDANGE DE L HUILE FUITE DE CARBURANT CAMBIO DE ACEITE FUGAS DE COMBUSTIBLE NOTA Clasificaci n del aceite de motor recomen dado Servicio API SE o SF si...

Page 38: ...2070J 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 Ins...

Page 39: ...nstaller Filtre du r servoir de carburant Bouchon du r servoir de carburant AVERTISSEMENT V rifier que le bouchon du r servoir est solide ment serr 4 Compruebe Fugas Compruebe el dep sito el grifo de...

Page 40: ...efer 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 str...

Page 41: ...5 Couvercle 1 Voir COUVERCLES PANNEAUX ET BOUCHONS CR PINE DE LA CONDUITE DE CARBURANT FILTRO DEL TUBO DE COMBUSTIBLE FILTRO DEL TUBO DE COMBUSTIBLE ADVERTENCIA No fume y mant ngase alejado de las ll...

Page 42: ...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 kero...

Page 43: ...e air 2 puis installer l ensemble dans le bo tier de filtre air ELEMENTO DEL FILTRO DEL AIRE 1 Extraiga Panel 4 Cubierta 5 Consulte la secci n CUBIERTAS PANELES Y TAPAS 2 Extraiga Ganchos 1 Caja del f...

Page 44: ...ure 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 filt...

Page 45: ...3 3 D poser Bande du pot d chappement 1 Capuchon du pot d chappement 2 Silencieux du pot d chappement 3 Pare tincelles 4 8 Instale Caja del elemento del filtro de aire 1 Ganchos 2 NOTA Alinee la proy...

Page 46: ...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...

Page 47: ...RE 3 R GLAGE DU JEU DE SOUPAPE 1 D poser Panneau 4 Voir COUVERCLES PANNEAUX ET BOUCHONS 2 D poser Reniflard 1 Capuchon de bougie 2 Couvercle de culasse 3 Bougie 4 4 Saque la carbonilla Tubo de escape...

Page 48: ...he 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 spe...

Page 49: ...ssion froid 0 18 0 22 mm 0 007 0 009 in Soupape d chappement froid 0 18 0 22 mm 0 007 0 009 in Calibre d paisseur YU 26900 9 90890 03079 3 Tire del arrancador de retroceso con sua vidad para llevar el...

Page 50: ...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...

Page 51: ...rcle de culasse 10 Nm 1 0 m kg 7 2 ft lb Bougie 18 Nm 1 8 m kg 13 ft lb 5 Ajuste Holgura de v lvulas Pasos del ajuste Afloje la contratuerca 1 Apriete el ajustador 2 o afl jelo para obte ner la holgur...

Page 52: ...tarter 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 A...

Page 53: ...Extraiga Dep sito de combustible Consulte la secci n DEP SITO DE COMBUSTIBLE Y CAJA DE CON TROL del CAP TULO 3 Conjunto del elemento del filtro de aire Consulte las secciones CONJUNTO DEL FILTRO DE AI...

Page 54: ...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 ch...

Page 55: ...la magneto del volante Arrancador de retroceso Consulte la secci n ARRANCADOR DE RETROCESO Y MAGNETO DEL VOLANTE del CAP TULO 3 Carburador Consulte la secci n CARBURADOR del CAP TULO 3 Conjunto del e...

Page 56: ...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...

Page 57: ...age de distribution et jeu de soupape incorrects T R Bougie 18 Nm 1 8 m kg 13 ft lb 5 Mida Compresi n Para medir la compresi n coloque el interruptor principal en START o en ON y tire del arrancador d...

Page 58: ...n the economy switch 1 to OFF a Measure the engine speed no load 120 V 60 Hz 220 V 50 Hz 230 V 50 Hz 4 Install Panel 4 Refer to COVERS PANELS AND CAPS ECONOMY ENGINE SPEED 1 Remove Panel 4 Refer to CO...

Page 59: ...rge 3 550 tr mn Compte tours auto aliment induc tion YU 8036 B Compte tours moteur 90890 03113 90793 80009 90793 80032 VELOCIDAD DEL MOTOR SIN CARGA 1 Extraiga Panel 4 Consulte la secci n CUBIERTAS PA...

Page 60: ...z 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 CHOKE CABLE 1 Inspect Choke knob pull the choke knob all the way out Choke knob automat...

Page 61: ...COUVERCLES PANNEAUX ET BOUCHONS R gime moteur conomique sans charge 2 800 50 tr mn 3 Inspeccione Velocidad del motor de ahorro de energ a Velocidad del motor especificada Correcta Fuera de especifica...

Page 62: ...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 t...

Page 63: ...e cartement des lectrodes 0 7 0 8 mm 0 028 0 031 in Bougie standard avec r sistance BPR4ES NGK SISTEMA EL CTRICO BUJ A ADVERTENCIA Inspeccione y ajuste las zonas alrededor de la culata de cilindros de...

Page 64: ...SVU2280 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 Engi...

Page 65: ...Le moteur ne d marre pas Voir SYS T ME DE D MARRAGE LECTRIQUE au CHAPITRE 4 120 V 60 Hz 220 V 50 Hz 230 V 50 Hz 5 Apriete Buj a NOTA Para evitar da os en la rosca apriete la buj a con los dedos a ante...

Page 66: ...R SYSTEM in CHAPTER 4 1 a 1 a SWL2050T 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 OVERLOA...

Page 67: ...rcharge Panneau de contr le Voir PANNEAU DE CONTR LE au CHAPITRE 3 INTERRUPTOR DE AHORRO DE ENERG A 1 Compruebe Interruptor de ahorro de energ a 1 120 V 60 Hz 220 V 50 Hz 230 V 50 Hz Pasos de la compr...

Page 68: ...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 s...

Page 69: ...C 120 V 60 Hz DISYUNTOR DE CC DISYUNTOR DE CC 120 V 60 Hz DISYUNTOR DE CC 1 Compruebe Disyuntor de CC Pasos de la comprobaci n Compruebe si el mando del disyuntor de CC 1 est colocado en RESET a Si el...

Page 70: ...3 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...

Page 71: ...DE CA DISYUNTOR SIN FUSIBLE 120 V 60 Hz 23 5 A RECEPT CULO 1 Compruebe Recept culo de CC 12 V 8 3 A 1 Recept culo de CC 12 V 12 A 2 Recept culos de CA 15 A 3 Recept culo de CA 23 3 A 4 Recept culos de...

Page 72: ...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...

Page 73: ...BLES INTERRUPTOR DE CA DISYUNTOR SIN FUSIBLE 120 V 60 Hz 15 A FUSIBLES INTERRUPTOR DE CA DISYUNTOR SIN FUSIBLE 120 V 60 Hz 15 A 1 Ajuste el interruptor de CA disyuntor sin fusible 1 a la posici n ON a...

Page 74: ...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 Improvi...

Page 75: ...BOUCHONS Multim tre YU 03112 C 90890 03112 Amp rage du fusible 10 A FUSIBLES FUSIBLES 4 Compruebe Fusibles Pasos de la comprobaci n Conecte el mult metro de bolsillo 1 a un fusible y compruebe la con...

Page 76: ...teries 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...

Page 77: ...e d une brosse m tallique Connexion d fectueuse Corriger N B Apr s avoir nettoy les bornes les graisser l g re ment BATTERIE BORNE DE BATTERIE BATER A TERMINAL DE LA BATER A BATER A ADVERTENCIA El flu...

Page 78: ...t 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 electrol...

Page 79: ...terie ce qui r duit la dur e de vie de la batterie BORNE DE BATTERIE LECTROLYTE DE LA BATTERIE TERMINAL DE LA BATER A ELECTR LITO DE BATER A 4 Instale Bater a Cinta de bater a Soporte de bater a ATENC...

Page 80: ...se 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...

Page 81: ...er Ne jamais retirer le conteneur de la batterie tant que tout l lectrolyte ne s en est pas coul LECTROLYTE DE LA BATTERIE ELECTR LITO DE BATER A a Ponga la bater a sobre una superficie plana b Extrai...

Page 82: ...zontally 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...

Page 83: ...n dans un espace clos Toujours prot ger les yeux en cas de travaux proximit de batteries CONSERVER HORS DE PORT E DES ENFANTS LECTROLYTE DE LA BATTERIE ELECTR LITO DE BATER A g Deje el vaso en esta po...

Page 84: ...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 g...

Page 85: ...rage et dur e de charge 1 2 A 5 10 heures Tension de charge 12 8 V ou plus LECTROLYTE DE LA BATTERIE CHARGE DE LA BATTERIE ELECTR LITO DE BATER A CARGA DE LA BATER A 2 Compruebe Con un volt metro digi...

Page 86: ...vers removal 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 Pa...

Page 87: ...NT 1 Couvercle 1 1 2 Couvercle 5 1 3 Panneau 1 1 4 Panneau 3 1 5 Support de batterie 1 6 Couvercle 2 1 MOTOR PANELES Y CUBIERTAS Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Retirada...

Page 88: ...ks 7 Cover 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 remova...

Page 89: ...n est pas n cessaire de d poser le couvercle 3 du bo tier lectrique Pour le remontage inverser la proc dure de d pose Orden Nombre de la tarea Nombre de la pieza Cant Observaciones 7 Cubierta 6 1 8 Cu...

Page 90: ...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...

Page 91: ...nt des c bles fils et flexibles Pour le remontage inverser la proc dure de d pose PANEL DE CONTROL Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n del panel de control Extrai...

Page 92: ...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 A...

Page 93: ...ge inverser la proc dure de d montage Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Desmontaje del panel de control Extraiga las piezas en el orden siguiente 1 Interruptor principal 1...

Page 94: ...isted 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 discon...

Page 95: ...rburant 1 3 Couvercle 4 1 4 R servoir de carburant 1 5 Cr pine de la conduite de carburant 1 6 Filtre du r servoir de carburant 1 DEP SITO DE COMBUSTIBLE Y CAJA DE CONTROL 120 V 60 Hz 220 V 50 Hz 230...

Page 96: ...the 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...

Page 97: ...RIQUE au CHAPITRE 5 pour contr ler l achemine ment des c bles fils et flexibles Pour le remontage inverser la proc dure de d pose Orden Nombre de la tarea Nombre de la pieza Cant Observaciones 7 Indic...

Page 98: ...el 4 Refer to COVERS PANELS AND CAPS in CHAPTER 2 1 Air filter assembly 1 2 Breather hose 1 3 Air intake duct 1 4 Air filter element 2 NOTE Remove air filter element 1 and air filter element 2 as a se...

Page 99: ...rcle du bloc de contr le 1 Pour le remontage inverser la proc dure de d pose CONJUNTO DEL FILTRO DE AIRE Y UNIDAD DE CONTROL 120 V 60 Hz 220 V 50 Hz 120 V 60 Hz Orden Nombre de la tarea Nombre de la p...

Page 100: ...4 cover 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 fi...

Page 101: ...e contr le 1 8 Coupleur 1 D connecter 9 Filtre antibruit 1 Pour le remontage inverser la proc dure de d pose CONJUNTO DEL FILTRO DE AIRE UNIDAD DE CONTROL Y FILTRO DE RUIDO 230 V 50 Hz Orden Nombre de...

Page 102: ...r filter 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 b...

Page 103: ...ur de d marreur 3 Fil du moteur du d marreur 1 4 Redresseur 1 5 Poign e du lanceur 1 ARRANCADOR DE RETROCESO Y MAGNETO DEL VOLANTE Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extrac...

Page 104: ...r 1 10 Starter pulley 1 11 TCI unit 1 12 Flywheel magneto 1 13 Woodruff key 1 14 Charging coil 1 NOTE After installing all parts refer to WIRE ROUTING DIAGRAM in CHAPTER 5 to check the cable lead and...

Page 105: ...ntr ler l achemine ment des c bles fils et flexibles Pour le remontage inverser la proc dure de d pose Orden Nombre de la tarea Nombre de la pieza Cant Observaciones 6 Conjunto del arrancador de retro...

Page 106: ...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...

Page 107: ...6 Ressort 2 7 Tambour de poulie 1 8 Ressort du lanceur 1 9 Bo tier du lanceur 1 Pour le remontage inverser la proc dure de d montage Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Desm...

Page 108: ...VAL 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 availabl...

Page 109: ...NTION Ne pas maintenir le volant par ses ailettes cela risquerait de les endommager EXTRACCI N DEL ARRANCADOR DE RETROCESO 1 Extraiga Manija del arrancador 1 NOTA Al extraer la manija del arrancador d...

Page 110: ...to 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 u...

Page 111: ...et le volant 0 5 0 1 mm 0 020 0 004 in INSTALACI N DE LA MAGNETO DEL VOLANTE 1 Instale Chaveta Woodruff 1 Magneto del volante 2 ATENCION Aseg rese de quitar el aceite o grasa de la parte c nica del c...

Page 112: ...ndle 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...

Page 113: ...u lanceur 1 2 Inspecter Ressort du lanceur 2 Dommages d t rioration Remplacer 3 Inspecter Cliquet d entra nement 1 Plateau d entra nement 2 Usure dommages Remplacer DESMONTAJE DEL ARRANCADOR DE RETROC...

Page 114: ...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 p...

Page 115: ...2 au niveau des rep res R a 4 Installer Clip 1 Plateau d entra nement 2 N B Aligner la gorge a du plateau d entra nement 2 avec l entretoise du tambour de poulie b puis ins taller les pi ces CONJUNTO...

Page 116: ...ter 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...

Page 117: ...sens inverse des aiguilles d une montre N B Faire un n ud b l extr mit du c ble de lanceur afin d emp cher ce dernier de se r tracter dans le bo tier du lanceur 5 Instale Perno 1 Despu s de apretar e...

Page 118: ...in CHAPTER 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 co...

Page 119: ...ur 1 Pour le remontage inverser la proc dure de d pose CONJUNTO DEL MOTOR Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n del motor Extraiga las piezas en el orden siguiente...

Page 120: ...d caster 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 remo...

Page 121: ...ur 4 2 Cadre 1 3 Roulette 1 1 4 Roulette 2 1 5 Roulette 3 2 Pour le remontage inverser la proc dure de d pose CHASIS Y RUEDAS Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n...

Page 122: ...shroud 1 1 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...

Page 123: ...r 1 10 Grille de prise d air 2 du tuyau d chappe ment 1 Pour le remontage inverser la proc dure de d pose SILENCIADOR Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n del sile...

Page 124: ...lustration 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 hol...

Page 125: ...rou du pot d chappement 7 0 Nm 0 7 m kg 5 1 ft lb Boulon du pot d chappement 16 Nm 1 6 m kg 11 ft lb INSTALACI N DEL SILENCIADOR 1 Instale Dispositivo contra chispas NOTA Para instalar el dispositivo...

Page 126: ...to MUFFLER 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 the...

Page 127: ...3 Tube 2 4 Goupille de serrage 2 Pour le remontage inverser la proc dure de d pose GENERADOR Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n del generador Extraiga las piezas...

Page 128: ...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 stat...

Page 129: ...nt visibles dans les trous du rotor puis d poser les boulons EXTRACCI N DEL CONJUNTO DEL GENERADOR ATENCION La fuerza magn tica del rotor de la magneto es muy intensa Por lo tanto aseg rese de retirar...

Page 130: ...otor 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 g...

Page 131: ...33270 B 90890 01362 T R Boulons de l ens emble bobine de sta tor 10 Nm 1 0 m kg 7 2 ft lb 4 Extraiga Conjunto del generador 1 NOTA Quite el rotor de la magneto junto con el conjunto de la bobina del e...

Page 132: ...les 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 sheav...

Page 133: ...sangle YS 01880 A 90890 01701 Cl pour assemblage rotor disponible dans le commerce 3 Instale Pernos del conjunto de la bobina del estator 2 NOTA Gire el rotor de la magneto hasta que los per nos del c...

Page 134: ...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...

Page 135: ...remontage inverser la proc dure de d pose CUBIERTA DE LA CULATA DE CILINDROS Y CULATA DE CILINDROS Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n de la cubierta de la culat...

Page 136: ...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 runo...

Page 137: ...de contact du cylindre 2 Inspecter Culasse Fissures ou d t riorations autour du trou de bougie Remplacer EXTRACCI N DE LA CULATA DE CILINDROS 1 Extraiga Culata de cilindros NOTA Gire el cig e al haci...

Page 138: ...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...

Page 139: ...Reniflard 1 N B Amener l extr mit du reniflard au contact de la but e de soupape a 3 Mida Combadura de la culata de cilindros Mida la combadura en la superficie de contacto de la culata de cilindros e...

Page 140: ...rder 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 inta...

Page 141: ...apet de tige de soupape 1 Pour le remontage inverser la proc dure de d pose V LVULA Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n de v lvulas Extraiga las piezas en el orde...

Page 142: ...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 Exhau...

Page 143: ...45 mm 0 2142 0 2144 in Limite d usure Admission 5 418 mm 0 2133 in chappement 5 410 mm 0 2130 in EXTRACCI N DEL MUELLE DE V LVULA Y DE LA V LVULA 1 Extraiga Chaveta de v lvula 1 Retenedor del muelle d...

Page 144: ...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 m...

Page 145: ...act Remplacer INSPECTION DU BRAS DE VERROU 1 Inspecter Bras de verrou Usure dommages fissures Remplacer 3 Mida Descentramiento del v stago de v lvula Fuera de especificaciones Reempla zar NOTA El valo...

Page 146: ...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 wi...

Page 147: ...de la surface de contact du si ge de soupape admission et chap pement 0 9 1 1 mm 0 0354 0 0433 in Limite 1 6 mm 0 0630 in INSPECCI N DEL ASIENTO DE V LVULA 1 Retire la carbonilla de la superficie de...

Page 148: ...LVE 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...

Page 149: ...rodage essuyer le pro duit de rodage du collet de soupape et du si ge de soupape 6 Retire la carbonilla de la superficie de contacto a y del asiento de v lvula Anchura de contacto de la superficie de...

Page 150: ...er 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 CAUTI...

Page 151: ...TION Ne pas comprimer le ressort de soupape plus que n cessaire Compresseur de ressort de soupape YM 01253 90890 01253 New CONJUNTO DE LA V LVULA Y MUELLE DE V LVULA 1 Instale V lvula 1 Muelle de v lv...

Page 152: ...ine 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 G...

Page 153: ...es 1 8 Poussoir 2 Pour le remontage inverser la proc dure de d pose CUBIERTA DEL C RTER Y RBOL DE LEVAS Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n de la cubierta del c r...

Page 154: ...gth 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...

Page 155: ...a Hors sp cifications Remplacer Diam tre de l arbre cames 14 965 14 990 mm 0 5892 0 5902 in Limite d usure 14 950 mm 0 5886 in EXTRACCI N DE LA CUBIERTA DEL C RTER 1 Extraiga Cubierta del c rter NOTA...

Page 156: ...nkshaft 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 C...

Page 157: ...cifi en deux temps et dans l ordre de 1 6 T R Boulons du couvercle de carter moteur 1er 12 Nm 1 2 m kg 8 7 ft lb 2 me 22 Nm 2 2 m kg 16 ft lb INSPECCI N DEL ALZAV LVULAS 1 Inspeccione Alzav lvulas Da...

Page 158: ...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 GENE...

Page 159: ...piston 3 Pour le remontage inverser la proc dure de d pose PIST N BIELA CIG E AL Y C RTEL Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n de pist n biela cig e al y c rter Ex...

Page 160: ...er 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 c...

Page 161: ...0 05 mm 0 0020 in Diam tre de la jupe de piston 65 975 65 990 mm 2 5974 2 5980 in Limite d usure 65 9 mm 2 5945 in INSPECCI N DEL C RTER CILINDROS 1 Mida Di metro interior del cilindro NOTA Tome medid...

Page 162: ...6 002 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...

Page 163: ...e quelconque utiliser un couteau ou un racloir pour l liminer d licatement de mani re pouvoir ais ment introduire le piston manuellement 2 Mida Holgura del pist n Fuera de especificaciones Rectificar...

Page 164: ...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 cl...

Page 165: ...ston Limite d usure Segment sup rieur 0 04 0 08 mm 0 0016 0 0031 in 0 13 mm 0 0051 in 2 me seg ment 0 02 0 06 mm 0 0008 0 0024 in 0 12 mm 0 0047 in INSPECCI N DE LOS ANILLOS DE PIST N 1 Mida Abertura...

Page 166: ...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 micromet...

Page 167: ...sp cifications Remplacer Diam tre externe du maneton de vile brequin 27 969 27 984 mm 1 1011 1 1017 in Limite d usure 27 9 mm 1 0984 in INSPECCI N DEL CIG E AL 1 Mida L mite de descentramiento del cig...

Page 168: ...g 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 porti...

Page 169: ...lon du chapeau de bielle 12 Nm 1 2 m kg 8 7 ft lb Espace de graissage de la t te de bielle 0 015 0 040 mm 0 0006 0 0016 in Limite d usure 0 1 mm 0 0039 in INSPECCI N DE LA HOLGURA DE ACEITE DE LA BIEL...

Page 170: ...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 Pis...

Page 171: ...bielle soit face au couvercle de carter Veiller ce que le rep re b de la t te de piston soit face au poussoir de soupape New ANILLOS DE PIST N Y CONJUNTO DEL PIST N 1 Instale Anillo superior 1 2 anil...

Page 172: ...TE 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 Connec...

Page 173: ...mes Couvercle de carter moteur Voir COUVERCLE DE CARTER MOTEUR ET ARBRE CAMES T R Boulon du chapeau de bielle 12 Nm 1 2 m kg 8 7 ft lb CONJUNTO DEL CIG E AL 1 Aseg rese de que la abertura final de cad...

Page 174: ...OVERS 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 NOI...

Page 175: ...pleur de moteur de commande des gaz 1 6 Carburateur 1 7 Joint 1 CARBURADOR Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Extracci n del carburador Extraiga las piezas en el orden sigu...

Page 176: ...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 177: ...Qt Remarques 8 Joint de carburateur 1 9 Joint 1 Pour le remontage inverser la proc dure de d pose Orden Nombre de la tarea Nombre de la pieza Cant Observaciones 8 Junta del carburador 1 9 Empaquetadur...

Page 178: ...R Order Job name Part name Q ty Remarks Carburetor disassembly Remove the parts in the order listed below Throttle control motor assembly 1 Bracket 1 Drain hose 1 Bolt 1 Gasket 1 Drain screw 1 Float c...

Page 179: ...Support 1 Flexible de vidange 1 Boulon 1 Joint 1 Vis de purge 1 Cuve du flotteur 1 Joint 1 Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Desmontaje del carburador Extraiga las piezas...

Page 180: ...RETOR Order Job name Part name Q ty Remarks Float pin 1 Float 1 Needle valve 1 Main nozzle 1 Main jet 1 Air vent hose 1 Throttle stop screw 1 Pilot screw 1 Pilot jet 1 For assembly reverse the disasse...

Page 181: ...e r glage du ralenti 1 Buse de ralenti 1 Pour le remontage inverser la proc dure de d montage Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Pasador del flotador 1 Flotador 1 V lvula d...

Page 182: ...ve 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 Bl...

Page 183: ...ir com prim 3 Inspecter Si ge de soupape Usure dommages Remplacer Poussi res Nettoyer 1 Usure au niveau de la rainure 2 Poussi res INSPECCI N DE LA ALTURA DEL FLOTADOR 1 Mida Altura del flotador Fuera...

Page 184: ...at the throttle valve is smoothly returned in direction d by the spring force when releasing the finger If it is not returned smoothly in direction d be sure to reassemble these parts and recheck the...

Page 185: ...pu s del montaje empuje suavemente la v lvula de mariposa con un dedo en la direcci n c dentro del juego e del eje y compruebe si la fuerza del resorte devuelve la v lvula de mariposa suavemente en la...

Page 186: ...e 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...

Page 187: ...OD 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 cylind...

Page 188: ...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 Adjus...

Page 189: ...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 pressio...

Page 190: ...nob 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 D...

Page 191: ...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 100 250 7 25 C 77 F...

Page 192: ...NOMY 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 ec...

Page 193: ...ue le carburant cir cule jusqu au robinet de car burant Nettoyer le r servoir de carburant le robi net de carburant et la cr pine de la conduite de carburant CORRECT INCORRECT Contr ler la propret des...

Page 194: ...ou rempla cer V rifier que les rep res d allumage du vilebrequin et de l arbre cames sont ali gn s CORRECT INCORRECT R parer ou remplacer V rifier que le piston le seg ment de piston ou le cylindre n...

Page 195: ...rrectement serr s V rifier l absence d aspira tion d air due un raccord ou joint de carburateur endommag Serrer fermement les boulons du car burateur Remplacer le rac cord ou le joint de carburateur C...

Page 196: ...s CORRECT INCORRECT D monter ou nettoyer V rifier l absence d aspiration d air due un joint d axe de papillon un raccord de carburateur ou un joint endommag s CORRECT INCORRECT D monter ou remplacer...

Page 197: ...rer le bouton du starter d environ 1 3 1 2 puis con tr ler le fonctionnement du moteur STABLE INSTABLE V rifier l absence d aspiration d air due un joint d axe de papillon un raccord de carburateur ou...

Page 198: ...stance CORRECT INCORRECT Remplacer le moteur de commande des gaz Mesurer la r sistance de la bobine entre 3 1 3 2 3 4 et 3 5 du moteur de commande des gaz Sensibilit du multim tre 100 250 7 25 C 77 F...

Page 199: ...ortie CA CORRECT INCORRECT Voir SYST ME G N RATEUR au CHAPITRE 4 Contr ler l tat du moteur de com mande des gaz CORRECT INCORRECT Remplacer le moteur de commande des gaz Contr ler le contacteur conomi...

Page 200: ...NCO RRECTO Reemplace Compruebe la posici n de la palanca del grifo ON OFF Ajuste a la posici n ON Compruebe si llega com bustible al grifo Limpie el dep sito grifo y filtro del tubo de combustible COR...

Page 201: ...TO DESGASTE Rectifique o reem place Compruebe si las marcas de distribuci n del cig e al y del rbol de levas est n alineadas CORRECTO INCO RRECTO Corrija o reemplace Compruebe si el pist n anillos de...

Page 202: ...do a que alguna junta o ret n del carburador est da ado Apriete firme mente los pernos del carburador Reemplace la junta o ret n de carburador por una nueva CORRECTO INCO RRECTO Mida la holgura de las...

Page 203: ...pie Compruebe si no existe admisi n de aire debido a que un ret n del eje del acelerador junta del carburador o empaquetadura est da ado CORRECTO INCORRECTO Desmonte o reemplace Compruebe la comprensi...

Page 204: ...y 1 2 y compruebe el estado de funcionamiento del motor ESTABLE INESTABLE Compruebe si no existe admisi n de aire debido a que un ret n del eje del acelerador junta del carburador o empaquetadura est...

Page 205: ...suavemente con leve resistencia CORRECTO INCORRECTO Reemplace el motor de control del acelerador Mida la resistencia de la bobina entre 3 1 3 2 3 4 y 3 5 del motor de control del acelerador Rango del...

Page 206: ...UENTRA EN ON Compruebe la salida de CA CORRECTO INCORRECTO Consulte la secci n SISTEMA GENERADOR del CAP TULO 4 Compruebe el estado del motor de control del acelerador CORRECTO INCORRECTO Reemplace el...

Page 207: ......

Page 208: ...k 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 sw...

Page 209: ...O Veilleuse vert P T moin de niveau d huile rouge SISTEMA EL CTRICO COMPONENTES EL CTRICOS 120 V 60 Hz 1 Conjunto del generador 2 Interruptor de nivel de aceite 3 Motor del arrancador 4 Unidad de con...

Page 210: ...to 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 Groun...

Page 211: ...surcharge rouge K Veilleuse vert L Rupteur CC M T moin de niveau d huile rouge 220 V 50 Hz 1 Conjunto del generador 2 Interruptor de nivel de aceite 3 Motor del arrancador 4 Unidad de control 5 Bobina...

Page 212: ...r 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...

Page 213: ...iveau d huile O Filtre antibruit 2 COMPOSANTS LECTRIQUES COMPONENTES EL CTRICOS 230 V 50 Hz 1 Conjunto del generador 2 Interruptor de nivel de aceite 3 Motor del arrancador 4 Unidad de control 5 Bobin...

Page 214: ...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 1 ra...

Page 215: ...eur commutez le plu sieurs fois sur marche arr t Multim tre YU 03112 C 90890 03112 CONTACTEURS INTERRUPTORES INTERRUPTORES COMPROBACI N DE LA CONTINUIDAD DEL INTERRUPTOR Use un mult metro para comprob...

Page 216: ...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...

Page 217: ...3 as shown Spark plug cap 1 Dynamic spark tester or ignition checker Dynamic tester lead or ignition checker lead Spark plug 4 For USA and Canada Except for USA and Canada SVU4055 SVU4060 OUT OF SPEC...

Page 218: ...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 plu...

Page 219: ...istance 11 5 k 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 1 to the main switch PWV0480 NO CONTINU...

Page 220: ...nuity 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 fl...

Page 221: ...gnition 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...

Page 222: ...annage 1 Panneau 4 2 R servoir de carburant 3 Panneau de contr le 4 Volant 5 Couvercle du carter moteur Utiliser les outils sp ciaux suivants pour le d pannage TINCELLE FAIBLE OU ABSENTE Multim tre YU...

Page 223: ...eur d tincelle d allumage dynamique ou contr leur d allumage Fil du contr leur dynamique ou fil du con tr leur d allumage Bougie 4 Pour les tats Unis et le Canada Except pour les tats Unis et le Canad...

Page 224: ...ller Tourner le capuchon de bougie dans le sens des aiguilles d une montre Lors de l installation du capuchon de bougie v rifier que le fil de bougie n est pas craquel ou endommag Recouper 5 mm l extr...

Page 225: ...FICATIONS Remplacer le bloc TCI 2 1 SWL4050J 6 Contacteur principal D connecter le coupleur du contacteur princi pal Connecter le multim tre 1 au contacteur principal PWV0480 PAS DE CONTINUIT Placer l...

Page 226: ...contacteur de niveau d huile pour en contr ler la continuit PWV0460J CONTINUIT PAS DE CONTINUIT Remplacer le contacteur de niveau d huile PWV0450J CORRECT 8 Jeu entre le bloc TCI et le volant Mesurer...

Page 227: ...st me d allumage Contr ler l absence de salet et de corrosion la borne du connecteur et la bonne connexion du connecteur Remplacer le volant Remplacer le bloc TCI Remplacer le bloc limiteur de r gime...

Page 228: ...ci n de aver as 1 Panel 4 2 Dep sito de combustible 3 Panel de control 4 Magneto del volante 5 Cubierta del c rter Emplee las herramientas especiales siguientes para esta localizaci n y reparaci n de...

Page 229: ...1 de buj a Comprobador de chispas din mico o comprobador de encendido Cable del comprobador de chispas din mico o del comprobador de encen dido Buj a 4 Para EE UU y Canad Excepto para EE UU y Canad S...

Page 230: ...hacia la derecha la tapa de buj a Al instalar la tapa de buj a inspeccione si el cable de buj a est roto o deteriorado Corte 5 mm del extremo del cable y vuelva a conectarlo a la tapa FUERA DE ESPECI...

Page 231: ...IFICACIONES Reemplace la unidad TCI 2 1 SWL4050J 6 Interruptor principal Desconecte el acoplador del interruptor principal Conecte el mult metro de bolsillo 1 al interruptor principal PWV0480 NO HAY C...

Page 232: ...idad PWV0460J CONTINUIDAD NO HAY CONTINUIDAD Reemplace el interruptor de nivel de aceite PWV0450J CORRECTO 8 Huelgo de aire entre la unidad TCI y la magneto del volante Mida el huelgo de aire entre la...

Page 233: ...ndido Compruebe si el terminal del conector est contaminado u oxidado y si es correcta la conexi n del conector Reemplace la magneto del volante Reemplace la unidad TCI Reemplace el limitador de veloc...

Page 234: ...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 p...

Page 235: ...is 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 t...

Page 236: ...d 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 har...

Page 237: ...EUR DU D MARREUR NE FONCTIONNE PAS Multim tre YU 03112 C 90890 03112 Compte tours auto aliment induc tion YU 8036 B Compte tours moteur 90890 03113 90793 80009 90793 80032 CONTINUIT 1 Fusible D poser...

Page 238: ...des tincelles Il convient donc de veiller ce qu il n y ait pas de gaz ni de liquides inflammables proxi mit CONTINUIT 4 Relais du d marreur D connecter le relais de d marreur du cou pleur Connecter le...

Page 239: ...nde n gative du multim tre brun 2 Placer le contacteur principal sur START et contr ler la continuit du contacteur principal PAS DE CONTINUIT Remplacer le contacteur principal OFF ON START Br Br R R B...

Page 240: ...eparaci n de aver as EL MOTOR DEL ARRANCADOR NO FUNCIONA Mult metro de bolsillo YU 03112 C 90890 03112 Tac metro autom tico inductivo YU 8036 B Tac metro de motor 90890 03113 90793 80009 90793 80032 C...

Page 241: ...n pro duzca chispas por lo que debe asegu rarse de que no haya fluido ni gas inflamable en los alrededores CONTINUIDAD 4 Rel del arrancador Desconecte el rel del arrancador del acoplador Conecte el ca...

Page 242: ...1 Sonda negativa del mult metro marr n 2 Coloque el interruptor principal en START y compruebe la continui dad de dicho interruptor NO HAY CONTINUIDAD Reemplace el interruptor principal OFF ON START...

Page 243: ...ELEC...

Page 244: ...n 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...

Page 245: ...ine d armature 1 9 Bo tier de d marreur 1 Pour le remontage inverser la proc dure de d montage MOTOR DEL ARRANCADOR Orden Nombre de la tarea Nombre de la pieza Cant Observaciones Desmontaje del motor...

Page 246: ...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 Ins...

Page 247: ...ications Remplacer le moteur du d marreur Diam tre du commutateur 22 mm 0 87 in Limite d usure 21 mm 0 83 in 1 Mida Longitud de la escobilla a Fuera de especificaciones Reempla zar las escobillas como...

Page 248: ...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 commutat...

Page 249: ...bon fonctionnement du commutateur D gagement du mica 1 5 mm 0 06 in SYST ME DE D MARRAGE LECTRIQUE SISTEMA DE ARRANQUE EL CTRICO 6 Mida Indentado de mica a Fuera de especificaciones Para encajar el co...

Page 250: ...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 1 t...

Page 251: ...tive 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 1...

Page 252: ...y 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 Wir...

Page 253: ...ge 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...

Page 254: ...Measure the resistance between the Orange to Orange lead Tester range 1 Subcoil resistance 0 17 20 at 20 C 68 F GOOD DISCONNECTED SHORT CIRCUIT Replace the generator assembly L L O L L O O O SWL4190...

Page 255: ...THROTTLE 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 pr...

Page 256: ...minal 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 term...

Page 257: ...HARG E Multim tre YU 03112 C 90890 03112 Compte tours auto aliment induc tion YU 8036 B Compte tours moteur 90890 03113 90793 80009 90793 80032 CONTINUIT 1 Fusible D poser le fusible Connecter le mult...

Page 258: ...charge 12 16 V 1 2 CONFORME AUX SP CIFICATIONS Connecter correctement le syst me de charge CORRECT 4 R sistance de l inductance de charge D connecter le connecteur de l inductance de charge Connecter...

Page 259: ...if du multim tre Blanc 1 Fil n gatif du multim tre Rouge 2 Continuit Fil positif du multim tre Rouge 2 Fil n gatif du multim tre Blanc 1 Pas de conti nuit 1 2 SWL4135 PAS DE CONTINUIT Remplacer le red...

Page 260: ...le D connecter le coupleur de la bobine secondaire 1 Connecter les fils bleus puis les fils orange D connecter le coupleur de la bobine principale D marrer le moteur Connecter la pointe de la sonde du...

Page 261: ...r le moteur Mesurer la r sistance entre le fil orange orange Sen sibilit du multim tre 1 R sistance de la bobine secondaire 0 17 20 20 C 68 F CORRECT D CONNECT COURT CIRCUIT Remplacer l ensemble de g...

Page 262: ...la tension CA de la bobine secondaire D connecter le coupleur de la bobine secondaire 1 Connecter les fils bleus puis les fils orange D marrer le moteur Connecter la pointe de la sonde du multim tre...

Page 263: ...bleue 4 OUI Borne bleue 4 Borne blanche 2 NON Borne blanche 2 Borne bleue 5 OUI Borne bleue 5 Borne blanche 2 NON Borne noire 3 Borne bleue 4 NON Borne bleue 4 Borne noire 3 OUI Borne noire 3 Borne bl...

Page 264: ...as LA BATER A NO EST CARGADA Mult metro de bolsillo YU 03112 C 90890 03112 Tac metro autom tico inductivo YU 8036 B Tac metro de motor 90890 03113 90793 80009 90793 80032 CONTINUIDAD 1 Fusible Retire...

Page 265: ...de carga 12 16 V 1 2 CUMPLE LAS ESPECIFICACIONES Conexi n correcta del sistema de carga CORRECTO 4 Resistencia de la bobina de carga Desenchufe el conector de la bobina de carga Conecte el mult metro...

Page 266: ...tivo del mult metro Blanco 1 Cable negativo del mult metro Rojo 2 Continui dad Cable positivo del mult metro Rojo 2 Cable negativo del mult metro Blanco 1 No hay continui dad 1 2 SWL4135 NO HAY CONTIN...

Page 267: ...TULO 3 Inspecci n de la tensi n de CA de la bobina principal Desconecte el acoplador de la subbobina 1 Conecte el cable azul y luego el cable naranja Desconecte el acoplador de la bobina principal Ar...

Page 268: ...a naranja Rango del mult metro 1 Resistencia de la subbobina 0 17 20 a 20 C 68 F CORRECTO DESCONECTADO CORTOCIRCUITO Reemplace el conjunto del generador L L O L L O O O SWL4190 Inspecci n de la contin...

Page 269: ...SISTEMA DE CONTROL DEL ACELERADOR del CAP TULO 3 Inspecci n de la tensi n de CA de la subbobina Desconecte el acoplador de la subbobina 1 Conecte el cable azul y luego el cable naranja Arranque el mo...

Page 270: ...inal azul 4 S Terminal azul 4 Terminalblanco2 NO Terminalblanco2 Terminal azul 5 S Terminal azul 5 Terminalblanco2 NO Terminal negro 3 Terminal azul 4 NO Terminal azul 4 Terminal negro 3 S Terminal ne...

Page 271: ......

Page 272: ...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...

Page 273: ...CIFICACIONES ESPECIFICACIONES GENERALES Unidad N mero de c digo del modelo Dimensiones Longitud total mm in Anchura total mm in Altura total mm in Peso en seco kg lb Motor Tipo de motor OHV de 4 tiemp...

Page 274: ...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 out...

Page 275: ...de distorsion d onde Moinos de 2 5 Mod le Sistema el ctrico Sistema de encendido Tipo de buj a Huelgo mm in Generador Tipo Im n multipolar de campo giratorio Excitaci n inicial Im n permanente M todo...

Page 276: ...n coil Three phase DC output subcoil Single phase Insulation resistance M 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...

Page 277: ...ance de l isolant M Sup rieure 10 Type d isolant Type B Prise CA CC Mod le N mero de fases Salida de CA bobina principal Tres fases Salida de CC subbobina Monof sico Resistencia de aislamiento M M s d...

Page 278: ...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 0...

Page 279: ...Cylindre mm in Diam tre interne D Limite Limite de r duction conique ESPECIFICACIONES DE MANTENIMIENTO MOTOR Unidad Pist n mm in Holgura del pist n L mite Falda del pist n D L mite Punto de medici n...

Page 280: ...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...

Page 281: ...Limite de faux rond de la tige de soupape Mod le Cig e al mm in Holgura lateral de la cabeza de biela A L mite Descentramiento B L mite Di metro del pasador del cig e al C L mite Biela mm in Di metro...

Page 282: ...Free 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 Til...

Page 283: ...r de commande des gaz 7 Mod le Gu a de v lvula Di metro interior de la gu a ADM ESC L mite ADM ESC Holgura del v stago a la gu a ADM ESC Holgura de v lvulas en fr o ADM ESC Varilla de empuje mm in L m...

Page 284: ...07 Blue Blue Electrical Ignition timing at 3 600 r min BTDC 23 3 TCI unit Primary coil resistance 20 0 5 Secondary coil resistance 20 11 5 Air gap between TCI unit and flywheel magneto mm in 0 5 0 1...

Page 285: ...tateur mm in Limite D gagement du mica mm in Fusible Principal A GENERADOR Y SISTEMA EL CTRICO Unidad Generador Tipo fabricante Tensi n de CA de bobina principal 3 fases V Tensi n de CA de subbobina m...

Page 286: ...haft 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 Val...

Page 287: ...les du carter Roulement billes du couvercle de carter PUNTOS DE LUBRICACI N Y TIPOS DE LUBRICANTE Puntos de lubricaci n Tipo de lubricante Bordes de retenes de aceite Cabeza de biela Pasador de cig e...

Page 288: ...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...

Page 289: ...teur du d marreur Fil du moteur du d marreur Carburateur TORSIONES DE APRIETE Elemento Tama o de rosca Torsi n de apriete Nm m kg ft lb Buj a Cubierta de la culata de cilindros Culata de cilindros 1 2...

Page 290: ...M4 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 Cove...

Page 291: ...ort de batterie D signation Filet Couple de serrage Nm m kg ft lb Cable interior del estrangulador Cable exterior del estrangulador Cable del estrangulador Motor de control del acelerador Soporte del...

Page 292: ...eads 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...

Page 293: ...oteur COUPLE G N RAL CARACT RISTIQUES D FINITION DES UNIT S ESPECIFICACIONES GENERALES DE TORSIONES DE APRIETE DEFINICI N DE UNIDADES ESPECIFICACIONES GENERALES DE TORSIONES DE APRIETE Esta gr fica es...

Page 294: ...L5020T SWL5030T BEHIND CONTROL BOX SWL5010T BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR White tape for identifying position Red tape for distin guishing leads Yellow tape for identifying position To...

Page 295: ...Noir Br Brun L Bleu G Vert Gy Gris R Rouge W Blanc Y Jaune B W Noir blanc DIAGRAMA DEL RECORRIDO DE CABLES 120 V 60 Hz PANEL DE CONTROL DETR S DEL PANEL DE CONTROL Y EL INTERIOR DE LA CAJA DE CONTROL...

Page 296: ...SWL5030T BEHIND CONTROL BOX SWL5040T BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR White tape for identi fying position Red tape for distin guishing leads Yellow tape for iden tifying position To cont...

Page 297: ...B Noir Br Brun L Bleu R Rouge W Blanc Y Jaune B W Noir blanc G Y Vert jaune 220 V 50 Hz PANEL DE CONTROL DETR S DEL PANEL DE CONTROL Y EL INTERIOR DE LA CAJA DE CONTROL DETR S DE LA CAJA DE CONTROL Ci...

Page 298: ...HIND CONTROL BOX SWL5060T BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR White tape for identi fying position Red tape for distin guishing leads Yellow tape for iden tifying position To control box To...

Page 299: ...UR B Noir Br Brun L Bleu R Rouge W Blanc Y Jaune B W Noir blanc G Y Vert jaune 230 V 50 Hz PANEL DE CONTROL DETR S DEL PANEL DE CONTROL Y EL INTERIOR DE LA CAJA DE CONTROL DETR S DE LA CAJA DE CONTROL...

Page 300: ...HIND CONTROL BOX SWL5060T BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR White tape for identi fying position Red tape for distin guishing leads Yellow tape for iden tifying position To control box To...

Page 301: ...UR B Noir Br Brun L Bleu R Rouge W Blanc Y Jaune B W Noir blanc G Y Vert jaune 230 V 50 Hz PANEL DE CONTROL DETR S DEL PANEL DE CONTROL Y EL INTERIOR DE LA CAJA DE CONTROL DETR S DE LA CAJA DE CONTROL...

Page 302: ...Starter motor lead 6 Negative battery lead 7 DC rectifier 8 Rectifier 9 Starter relay Route the TCI unit lead through the notch in the fan case Route the oil level switch lead through the hole in the...

Page 303: ...arter moteur Acheminer les harnais de c bles comme illustr 120 V 60 Hz 220 V 50 Hz MOTOR Y GENERADOR 1 Cable de la unidad TCI 2 Cable del interruptor de nivel de aceite 3 Cable de la bobina de carga 4...

Page 304: ...lead through the hole in the recoil starter cover Install vertically To starter motor To battery Connect the ground lead green yellow within the range indicated in the illustration Connect the negati...

Page 305: ...tif de la batterie dans la plage indiqu e dans l illustration Vers le redresseur CC A la unidad de control Pase el cable de la bobina de carga por el orifi cio del c rter Pase el cable del motor del a...

Page 306: ...6 Negative battery lead 7 DC rectifier 8 Rectifier 9 Starter relay 0 Noise filter Route the TCI unit lead through the notch in the fan case Route the oil level switch lead through the hole in the cra...

Page 307: ...arter moteur Acheminer les harnais de c bles comme illustr 230 V 50 Hz MOTOR Y GENERADOR 1 Cable de la unidad TCI 2 Cable del interruptor de nivel de aceite 3 Cable de la bobina de carga 4 Cable del r...

Page 308: ...h the hole in the recoil starter cover Install vertically To starter motor To battery Connect the ground lead green yellow within the range indicated in the illustration Connect the negative battery l...

Page 309: ...s la plage indiqu e dans l illustration Vers le redresseur CC Vers le filtre antibruit A la unidad de control Pase el cable de la bobina de carga por el orifi cio del c rter Pase el cable del motor de...

Page 310: ...unit 9 Starter motor lead Install the spark plug cap as shown in the illus tration Route the oil level switch as shown in the illus tration Route the spark plug lead so that it is aligned with the ai...

Page 311: ...u bloc TCI par l encoche du cou vercle du volant 1 Tapa de buj a 2 Interruptor de nivel de aceite 3 Cable de buj a 4 Cable de la unidad TCI 5 Bobina de carga 6 Cable de la bobina de carga 7 Motor del...

Page 312: ...g coil lead as shown Securely install the charging coil grommet into the hole in the crankcase Connect the starter motor lead and then cover the terminal with the cover A A B B 9 8 1 3 4 5 6 7 2 1 SWL...

Page 313: ...Connecter le fil du moteur du d marreur puis couvrir la borne l aide du couvercle Coloque el cable de la bobina de carga como se indica Instale bien la arandela de la bobina de carga en el orificio de...

Page 314: ...n hose 8 Air intake duct Route the air vent hose over the fuel hose fuel cock to carburetor Securely install the air intake duct so that it con tacts the bottom of the air filter assembly case To hole...

Page 315: ...du ch ssis Vers le trou b du ch ssis 1 Cable del estrangulador 2 Manguera de combustible grifo de combustible al carburador 3 Manguera de ventilaci n del aire 4 Carburador 5 Conjunto del filtro de ai...

Page 316: ...d then rotate the air intake duct frame installation end to attach the flange to the frame Face the cut end of the air vent hose downward Position the air vent hose end and cylinder head breather hose...

Page 317: ...15 20 mm 0 6 0 8 in Inserte el conducto de toma de aire hasta que el reborde entre en contacto con el orificio de ins talaci n del bastidor y luego gire el conducto extremo de la instalaci n del basti...

Page 318: ...cock to carburetor 4 Fuel hose fuel tank to fuel cock Install the fuel hose fuel cock to carburetor with the hose carburetor end bent to the angle shown in the illustration 10 35 5 mm 1 4 0 2 in 4 2 3...

Page 319: ...le c t carbura teur l angle indiqu dans l illustration 10 35 5 mm 1 4 0 2 in 1 Carburador 2 Grifo de combustible 3 Manguera de combustible grifo de combustible al carburador 4 Manguera de combustible...

Page 320: ...uile I Bloc limiteur de r gime du moteur avertissement de niveau d huile J Contacteur de niveau d huile K Fusible 10 A L Relais du d marreur M Moteur du d marreur N Batterie O Redresseur P Inductance...

Page 321: ...Bloc limiteur de r gime du moteur avertissement de niveau d huile G Contacteur de niveau d huile H Fusible 10 A I Relais du d marreur J Moteur du d marreur K Batterie L Redresseur M Inductance de char...

Page 322: ...niveau d huile H Bloc limiteur de r gime du moteur avertissement de niveau d huile I Contacteur de niveau d huile J Fusible 10 A K Relais du d marreur L Moteur du d marreur M Batterie N Redresseur O...

Page 323: ......

Page 324: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIM SUR PAPIER RECYCL 2002 12 0 5 1 CR IMPRESO EN PAPEL RECICLADO E F S YAMAHA MOTOR CO LTD...

Page 325: ...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...

Page 326: ...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...

Page 327: ...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...

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