Yamaha EF4000DFW EF5200DE EF6600DE Generator Full Service & Repair Manual

EF4000DFW EF4000DEFW EF5200D EF5200DE EF6600D EF6600DE SERVICE MANUAL 7DA-F8197-10 LIT-19616-01-60

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 understanding of the mechanical precepts and procedures inherent to generator repair tech- nology. 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 emission 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 nota- tions. 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. WARNING A WARNING indicates a hazardous situa- tion which, if not avoided, could result in death or serious injury. NOTICE 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. EF4000DFW/EF4000DEFW EF5200D/EF5200DE EF6600D/EF6600DE SERVICE MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st Edition, August 2011 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-19616-01-60

HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 9 The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page 1. 9 Sub-section titles appear in smaller print than the section title 2. 9 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section 3. 9 Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step 4. 9 Symbols indicate parts to be lubricated or replaced 5. Refer to “ILLUSTRATED SYMBOLS”. 9 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 6. 9 Jobs requiring more information (such as special tools and technical data) are described sequentially 7. 3-33 ENG VALVE 1 4 9 8 7 Nm (0.7 m · kgf, 5.1 ft · lbf) 2 5 6 7 10 1 3 2 5 6 7 4 Order Job/Parts to remove Q’ty Remarks Removing the valve Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD COVER, CYLINDER HEAD” on 3-29. 1 Locknut 2 2 Adjuster 2 3 Rocker arm shaft 1 4 Rocker arm 2 5 Valve cotter 2 6 Valve spring retainer 2 7 Valve spring 2 8 Exhaust valve 1 9 Intake valve 1 10 Valve stem seal 1 Intake side only. For installation, reverse the removal procedure. VALVE 3-34 ENG VALVE 1 2 3 4 5 SCF3180 302-001 a REMOVING THE VALVE AND VALVE SPRING 1. Remove: 9 Valve cotters 1 9 Valve spring retainers 2 9 Valve springs 3 9 Valves 4 9 Valve stem seal (Intake side only) Remove the parts using the valve spring compressor 5. TIP Do not compress the spring more than neces- sary. Valve spring compressor: YM-01253, 90890-01253 CHECKING THE VALVE AND VALVE SPRING 1. Measure: 9 Valve stem length a 9 Valve head diameter b Valve stem length: Intake: 88.1 mm (3.47 in) Exhaust: 87.9 mm (3.46 in) Valve head diameter: Intake: 32.0 mm (1.26 in) Exhaust: 27.0 mm (1.06 in) Out of specifications → Replace. 2. Measure: 9 Valve stem diameter a Valve stem diameter: Standard Intake: 5.948–5.963 mm (0.2342–0.2348 in) Exhaust: 5.940–5.955 mm (0.2339–0.2344 in) Wear limit Intake: 5.9 mm (0.23 in) Exhaust: 5.9 mm (0.23 in) Out of specifications → Replace. 1 3 4 5 6 7 2

ILLUSTRATED SYMBOLS (Refer to the illustration) SYMBOL DEFINITION SYMBOL DEFINITION General information Periodic checks and adjustments 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 ® )

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

CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION .....................1-1 ENGINE SERIAL NUMBER..................1-1 STARTING SERIAL NUMBER ..............1-1 IMPORTANT INFORMATION ....................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY .....................................1-2 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 BASIC SERVICE INFORMATION..............1-4 ELECTRICAL SYSTEM ........................1-4 SPECIAL TOOLS AND TESTERS .............1-7 CHAPTER 2. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ........................................2-1 MAINTENANCE INTERVALS CHART ......2-1 PERIODIC MAINTENANCE/ LUBRICATION INTERVALS ......................2-1 PERIODIC MAINTENANCE ......................2-3 SPARK PLUG .......................................2-3 FUEL LEAKAGE ...................................2-5 ENGINE OIL LEAKAGE .......................2-5 ENGINE OIL LEVEL .............................2-5 REPLACING THE ENGINE OIL ...........2-6 AIR FILTER ELEMENT .........................2-7 MUFFLER .............................................2-8 FUEL TANK FILTER..............................2-9 FUEL COCK STRAINER ....................2-10 BATTERY (EF4000DEFW/ EF5200DE/EF6600DE).......................2-10 BREATHER HOSE..............................2-11 CYLINDER HEAD DECARBONIZATION ..........................2-11 ADJUSTING THE VALVE CLEARANCE ......................................2-11 ADJUSTING THE ENGINE SPEED ...2-14 RECOIL STARTER .............................2-15 FITTINGS AND FASTENERS ............2-15 CHAPTER 3. ENGINE ENGINE INSPECTION...............................3-1 MEASURING THE COMPRESSION PRESSURE ..........................................3-1 CONTROL BOX .........................................3-3 AIR FILTER ................................................3-5 FUEL TANK, CANISTER ...........................3-6 CHECKING THE CANISTER................3-7 MUFFLER ..................................................3-8 INSTALLING THE EXHAUST PIPE AND MUFFLER ....................................3-9 ENGINE ....................................................3-10 RECOIL STARTER ..................................3-11 REMOVING THE RECOIL STARTER ............................................3-12 CHECKING THE RECOIL STARTER ............................................3-13 INSTALLING THE RECOIL STARTER ............................................3-13 FLYWHEEL ..............................................3-15 REMOVING THE FLYWHEEL ............3-16 INSTALLING THE FLYWHEEL ...........3-17 INSTALLING THE TCI UNIT ...............3-18 GENERATOR ...........................................3-19 REMOVING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY .........................................3-21 INSTALLING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY .........................................3-22

GOVERNOR .............................................3-24 REMOVING THE FLYWEIGHT SHAFT ASSEMBLY AND GOVERNOR SHAFT ..........................3-26 DISASSEMBLING THE FLYWEIGHT SHAFT ASSEMBLY ............................3-26 CHECKING THE FLYWEIGHT SHAFT ASSEMBLY AND GOVERNOR SHAFT ..........................3-27 ASSEMBLING THE FLYWEIGHT SHAFT ASSEMBLY ............................3-27 INSTALLING THE FLYWEIGHT SHAFT ASSEMBLY AND GOVERNOR SHAFT ..........................3-27 ADJUSTING THE GOVERNOR..........3-28 CYLINDER HEAD COVER, CYLINDER HEAD ....................................3-29 CHECKING THE PUSH ROD .............3-31 CHECKING THE CYLINDER HEAD ..................................................3-31 INSTALLING THE CYLINDER HEAD ASSEMBLY ..............................3-32 VALVE ......................................................3-33 REMOVING THE VALVE AND VALVE SPRING ..................................3-34 CHECKING THE VALVE AND VALVE SPRING ..................................3-34 CHECKING THE ROCKER ARM .......3-36 CHECKING THE VALVE SEAT ...........3-36 VALVE LAPPING ................................3-38 INSTALLING THE VALVE AND VALVE SPRING ..................................3-38 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT .......3-40 REMOVING THE BALANCER SHAFT, CAMSHAFT, AND VALVE LIFTER................................................3-42 CHECKING THE BALANCER SHAFT ................................................3-42 CHECKING THE CAMSHAFT ............3-43 CHECKING THE VALVE LIFTER........3-44 INSTALLING THE VALVE LIFTER, BALANCER SHAFT, AND CAMSHAFT ........................................3-44 CHECKING THE CRANKCASE COVER ...............................................3-44 INSTALLING THE CRANKCASE COVER ...............................................3-45 CHECKING THE CYLINDER..............3-45 CHECKING THE CRANKCASE .........3-46 CHECKING THE PISTON AND PISTON PIN........................................3-47 CHECKING THE PISTON RING ........3-48 CHECKING THE CRANKSHAFT .......3-49 CHECKING THE CONNECTING ROD OIL CLEARANCE ......................3-51 INSTALLING THE PISTON AND PISTON RING.....................................3-52 INSTALLING THE CRANKSHAFT ......3-53 CHAPTER 4. CARBURETOR REMOVING THE CARBURETOR ..............4-1 DISASSEMBLING THE CARBURETOR ...4-3 EF4000DFW/EF5200D/EF6600D .........4-3 EF4000DEFW/EF5200DE/ EF6600DE ............................................4-5 CHECKING THE CARBURETOR .........4-7 CHECKING THE AUTO CHOKE (EF4000DEFW/EF5200DE/ EF6600DE) ...........................................4-8 CHECKING THE FUEL CUT SOLENOID VALVE................................4-9 CHAPTER 5. ELECTRICAL ELECTRICAL COMPONENTS ..................5-1 CIRCUIT DIAGRAM ...................................5-2 EF4000DFW .........................................5-2 EF4000DEFW .......................................5-3 EF5200D/EF6600D...............................5-4 EF5200DE/EF6600DE ..........................5-5 CONTROL PANEL .....................................5-6 EF4000DFW/EF4000DEFW .................5-6 EF5200D/EF5200DE/EF6600D/ EF6600DE ............................................5-8 BATTERY (EF4000DEFW/EF5200DE/EF6600DE) ...5-10 CHECKING THE BATTERY ................5-10

FUSE (EF4000DEFW/EF5200DE/EF6600DE) ...5-12 CHECKING THE FUSE ......................5-12 SWITCHES...............................................5-14 CHECKING THE SWITCH CONTINUITY .....................................5-14 IGNITION SYSTEM..................................5-15 TROUBLESHOOTING CHART...........5-15 ELECTRIC STARTING SYSTEM (EF4000DEFW/EF5200DE/EF6600DE) ...5-21 TROUBLESHOOTING CHART...........5-21 REMOVING THE STARTER MOTOR ...............................................5-23 DISASSEMBLING THE STARTER MOTOR ...............................................5-24 CHECKING THE ARMATURE COIL...5-25 CHECKING THE BRUSH ...................5-26 CHECKING THE MAGNETIC SWITCH ..............................................5-26 CHARGING SYSTEM (EF4000DEFW/EF5200DE/EF6600DE) ...5-27 TROUBLESHOOTING CHART...........5-27 GENERATOR SYSTEM ...........................5-29 TROUBLESHOOTING CHART...........5-29 ECONOMY CONTROL SYSTEM ............5-40 ECONOMY CONTROL SYSTEM DIAGRAM ...........................................5-40 TROUBLESHOOTING CHART...........5-41 CHAPTER 6. TROUBLESHOOTING ENGINE ......................................................6-1 CHAPTER 7. SPECIFICATIONS GENERAL SPECIFICATIONS ...................7-1 MAINTENANCE SPECIFICATIONS ..........7-4 ENGINE ................................................7-4 ELECTRICAL ........................................7-7 GENERATOR ........................................7-8 TIGHTENING TORQUES .........................7-10 GENERAL TORQUE SPECIFICATIONS....................................7-12 LUBRICATION POINTS AND TYPE OF LUBRICANTS ..........................................7-13 WIRE ROUTING DIAGRAM ....................7-14 CONTROL PANEL AND CONTROL BOX (EF4000DFW) ............................7-14 CONTROL PANEL AND CONTROL BOX (EF4000DEFW) ..........................7-16 CONTROL PANEL AND CONTROL BOX (EF5200D/EF6600D) ..................7-18 CONTROL PANEL AND CONTROL BOX (EF5200DE/EF6600DE) .............7-20 BACK SIDE AND LEFT SIDE VIEW...7-22 UPPER SIDE VIEW ............................7-23 ENGINE ..............................................7-25 GENERATOR ......................................7-26

Yamaha EF4000DFW EF5200DE EF6600DE Generator Full Service & Repair Manual

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