Yamaha EF7200DE, EF7200D Service Manual Download Page 106

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5-31

ELEC

IGNITION SYSTEM

4. Spark plug cap resistance

Remove the spark plug cap from the

high tension cord.

Connect the pocket tester (

× 1k) to the

spark plug cap.

Ω

× 1k

Tester

lead

→

Spark plug side

Tester

lead

→

High tension cord side

Spark plug cap resistance:
4.0–6.0 k

5. Ignition coil (TCI unit) resistance

Remove the ignition coil (TCI unit).

Connect the pocket tester (

× 1) to the

primary terminal.

Tester

lead

→

Black/White terminal

Tester

lead

→

Body ground

Primary coil resistance:
0.6

± 20 %

TIP

Do not pull out the spark plug cap from the

high tension cord.

Remove

→

Turn the spark plug cap coun-

terclockwise.

Install

→

Turn the spark plug cap clock-

wise.

Check the high tension cord for cracks or

deterioration before installing the spark plug
cap.

Cut 5 mm off the end of the high tension

cord, and then connect it to the spark plug
cap.

Replace the spark plug cap.

MEETS

SPECIFICATION

OUT OF

SPECIFICATION

Replace the TCI unit.

MEETS

SPECIFICATION

OUT OF

SPECIFICATION

Summary of Contents for EF7200DE, EF7200D

Page 1: ...SERVICE MANUAL EF7000 EF7000E EF7200 EF7200E EF7200DE 7P6 F8197 E0 2014_05 1 7P6 F8197 E0_cover indd 1 2014 05 29 15 46 41 ...

Page 2: ... Voltage Regulator o Oil warning unit p Economy control unit a Oil warning light s Economy control switch d Engine f Economy control solenoid g Starter relay h Starter motor j Auto choke k Fuel cut solenoid valve l Battery Charging coil z TCI unit x Spark plug c Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green O Orange R Red W White EF7200DE CAN 2014 CIRCUIT DIAGRAM Y Yel...

Page 3: ...manufactured by Yamaha Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will where applicable appear in future editions of this manual EF7000 EF7000E EF7200 EF7200E EF7200DE SERVICE MANUAL 2014 by Yamaha Motor Powered Products Co Ltd 1st Edition May 2014 All rights reserved Any reprinting or unauthorized use without the wr...

Page 4: ...rocedure only For installation reverse the steps 9 Jobs requiring more information such as special tools and technical data are described sequentially 7 3 20 ENG PISTON CAMSHAFT CRANKCASE AND CRANKSHAFT 1 2 3 3 4 5 6 7 7 8 9 10 20 Nm 2 0 m á kgf 14 ft á lbf Order Job Parts to remove Q ty Remarks Removing the piston camshaft and crankshaft Remove the parts in the order listed Crankcase Refer to CRA...

Page 5: ...ts Engine Carburetor Electrical Troubleshooting Specifications Filling fluid Lubricant Special tool T R Tightening torque Wear limit clearance Engine speed Electrical data Replace the part with a new one LS Lithium soap base grease M Molybdenum disulfide grease E Engine oil M Molybdenum disulfide oil LT Apply locking agent LOCTITE ...

Page 6: ......

Page 7: ...INDEX GENERAL INFORMATION GEN INFO PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ ENGINE ENG CARBURETOR ELECTRICAL TROUBLESHOOTING CARB ELEC TRBL SPECIFICATIONS SPEC 1 2 3 4 5 6 7 ...

Page 8: ...COCK STRAINER 2 11 BREATHER HOSE 2 12 CYLINDER HEAD DECARBONIZATION 2 12 ADJUSTING THE VALVE CLEARANCE 2 12 ADJUSTING THE ENGINE SPEED Except for EF7000 EF7200 2 15 ADJUSTING THE ENGINE SPEED For EF7000 EF7200 2 16 RECOIL STARTER 2 17 FITTINGS AND FASTENERS 2 17 CHAPTER 3 ENGINE CONTROL BOX 3 1 EF7200DE 3 1 Except for EF7200DE 3 3 INSTALLING THE CONTROL BOX 3 5 AIR FILTER 3 6 FUEL TANK CANISTER 3 ...

Page 9: ...7000E EF7200E EF7200DE 5 18 CHECKING AND CHARGING THE BATTERY 5 19 FUSE EF7000E EF7200E EF7200DE 5 26 CHECKING THE FUSE 5 26 SWITCHES 5 28 CHECKING THE SWITCH CONTINUITY 5 28 IGNITION SYSTEM 5 29 TROUBLESHOOTING CHART 5 29 ELECTRIC STARTING SYSTEM EF7000E EF7200E EF7200DE 5 35 TROUBLESHOOTING CHART 5 35 REMOVING THE STARTER MOTOR 5 37 DISASSEMBLING THE STARTER MOTOR 5 38 CHECKING THE BRUSH 5 39 AS...

Page 10: ...ONTROL BOX EF7000E EF7200E 7 16 CONTROL PANEL AND CONTROL BOX Except for EF7200DE CAN 7 18 CONTROL PANEL AND CONTROL BOX For EF7200DE CAN 7 20 BACK SIDE AND LEFT SIDE VIEW For EF7200DE CAN 7 22 UPPER SIDE VIEW EF7000E EF7200E EF7200DE 7 23 UPPER SIDE VIEW EF7000 EF7200 7 24 ENGINE 7 25 GENERATOR EF7000 EF7000E EF7200 EF7200E 7 26 GENERATOR Except for EF7200DE CAN 7 27 GENERATOR For EF7200DE CAN 7 ...

Page 11: ...1 15 A 125 V 2 30 A 125 V 1 30 A 250 V 125 V 1 15 A 125 V 2 30 A 125 V 1 30 A 250 V 125 V 1 20 A 250 V 2 20 A 250 V 2 15 A 250 V 2 20 A 250 V 2 20 A 250 V 2 20 A 250 V 2 20 A 250 V 2 Starter motor 3 3 3 3 3 3 3 Dual voltage 3 3 3 Voltage hour meter 3 3 3 3 3 3 3 3 3 3 Oil warning light 3 3 3 3 3 3 3 3 3 3 Economy control system 3 3 3 3 3 3 3 Auto choke 3 3 3 3 3 3 3 Fuel level gauge 3 3 3 3 3 3 3 ...

Page 12: ...e label 1 affixed to the position 2 of the generator as shown in the illustration A For EF7200DE CAN B Except for EF7200DE CAN TIP 9 The first three digits identify the model and the remaining digits indicates the production number 9 Designs and specifications are subject to change without notice 1 2 1 2 A B ...

Page 13: ...se and sealers or the equivalents 3 Expendable parts Always replace the gaskets O rings cotter pins and circlips with new parts when servicing engine 4 Tightening torque Be sure to follow torque specifications When tightening bolts nuts or screws start with the largest diameter fastener and work from an inner position to an outer position in a crisscross pat tern 5 Notes on disassembly and assembl...

Page 14: ...d O rings must be cleaned 2 Properly oil all mating parts and bearings during reassembly Apply grease to the oil seal lips BEARINGS AND OIL SEALS Install the bearing s 1 and oil seal s 2 with their manufacture s marks or numbers facing outward In other words the stamped letters must be on the side exposed to view When installing oil seal s apply a light coating of lightweight lithium base grease t...

Page 15: ...osen or damage the leads a Checking the connections Check the leads couplers and connectors for stains rust mois ture etc 1 Disconnect 9 Lead 9 Coupler 9 Connector NOTICE 9 When disconnecting a coupler release the coupler lock hold both sections of the coupler securely and then dis connect the coupler 9 There are many types of coupler locks therefore be sure to check the type of coupler lock befor...

Page 16: ...nnector together until they are connected securely 9 Make sure all connections are tight 4 Check 9 Continuity with the pocket tester Analog pocket tester YU 03112 C Pocket tester 90890 03112 TIP 9 If there is no continuity clean the terminals 9 When checking the wire harness perform steps 1 to 3 9 Make sure to check the connector and coupler of the TCI unit CDI unit when replacing the TCI unit CDI...

Page 17: ... or a suitable commercially available test harness 5 Check 9 Resistance Analog pocket tester YU 03112 C Pocket tester 90890 03112 TIP The resistance values shown were obtained at the standard meas uring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Intake air temperature sensor resistance 5 40 6 60 kW at 0 C 32 F 290 390 W a...

Page 18: ...tarting with 90890 1 Feeler gauge set P N YU 26900 9 Thickness gauge P N 90890 03180 This gauge is used to adjust valve clearance piston clearance and piston ring end gap 2 Cylinder gauge Commercially obtainable This instrument is used for checking cylinder bore size and condition 3 Digital tachometer P N YU 39951 B 90890 06760 This tool is needed for observing engine r min 4 Engine compression te...

Page 19: ...avy duty puller P N YU 33270 B Flywheel puller P N 90890 01362 This tool is necessary for removing the flywheel SVU1230 7 Analog pocket tester P N YU 03112 C Pocket tester P N 90890 03112 This instrument is necessary for checking the electrical system 8 Oppama pet 4000 spark checker P N YM 34487 Ignition checker P N 90890 06754 This instrument is necessary for checking the ignition system componen...

Page 20: ...M 08037 90890 05158 This tool is used to compress the piston rings when installing the piston SPECIAL TOOLS AND TESTERS 14 Rotor shock puller assy P N YU 1047 90890 01259 This tool is used to remove the rotor assembly 15 Rotor puller attachment M14 P1 25 P N YU 1379 90890 01379 This tool is used to remove the rotor assembly M14XP1 25 ...

Page 21: ...1 11 GEN INFO ...

Page 22: ...ital to proper engine operation and maximum performance PERIODIC MAINTENANCE LUBRICATION INTERVALS Item Routine Pre operation check Every 6 months or 100 Hr 12 months or 300 Hr Spark plug Check condition Clean and replace if necessary Fuel Check fuel level and leakage Fuel hose Check fuel hose for cracks or dam age Replace if necessary Engine oil Check oil level in engine Replace 1 Air filter elem...

Page 23: ...ent of the engine oil is after one month or 20 hours of operation 2 The air filter element needs to be cleaned more frequently when using in unusually wet or dusty areas Since these items require special tools data and technical skills have a Yamaha dealer per form the service ...

Page 24: ...oled down completely 1 Remove 9 Spark plug cap 1 9 Spark plug NOTICE Before removing the spark plug use com pressed air to clean the cylinder head cover to prevent dirt from falling into the engine 2 Check 9 Spark plug type Not correct Replace Spark plug type BPR4ES NGK 9 Electrode 1 Wear damage Replace 9 Insulator color 2 Not normal Replace a 1 2 1 ...

Page 25: ...ght ening it to the specified torque b a b 3 Measure 9 Spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap If necessary clean the spark plug with a spark plug cleaner Feeler gauge set YU 26900 9 Thickness gauge 90890 03180 Spark plug gap 0 7 0 8 mm 0 028 0 031 in TIP Before installing the spark plug clean the gas ket surface and plug surface ...

Page 26: ... 9 Oil level with the oil warning light 1 Check whether the oil warning light comes on by operating the recoil start er or turn the engine switch Oil warning light comes on Add oil Oil warning light does not comes on OK 2 Remove 9 Oil filler cap 1 3 Check 9 Check that engine oil is at the specified level a Oil level checking steps a Place the engine on a level surface b Warm up the engine for seve...

Page 27: ...3 9 Oil drain bolt 2 27 Nm 2 7 m kgf 20 ft lbf 5 Fill 9 Engine oil Make sure to fill with the recommended engine oil from the oil filler hole in the crankcase Recommended engine oil A YAMALUBE 4 10W 40 SAE 10W 30 or 10W 40 B SAE 30 C SAE 20 D SAE 10W Recommended engine oil grade API Service SE type or higher Engine oil quantity 1 1 L 1 16 US qt 0 97 Imp qt 6 Check 9 Engine oil level Refer to ENGIN...

Page 28: ...ve 9 Air filter element 3 3 Check 9 Air filter element Damage Replace Clogged Wash the element with sol vent and then dry it thoroughly Oil the element and squeeze out the excess oil WARNING Do not wash the element with gasoline or with acidic alkalic or organic solvents NOTICE Do not wring out the element This could cause it to tear 4 Install 9 Air filter element 9 Air filter cover 9 Air filter c...

Page 29: ...een run Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during check or repair 1 2 1 1 2 3 4 1 Remove 9 Muffler cover bolts 1 9 Muffler cover 2 2 Remove 9 Muffler band 1 9 Muffler cap 2 9 Muffler screen 3 9 Washer 4 3 Remove 9 Muffler Refer to MUFFLER on 3 10 ...

Page 30: ...noise damping material may come out and the damping effect may be reduced 5 Decarbonize 9 Muffler screen NOTICE When cleaning with a wire brush use it softly to avoid damage or scratch the muf fler screen 6 Install 9 Muffler Refer to MUFFLER on 3 10 9 Washer 9 Muffler screen 9 Muffler cap 9 Muffler band 2 0 Nm 0 20 m kgf 1 4 ft lbf 9 Muffler cover 9 Muffler cover bolts 12 Nm 1 2 m kgf 8 7 ft lbf P...

Page 31: ... when handling or in the vicinity of fuel 1 Remove 9 Fuel tank cap 1 9 Fuel tank filter 2 2 Check 9 Fuel tank filter Damage Replace Dirt clog Clean TIP Clean the fuel tank filter with clean gasoline and then dry it thoroughly 3 Install 9 Fuel tank filter 9 Fuel tank cap WARNING Make sure that the fuel tank cap is tight ened securely 1 2 ...

Page 32: ... fuel cock lever to the OFF posi tion 2 Remove 9 Strainer cup 1 9 Gasket 2 9 Fuel cock strainer 3 3 Check 9 Fuel cock strainer Damage Replace Dirt clog Clean TIP Clean the fuel cock strainer with clean gaso line and then dry it thoroughly 4 Install 9 Fuel cock strainer 9 Gasket 9 Strainer cup 1 3 Nm 0 13 m kgf 0 94 ft lbf WARNING Make sure that the strainer cup is tight ened securely 1 2 3 ...

Page 33: ...ts Refer to CHECKING THE CYLINDER HEAD in 7VB F8197 E0 chapter 3 3 Install 9 Cylinder head R e fe r t o I N S TA L L I N G T H E CYLINDER HEAD ASSEMBLY in 7VB F8197 E0 chapter 3 ADJUSTING THE VALVE CLEARANCE 1 Remove 9 Spark plug cap 1 9 Spark plug 2 NOTICE Before removing the spark plug use com pressed air to clean the cylinder head cover to prevent dirt from falling into the engine 2 Remove 9 Br...

Page 34: ...cooled down enough to be touched Feeler gauge set YU 26900 9 Thickness gauge 90890 03180 Valve clearance Intake valve cold 0 05 0 09 mm 0 0020 0 0035 in Exhaust valve cold 0 05 0 09 mm 0 0020 0 0035 in 3 Pull the recoil starter slowly and then set the piston at TDC top dead center on the compression stroke TIP Check the piston position by inserting a screw driver into the spark plug hole ...

Page 35: ...clearance Move the thick ness gauge up and down to check for the proper resistance Six piece tappet set YM A5970 Tappet adjusting tool 90890 01311 Feeler gauge set YU 26900 9 Thickness gauge 90890 03180 Adjuster Valve clearance Turn clockwise Decrease Turn counterclockwise Increase c Tighten the locknuts 1 7 Nm 0 7 m kgf 5 1 ft lbf 6 Install 9 Cylinder head cover gasket 9 Cylinder head cover 11 Nm...

Page 36: ...ification Adjust Economy control engine speed with no load 2300 2400 r min Engine speed with no load 3110 3210 r min 4 Adjust 9 Economy control engine speed Adjustment steps a Turn the economy control switch 1 to I ON b Turn the adjusting screw to obtain the proper engine speed 9 Engine speed Adjustment steps a Turn the economy control switch 1 to 3 OFF b Turn the adjusting screw to obtain the pro...

Page 37: ...tal tachometer 1 Digital tachometer YU 39951 B 90890 06760 4 Adjust 9 Engine speed Adjustment step a Turn the adjusting screw to obtain the proper engine speed Turn to a The engine speed decreases Turn to b The engine speed increases 3 Measure 9 Engine speed with no load Out of specification Adjust Engine speed with no load 3110 3210 r min ...

Page 38: ...l starter operate smoothly Rough movement Replace the defective part s Refer to RECOIL STARTER in 7VB F8197 E0 chapter 3 FITTINGS AND FASTENERS 1 Check 9 All fittings and fasteners Looseness Tighten Rough movement Replace the defective part s Damage pitting Replace ...

Page 39: ...lead Disconnect Carrier frame Refer to HANDLE AND WHEELS FOR EF7200DE CAN on 3 23 Fuel tank Refer to FUEL TANK CANISTER on 3 7 1 Generator cover 1 2 Control box 1 3 Ground lead 1 4 Stator assembly main coil lead 3 5 Stator assembly sub coil coupler 1 6 Exciter field coil coupler 1 ENGINE For complete information about procedures for engine maintenance it is necessary to refer to the MZ SERIES ENGI...

Page 40: ... 9 Order Job Parts to remove Q ty Remarks 7 Economy control solenoid lead con nector 2 8 Oil level switch lead connector 1 9 TCI unit lead connector 2 10 Starter relay lead connector 1 11 Charging coil lead connector 2 12 Auto choke lead connector 2 13 Fuel cut solenoid valve lead connec tor 2 14 Positive battery lead connector 1 ...

Page 41: ... the control box Remove the parts in the order listed Negative battery lead Disconnect EF7000E EF7200E Fuel tank Refer to FUEL TANK CANISTER on 3 7 1 Generator cover 1 2 Control box 1 3 Ground lead 1 4 Stator assembly main coil lead 2 5 Stator assembly sub coil coupler 1 6 Exciter field coil coupler 1 7 Economy control solenoid lead con nector 2 EF7000E EF7200E Except for EF7200DE ...

Page 42: ... Order Job Parts to remove Q ty Remarks 8 Oil level switch lead connector 1 9 TCI unit lead connector 2 10 Starter relay lead connector 1 EF7000E EF7200E 11 Charging coil lead connector 2 12 Auto choke lead connector 2 EF7000E EF7200E 13 Fuel cut solenoid valve lead connec tor 2 14 Positive battery lead connector 1 EF7000E EF7200E ...

Page 43: ... box 1 9 Control box bolts 9 Control box nuts 7 Nm 0 7 m kgf 5 1 ft lbf c A A Behind the control box TIP 9 Install the a portion of the control box to the frame b at both sides 9 When installing the grommet c make sure that it is facing direction shown in the illus tration ...

Page 44: ... 2 ft á lbf 1 6 Nm 0 16 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks Removing the air filter Remove the parts in the order listed 1 Air filter cover 1 2 Air filter element 1 3 Element fitting plate 1 4 Plate 1 5 Air filter case 1 6 Breather hose 1 7 Gasket 1 AIR FILTER ...

Page 45: ...Parts to remove Q ty Remarks Removing the fuel tank canister Remove the parts in the order listed Carrier frame Refer to HANDLE AND WHEELS FOR EF7200DE CAN on 3 23 Control box Refer to CONTROL BOX on 3 1 1 Fuel hose 1 Turn the fuel cock lever to the OFF position 2 Clip 2 3 Pipe 2 1 For EF7200DE CAN 4 Pipe 3 1 5 Canister 1 6 Pipe 4 1 7 Canister bracket 1 8 Member 1 9 Fuel tank 1 10 Locating damper ...

Page 46: ... kgf 0 58 ft á lbf 1 3 Nm 0 13 m á kgf 0 94 ft á lbf 16 Nm 1 6 m á kgf 12 ft á lbf 11 12 14 15 16 17 18 19 13 Order Job Parts to remove Q ty Remarks 11 Fuel tank cap 1 12 Fuel tank filter 1 13 Fuel level gauge 1 14 Fuel cock 1 15 Strainer cup 1 16 Gasket 1 17 Fuel cock strainer 1 18 Gasket 1 19 O ring 1 ...

Page 47: ...3 9 ENG FUEL TANK CANISTER CHECKING THE CANISTER For EF7200DE CAN 1 Check 9 Pipes 1 Cracks damage Replace Poor connection Correct 9 Canister 2 Cracks damage Replace 1 1 1 2 ...

Page 48: ...bf 16 Nm 1 6 m kgf 12 ft lbf 16 Nm 1 6 m kgf 12 ft lbf Order Job Parts to remove Q ty Remarks Removing the muffler Remove the parts in the order listed 1 Muffler cover 1 2 Muffler damper 2 3 Muffler band 1 4 Muffler cap 1 5 Muffler screen 1 6 Washer 1 7 Muffler 1 8 Exhaust gasket 1 MUFFLER ...

Page 49: ...orarily tighten the nuts 2 and bolts 3 4 until just comes in contact with the surface 2 Tighten 9 Exhaust nuts 2 9 Muffler bolt 3 9 Muffler bolt 4 16 Nm 1 6 m kgf 12 ft lbf TIP Tighten the nuts and bolts to the specified torque in order of exhaust nuts 2 muffler bolt 3 and muffler bolt 4 3 Install 9 Muffler damper 9 Muffler cover 5 12 Nm 1 2 m kgf 8 7 ft lbf ...

Page 50: ...Drain Refer to REPLACING THE ENGINE OIL on 2 6 Handle and wheels Refer to HANDLE AND WHEELS FOR EF7200DE CAN on 3 23 Control box Refer to CONTROL BOX on 3 1 Fuel tank Canister Refer to FUEL TANK CANISTER on 3 7 Air filter Refer to AIR FILTER on 3 6 Muffler Refer to MUFFLER on 3 10 Battery Refer to BATTERY EF7000E EF7200E EF7200DE on 5 18 1 Ground lead 1 For EF7200DE CAN 2 Engine mounting nut 4 3 E...

Page 51: ...emove the parts in the order listed Handle and wheels Refer to HANDLE AND WHEELS FOR EF7200DE CAN on 3 23 Control box Refer to CONTROL BOX on 3 1 Air filter Refer to AIR FILTER on 3 6 Muffler Refer to MUFFLER on 3 10 Fuel tank Refer to FUEL TANK CANISTER on 3 7 Engine assembly Refer to ENGINE on 3 12 Recoil starter Refer to RECOIL STARTER in 7VB F8197 E0 chapter 3 1 Rear frame 1 Put a support unde...

Page 52: ... ft lbf 5 6 10 Nm 1 0 m kgf 7 2 ft lbf 4 5 Nm 0 45 m kgf 3 3 ft lbf 9 Nm 0 9 m kgf 6 5 ft lbf 3 8 Nm 0 38 m kgf 2 8 ft lbf 3 8 Nm 0 38 m kgf 2 8 ft lbf Order Job Parts to remove Q ty Remarks 5 Rotor assembly 1 6 Generator fan 1 A For EF7200DE B Except for EF7200DE ...

Page 53: ...rame 1 TIP To remove the rear frame 1 strike it with a rubber hammer since the bearing may be stuck in the frame 2 Remove 9 Stator cover 1 9 Stator assembly 2 NOTICE Do not drop or damage the stator assem bly 2 1 1 1 2 1 2 1 3 Remove 9 Exciter field coil screws 1 9 Exciter field coil 2 ...

Page 54: ...90890 01701 1 2 3 GENERATOR 6 Remove 9 Rotor assembly 1 NOTICE Do not drop or damage the rotor assembly 1 TIP Remove the rotor assembly 1 using the rotor shock puller assy 2 1 2 1 2 5 Assemble the special tools 9 Rotor shock puller assy 1 9 Rotor puller attachment 2 Rotor shock puller assy YU 1047 90890 01259 Rotor puller attachment M14 1 25 YU 1379 90890 01379 ...

Page 55: ...the rotor bearing with the slot b on the rear frame 9 Align the projection c on the stator assem bly with the slot d on the rear frame INSTALLING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY 1 Install 9 Rotor assembly 2 Tighten 9 Rotor assembly bolt 1 42 Nm 4 2 m kgf 30 ft lbf TIP Tighten the rotor assembly bolt 1 by attach ing the sheave holder 2 to hold the flywheel 3 Primary clutch holder YS 01880 A ...

Page 56: ...b Parts to remove Q ty Remarks Removing the crankcase Remove the parts in the order listed Engine assembly Refer to ENGINE on 3 12 Generator assembly Refer to GENERATOR on 3 13 Cylinder head assembly Refer to CYLINDER HEAD COVER CYLINDER HEAD in 7VB F8197 E0 chapter 3 Flywheel Refer to FLYWHEEL in 7VB F8197 E0 chapter 3 1 Crankcase cover 1 2 Oil filler cap 1 3 Gasket 1 4 Dowel pin 2 5 Clamp 1 6 Oi...

Page 57: ...ft lbf 27 Nm 2 7 m kgf 20 ft lbf 12 Nm 1 2 m kgf 8 7 ft lbf 30 Nm 3 0 m kgf 22 ft lbf 1st 2nd 27 Nm 2 7 m kgf 20 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 9 8 7 Order Job Parts to remove Q ty Remarks 7 Flyweight shaft assembly 1 8 Clip 1 9 Governor shaft 1 10 Negative battery lead 1 EF7000E EF7200E EF7200DE ...

Page 58: ...ty Remarks Removing the piston camshaft and crankshaft Remove the parts in the order listed Crankcase Refer to CRANKCASE on 3 18 1 Balancer shaft 1 2 Camshaft 1 3 Valve lifter 2 4 Connecting rod cap 1 5 Crankshaft 1 6 Connecting rod 1 7 Piston pin circlip 2 8 Piston pin 1 9 Piston 1 10 Piston ring set 1 PISTON CAMSHAFT AND CRANKSHAFT ...

Page 59: ...1 when the bal ancer shaft gear mark a and the crankshaft gear mark b are aligned 2 Remove 9 Camshaft 2 TIP Remove the camshaft 2 when the camshaft gear mark c and the crankshaft gear mark d are aligned 3 Remove 9 Intake valve lifter 9 Exhaust valve lifter CHECKING THE BALANCER SHAFT 1 Check 9 Balancer gear teeth 9 Balancer shaft Wear damage Replace 2 1 b a c d ...

Page 60: ...n the balancer shaft 1 gear mark a with the crankshaft gear mark b 3 Install 9 Camshaft 1 NOTICE Be sure to align the camshaft 1 gear mark a with the crankshaft gear mark b 1 5 3 7 2 6 4 8 8 INSTALLING THE CRANKCASE COVER 1 Install 9 Crankcase cover 9 Crankcase cover bolts 1 to 8 TIP Tighten the bolts to the specified torque in two stages and in order from 1 to 8 1st 12 Nm 1 2 m kgf 8 7 ft lbf 2nd...

Page 61: ...f 12 ft lbf HANDLE AND WHEELS FOR EF7200DE CAN Order Job Parts to remove Q ty Remarks Removing the handle and wheels Remove the parts in the order listed 1 Wheel axle frame 1 TIP Lift the generator 20 cm 7 87 in off the ground using a winch or other suit able lifting device 2 Cotter pin 2 3 Washer 2 4 Wheel 2 5 Main stand 2 6 Handle 1 7 Locating damper 1 8 Bracket handle 1 9 Sleeve 1 10 Plate 4 11...

Page 62: ...f 5 1 ft lbf 16 Nm 1 6 m kgf 12 ft lbf 16 Nm 1 6 m kgf 12 ft lbf 16 Nm 1 6 m kgf 12 ft lbf 16 Nm 1 6 m kgf 12 ft lbf 16 Nm 1 6 m kgf 12 ft lbf 14 15 16 Order Job Parts to remove Q ty Remarks 14 Stopper 1 15 Plate 1 16 Damper 1 17 Engine hanger 1 18 Carrier frame 1 ...

Page 63: ...IP 9 Fasten the engine hanger 1 to the carrier frame 2 with the engine hanger bolts 3 9 Match the punch marks a as shown in the illustration 2 Install 9 Damper 1 9 Plate 2 9 Stopper 3 9 Stopper bolt 4 7 Nm 0 7 m kgf 5 1 ft lbf TIP Install the damper 1 and plate 2 into the stopper 3 and tightly fasten it to carrier frame with the stopper bolt 4 1 2 3 3 a 1 1 2 3 4 ...

Page 64: ... and lock lever 4 in this order and tight en the lock lever nut 5 9 Make sure that the collar 3 is placed into the washer 2 9 Lock lever pin should be above stopper 7 4 Install 9 Carrier frame 1 9 Plate 2 9 Plate bolts 3 16 Nm 1 6 m kgf 12 ft lbf a 10 cm 3 94 in TIP 9 Place the carrier frame 1 10 cm 3 94 in from the end of generator body 9 Place the carrier frame 1 assembled to this point on the g...

Page 65: ...Bracket handle 1 TIP Install the bracket handle 1 to the sleeve 2 7 Install 9 Locating damper 1 TIP Install the locating damper 1 on the sleeve 2 8 Install 9 Handle 1 9 Handle bolts 2 16 Nm 1 6 m kgf 12 ft lbf TIP 9 Place the handle 1 on the carrier frame and then fasten with the handle bolts 2 9 Lock the handle 1 into position with the lock lever 3 ...

Page 66: ...ff the ground using a winch or other suitable lift ing device 9 Fasten the main stand 1 to the left side of the generator frame as viewed when look ing at the control panel with the main stand bolts 2 and nuts 3 2 Install 9 Wheels 1 9 Wheel axle frame 2 TIP 9 Install the wheels 1 into wheel axle frame 2 9 Make sure the installation direction a of the wheels 1 are correct 1 2 3 3 1 2 3 3 1 2 1 2 a ...

Page 67: ...xle 9 Insert cotter pins 2 into wheel axle frame and then bend as shown in the illustration 4 Install 9 Wheel axle frame 1 9 Wheel axle frame bolts 2 9 Wheel axle frame nuts 3 16 Nm 1 6 m kgf 12 ft lbf TIP Fasten the wheel axle frame 1 to the genera tor frame with the wheel axle frame bolts 2 and nuts 3 1 2 1 2 2 1 2 3 2 3 ...

Page 68: ...F7200DE Carrier frame Refer to HANDLE AND WHEELS FOR EF7200DE CAN on 3 23 Fuel tank Refer to FUEL TANK CANISTER on 3 7 Air filter Refer to AIR FILTER on 3 6 1 Fuel cut solenoid valve lead 2 2 Auto choke lead 2 EF7000E EF7200E EF7200DE 3 Carburetor assembly 1 CARBURETOR For complete information about procedures for carburetor maintenance it is necessary to refer to the MZ SERIES ENGINE SERVICE MANU...

Page 69: ...4 2 CARB 4 REMOVING THE CARBURETOR 6 7 5 4 Order Job Parts to remove Q ty Remarks 4 Link rod Spring 1 1 5 Gasket 1 6 Joint 1 7 Gasket 1 A EF7000 EF7200 ...

Page 70: ...0 7 Nm 0 07 m kgf 0 51 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 0 7 Nm 0 07 m kgf 0 51 ft lbf 6 7 8 9 0 q w Order Job Parts to remove Q ty Remarks Disassembling the carburetor Disassemble the parts in the order listed 1 Drain screw 1 2 Main jet holder 1 3 O ring 1 4 Gasket 1 5 Main jet 1 6 Float chamber 1 7 Gasket 1 8 Main nozzle 1 9 Needle assembly 1 0 Float pin 1 q Float 1 w Cap 1 Except for EF7200 S...

Page 71: ...AFR 2 turns out For EF7200 SEA AFR r Throttle screw Spring 1 1 t Pilot jet O ring 1 1 DISASSEMBLING THE CARBURETOR 2 5 Nm 0 25 m kgf 1 8 ft lbf 1 0 Nm 0 10 m kgf 0 72 ft lbf 4 0 Nm 0 40 m kgf 2 9 ft lbf 7 Nm 0 7 m kgf 5 1 ft lbf 0 7 Nm 0 07 m kgf 0 51 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 0 7 Nm 0 07 m kgf 0 51 ft lbf r t e ...

Page 72: ... ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 0 7 Nm 0 07 m kgf 0 51 ft lbf 6 7 8 9 0 q w e Order Job Parts to remove Q ty Remarks Disassembling the carburetor Disassemble the parts in the order listed 1 Drain screw 1 2 Main jet holder 1 3 O ring 1 4 Gasket 1 5 Main jet 1 6 Float chamber 1 7 Gasket 1 8 Main nozzle 1 9 Needle assembly 1 0 Float pin 1 q Float 1 w Cap 1 e Pilot adjusting screw Spring 1 1 2 1 ...

Page 73: ...72 ft lbf 4 0 Nm 0 40 m kgf 2 9 ft lbf 7 Nm 0 7 m kgf 5 1 ft lbf 0 7 Nm 0 07 m kgf 0 51 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 0 7 Nm 0 07 m kgf 0 51 ft lbf r y t u Order Job Parts to remove Q ty Remarks r Throttle screw Spring 1 1 t Pilot jet O ring 1 1 y Plate 1 u Choke solenoid assembly 1 ...

Page 74: ...ecification Replace W 1 DISASSEMBLING THE CARBURETOR 3 Remove 9 Panel cover Refer to CONTROL PANEL on 5 8 9 Rectifier 1 1 2 Check 9 Fuel cut solenoid valve operation Check whether the sound of the valve operation can be heard when the 12V power from the battery is supplied to the lead of the fuel cut solenoid valve Battery positive Blue Red Battery negative Blue White No sound heard Replace Operat...

Page 75: ... 4 Check 9 Rectifier Connect the pocket tester W 1 Check for continuity between the termi nals Rectifier continuity 1 2 3 4 1 1 1 1 2 1 3 4 1 Replace if any faults are found Tester lead Tester lead DISASSEMBLING THE CARBURETOR ...

Page 76: ...5 6 q 1 2 7 8 9 0 3 4 5 6 q ELECTRICAL COMPONENTS 1 Control box 2 Oil warning unit 3 Rectifier 4 Economy control solenoid EF7000E EF7200E EF7200DE 5 Economy control unit EF7000E EF7200E EF7200DE 6 Spark plug 7 AVR Automatic Voltage Regulator 8 Stator and rotor assembly 9 Battery EF7000E EF7200E EF7200DE 0 TCI unit q Starter motor EF7000E EF7200E EF7200DE A For EF7200DE CAN B Except for EF7200DE CA...

Page 77: ...4 AC receptacle 5 AC switch N F B EF7000E CHN 1 Oil warning light 2 Economy control switch 3 Engine switch 4 Voltage hour meter 5 AC receptacle 6 AC switch N F B EF7200E Except for OCE 1 Oil warning light 2 Economy control switch 3 Engine switch 4 Voltage hour meter 5 AC receptacle 6 AC switch N F B 2 3 1 4 5 2 3 1 4 5 3 2 4 1 5 6 3 2 4 1 5 6 EF7000 CHN EF7200 SEA AFR RUS EF7000E CHN EF7200E Excep...

Page 78: ... EF7200DE CAN 1 Oil warning light 2 Economy control switch 3 Engine switch 4 Voltage hour meter 5 AC receptacle 6 AC switch N F B EF7200DE Except for CAN 1 Oil warning light 2 Economy control switch 3 Engine switch 4 Voltage hour meter 5 AC receptacle 6 AC switch N F B 3 2 4 1 5 6 3 4 5 5 6 2 1 6 6 3 2 4 1 5 6 EF7200E OCE EF7200DE CAN EF7200DE Except for CAN ...

Page 79: ... switch N F B 0 AC receptacle q Rectifier w Engine switch e Voltage adjuster r Condenser t AVR Automatic Voltage Regulator y Oil warning unit u Oil warning light i Engine o Fuel cut solenoid valve p Charging coil a TCI unit s Spark plug d Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green O Orange R Red W White Y Yellow B W Black White G R Green Red G Y Green Yellow L R Blu...

Page 80: ... Voltage adjuster u Condenser i AVR Automatic Voltage Regulator o Oil warning unit p Economy control unit a Oil warning light s Economy control switch d Engine f Economy control solenoid g Starter relay h Starter motor j Auto choke k Fuel cut solenoid valve l Battery Charging coil z TCI unit x Spark plug c Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green O Orange R Red W ...

Page 81: ...tifier regulator y Voltage adjuster u Condenser i AVR Automatic Voltage Regulator o Oil warning unit p Economy control unit a Oil warning light s Economy control switch d Engine f Economy control solenoid g Starter relay h Starter motor j Auto choke k Fuel cut solenoid valve l Battery Charging coil z TCI unit x Spark plug c Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green...

Page 82: ...er regulator y Voltage adjuster u Condenser i AVR Automatic Voltage Regulator o Oil warning unit p Economy control unit a Oil warning light s Economy control switch d Engine f Economy control solenoid g Starter relay h Starter motor j Auto choke k Fuel cut solenoid valve l Battery Charging coil z TCI unit x Spark plug c Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green O O...

Page 83: ... 0 18 m á kgf 1 3 ft á lbf 1 7 Nm 0 17 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks Removing the control panel Remove the parts in the order listed 1 Panel cover 1 2 Voltage hour meter 1 3 Oil warning light 1 4 Engine switch 1 5 AC receptacle 2 6 AC switch N F B 1 Lever switch 7 Oil warning unit 1 8 Rectifier 1 9 Condenser holder 1 10 Condenser 1 CONTROL PANEL EF7000 EF7200 CONTROL ...

Page 84: ... 0 04 m á kgf 0 29 ft á lbf 1 4 Nm 0 14 m á kgf 1 0 ft á lbf 1 3 Nm 0 13 m á kgf 0 94 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 7 Nm 0 17 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks 11 Voltage adjuster 1 12 AVR 1 Automatic Voltage Regulator 13 Control box 1 CONTROL PANEL ...

Page 85: ...8 Nm 0 18 m á kgf 1 3 ft á lbf 1 7 Nm 0 17 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks Removing the control panel Remove the parts in the order listed 1 Panel cover 1 2 Economy control switch 1 3 Voltage hour meter 1 4 Oil warning light 1 5 Engine switch 1 6 AC receptacle 2 7 AC switch N F B 1 Lever switch 8 Fuse 1 9 Oil warning unit 1 10 Rectifier 1 11 Economy control unit 1 12 Co...

Page 86: ... kgf 1 0 ft á lbf 1 3 Nm 0 13 m á kgf 0 94 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 7 Nm 0 17 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks 14 Voltage adjuster 1 15 AVR 1 Automatic Voltage Regulator 16 Control box 1 17 Rectifier regulator 1 CONTROL PANEL ...

Page 87: ...m á kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 7 Nm 0 17 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks Removing the control panel Remove the parts in the order listed 1 Panel cover 1 2 Economy control switch 1 3 Voltage hour meter 1 4 Oil warning light 1 5 AC receptacle 2 6 Engine switch 1 7 AC switch N F B 1 Lever switch 8 Fuse 1 9 Oil warning unit 1 10 Rectifier 1 11 Econo...

Page 88: ...6 Nm 0 06 m á kgf 0 43 ft á lbf 1 4 Nm 0 14 m á kgf 1 0 ft á lbf 1 3 Nm 0 13 m á kgf 0 94 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 7 Nm 0 17 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks 14 Voltage adjuster 1 15 AVR 1 Automatic Voltage Regulator 16 Control box 1 17 Rectifier regulator 1 ...

Page 89: ... kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 7 Nm 0 17 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks Removing the control panel Remove the parts in the order listed 1 Panel cover 1 2 Economy control switch 1 3 Voltage hour meter 1 4 Oil warning light 1 5 Engine switch 1 6 AC receptacle 3 7 AC switch N F B 2 Lever switch 8 Fuse 1 9 Oil warning unit 1 10 Rectifier 1 11 Economy ...

Page 90: ... 4 Nm 0 14 m á kgf 1 0 ft á lbf 1 3 Nm 0 13 m á kgf 0 94 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 7 Nm 0 17 m á kgf 1 2 ft á lbf Order Job Parts to remove Q ty Remarks 14 Voltage adjuster 1 15 AVR 1 Automatic Voltage Regulator 16 Control box 1 17 Rectifier regulator 1 ...

Page 91: ...f 0 94 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf Order Job Parts to remove Q ty Remarks Removing the control panel Remove the parts in the order listed 1 Panel cover 1 2 Economy control switch 1 3 Voltage hour meter 1 4 Oil warning light 1 5 Engine switch 1 6 AC receptacle 3 7 AC switch N F B 3 Push switch 8 AC switch N F B 2 Lever switch 9 Fuse 1 10 Oil warning un...

Page 92: ... 7 m á kgf 5 1 ft á lbf 0 4 Nm 0 04 m á kgf 0 29 ft á lbf 1 3 Nm 0 13 m á kgf 0 94 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 1 8 Nm 0 18 m á kgf 1 3 ft á lbf 0 4 Nm 0 04 m á kgf 0 29 ft á lbf Order Job Parts to remove Q ty Remarks 14 Condenser 1 15 Voltage adjuster 1 16 AVR 1 Automatic Voltage Regulator 17 Control box 1 18 Rectifier regulator 1 ...

Page 93: ...arts to remove Q ty Remarks Removing the battery Remove the parts in the order listed 1 Negative battery lead 1 Disconnect 2 Positive battery lead 1 Disconnect 3 Wing nut 2 4 Battery mounting plate 1 5 Battery mounting rod 2 6 Battery 1 BATTERY EF7000E EF7200E EF7200DE ...

Page 94: ...ep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes 9 DO NOT SMOKE when charging or han dling batteries 9 KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 9 Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL 9 Skin Wash with water 9 Eyes Flush with water for 15 minutes...

Page 95: ... overcharged the electrolyte level will drop considerably Therefore take spe cial care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the bat tery terminals 1 Disc...

Page 96: ...rcuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example A Open circuit voltage V B Charging time hours C Relationship between the open circuit voltage and the charging time at 20 C 68 F D These values vary with the temperature the con dition of the battery plates and the electrolyte level Example Open circuit voltage 12 0 V Charging...

Page 97: ...are connected to the battery 9 Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger 9 Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may gen erate heat in the contact area and a weak clip spring may cause sparks 9 If the battery b...

Page 98: ...icient If too high the battery will be over charged c Make sure that the current is higher than the standard charging current written on the battery TIP If the current is lower than the standard charg ing current written on the battery set the charging voltage adjust dial at 20 24 V and monitor the amperage for 3 5 minutes to check the battery 9 Standard charging current is reached Battery is good...

Page 99: ... battery A varia ble voltage charger is recommended d Charge the battery until the battery s charg ing voltage is 15 V TIP Set the charging time at 20 hours maximum d Adjust the voltage so that the current is at the standard charging level e Set the time according to the charging time suitable for the open circuit voltage f If charging requires more than 5 hours it is advisable to check the chargi...

Page 100: ...is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery 6 Check 9 Battery terminals Dirt Clean with a wire brush Loose connections Connect proper ly 7 Install 9 Battery 9 Battery mounting plate 8 Connect 9 Positive battery lead NOTICE First connect the positive battery lead and then the negative battery lead 9 Connect 9 Negative battery lead ...

Page 101: ...o STOP when checking or replacing a fuse 1 Remove 9 Panel cover 9 Panel cover screws 1 1 2 Remove 9 Fuse 1 3 Check 9 Fuse Checking steps a Connect the pocket tester W 1 to the fuse and check the continuity TIP Set the pocket tester selector to W 1 Analog pocket tester YU 03112 C Pocket tester 90890 03112 b If the pocket tester indicates replace the fuse ...

Page 102: ...cal circuit is operational d If the fuse immediately blows again check the electrical circuit Fuse amperage 20 A 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 5 Install 9 Fuse 6 Install 9 Panel cover 9 Panel cover screws 1 3 Nm 0 13 m ...

Page 103: ...cket tester 90890 03112 TIP 9 Set the pocket tester to 0 before starting a test 9 To test the switch for continuity set the pocket tester to the W 1 range 9 Turn the switch on and off several times during the test A A typical example of switch continuity test Measurement example of the electric compo nents A Connect the connector and check W W W W A A B B Disconnect the connector and check SWITCHE...

Page 104: ...plug GOOD NOT GOOD Inspection steps 1 Engine oil level 2 Spark plug 3 Ignition spark gap 4 Spark plug cap resistance 5 Ignition coil TCI unit resistance 6 Ignition coil TCI unit resistance 7 Air gap 8 Engine switch 9 Oil level switch 10 Wire harness TIP 9 Remove the following part s before troubleshooting 1 Control panel 2 Recoil starter 9 Use the following special tool s for troubleshooting Analo...

Page 105: ...lug 9 Connect the ignition checker 2 as shown 3 2 1 a Spark plug cap 1 Ignition checker 2 Ignition checker lead Spark plug 3 9 Turn the crankshaft and measure the ignition spark gap a Minimum spark gap 6 0 mm 0 236 in MEETS SPECIFICATION OUT OF SPECIFICATION OR NO SPARK The ignition system is good ...

Page 106: ...imary terminal 1 2 Tester lead Black White terminal 1 Tester lead Body ground 2 Primary coil resistance 0 6 W 20 TIP 9 Do not pull out the spark plug cap from the high tension cord 9 Remove Turn the spark plug cap coun terclockwise 9 Install Turn the spark plug cap clock wise 9 Check the high tension cord for cracks or deterioration before installing the spark plug cap 9 Cut 5 mm off the end of th...

Page 107: ...r lead High tension cord 1 Tester lead Black White terminal 2 Secondary coil resistance 12 kW 20 7 Air gap 9 Measure the thickness between the magnet rotor and TCI unit TCI unit air gap 0 4 0 6 mm 0 0157 0 0236 in Replace the TCI unit MEETS SPECIFICATION OUT OF SPECIFICATION Adjust the air gap MEETS SPECIFICATION OUT OF SPECIFICATION IGNITION SYSTEM ...

Page 108: ...minal 9 Check the engine switch continuity 1 3 4 2 A B W B L R Y 1 2 3 4 B A EF7000 EF7200 B Except for EF7000 EF7200 Tester lead Yellow terminal 1 Tester lead Blue Red terminal 2 Tester lead Black White terminal 3 Tester lead Black terminal 4 Switch ON Continuity Switch STOP No continuity Replace the engine switch MEETS SPECIFICATION OUT OF SPECIFICATION ...

Page 109: ...heck for conti nuity 1 2 1 2 A B Tester lead Oil level switch lead 1 Tester lead Body ground 2 A Continuity Correct B No continuity Correct 10 Wire harness 9 Check the terminal of the connector for contamination rust or disconnection Replace the oil level switch MEETS SPECIFICATION OUT OF SPECIFICATION Correct or replace the connector Replace the TCI unit GOOD NOT GOOD IGNITION SYSTEM ...

Page 110: ...e the battery voltage Tester lead battery positive terminal Tester lead battery negative terminal Battery voltage 12 8 V or more Replace the fuse 9 Clean the battery terminals 9 Recharge or replace the battery CONTINUITY NO CONTINUITY OUT OF SPECIFICATION MEETS SPECIFICATION Inspection steps 1 Fuse 2 Battery voltage 3 Starter motor 4 Starter relay TIP 9 Remove the following part s before troublesh...

Page 111: ...er motor operation Replace the engine switch MOVES MOVES 1 Jumper lead 1 Jumper lead Replace the starter relay DOES NOT MOVE Check the battery Refer to BATTERY EF7000E EF7200E EF7200DE on 5 18 DOES NOT MOVE GOOD NOT GOOD Repair and or charge the battery Repair and or replace the starter motor WARNING 9 A wire that is used as a jumper lead must have the equivalent capacity or more as that of the ba...

Page 112: ...g the starter motor Remove the parts in the order listed Negative battery lead Disconnect Carrier frame Refer to HANDLE AND WHEELS FOR EF7200DE CAN on 3 23 Control box Refer to CONTROL BOX on 3 1 Fuel tank Refer to FUEL TANK CANISTER on 3 7 1 Positive battery lead 1 Disconnect 2 Starter relay lead 1 Disconnect 3 Starter motor assembly 1 REMOVING THE STARTER MOTOR ...

Page 113: ... Nm 0 9 m kgf 6 5 ft lbf 11 Nm 1 1 m kgf 8 0 ft lbf 1 9 8 7 6 2 3 4 5 Order Job Parts to remove Q ty Remarks Disassembling the starter motor Disassemble the parts in the order listed 1 Rear bracket 1 2 Insulator 1 3 Brush spring 4 4 Brush 4 5 Yoke 1 6 Armature 1 7 Starter relay 1 8 Starter drive lever 1 9 Starter case 1 ...

Page 114: ... length of each brush 1 Out of specification Replace Brush wear limit length 6 0 mm 0 24 in 2 Check 9 Brush spring 2 Fatigue damage Replace ASSEMBLING THE STARTER MOTOR 1 Install 9 Starter drive lever 1 2 Install 9 Armature and starter drive lever 1 3 Install 9 Starter relay 1 11 Nm 1 1 m kgf 8 0 ft lbf ...

Page 115: ...ad battery negative termi nal Battery voltage 12 V 9 Clean the battery terminals 9 Recharge or replace the battery OUT OF SPECIFICATION MEETS SPECIFICATION Inspection steps 1 Battery voltage 2 Charging voltage 3 Fuse 4 Charging coil resistance TIP 9 Remove the following part s before troubleshooting 1 Control panel 2 Recoil starter 3 Flywheel 9 Use the following special tool s for troubleshooting ...

Page 116: ...the fuse for continuity Refer to FUSE EF7000E EF7200E EF7200DE on 5 26 Replace the fuse NO CONTINUITY CONTINUITY 2 Charging voltage 9 Start the engine 9 Accelerate to 3600 r min 9 Measure the charging voltage DC20V Battery charging voltage More than 14 0 V MORE THAN 14 0 V Properly connect the charging system MEETS SPECIFICATION ...

Page 117: ...connect the charging coil leads 9 Connect the pocket tester W 1 1 2 3 W G R 9 Measure the charging coil resistance Charging coil resistance White 1 Ground 2 2 0 W 20 Green Red 3 Ground 2 1 8 W 20 Replace the charging coil OUT OF SPECIFICATION Replace the regulator MEETS SPECIFICATION ...

Page 118: ... Inspection steps 1 AC switch N F B 2 Engine speed 3 Condenser 4 Main coil AC voltage 5 AC switch N F B 6 AC receptacle AC voltage 7 Sub coil AC voltage 8 Sub coil resistance 9 Main coil AC voltage 10 Main coil resistance 11 Rotor remagnetization 12 Exciter field coil AC voltage 13 Exciter field coil resistance 14 Short to ground and Coils shorted together test 15 Rectifier rotor assembly 16 Excit...

Page 119: ...rns back quickly 2 The needle does not swing 3 The needle does not return GOOD Replace the condenser Refer to CONTROL PANEL on 5 8 WARNING 9 Discharge the old condenser by short ing the two terminals together 9 Use an insulated screwdriver 9 Do not touch either of the terminals or the ground before the condenser is dis charged NOT GOOD W 1k W 1k W 1k GENERATOR SYSTEM ...

Page 120: ...the engine with no load AC300V W R L A AC300V W R B A EF7200DE B Except for EF7200DE Main coil AC voltage 120 V White Red 126 6 V 240 V White Blue 255 1 V 220 V White Red 236 V 230 V White Red 236 V 5 AC switch N F B 9 Check the AC switch N F B position OUT OF SPECIFICATION Proceed to Step 8 MEETS SPECIFICATION ON OFF Turn or push the switch on GENERATOR SYSTEM ...

Page 121: ...eptacle AC voltage 126 6 V 120 V receptacle 255 1 V 240 V receptacle 236 V 220 V receptacle 236 V 230 V receptacle Check for damaged AC receptacle DAMAGED Check and repair wiring from the generator to the control panel OK Replace the AC receptacle OUT OF SPECIFICATION MEETS SPECIFICATION No further action necessary CONTINUITY Check AC switch N F B for continuity in the on position NO CONTINUITY GE...

Page 122: ...ad Green terminal Tester lead Green terminal Sub coil AC voltage 120 240 V 9 9 9 9 V 220 V 8 9 V 230 V 8 9 V MEETS SPECIFICATION 8 Sub coil resistance 9 Connect the pocket tester W 1 as shown Ω 1 G W G A Ω 1 G W G B A EF7200DE B Except for EF7200DE Tester lead Green terminal Tester lead Green terminal Sub coil resistance 120 240 V 0 366 W 10 220 V 0 508 W 10 230 V 0 508 W 10 OUT OF SPECIFICATION O...

Page 123: ...0DE Main coil AC voltage 120 V White Red 26 V 240 V White Blue 51 V 220 V White Red 36 V 230 V White Red 36 V 10 Main coil resistance 9 Connect the pocket tester W 1 to the stator assembly main coil lead Ω 1 W R L A Ω 1 W R B A EF7200DE B Except for EF7200DE Main coil resistance 120 V White Red 0 218 W 10 240 V White Blue 0 507 W 10 220 V White Red 0 503 W 10 230 V White Red 0 503 W 10 OUT OF SPEC...

Page 124: ... side of the exciter field coil coupler battery to coupler terminal Black and battery to coupler terminal White for 2 5 seconds 9 Remove the battery and reconnect the exciter field coil coupler 9 Recheck the main coil AC output voltage OUT OF SPECIFICATION Proceed to step 12 MEETS SPECIFICATION No further action necessary NOTICE Do not connect the battery for more than a few seconds This may deter...

Page 125: ...e the exciter field coil voltage Exciter field coil AC voltage Black White 17 V OUT OF SPECIFICATION MEETS SPECIFICATION 13 Exciter field coil resistance 9 Disconnect the exciter field coil coupler 9 Connect the pocket tester W 1 as shown B W 9 Measure the exciter field coil resistance Exciter field coil resistance Black White 46 5 W 10 OUT OF SPECIFICATION Replace the exciter field coil ...

Page 126: ...est Connect the lead to the stator housing and lead to any wire of the main coil Repeat same procedure with the sub and exciter field coils Coils shorted together test Connect the lead to any wire of main coil and lead to either green wire on the sub coil 9 Measure resistance All tests should read an open circuit or dis continuity any other reading indicates a defective main coil assembly or excit...

Page 127: ...move the rotor assembly 9 Connect the pocket tester W 1 as shown 1 4 3 2 Rectifier continuity Pocket tester connecting point Good Red Black 1 2 2 2 1 1 3 3 1 1 4 4 1 2 2 3 3 2 2 2 4 4 2 2 3 4 4 3 2 2 Continuity No continuity NOT GOOD Replace the rectifier GOOD ...

Page 128: ...R SYSTEM 16 Exciter armature coil resistance 9 Connect the pocket tester W 1 as shown Ω 1 Exciter armature coil resistance 1 82 W 10 MEETS SPECIFICATION OUT OF SPECIFICATION Replace the rotor assembly Replace the AVR 1 1 ...

Page 129: ...ol solenoid Remove the parts in the order listed Carrier frame Refer to HANDLE AND WHEELS FOR EF7200DE CAN on 3 23 Control box Refer to CONTROL BOX on 3 1 Fuel tank Refer to FUEL TANK CANISTER on 3 7 1 Economy control solenoid 1 2 Spring 1 3 Bracket 1 ECONOMY CONTROL SYSTEM EF7000E EF7200E EF7200DE ECONOMY CONTROL SOLENOID ECONOMY CONTROL SYSTEM EF7000E EF7200E EF7200DE ...

Page 130: ...lts 2 TIP Temporary tighten the economy control sole noid bolts 2 Adjust 9 Economy control solenoid Adjustment steps a Turn the governor arm 1 counterclock wise until it stops b Pull the plunger 2 in direction of the arrow to the position shown in the illus tration c Keep the position on step a and step b tighten the economy control sole noid bolts 3 7 Nm 0 7 m kgf 5 1 ft lbf ...

Page 131: ...arks 1 Economy control solenoid Operate the governor arm 2 Throttle valve Control the engine speed 3 Economy control switch Switching 4 Economy control unit Control the economy control solenoid 5 Receptacle 6 Governor weight Check the engine speed 7 Governor arm ECONOMY CONTROL SYSTEM DIAGRAM ...

Page 132: ...UT OF SPECIFICATION ECONOMY CONTROL SYSTEM EF7000E EF7200E EF7200DE Inspection steps 1 Economy control engine speed 2 Economy control voltage 3 Economy control switch 4 Economy control solenoid voltage 5 Economy control solenoid resistance TIP 9 The economy control system will not function if a load of 0 8 A or less is used 9 Remove the following part s before troubleshooting 1 Control box 2 Contr...

Page 133: ... 10 17 V DC 3 Economy control switch 9 Disconnect the economy control switch connector 9 Connect the pocket tester W 1 to the economy control switch terminal 9 Check the economy control switch conti nuity Tester lead Economy control switch terminal Tester lead Economy control switch terminal Economy control switch is on Continuity Economy control switch is off No continuity Replace the economy con...

Page 134: ...ATION OUT OF SPECIFICATION 4 Economy control solenoid voltage 9 Connect the pocket tester DC 20 V to the economy control solenoid connector Tester lead Orange lead Tester lead Green lead DC20V G O 9 Start the engine 9 Measure the economy control solenoid voltage Economy control solenoid voltage 10 8 13 2 V DC ...

Page 135: ...rol solenoid resistance 9 Disconnect the economy control solenoid connector 9 Connect the pocket tester W 10 as shown Ω 10 9 Measure the economy control solenoid resistance Economy control solenoid resistance 26 W 5 Replace the economy control solenoid OUT OF SPECIFICATION ...

Page 136: ...el tank cap is clogged GOOD CLOGGED Set to ON Check the fuel cock lever position ON OFF Clean or replace the fuel tank or fuel hose Check if fuel flows to fuel cock FLOW OK NO FLOW Check that the oil warning light comes on by pull ing the starter rope or turn the engine switch LIGHTS ON DOSE NOT LIGHT Check the connections between the oil warning unit and oil level switch GOOD NOT GOOD Replace the...

Page 137: ...to the spark plug cap and then ground the spark plug to check for spark GOOD SPARK WEAK OR NO SPARK Clean or replace 9 Check the spark plug for dirt and check the spark plug gap 9 Check for the voltage leakage due to faulty con nection or broken insulation of the high tension cord 9 Check the TCI unit connector for corrosion or faulty connection 9 Check the ignition system Refer to IGNITION SYSTEM...

Page 138: ...GINE Correct Check if the marks on the crankshaft and cam shaft are aligned ALIGNED NOT ALIGNED Rebore or replace Check if there is seizure wear or damage on the piston piston ring or cylinder GOOD SEIZURE OR WORN ...

Page 139: ...9 Tighten the carburetor nuts securely 9 Replace the carburetor joint or gasket with a new one Check if there is air suction from the carburetor joint gasket or throttle shaft GOOD NOT GOOD Adjust Measure the valve clearance GOOD OUT OF SPECIFICATION Clean Check if the fuel hose is clogged GOOD CLOGGED Adjust Check the TCI unit air gap GOOD NOT GOOD Repair or replace Check if there is seizure wear...

Page 140: ...ean Check the air filter element for dirt GOOD DIRTY Clean adjust or replace Check the spark plug for dirt and check the spark plug gap GOOD DIRTY OR OUT OF SPECIFICATION Adjust Measure the valve clearance GOOD OUT OF SPECIFICATION Resurface or replace Check the valve face and valve seat for wear GOOD WORN Correct Check if the marks on the crankshaft and cam shaft are aligned GOOD NOT GOOD Rebore ...

Page 141: ...ges such as the main jet in the carburetor are clogged GOOD CLOGGED 9 Tighten the carburetor nuts securely 9 Replace the carburetor joint or gasket with a new one Check if there is air suction from the carburetor joint gasket or throttle shaft GOOD NOT GOOD ...

Page 142: ... plug for dirt and check the spark plug gap GOOD DIRTY OR OUT OF SPECIFICATION 9 Tighten the carburetor nuts securely 9 Replace the carburetor joint or gasket with a new one Check if there is air suction from the carburetor joint gasket or throttle shaft GOOD NOT GOOD Clean the parts Check if the slow or main passages such as pilot jet and main jet in the carburetor are clogged GOOD NOT GOOD Adjus...

Page 143: ...eck if there is seizure wear or damage on the piston piston ring or cylinder GOOD SEIZURE OR WORN Resurface or replace Check the valve face and valve seat for wear GOOD WORN Adjust Check the valve clearance SUFFICIENT OUT OF SPECIFICATION ...

Page 144: ... that the governor link operate smoothly GOOD NO GOOD Replace Check that the governor spring is stretched GOOD STRETCHED Adjust Check the governor adjustment GOOD NOT GOOD Adjust or replace Check the governor weight and governor bushing function GOOD NOT GOOD ...

Page 145: ... 565 22 2 Dry weight kg lb 106 233 7 For EF7200DE CAN 94 207 2 EF7200DE 93 205 0 EF7200E EF7000E 84 185 2 EF7200 EF7000 Noise level dB LWA 100 0 EF7200DE 96 5 dB A 7m 74 5 EF7200DE 71 0 Engine Engine type Air cooled 4 stroke gasoline OHV Cylinder arrangement Inclined 1 cylinder Displacement L cm3 0 358 358 Bore Stroke mm in 85 0 63 2 3 35 2 49 Compression ratio 8 2 1 Standard compression pressure ...

Page 146: ...tating direction Clockwise from flywheel Governor type Centrifugal weight system Electrical Ignition system Ignition timing 3600 r min Spark plug type Spark plug gap mm in TCI BTDC 20 3 BPR4ES NGK 0 7 0 8 0 028 0 031 Generator Type Brushless self exciting single phase synchro nous generator Number of phase Single phase Number of poles 2 Excitation Self magnetization Initial excitation Residual mag...

Page 147: ...0DE 30 A 250 V 125 V 1 EF7200DE 15 A 250 V 2 For EF7200E OCE 20 A 250 V 2 Noise level is measured when the economy control switch is turned to I ON LWA shows the sound power level under the ISO3744 satisfied test conditions The noise level in dB A 7 m is the arithmetic mean value in four directions measured 7 meters away from each side of the generator The noise level may vary in different environ...

Page 148: ...p ring Type Barrel Dimensions B T 1 2 3 1 0 0472 0 1220 End gap 0 20 0 35 0 008 0 014 Limit 0 6 0 0236 Side clearance 0 04 0 08 0 0016 0 0031 Limit 0 13 0 0051 2nd ring Type Taper Dimensions B T 1 2 3 2 0 0472 0 1260 End gap 0 30 0 45 0 0118 0 0177 Limit 0 8 0 0315 Side clearance 0 03 0 07 0 0012 0 0028 Limit 0 13 0 0051 Oil ring Type 3 piece type Dimensions B T 2 5 2 5 0 0984 0 0984 End gap 0 20 ...

Page 149: ...20 0 7876 0 7882 Oil clearance 0 006 0 025 0 0002 0 0010 Big end diameter B 36 000 36 015 1 4173 1 4179 Oil clearance 0 016 0 046 0 0006 0 0018 Limit 0 10 0 0040 Camshaft mm in Camshaft outside diameter Cam dimension A IN 32 55 0 05 1 281 0 002 Limit 32 40 1 276 A EX 32 55 0 05 1 281 0 002 Limit 32 40 1 276 B IN 26 08 0 05 1 027 0 002 Limit 25 93 1 021 B EX 26 08 0 05 1 027 0 002 Limit 25 93 1 021...

Page 150: ...3 Limit IN 1 6 0 063 EX 1 6 0 063 Valve stem runout limit 0 01 0 0004 θ 90 Valve guide Guide inside diameter IN 6 000 6 012 0 2362 0 2367 EX 6 000 6 012 0 2362 0 2367 Stem to guide clearance IN 0 037 0 064 0 00146 0 00252 EX 0 045 0 072 0 00177 0 00283 Valve clearance cold IN 0 05 0 09 0 0020 0 0035 EX 0 05 0 09 0 0020 0 0035 Push rod mm in Runout limit 0 5 0 02 Valve spring mm in Free length IN 3...

Page 151: ...ng attach hole 2 4 EF7200DE Holes numbers are 1 5 from right to left when looking down the governor arm from the panel side ELECTRICAL Electrical Ignition system Ignition timing at 3600 r min BTDC 20 3 Spark plug type BPR4ES NGK Gap mm in 0 7 0 8 0 028 0 031 Primary coil resistance W 20 0 6 Secondary coil resistance kW 20 12 Spark plug cap resistance kW 4 0 6 0 TCI unit air gap mm in 0 4 0 6 0 015...

Page 152: ...d 120 V White Red V 126 6 EF7200DE 240 V White Blue V 255 1 EF7200DE 230 V White Red V 236 For EF7200E OCE 220 V White Red V 236 EF7000 EF7000E EF7200 EF7200E Main coil AC voltage with the sub coil coupler disconnected no load 120 V White Red V 26 EF7200DE 240 V White Blue V 51 EF7200DE 230 V White Red V 36 For EF7200E OCE 220 V White Red V 36 EF7000 EF7000E EF7200 EF7200E Sub coil AC voltage with...

Page 153: ... Green W 10 0 366 EF7200DE 230 V Green Green W 10 0 508 For EF7200E OCE 220 V Green Green W 10 0 508 EF7000 EF7000E EF7200 EF7200E Field coil resistance rotor assembly W 10 30 2 Exciter field coil resistance Black White W 10 46 5 Exciter armature coil resistance W 10 1 82 ...

Page 154: ...6 1 6 12 Muffler bolt M8 1 25 16 1 6 12 Muffler cover bolt M6 1 0 12 1 2 8 7 Muffler band screw 2 0 0 20 1 4 Rear frame bolt M6 1 0 10 1 0 7 2 Engine mounting nut M10 1 25 32 3 2 23 Recoil starter bolt M6 1 0 7 0 7 5 1 Flywheel cover bolt M6 1 0 7 0 7 5 1 TCI unit bolt M6 1 0 10 1 0 7 2 Flywheel nut M18 1 5 100 10 72 Charging coil bolt M6 1 0 7 0 7 5 1 Charging coil clamp bolt M6 1 0 7 0 7 5 1 Rot...

Page 155: ...14 Carburetor drain screw 2 5 0 25 1 8 Main jet holder 7 0 7 5 1 Main jet 0 7 0 07 0 51 Fuel cut solenoid valve 4 0 0 40 2 9 Panel cover screw 1 3 0 13 0 94 AC switch N F B screw M3 5 0 0 6 0 06 0 43 AC switch N F B nut For EF7200DE CAN M11 1 4 0 14 1 0 AC switch N F B terminal nut EF7200DE M5 3 9 3 0 0 30 2 2 AC switch N F B terminal screw M4 1 3 0 13 0 94 AC receptacle nut M4 1 8 0 18 1 3 AC rec...

Page 156: ...E CAN M8 1 25 16 1 6 12 Plate bolt For EF7200DE CAN M8 1 25 16 1 6 12 Handle bolt For EF7200DE CAN M8 1 25 16 1 6 12 Main stand nut For EF7200DE CAN M8 1 25 16 1 6 12 Wheel axle frame nut For EF7200DE CAN M8 1 25 16 1 6 12 TIGHTENING TORQUES GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fas teners with standard I S O pitch treads Torque specif...

Page 157: ...in E Crankshaft journal Connecting rod cap bolt E Piston pin E Piston E Balancer shaft journal E Balancer shaft gear teeth E Crankshaft gear teeth E Valve stem E Valve stem end Valve rocker arm shaft Valve push rod E Valve lifter stem E Camshaft lobe E Camshaft gear teeth E Decompressor pin E Camshaft journal E Governor collar internal surface E Governor shaft meet surface E Governor weight contac...

Page 158: ...terminal r Panel cover A Control box B 32 6 mm 1 28 in C 16 mm 0 63 in D Behind the control box panel E Connect the condenser lead coupler as shown in the illus tration paying attention to polarity F Negative side mark G Pay attention to the polarity when connecting the lead to the condenser H Pawls on voltage hour meter properly engaged I Pawls on voltage hour meter improperly engaged J Make sure...

Page 159: ...7 15 SPEC WIRE ROUTING DIAGRAM M To generator Color code B Black Br Brown R Red W White Y Yellow B W Black White G R Green Red G Y Green Yellow L R Blue Red L W Blue White ...

Page 160: ...tifier regulator A Control box B Except for OCE C For OCE D 32 6 mm 1 28 in E 16 mm 0 63 in F Route the brown lead through the coil of the economy control unit G Behind the control box panel H Connect the condenser lead coupler as shown in the illus tration paying attention to polarity I Negative side mark J Pay attention to the polarity when connecting the lead to the condenser K Pawls on voltage...

Page 161: ... that the pawls are properly engaged on both sides of the panel cover N Behind the control box O To engine P To generator Color code B Black Br Brown O Orange R Red W White Y Yellow B W Black White G R Green Red G Y Green Yellow L W Blue White ...

Page 162: ...anel cover o Rectifier regulator A Control box B 32 6 mm 1 28 in C 16 mm 0 63 in D Route the brown lead through the coil of the economy control unit E Behind the control box panel F Connect the condenser lead coupler as shown in the illus tration paying attention to polarity G Pawls on voltage hour meter properly engaged H Pawls on voltage hour meter improperly engaged I Make sure that the pawls a...

Page 163: ...en connecting the lead to the condenser L Install the lead between the screw and plate M Behind the control box N To engine O To generator Color code B Black Br Brown L Blue O Orange R Red W White Y Yellow B W Black White G R Green Red G Y Green Yellow L W Blue White ...

Page 164: ...p Rectifier regulator A Control box B Route the brown lead through the coil of the economy control unit C Behind the control box panel D Connect the longer brown lead as shown E 30 45 F Identification tape White G Connect the condenser lead coupler as shown in the illus tration paying attention to polarity H Negative side mark I Pay attention to the polarity when connecting the lead to the condens...

Page 165: ...y engaged on both sides of the panel cover M Install the lead between the screw and plate N Behind the control box O To engine P To generator Color code B Black Br Brown L Blue O Orange R Red W White Y Yellow B W Black White G R Green Red G Y Green Yellow L W Blue White ...

Page 166: ...tank to canister 7 Carburetor 8 Air filter 9 Pipe 3 canister to air filter case 0 Pipe 4 q Canister A Install the washer within the 5th ball of the chain B Install the washer within the 20th ball of the chain C Pass the chain through a 5 hole in the fuel tank D 5 mm or less BACK SIDE AND LEFT SIDE VIEW For EF7200DE CAN ...

Page 167: ...e battery lead w Charging coil lead connector e Oil level switch lead connector r Economy control solenoid lead connector t Starter motor y Economy control solenoid u Fuel cut solenoid valve lead connector A Avoid contact of the lead with the muffler and governor arm by making an adjustment with the clamp B 25 B Black G Green L Blue O Orange R Red W White B W Black White G R Green Red L R Blue Red...

Page 168: ... Charging coil lead connector 7 Oil level switch lead connector 8 Clamp A Avoid contact of the lead with the muffler and governor arm by making an adjustment with the clamp B Black L Blue O Orange B W Black White G R Green Red L R Blue Red L W Blue White UPPER SIDE VIEW EF7000 EF7200 WIRE ROUTING DIAGRAM Color code ...

Page 169: ...e the oil level switch lead as shown C Make sure that the high ten sion cord is not pinched when installing the flywheel cover D Place the lead on the TCI unit side to secure E Secure the lead with the cover installed F Route the TCI unit lead through the hole in the crank case G Adjust the TCI unit air gap between to 0 4 0 6 mm 0 0157 0 0236 in on both sides H Install the lead so that there is no...

Page 170: ...sembly sub coil cou pler 6 Damper 7 Holder 8 Clamp 9 Stator assembly sub coil lead 0 Stator assembly main coil lead A Details of the stator assembly lead installation B Details of the stator assembly lead coupler installation C Do not bend the exciter field coil lead when connecting Br Brown R Red W White GENERATOR EF7000 EF7000E EF7200 EF7200E Color code ...

Page 171: ...embly sub coil cou pler 6 Damper 7 Holder 8 Clamp 9 Stator assembly sub coil lead 0 Stator assembly main coil lead A Details of the stator assembly lead installation B Details of the stator assembly lead coupler installation C Do not bend the exciter field coil lead when connecting Br Brown L Blue R Red W White GENERATOR Except for EF7200DE CAN Color code ...

Page 172: ...y sub coil cou pler 7 Damper 8 Holder 9 Clamp 0 Ground lead q Stator assembly sub coil lead w Stator assembly main coil lead A Details of the stator assembly lead installation B Details of the stator assembly lead coupler installation C Do not bend the exciter field coil lead when connecting D 30 60 Br Brown L Blue R Red W White GENERATOR For EF7200DE CAN Color code ...

Page 173: ......

Page 174: ...ngine switch e Voltage adjuster r Condenser t AVR Automatic Voltage Regulator y Oil warning unit u Oil warning light i Engine o Fuel cut solenoid valve p Charging coil a TCI unit s Spark plug d Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green O Orange R Red W White Y Yellow B W Black White G R Green Red G Y Green Yellow L R Blue Red L W Blue White R G Red Green EF7000 EF7...

Page 175: ...omatic Voltage Regulator o Oil warning unit p Economy control unit a Oil warning light s Economy control switch d Engine f Economy control solenoid g Starter relay h Starter motor j Auto choke k Fuel cut solenoid valve l Battery Charging coil z TCI unit x Spark plug c Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green O Orange R Red W White EF7000E EF7200E 2014 CIRCUIT DIAG...

Page 176: ...fier regulator y Voltage adjuster u Condenser i AVR Automatic Voltage Regulator o Oil warning unit p Economy control unit a Oil warning light s Economy control switch d Engine f Economy control solenoid g Starter relay h Starter motor j Auto choke k Fuel cut solenoid valve l Battery Charging coil z TCI unit x Spark plug c Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green O...

Page 177: ... Voltage Regulator o Oil warning unit p Economy control unit a Oil warning light s Economy control switch d Engine f Economy control solenoid g Starter relay h Starter motor j Auto choke k Fuel cut solenoid valve l Battery Charging coil z TCI unit x Spark plug c Oil level switch Color code B Black Br Brown G Green L Blue Lg Light green O Orange R Red W White EF7200DE CAN 2014 CIRCUIT DIAGRAM Y Yel...

Page 178: ...SERVICE MANUAL EF7000 EF7000E EF7200 EF7200E EF7200DE 7P6 F8197 E0 2014_05 1 7P6 F8197 E0_cover indd 1 2014 05 29 15 46 41 ...

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