Yamaha Generator EF2000is Service Repair Manual

SERVICE MANUAL EF2000iS LIT-19616-01-53 7DK-28197-10

FOREWORD This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha generators have a basic under- standing of the mechanical precepts and procedures inherent to generator repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company Ltd. is continually striving to further improve all models manufac- tured 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. TIP This Service Manual contains information regarding periodic maintenance to the emis- sion control system. Please read this material carefully. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION Particularly important information is distin- guished in this manual by the following notations. This is the safety alert symbol. It is used to alert you to potential personal injury haz- ards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situa- tion which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the machine or other property. TIP A TIP provides key information to make procedures easier or clearer. MANUAL FORMAT The procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explana- tions of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 9 Bearings Pitting/damage → Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying the correct disassembly and assembly procedures. NOTICE WARNING EF2000iS SERVICE MANUAL ©2009 by Yamaha Motor Corporation, U.S.A. 1st Edition, March 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in USA LIT-19616-01-53

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 through 7 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspections and adjustments 3 Engine 4 Carburetor 5 Electrical 6 Trouble shooting 7 Specifications Illustrated symbols 8 through r are used to identify the specific tools and test equipment. 8 Filling fluid 9 Lubricant 0 Special tool q Tightening w Wear limit, clearance e Engine speed r Electrical data Illustrated symbols t through d in the exploded diagram indicate the grades of lubricant and the locations of the lubrication points. t Apply engine oil y Apply gear oil u Apply molybdenum disulfide oil i Apply wheel bearing grease o Apply lightweight lithium-soap base grease p Apply molybdenum disulfide grease a Apply a locking agent (LOCTITE ® ) s Apply Yamaha bond d Use a new one GEN INFO INSP ADJ ENG ELEC T R . . E G M B LS M LT 4 New 1 2 3 4 5 6 CARB SPEC 7 TRBL + 8 9 0 q w e r t y u i o p a s d

INDEX GENERAL INFORMATION GEN INFO PERIODIC INSPECTIONS AND ADJUSTMENTS INSP ADJ ENGINE ENG CARBURETOR CARB ELECTRICAL ELEC TROUBLESHOOTING TRBL SPECIFICATIONS SPEC 1 2 3 4 5 6 7

CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ................... 1-1 SERIAL NUMBER .............................. 1-1 STARTING SERIAL NUMBER ............ 1-1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY CAUTION ON SERVICE ............................................ 1-2 NOTES ON SERVICE ........................ 1-2 ALL REPLACEMENT PARTS ............. 1-3 GASKETS, OIL SEALS, AND O-RINGS ............................................ 1-3 BEARINGS AND OIL SEALS ............. 1-3 SPECIAL TOOLS AND TESTERS ........... 1-4 CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ...................................... 2-1 MAINTENANCE INTERVALS CHART .... 2-1 PERIODIC MAINTENANCE/ LUBRICATION INTERVALS .................... 2-1 COVERS AND FUEL TANK ..................... 2-3 COVERS ..............................................2-3 COVERS AND FUEL TANK .................2-4 COVERS AND FUEL TANK REMOVAL ........................................... 2-5 COVERS AND FUEL TANK INSTALLATION ................................... 2-6 ENGINE .................................................... 2-7 ENGINE OIL LEAKAGE CHECKING ......................................... 2-7 OIL LEVEL CHECKING ...................... 2-7 OIL REPLACEMENT .......................... 2-8 FUEL LEAKAGE ................................. 2-9 FUEL TANK FILTER ........................... 2-9 FUEL COCK STRAINER .................. 2-10 AIR FILTER ELEMENT ..................... 2-12 MUFFLER ......................................... 2-13 VALVE CLEARANCE ADJUSTMENT .................................. 2-14 COMPRESSION PRESSURE .......... 2-17 RATED ENGINE SPEED .................. 2-18 BREATHER HOSE ........................... 2-19 ELECTRICAL ......................................... 2-20 SPARK PLUG ................................... 2-20 ENGINE SWITCH ............................. 2-21 ECONOMY CONTROL SWITCH ..... 2-21 AC PILOT LIGHT .............................. 2-22 OVERLOAD WARNING LIGHT ........ 2-22 RECEPTACLE .................................. 2-23 DC PROTECTOR ............................. 2-24 CHAPTER 3. ENGINE CONTROL BOX ....................................... 3-1 CONTROL BOX .................................. 3-1 CONTROL PANEL .............................. 3-2 MUFFLER ................................................ 3-3 MUFFLER ASSEMBLY ....................... 3-4 ENGINE .................................................... 3-5 RECOIL STARTER, ROTOR AND CDI MAGNETO ........................................ 3-6 RECOIL STARTER ............................. 3-7 RECOIL STARTER DISASSEMBLY ... 3-8 RECOIL STARTER INSPECTION ...... 3-8 RECOIL STARTER ASSEMBLY ......... 3-9 CDI MAGNETO AND ROTOR REMOVAL ......................................... 3-11 CDI MAGNETO AND ROTOR INSTALLATION .................................. 3-11 GENERATOR ......................................... 3-13 GENERATOR ROTOR AND STATOR ASSEMBLY REMOVAL ...... 3-14 GENERATOR ROTOR AND STATOR ASSEMBLY INSTALLATION ............. 3-16 CYLINDER HEAD COVER AND CYLINDER HEAD .................................. 3-17 PUSH ROD INSPECTION ................ 3-19 CYLINDER HEAD INSPECTION ..... 3-19 CYLINDER HEAD ASSEMBLY ......... 3-20 CYLINDER HEAD COVER ............... 3-20

VALVE .................................................... 3-21 VALVE AND VALVE SPRING REMOVAL ......................................... 3-22 VALVE AND VALVE SPRING INSPECTION .................................... 3-22 ROCKER ARM INSPECTION .......... 3-23 VALVE SEAT INSPECTION .............. 3-24 VALVE LAPPING .............................. 3-25 VALVE AND VALVE SPRING ASSEMBLY ....................................... 3-26 CRANKCASE COVER AND CAMSHAFT ........................................... 3-27 CAMSHAFT INSPECTION ............... 3-29 VALVE LIFTER INSPECTION .......... 3-30 CRANKCASE COVER INSPECTION .................................... 3-30 CAMSHAFT ASSEMBLY .................. 3-30 CRANKCASE COVER INSTALLATION ................................. 3-30 PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE ..... 3-32 CYLINDER INSPECTION ................. 3-34 PISTON AND PISTON PIN INSPECTION .................................... 3-34 PISTON RING INSPECTION ........... 3-36 CRANKSHAFT INSPECTION .......... 3-37 CONNECTING ROD OIL CLEARANCE INSPECTION ............. 3-37 PISTON AND PISTON RING INSTALLATION ................................. 3-38 CRANKSHAFT ASSEMBLY ............. 3-39 CHAPTER 4. CARBURETOR CARBURETOR AND AIR FILTER .......... 4-1 CARBURETOR DISASSEMBLY ......... 4-2 FLOAT HEIGHT INSPECTION ........... 4-4 THROTTLE CONTROL MOTOR ........ 4-5 CHOKE CABLE .................................. 4-5 CHAPTER 5. ELECTRICAL ELECTRICAL COMPONENTS ................ 5-1 CIRCUIT DIAGRAM ................................. 5-2 CONTROL UNIT ...................................... 5-3 RECITIFIER ........................................ 5-4 CONTROL UNIT ................................. 5-4 SWITCHES ...............................................5-5 CHECKING SWITCH CONTINUITY ...................................... 5-5 IGNITION SYSTEM ................................. 5-6 TROUBLESHOOTING CHART .......... 5-6 GENERATOR SYSTEM ..........................5-11 TROUBLESHOOTING CHART ........ 5-11 CHAPTER 6. TROUBLESHOOTING ENGINE .................................................... 6-1 THROTTLE CONTROL SYSTEM ............ 6-6 CHAPTER 7. SPECIFICATIONS GENERAL SPECIFICATIONS ................. 7-1 MAINTENANCE SPECIFICATIONS ........ 7-3 ENGINE .............................................. 7-3 ELECTRICAL ...................................... 7-6 GENERATOR ...................................... 7-7 TIGHTENING TORQUE ........................... 7-8 GENERAL TORQUE SPECIFICATIONS .................................... 7-9 DEFINITION OF UNITS ........................... 7-9 LUBRICATION POINT AND TYPE OF LUBRICANTS ........................................ 7-10 WIRE ROUTING DIAGRAM .................. 7-11 CONTROL PANEL AND CONTROL BOX ................................ 7-11 ENGINE AND GENERATOR ............ 7-12

GEN INFO 1-1 MACHINE IDENTIFICATION 1 Serial NO. 7DK – 7DK-24163-00 2 GENERAL INFORMATION MACHINE IDENTIFICATION SERIAL NUMBER The serial number is printed at the line 2 on a label 1 which is affixed to the generator as shown. TIP The first three characters of this number are for model identification, the remaining digits are the unit production number. STARTING SERIAL NUMBER 7DK-090201- TIP Designs and specifications are subject to change without notice.

GEN INFO 1-2 SVU1030 SVU1040 SVU1050 SVU1060 SVU1070 SVU1080 SVU1090 SVU1100 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY CAUTION ON SERVICE 1. Fire prevention When servicing the engine, always keep the engine and yourself away from fire. NOTES ON SERVICE 1. Correct tools Be sure to use the correct special tool for the job to guard against damage. IMPORTANT INFORMATION 2. Oil, grease and seals Be sure to use genuine Yamaha oils, grease 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 assembly a. Parts should be cleaned in solvent and blown dry with compressed air after disassembly. b. Contact surfaces of moving parts should be oiled when reassembled. c. Make sure that the parts, move smoothly after each section of the machine is assembled. 1 2 3 4 5

GEN INFO 1-3 SVU1110 SVU1120 ALL REPLACEMENT PARTS We recommend the use of genuine Yamaha parts for all replace- ments. Use oil and/or grease, recommended by Yamaha, for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gaskets surfaces, oil seal lips, and 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 let- ters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. NOTICE IMPORTANT INFORMATION

Yamaha Generator EF2000is Service Repair Manual

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