Yamaha EF7000 Service Manual
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Yamaha EF7000 Service Manual

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SERVICE MANUAL
EF7000
EF7000E
EF7200
EF7200E
EF7200DE
7P6-F8197-E0

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Summary of Contents for Yamaha EF7000

  • Page 1 SERVICE MANUAL EF7000 EF7000E EF7200 EF7200E EF7200DE 7P6-F8197-E0...
  • Page 3 7VB-F8197-E0 ards. Obey all safety messages that follow this symbol to avoid possible injury or This manual was written by the Yamaha Motor death. Powered Products Co., Ltd. primarily for use by Yamaha dealers and their qualified WARNING mechanics.
  • Page 4 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.
  • Page 5 ILLUSTRATED SYMBOLS (Refer to the illustration) SYMBOL DEFINITION SYMBOL DEFINITION Periodic checks and General information adjustments Engine Carburetor Electrical Troubleshooting Specifications Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data Replace the part with a new one. Lithium-soap base grease Molybdenum disulfide grease Engine oil...
  • Page 7 INDEX GENERAL INFORMATION INFO PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CARB ELECTRICAL ELEC TROUBLESHOOTING TRBL SPECIFICATIONS SPEC...

  • Page 8: Table Of Contents

    CHAPTER 1. ADJUSTING THE ENGINE SPEED (Except for EF7000/EF7200) ....2-15 GENERAL INFORMATION ADJUSTING THE ENGINE SPEED (For EF7000/EF7200) ......2-16 MODEL VARIATIONS ........1-1 RECOIL STARTER ......2-17 FITTINGS AND FASTENERS ....2-17 MACHINE IDENTIFICATION .....1-2 SERIAL NUMBER ........1-2 CHAPTER 3. ENGINE IMPORTANT INFORMATION ....1-3...
  • Page 9 MOTOR ..........5-39 CHAPTER 5. ELECTRICAL CHARGING SYSTEM (EF7000E/EF7200E/EF7200DE) ....5-40 ELECTRICAL COMPONENTS ....5-1 TROUBLESHOOTING CHART ...5-40 EF7000 (CHN) ........5-2 EF7000E (CHN) ........5-2 GENERATOR SYSTEM ......5-43 EF7200 (SEA/AFR/RUS) ......5-2 TROUBLESHOOTING CHART ...5-43 EF7200E (Except for OCE) ....5-2 EF7200E (OCE) ........5-3 ECONOMY CONTROL SYSTEM EF7200DE (Except for CAN) ....5-3...
  • Page 10 SPECIFICATIONS ........7-12 LUBRICATION POINTS AND TYPE OF LUBRICANTS ..........7-13 WIRE ROUTING DIAGRAM ....7-14 CONTROL PANEL AND CONTROL BOX (EF7000/EF7200) .......7-14 CONTROL PANEL AND CONTROL 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...

  • Page 11: Chapter 1. General Information

    MODEL VARIATIONS INFO GENERAL INFORMATION MODEL VARIATIONS...

  • Page 12: Machine Identification

    MACHINE IDENTIFICATION INFO MACHINE IDENTIFICATION SERIAL NUMBER The serial number is printed on the label 1 affixed to the position 2 of the generator as shown in the illustration. A For EF7200DE CAN B Except for EF7200DE CAN 9 The first three digits identify the model, and the remaining digits indicates the production number.

  • Page 13: Important Information

    Be sure to use the correct special tool for the job to guard against damage. SVU1040 2. Oil, grease and seals Be sure to use genuine Yamaha oils, grease and sealers, or the equivalents. SVU1050 3. Expendable parts Always replace the gaskets, O-rings, cotter pins and circlips with new parts when servicing engine.

  • Page 14: All Replacement Parts

    IMPORTANT INFORMATION INFO 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.

  • Page 15: Basic Service Information

    BASIC SERVICE INFORMATION INFO BASIC SERVICE INFORMATION ELECTRICAL SYSTEM Checking the electrical system Before checking the electrical system, make sure that the battery voltage is at least 12 V. NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end a of the cou- pler, taking care not to loosen or damage the leads.
  • Page 16 BASIC SERVICE INFORMATION INFO 2. Check: 9 Lead 9 Coupler 9 Connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. 3. Connect: 9 Lead 9 Coupler 9 Connector 9 When connecting a coupler or connector, push both sections of the coupler or connector together until they are connected securely.
  • Page 17 BASIC SERVICE INFORMATION INFO NOTICE For waterproof couplers, never insert the tester leads directly into the coupler. When performing any checks using a water- proof coupler, use the specified test harness or a suitable commercially available test harness. 5. Check: 9 Resistance Analog pocket tester: YU-03112-C...

  • Page 18: Special Tools And Testers

    SPECIAL TOOLS AND TESTERS INFO SPECIAL TOOLS AND TESTERS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help pre- vent damage caused by the use of improper tools or improvised techniques.
  • Page 19 SPECIAL TOOLS AND TESTERS INFO 6. Dial indicator gauge P/N. YU-A8428 Dial gauge P/N. 90890-03097 This instrument is used for checking crankshaft side clearance. SVU1190 7. Analog pocket tester P/N. YU-03112-C Pocket tester P/N. 90890-03112 This instrument is necessary for checking the electrical system. SVU1230 8.
  • Page 20 SPECIAL TOOLS AND TESTERS INFO 12. Valve spring compressor P/N. 90890-01253 This tool is used to remove the valve springs. 13. Piston ring compressor P/N. YM-08037, 90890-05158 This tool is used to compress the piston rings when installing the piston. 14.
  • Page 21 INFO 1-11...

  • Page 22: Chapter 2. Periodic Checks And Adjustments

    INTRODUCTION/MAINTENANCE INTERVALS CHART/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine opera- tion and a longer service life. The need for costly overhaul work will be greatly reduced. This infor- mation applies to machines already in service as well as new machines that are being prepared for sale.
  • Page 23 *1····· Initial replacement 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: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SPARK PLUG WARNING Check and adjust the areas around the cyl- inder head after the engine has cooled 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.
  • Page 25 PERIODIC MAINTENANCE 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) Before installing the spark plug, clean the gas- ket surface and plug surface.

  • Page 26: Fuel Leakage

    PERIODIC MAINTENANCE FUEL LEAKAGE 1. Check: 9 Leakage Check at fuel tank, fuel cock, fuel hose, and carburetor. NOTICE Replace fuel hose every four years. ENGINE OIL LEAKAGE 1. Place the generator on a level surface. 2. Check the areas outside of the engine for oil leakage.

  • Page 27: Replacing The Engine Oil

    PERIODIC MAINTENANCE REPLACING THE ENGINE OIL 1. Warm up the engine for several minutes, and then stop the engine. 2. Remove: 9 Oil filler cap 1 9 Oil drain bolt 2 9 Oil drain bolt gasket 3 3. Drain: 9 Engine oil Place the oil pan under the engine and drain the engine oil.

  • Page 28: Air Filter Element

    PERIODIC MAINTENANCE AIR FILTER ELEMENT NOTICE Be sure not to run the engine without air filter element. Otherwise this can result in excessive piston and/or cylinder wear. 1. Remove: 9 Air filter cover screws 1 9 Air filter cover 2 2.

  • Page 29: Muffler

    PERIODIC MAINTENANCE MUFFLER WARNING The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during check or repair.
  • Page 30 PERIODIC MAINTENANCE 4. Decarbonize: 9 Muffler Tap on the muffler in the area shown in the illustration to loosen carbon build- up, and then shake it out from the end of the muffler. NOTICE Do not use a wire to clean, otherwise the noise damping material may come out, and the damping effect may be reduced.

  • Page 31: Fuel Tank Filter

    PERIODIC MAINTENANCE FUEL TANK FILTER WARNING Do not smoke, and keep away from open flames, sparks, or any other source of fire when handling or in the vicinity of fuel. 1. Remove: 9 Fuel tank cap 1 9 Fuel tank filter 2 2.

  • Page 32: Fuel Cock Strainer

    PERIODIC MAINTENANCE FUEL COCK STRAINER WARNING Do not smoke, and keep away from open flames, sparks, or any other source of fire when handling or in the vicinity of fuel. 1. Turn the fuel cock lever to the “OFF” posi- tion.

  • Page 33: Breather Hose

    PERIODIC MAINTENANCE BREATHER HOSE 1. Check: 9 Breather hose 1 Crack/damage → Replace. Poor connection → Correct. CYLINDER HEAD DECARBONIZATION 1. Remove: 9 Cylinder head (Refer to “CYLINDER HEAD COVER, CYLINDER HEAD” in 7VB-F8197-E0 chapter 3) 2. Eliminate: 9 Carbon deposits (Refer to “CHECKING THE CYLINDER HEAD”...
  • Page 34 PERIODIC MAINTENANCE 3. Pull the recoil starter slowly, and then set the piston at TDC (top-dead-center) on the compression stroke. Check the piston position by inserting a screw driver into the spark plug hole. 4. Measure: 9 Valve clearance (Between the rocker arm and valve stem end) Out of specification →...
  • Page 35 PERIODIC MAINTENANCE 5. Adjust: 9 Valve clearance Adjustment steps: a. Loosen the locknuts 1 and insert the 0.07 mm (0.0028 in) thickness gauge between the rocker arm and the valve tip. b. Using the tappet adjusting tool 2 turn the adjuster 3 in or out to obtain the proper valve clearance.

  • Page 36: Adjusting The Engine Speed (Except For Ef7000/Ef7200)

    PERIODIC MAINTENANCE ADJUSTING THE ENGINE SPEED (Except for EF7000/EF7200) 1. Warm up the engine for a few minutes. 2. Attach: 9 Digital tachometer 1 Digital tachometer: YU-39951-B, 90890-06760 3. Measure: 9 Economy control engine speed and engine speed (with no load) Out of specification →...

  • Page 37: Adjusting The Engine Speed (For Ef7000/Ef7200)

    PERIODIC MAINTENANCE ADJUSTING THE ENGINE SPEED (For EF7000/EF7200) 1. Warm up the engine for a few minutes. 2. Attach: 9 Digital tachometer 1 Digital tachometer: YU-39951-B, 90890-06760 3. Measure: 9 Engine speed (with no load) Out of specification → Adjust...

  • Page 38: Recoil Starter

    PERIODIC MAINTENANCE RECOIL STARTER 1. Check: 9 Recoil 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).

  • Page 39: Chapter 3. Engine

    CONTROL BOX ENGINE For complete information about procedures for engine maintenance, it is necessary to refer to the MZ SERIES ENGINE SERVICE MANUAL 7VB-F8197-E0. CONTROL BOX EF7200DE 3.8 Nm (0.38 m á kgf, 2.8 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 7 Nm (0.7 m á...
  • Page 40 CONTROL BOX 3.8 Nm (0.38 m á kgf, 2.8 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) Order Job/Parts to remove Q’ty Remarks Economy control solenoid lead con- nector Oil level switch lead connector TCI unit lead connector...

  • Page 41: Except For Ef7200De

    CONTROL BOX Except for EF7200DE 3.8 Nm (0.38 m á kgf, 2.8 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) Order Job/Parts to remove Q’ty Remarks Removing the control box Remove the parts in the order listed.
  • Page 42 CONTROL BOX 3.8 Nm (0.38 m á kgf, 2.8 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) Order Job/Parts to remove Q’ty Remarks Oil level switch lead connector TCI unit lead connector Starter relay lead connector EF7000E/EF7200E...

  • Page 43: Installing The Control Box

    CONTROL BOX INSTALLING THE CONTROL BOX 1. Install: 9 Control box 1 9 Control box bolts 9 Control box nuts 7 Nm (0.7 m · kgf, 5.1 ft · lbf) A Behind the control box 9 Install the a portion of the control box to the frame b at both sides.

  • Page 44: Air Filter

    AIR FILTER AIR FILTER 11 Nm (1.1 m á kgf, 8.0 ft á lbf) 10 Nm (1.0 m á kgf, 7.2 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.

  • Page 45: Fuel Tank, Canister

    FUEL TANK, CANISTER FUEL TANK, CANISTER 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 16 Nm (1.6 m á kgf, 12 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 1.3 Nm (0.13 m á kgf, 0.94 ft á lbf) 0.8 Nm (0.08 m á...
  • Page 46 FUEL TANK, CANISTER 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 16 Nm (1.6 m á kgf, 12 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 1.3 Nm (0.13 m á kgf, 0.94 ft á lbf) 0.8 Nm (0.08 m á...

  • Page 47: Checking The Canister (For Ef7200De Can)

    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.

  • Page 48: Muffler

    MUFFLER MUFFLER 16 Nm (1.6 m · kgf, 12 ft · lbf) 16 Nm (1.6 m · kgf, 12 ft · lbf) 2.0 Nm (0.20 m · kgf, 1.4 ft · lbf) 12 Nm (1.2 m · kgf, 8.7 ft · lbf) Order Job/Parts to remove Q’ty...

  • Page 49: Installing The Muffler

    MUFFLER INSTALLING THE MUFFLER 1. Install: 9 Exhaust gasket 1 9 Muffler assembly 9 Exhaust nuts 2 9 Muffler bolt 3 9 Muffler bolt 4 Temporarily tighten the nuts 2, and bolts 3, 4 until just comes in contact with the surface. 2.

  • Page 50: Engine

    ENGINE ENGINE 32 Nm (3.2 m á kgf, 23 ft á lbf) 32 Nm (3.2 m á kgf, 23 ft á lbf) 10 Nm (1.0 m á kgf, 7.2 ft á lbf) Order Job/Parts to remove Q’ty Remarks Removing the engine Remove the parts in the order listed.

  • Page 51: Generator

    GENERATOR GENERATOR 4.5 Nm (0.45 m · kgf, 3.3 ft · lbf) 9 Nm (0.9 m · kgf, 6.5 ft · lbf) 42 Nm (4.2 m · kgf, 30 ft · lbf) 3.8 Nm (0.38 m · kgf, 2.8 ft · lbf) 7 Nm (0.7 m ·...
  • Page 52 GENERATOR 4.5 Nm (0.45 m · kgf, 3.3 ft · lbf) 9 Nm (0.9 m · kgf, 6.5 ft · lbf) 42 Nm (4.2 m · kgf, 30 ft · lbf) 3.8 Nm (0.38 m · kgf, 2.8 ft · lbf) 7 Nm (0.7 m ·...

  • Page 53: Removing The Stator Assembly And Rotor Assembly

    GENERATOR REMOVING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY 1. Remove: 9 Rear frame 1 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-...
  • Page 54 GENERATOR 4. Remove: 9 Recoil starter 9 Rotor assembly bolt 1 Attach the sheave holder 2 to hold the fly- wheel 3. Primary clutch holder: YS-01880-A Sheave holder: 90890-01701 5. Assemble the special tools: 9 Rotor shock puller assy 1 9 Rotor puller attachment 2 Rotor shock puller assy.: YU-1047, 90890-01259...

  • Page 55: Installing The Stator Assembly And Rotor Assembly

    GENERATOR 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) Tighten the rotor assembly bolt 1 by attach- ing the sheave holder 2 to hold the flywheel Primary clutch holder: YS-01880-A Sheave holder:...

  • Page 56: Piston, Camshaft, Crankcase, And Crankshaft

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT CRANKCASE 7 Nm (0.7 m · kgf, 5.1 ft · lbf) 27 Nm (2.7 m · kgf, 20 ft · lbf) 27 Nm (2.7 m · kgf, 20 ft · lbf) 10 Nm (1.0 m ·...
  • Page 57 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT 7 Nm (0.7 m · kgf, 5.1 ft · lbf) 27 Nm (2.7 m · kgf, 20 ft · lbf) 27 Nm (2.7 m · kgf, 20 ft · lbf) 10 Nm (1.0 m · kgf, 7.2 ft · lbf) 10 Nm (1.0 m ·...

  • Page 58: Piston, Camshaft And Crankshaft

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT PISTON, CAMSHAFT AND CRANKSHAFT 20 Nm (2.0 m á kgf, 14 ft á lbf) Order Job/Parts to remove Q’ty Remarks Removing the piston, camshaft and Remove the parts in the order listed. crankshaft Crankcase Refer to “CRANKCASE” on 3-18. Balancer shaft Camshaft Valve lifter...

  • Page 59: Removing The Balancer Shaft, Camshaft, And Valve Lifter

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT REMOVING THE BALANCER SHAFT, CAMSHAFT, AND VALVE LIFTER 1. Remove: 9 Balancer shaft 1 Remove the balancer shaft 1 when the bal- ancer shaft gear mark a and the crankshaft gear mark b are aligned. 2.

  • Page 60: Installing The Valve Lifter, Balancer Shaft, And Camshaft

    PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT INSTALLING THE VALVE LIFTER, BALANCER SHAFT, AND CAMSHAFT 1. Install: 9 Intake valve lifter 9 Exhaust valve lifter 2. Install: 9 Balancer shaft 1 NOTICE Be sure to align the balancer shaft 1 gear mark a with the crankshaft gear mark b. 3.

  • Page 61: Handle And Wheels (For Ef7200De Can)

    HANDLE AND WHEELS (FOR EF7200DE CAN) HANDLE AND WHEELS (FOR EF7200DE CAN) 16 Nm (1.6 m · kgf, 12 ft · lbf) 7 Nm (0.7 m · kgf, 5.1 ft · lbf) 16 Nm (1.6 m · kgf, 12 ft · lbf) 16 Nm (1.6 m ·...
  • Page 62 HANDLE AND WHEELS (FOR EF7200DE CAN) 16 Nm (1.6 m · kgf, 12 ft · lbf) 7 Nm (0.7 m · kgf, 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 ·...
  • Page 63 HANDLE AND WHEELS (FOR EF7200DE CAN) INSTALLING THE HANDLE 1. Install: 9 Engine hanger 1 9 Carrier frame 2 9 Engine hanger bolts 3 16 Nm (1.6 m · kgf, 12 ft · lbf) 9 Fasten the engine hanger 1 to the carrier frame 2 with the engine hanger bolts 3.
  • Page 64 HANDLE AND WHEELS (FOR EF7200DE CAN) 3. Install: 9 Lock lever bolt 1 9 Washer 2 9 Collar 3 9 Lock lever 4 9 Lock lever nut 5 16 Nm (1.6 m · kgf, 12 ft · lbf) 9 Insert the lock lever bolt 1 into the carrier frame 6, and then put the washer 2, collar 3, and lock lever 4 in this order, and tight- en the lock lever nut 5.
  • Page 65 HANDLE AND WHEELS (FOR EF7200DE CAN) 5. Install: 9 Sleeve 1 Install the sleeve 1 on the generator frame 2. 6. Install: 9 Bracket handle 1 Install the bracket handle 1 to the sleeve 2. 7. Install: 9 Locating damper 1 Install the locating damper 1 on the sleeve 2.

  • Page 66: Installing The Wheels

    HANDLE AND WHEELS (FOR EF7200DE CAN) INSTALLING THE WHEELS 1. Install: 9 Main stand 1 9 Main stand bolts 2 9 Main stand nuts 3 16 Nm (1.6 m · kgf, 12 ft · lbf) 9 Lift the generator 20 cm (7.87 in) off the ground using a winch or other suitable lift- ing device.
  • Page 67 HANDLE AND WHEELS (FOR EF7200DE CAN) 3. Install: 9 Washers 1 9 Cotter pins 2 9 Install the washers 1 into wheel axle. 9 Insert cotter pins 2 into wheel axle frame, and then bend as shown in the illustration. 4.

  • Page 68: Chapter 4. Carburetor

    CARB REMOVING THE CARBURETOR CARBURETOR For complete information about procedures for carburetor maintenance, it is necessary to refer to the MZ SERIES ENGINE SERVICE MANUAL 7VB-F8197-E0. REMOVING THE CARBURETOR Order Job/Parts to remove Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Turn the fuel cock lever to the “OFF”...
  • Page 69 CARB REMOVING THE CARBURETOR Order Job/Parts to remove Q’ty Remarks Link rod/Spring Gasket Joint Gasket A EF7000/EF7200...

  • Page 70: Disassembling The Carburetor

    CARB DISASSEMBLING THE CARBURETOR DISASSEMBLING THE CARBURETOR EF7000/EF7200 0.7 Nm (0.07 m · kgf, 0.51 ft · lbf) 3.5 Nm (0.35 m · kgf, 2.5 ft · lbf) 1.0 Nm (0.10 m · kgf, 0.72 ft · lbf) 2.5 Nm (0.25 m · kgf, 1.8 ft · lbf) 4.0 Nm (0.40 m ·...
  • Page 71 CARB DISASSEMBLING THE CARBURETOR 0.7 Nm (0.07 m · kgf, 0.51 ft · lbf) 3.5 Nm (0.35 m · kgf, 2.5 ft · lbf) 1.0 Nm (0.10 m · kgf, 0.72 ft · lbf) 2.5 Nm (0.25 m · kgf, 1.8 ft · lbf) 4.0 Nm (0.40 m ·...

  • Page 72: Ef7000E/Ef7200E/Ef7200De

    CARB DISASSEMBLING THE CARBURETOR EF7000E/EF7200E/EF7200DE 3.5 Nm (0.35 m · kgf, 2.5 ft · lbf) 0.7 Nm (0.07 m · kgf, 0.51 ft · lbf) 1.0 Nm (0.10 m · kgf, 0.72 ft · lbf) 2.5 Nm (0.25 m · kgf, 1.8 ft · lbf) 4.0 Nm (0.40 m ·...
  • Page 73 CARB DISASSEMBLING THE CARBURETOR 3.5 Nm (0.35 m · kgf, 2.5 ft · lbf) 0.7 Nm (0.07 m · kgf, 0.51 ft · lbf) 1.0 Nm (0.10 m · kgf, 0.72 ft · lbf) 2.5 Nm (0.25 m · kgf, 1.8 ft · lbf) 4.0 Nm (0.40 m ·...

  • Page 74: Checking The Fuel Cut Solenoid Valve

    CARB DISASSEMBLING THE CARBURETOR CHECKING THE FUEL CUT SOLENOID VALVE 1. Check: W × 1 9 Fuel cut solenoid valve Connect the pocket tester (W × 1). Measure the fuel cut solenoid valve resistance. Fuel cut solenoid valve resistance: 9 W ± 10 % Analog pocket tester: YU-03112-C Pocket tester:...
  • Page 75 CARB DISASSEMBLING THE CARBURETOR 4. Check: 9 Rectifier Connect the pocket tester (W × 1). Check for continuity between the termi- nals. Rectifier continuity: Tester (–) lead Tester (+) lead — — — — — — — Replace if any faults are found.

  • Page 76: Chapter 5. Electrical

    ELEC ELECTRICAL COMPONENTS ELECTRICAL For complete information about procedures for electrical maintenance, it is necessary to refer to the MZ SERIES ENGINE SERVICE MANUAL 7VB-F8197-E0. 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)

  • Page 77: Ef7000 (Chn)

    ELEC ELECTRICAL COMPONENTS EF7000 (CHN) EF7000 (CHN) 1 Oil warning light 2 Engine switch 3 Voltage/hour meter 4 AC receptacle 5 AC switch (N.F.B.) EF7000E (CHN) 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.)

  • Page 78: Ef7200E (Oce)

    ELEC ELECTRICAL COMPONENTS EF7200E (OCE) EF7200E (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.) EF7200DE (Except for CAN) EF7200DE (Except for CAN) 1 Oil warning light 2 Economy control switch 3 Engine switch 4 Voltage/hour meter...

  • Page 79: Circuit Diagram

    ELEC CIRCUIT DIAGRAM CIRCUIT DIAGRAM EF7000/EF7200...

  • Page 80: Ef7000E/Ef7200E

    ELEC CIRCUIT DIAGRAM EF7000E/EF7200E...
  • Page 81 ELEC CIRCUIT DIAGRAM EF7200DE (Except for CAN)

  • Page 82: Ef7200De (Can)

    ELEC CIRCUIT DIAGRAM EF7200DE (CAN)

  • Page 83: Control Panel

    ELEC CONTROL PANEL CONTROL PANEL EF7000/EF7200 1.7 Nm (0.17 m á kgf, 1.2 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 0.4 Nm (0.04 m á kgf, 0.29 ft á lbf) 1.4 Nm (0.14 m á kgf, 1.0 ft á lbf) 0.4 Nm (0.04 m á...
  • Page 84 ELEC CONTROL PANEL 1.7 Nm (0.17 m á kgf, 1.2 ft á lbf) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 0.4 Nm (0.04 m á kgf, 0.29 ft á lbf) 1.4 Nm (0.14 m á kgf, 1.0 ft á lbf) 0.4 Nm (0.04 m á...
  • Page 85 ELEC CONTROL PANEL EF7000E/EF7200E (Except for OCE) 1.4 Nm (0.14 m á kgf, 1.0 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) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 0.4 Nm (0.04 m á...
  • Page 86 ELEC CONTROL PANEL 1.4 Nm (0.14 m á kgf, 1.0 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) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 0.4 Nm (0.04 m á...

  • Page 87: Ef7200E (Oce)

    ELEC CONTROL PANEL EF7200E (OCE) 1.4 Nm (0.14 m á kgf, 1.0 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) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 0.4 Nm (0.04 m á...
  • Page 88 ELEC CONTROL PANEL 1.4 Nm (0.14 m á kgf, 1.0 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) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 0.4 Nm (0.04 m á...

  • Page 89: Ef7200De (Except For Can)

    ELEC CONTROL PANEL EF7200DE (Except for CAN) 1.4 Nm (0.14 m á kgf, 1.0 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) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 0.4 Nm (0.04 m á...
  • Page 90 ELEC CONTROL PANEL 1.4 Nm (0.14 m á kgf, 1.0 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) 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 0.4 Nm (0.04 m á...

  • Page 91: Ef7200De (Can)

    ELEC CONTROL PANEL EF7200DE (CAN) 0.4 Nm (0.04 m á kgf, 0.29 ft á lbf) 1.4 Nm (0.14 m á kgf, 1.0 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) 7 Nm (0.7 m á...
  • Page 92 ELEC CONTROL PANEL 0.4 Nm (0.04 m á kgf, 0.29 ft á lbf) 1.4 Nm (0.14 m á kgf, 1.0 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) 7 Nm (0.7 m á...

  • Page 93: Battery

    ELEC BATTERY (EF7000E/EF7200E/EF7200DE) BATTERY (EF7000E/EF7200E/EF7200DE) Order Job/Parts to remove Q’ty Remarks Removing the battery Remove the parts in the order listed. Negative battery lead Disconnect. Positive battery lead Disconnect. Wing nut Battery mounting plate Battery mounting rod Battery 5-18...

  • Page 94: Checking And Charging The Battery

    ELEC BATTERY (EF7000E/EF7200E/EF7200DE) CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: 9 Wear protective eye gear when handling or working near batteries.
  • Page 95 ELEC BATTERY (EF7000E/EF7200E/EF7200DE) NOTICE 9 This is a VRLA (Valve Regulated Lead Acid) battery. Never remove the sealing caps because the balance between cells will not be maintained and battery per- formance will deteriorate. 9 Charging time, charging amperage and charging voltage for a VRLA (Valve Regulated Lead Acid) battery are differ- ent from those of conventional batteries.
  • Page 96 ELEC BATTERY (EF7000E/EF7200E/EF7200DE) 9 Positive tester probe → positive battery terminal 9 Negative tester probe → negative battery terminal Analog pocket tester: YU-03112-C Pocket tester: 90890-03112 9 The charge state of a VRLA (Valve Regulated Lead Acid) battery can be checked by measuring its open-circuit volt- age (i.e., the voltage when the positive bat- tery terminal is disconnected).
  • Page 97 ELEC BATTERY (EF7000E/EF7200E/EF7200DE) NOTICE 9 Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. 9 If it is impossible to regulate the charg- ing current on the battery charger, be careful not to overcharge the battery.
  • Page 98 ELEC BATTERY (EF7000E/EF7200E/EF7200DE) A. Open-circuit voltage (V) B. Time (minutes) C. Charging D. Ambient temperature 20 °C (68 °F) E. Check the open-circuit voltage. Charging method using a variable-current (voltage) charger a. Measure the open-circuit voltage prior to charging. Voltage should be measured 30 minutes after the engine is stopped.
  • Page 99 ELEC BATTERY (EF7000E/EF7200E/EF7200DE) 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 charging current after a lapse of 5 hours.
  • Page 100 ELEC BATTERY (EF7000E/EF7200E/EF7200DE) e. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. 6.

  • Page 101: Fuse (Ef7000E/Ef7200E/Ef7200De)

    ELEC FUSE (EF7000E/EF7200E/EF7200DE) FUSE (EF7000E/EF7200E/ EF7200DE) CHECKING THE FUSE NOTICE To avoid a short circuit, always set the engine switch to “STOP” when checking or replacing a fuse. 1. Remove: 9 Panel cover 9 Panel cover screws 1 2. Remove: 9 Fuse 1 3.
  • Page 102 ELEC FUSE (EF7000E/EF7200E/EF7200DE) 4. Replace: 9 Blown fuse Replacing steps: a. Set the engine switch to “STOP”. b. Install a new fuse of the correct amper- age. c. Set the engine switch to “ON” and veri- fy if the electrical circuit is operational. d.

  • Page 103: Switches

    ELEC SWITCHES SWITCHES CHECKING THE SWITCH CONTINUITY Use a tester to check the terminals for conti- nuity. If a continuity error is found at any point, replace the switch. Analog pocket tester: YU-03112-C Pocket tester: 90890-03112 9 Set the pocket tester to “0” before starting a test.

  • Page 104: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING CHART NO SPARK OR WEAK SPARK Inspection steps: 1. Engine oil level 6. Ignition coil (TCI unit) resistance 2. Spark plug 7. Air gap 3. Ignition spark gap 8. Engine switch 4. Spark plug cap resistance 9.
  • Page 105 ELEC IGNITION SYSTEM 3. Ignition spark gap 9 Disconnect the spark plug cap 1 from the spark plug. 9 Connect the ignition checker 2 as shown. Spark plug cap 1 → Ignition checker 2 Ignition checker lead → Spark plug 3 9 Turn the crankshaft and measure the ignition spark gap a.
  • Page 106 ELEC IGNITION SYSTEM 4. Spark plug cap resistance 9 Do not pull out the spark plug cap from the 9 Remove the spark plug cap from the high tension cord. high tension cord. 9 Remove → Turn the spark plug cap coun- 9 Connect the pocket tester (W ×...
  • Page 107 ELEC IGNITION SYSTEM 6. Ignition coil (TCI unit) resistance 9 Remove the ignition coil (TCI unit). 9 Connect the pocket tester (W × 1k) to the secondary terminal. Tester + lead → High tension cord 1 Tester - lead → Black/White terminal 2 Secondary coil resistance: 12 kW ±...
  • Page 108 9 Connect the pocket tester (W × 1) to the engine switch terminal. 9 Check the engine switch continuity. 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 →...
  • Page 109 ELEC IGNITION SYSTEM 9. Oil level switch 9 Remove the oil level switch from the bot- tom of the crankcase. (Refer to “CRANKCASE” on 3-18) 9 Connect the pocket tester (W × 1) to the oil level switch lead and check for conti- nuity.

  • Page 110: Electric Starting System (Ef7000E/Ef7200E/Ef7200De)

    ELECTRIC STARTING SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) ELECTRIC STARTING SYSTEM (EF7000E/EF7200E/EF7200DE) TROUBLESHOOTING CHART THE STARTER MOTOR DOES NOT OPERATE Inspection steps: 1. Fuse 3. Starter motor 2. Battery voltage 4. Starter relay 9 Remove the following part(s) before troubleshooting. 1) Control box 2) Control panel 3) Fuel tank 9 Use the following special tool(s) for troubleshooting.
  • Page 111 ELECTRIC STARTING SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) 3. Starter motor 9 Connect the jumper lead to the starter relay terminals on the battery side and the starter motor side. 1 Jumper lead 9 Check the starter motor operation. Check the battery. DOES NOT MOVE (Refer to “BATTERY (EF7000E/EF7200E/ MOVES EF7200DE)”...

  • Page 112: Removing The Starter Motor

    ELECTRIC STARTING SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) REMOVING THE STARTER MOTOR 16 Nm (1.6 m · kgf, 12 ft · lbf) 9 Nm (0.9 m · kgf, 6.5 ft · lbf) Order Job/Parts to remove Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Negative battery lead Disconnect.

  • Page 113: Disassembling The Starter Motor

    ELECTRIC STARTING SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) DISASSEMBLING THE STARTER MOTOR 6 Nm (0.6 m · kgf, 4.3 ft · lbf) 9 Nm (0.9 m · kgf, 6.5 ft · lbf) 11 Nm (1.1 m · kgf, 8.0 ft · lbf) Order Job/Parts to remove Q’ty Remarks...

  • Page 114: Checking The Brush

    ELECTRIC STARTING SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) CHECKING THE BRUSH 1. Measure: 9 Brush 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.

  • Page 115: Charging System (Ef7000E/Ef7200E/Ef7200De)

    ELEC CHARGING SYSTEM (EF7000E/EF7200E/EF7200DE) CHARGING SYSTEM (EF7000E/EF7200E/EF7200DE) TROUBLESHOOTING CHART THE BATTERY IS NOT CHARGED Inspection steps: 1. Battery voltage 3. Fuse 2. Charging voltage 4. Charging coil resistance 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 ELEC CHARGING SYSTEM (EF7000E/EF7200E/EF7200DE) 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 MEETS 14.0 V SPECIFICATION Properly connect the charging system. 3.
  • Page 117 ELEC CHARGING SYSTEM (EF7000E/EF7200E/EF7200DE) 4. Charging coil resistance 9 Disconnect the charging coil leads. 9 Connect the pocket tester (W × 1). 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 ±...

  • Page 118: Generator System

    ELEC GENERATOR SYSTEM GENERATOR SYSTEM TROUBLESHOOTING CHART GENERATOR DOES NOT GENERATE Inspection steps: 9. Main coil AC voltage 1. AC switch (N.F.B.) 10. Main coil resistance 2. Engine speed 11. Rotor remagnetization 3. Condenser 12. Exciter field coil AC voltage 4.
  • Page 119 ELEC GENERATOR SYSTEM 3. Condenser 9 Connect the pocket tester. 9 Turn the pocket tester switch from the “OFF” position to the “W × 1k” position. CORRECT FAULTY W×1k W×1k W×1k 1 The needle swings and returns back quickly. 2 The needle does not swing. 3 The needle does not return.
  • Page 120 ELEC GENERATOR SYSTEM 4. Main coil AC voltage 9 Remove the generator cover. (Refer to “CONTROL BOX” on 3-1). 9 Connect the pocket tester (AC 300 V) to the main coil terminal. 9 Start the engine (with no load). AC300V AC300V A EF7200DE B Except for EF7200DE...
  • Page 121 ELEC GENERATOR SYSTEM 6. AC receptacle AC voltage 9 Start the engine (with no load). 9 Connect the pocket tester (AC 300 V) to the AC receptacle. Tester + lead → AC receptacle Tester - lead → AC receptacle AC receptacle AC voltage: 126.6 V (120 V receptacle) 255.1 V (240 V receptacle) 236 V (220 V receptacle)
  • Page 122 ELEC GENERATOR SYSTEM 7. Sub coil AC voltage OUT OF SPECIFICATION 9 Disconnect the stator assembly (sub coil) coupler. 9 Connect the pocket tester (AC 20 V) as shown. 8. Sub coil resistance 9 Start the engine (with no load). 9 Connect the pocket tester (W ×...
  • Page 123 ELEC GENERATOR SYSTEM 9. Main coil AC voltage OUT OF SPECIFICATION 9 Disconnect the stator assembly (main coil) leads and stator assembly (sub coil) coupler. 9 Connect the pocket tester (AC 120 V) to 10. Main coil resistance the stator assembly (main coil) lead ter- 9 Connect the pocket tester (W ×...
  • Page 124 ELEC GENERATOR SYSTEM NOTICE 11. Rotor remagnetization Do not connect the battery for more than a 9 Disconnect the exciter field coil coupler few seconds. This may deteriorate the bat- (Black–White) at the end of the genera- tery. tor unit. 9 Start the engine (with no load).
  • Page 125 ELEC GENERATOR SYSTEM 12. Exciter field coil AC voltage 9 Disconnect the exciter field coil coupler. OUT OF SPECIFICATION 9 Connect the pocket tester (AC 20 V) as shown. 9 Start and run the engine. 13. Exciter field coil resistance 9 Disconnect the exciter field coil coupler.
  • Page 126 ELEC GENERATOR SYSTEM 14. “Short to ground” and “Coils shorted together” test 9 Disconnect the stator assembly (main coil) leads, stator assembly (sub coil) coupler, and exciter field coil coupler. Set the meter to the highest ohm setting. “Short to ground test” Connect the - lead to the stator housing and + lead to any wire of the main coil.
  • Page 127 ELEC GENERATOR SYSTEM 15. Rectifier (rotor assembly) 9 Remove the rotor assembly. 9 Connect the pocket tester (W × 1) as shown. Rectifier continuity: Pocket tester connecting point Good + (Red) - (Black) × × × × × × × ×...
  • Page 128 ELEC GENERATOR 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 % OUT OF MEETS SPECIFICATION SPECIFICATION Replace the rotor assembly. Replace the AVR 1 . 5-53...

  • Page 129: Economy Control System (Ef7000E/Ef7200E/Ef7200De)

    ECONOMY CONTROL SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) ECONOMY CONTROL SYSTEM (EF7000E/EF7200E/EF7200DE) ECONOMY CONTROL SOLENOID 7 Nm (0.7 m á kgf, 5.1 ft á lbf) 16 Nm (1.6 m á kgf, 12 ft á lbf) 16 Nm (1.6 m á kgf, 12 ft á lbf) Order Job/Parts to remove Q’ty...

  • Page 130: Installing The Economy Control Solenoid

    ECONOMY CONTROL SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) INSTALLING THE ECONOMY CONTROL SOLENOID 1. Install: 9 Economy control solenoid 1 9 Economy control solenoid bolts 2 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.

  • Page 131: Economy Control System Diagram

    ECONOMY CONTROL SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) ECONOMY CONTROL SYSTEM DIAGRAM Order Part name Remarks Economy control solenoid Operate the governor arm. Throttle valve Control the engine speed. Economy control switch Switching. Economy control unit Control the economy control solenoid. Receptacle — Governor weight Check the engine speed.

  • Page 132: Troubleshooting Chart

    9 Check that the economy control switch is 9 Start the engine (with no load). 9 Measure the engine speed. Economy control engine speed: 2300–2400 r/min OUT OF MEETS SPECIFICATION SPECIFICATION Adjust the engine speed. (Refer to “ADJUSTING THE ENGINE SPEED (Except for EF7000/EF7200)” on 2-15) 5-57...
  • Page 133 ECONOMY CONTROL SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) 2. Economy control voltage 9 Disconnect the economy control unit coupler. 9 Connect the pocket tester (DC 20 V) as shown. Tester + lead → Yellow lead Tester - lead → Blue/White lead G Y L/W 9 Start the engine.
  • Page 134 ECONOMY CONTROL SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) 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 9 Start the engine. 9 Measure the economy control solenoid voltage.
  • Page 135 ECONOMY CONTROL SYSTEM ELEC (EF7000E/EF7200E/EF7200DE) 5. Economy control 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 % OUT OF SPECIFICATION Replace the economy control solenoid.

  • Page 136: Chapter 6. Troubleshooting

    TRBL ENGINE TROUBLESHOOTING ENGINE ENGINE DOES NOT START 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 oil warning light, oil warning unit, or...
  • Page 137 TRBL ENGINE Remove the spark plug and attach it to the spark plug cap, and then ground the spark plug to check for spark. GOOD SPARK WEAK OR NO SPARK 9 Check the spark plug for dirt and check the spark plug gap.
  • Page 138 TRBL ENGINE Check if the marks on the crankshaft and cam- shaft are aligned. Correct. ALIGNED NOT ALIGNED Check if there is seizure, wear, or damage on the piston, piston ring, or cylinder. GOOD SEIZURE OR WORN Rebore or replace.
  • Page 139 TRBL ENGINE ENGINE STARTS BUT STALLS Check the fuel level. Add. SUFFICIENT INSUFFICIENT Check if the fuel tank cap is clogged. Clean or replace. GOOD CLOGGED Check if the fuel cock is clogged. Clean. GOOD CLOGGED Check if the fuel hose is clogged. Clean.
  • Page 140 TRBL ENGINE ENGINE SPEED DOES NOT INCREASE Check if the electric equipment consumes too much wattage for this generator. Remove the electric equipment with too GOOD TOO MUCH much wattage. Check the spark plug for dirt and check the spark plug gap.
  • Page 141 TRBL ENGINE Check if the main passages, such as the main jet in the carburetor, are clogged. Clean the parts. GOOD CLOGGED Check if there is air suction from the carburetor 9 Tighten the carburetor joint, gasket, or throttle shaft. nuts securely.
  • Page 142 TRBL ENGINE ENGINE SPEED IS UNEVEN Check the fuel level. Add. SUFFICIENT INSUFFICIENT Check if fuel has deteriorated. Replace. GOOD DETERIORATED Check if the fuel tank cap is clogged. Replace. GOOD CLOGGED Check if the fuel cock is clogged. Clean. GOOD CLOGGED Check the spark plug for dirt and check the spark...
  • Page 143 TRBL ENGINE Check the valve clearance. OUT OF SUFFICIENT Adjust. SPECIFICATION Check the valve face and valve seat for wear. Resurface or replace. GOOD WORN Check if there is seizure, wear, or damage on the piston, piston ring, or cylinder. Rebore or replace.
  • Page 144 TRBL ENGINE GOVERNOR OPERATION Check that the governor link operate smoothly. Adjust or replace. GOOD NO GOOD Check that the governor spring is stretched. Replace. GOOD STRETCHED Check the governor adjustment. Adjust. GOOD NOT GOOD Check the governor weight and governor bushing function.

  • Page 145: Chapter 7. Specifications

    Model code number: 7P6202 (EF7200DE) (CSA/SEA) 7P6203 (EF7200DE) (CAN) 7P6204 (EF7200DE) (SAU) 7P6300 (EF7200) (AFR/SEA) 7P6301 (EF7200E) (AFR/SEA) 7P6302 (EF7200E) (OCE) 7P6303 (EF7000) (CHN) 7P6304 (EF7000E) (CHN) 7P6305 (EF7200) (RUS) 7P6306 (EF7200E) (RUS) Dimensions: Overall length (*1) mm (in) 740 (29.1) (For EF7200DE CAN) Overall length (*2) 1070 (42.1) (For EF7200DE CAN)
  • Page 146 API Service SE type or higher Lubrication system Forced splashing Air filter system Semi-wet (urethane foam) Cooling system Air cooled Starting system Recoil starter (EF7000/EF7200) Electric and recoil starter (EF7000E/EF7200E/ EF7200DE) Stopping system Misfire Rotating direction Clockwise (from flywheel) Governor type...
  • Page 147 SPEC GENERAL SPECIFICATIONS Rated current 50.0/25.0 (EF7200DE) 21.7 (For EF7200E OCE) 22.7 Safety device type N.F.B. (No Fuse Breaker) Rated engine speed r/min 3600 Economy control engine speed r/min 2300–2400 (EF7000E/EF7200E/EF7200DE) Engine speed r/min 3110–3210 Voltage regulation Insulation resistance(*3) More than 10 Insulation class Stator E class...

  • Page 148: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Piston: mm (in) Piston clearance 0.015–0.029 (0.0006–0.0011) <Limit> 0.150 (0.0059) Piston skirt “D” 84.977–84.998 (3.3456–3.3464) <Limit> 84.900 (3.3425) Measuring point “H” 10 (0.4) Oversize 1st 85.25 (3.3563) 85.50 (3.3661) Piston pin hole inside diameter 20.004–20.015 (0.7876–0.7880) <Limit>...
  • Page 149 SPEC MAINTENANCE SPECIFICATIONS Crankshaft: mm (in) Big end side clearance “A” 0.20–0.65 (0.008–0.026) <Limit> 0.5 (0.0197) Runout “B” <Limit> 0.03 (0.0012) Crank pin outside diameter “C” 35.969–35.984 (1.4161–1.4167) <Limit> 35.9 (1.4134) Connecting rod: mm (in) Small end diameter “A” 20.006–20.020 (0.7876–0.7882) Oil clearance 0.006–0.025 (0.0002–0.0010) Big end diameter “B”...
  • Page 150 SPEC MAINTENANCE SPECIFICATIONS Valve: mm (in) Valve Head diameter “A” 32.0 (1.26) 28.0 (1.10) Stem diameter “B” 5.948–5.963 (0.2342–0.2348) 5.940–5.955 (0.2339–0.2344) <Limit> 5.918 (0.2330) 5.910 (0.2327) Stem length “C” 88.1 (3.47) 88.1 (3.47) Valve face contact width “D” 0.9–1.1 (0.0354–0.0433) 0.9–1.1 (0.0354–0.0433) <Limit>...

  • Page 151: Electrical

    SPEC MAINTENANCE SPECIFICATIONS Carburetor: mm (in) Type BV26-20 I.D. mark 7CH00 7CH10 (For EF7200 SEA/AFR) 7HD00 (EF7000E/EF7200E/EF7200DE) Bore size ø20 Main jet #105 Main air jet ø1.4 (0.055) ø1.5 (0.059) (For EF7200 SEA/AFR) Pilot air jet ø0.9 (0.053) Pilot outlet ø0.9 (0.053) Valve seat size ø1.8 (0.071)

  • Page 152: Generator

    120 V (White–Red) 126.6 (EF7200DE) 240 V (White–Blue) 255.1 (EF7200DE) 230 V (White–Red) 236 (For EF7200E OCE) 220 V (White–Red) 236 (EF7000/EF7000E/EF7200/EF7200E) Main coil AC voltage (with the sub coil coupler disconnected, no load) 120 V (White–Red) 26 (EF7200DE) 240 V (White–Blue) 51 (EF7200DE) 230 V (White–Red)
  • Page 153 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...

  • Page 154: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES Tightening torque Item Thread size Nm (m·kgf, ft·lbf) Generator cover bolt M6 × 1.0 7 (0.7, 5.1) Control box bolt/nut M6 × 1.0 7 (0.7, 5.1) Stator assembly (main coil) M5 × 0.8 3.8 (0.38, 2.8) lead nut Ground lead (wire harness) M5 ×...
  • Page 155 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Nm (m·kgf, ft·lbf) Cylinder head cover bolt M6 × 1.0 11 (1.1, 8.0) 1st: 12 (1.2, 8.7) Cylinder head bolt M10 × 1.25 2nd: 50 (5.0, 36) Intake stud bolt M8 × 1.25 9 (0.9, 6.5) Exhaust stud bolt M8 ×...

  • Page 156: General Torque Specifications

    TIGHTENING TORQUES/ SPEC GENERAL TORQUE SPECIFICATIONS Tightening torque Item Thread size Nm (m·kgf, ft·lbf) Economy control unit screw (EF7000E/EF7200E/ — 1.8 (0.18, 1.3) EF7200DE) Oil warning light nut M10 × 1.0 0.7 (0.07, 0.51) Voltage adjuster nut M8 × 0.75 1.3 (0.13, 0.94) Starter motor bolt (EF7000E/ M8 ×...

  • Page 157: Lubrication Points And Type Of Lubricants

    SPEC LUBRICATION POINTS AND TYPE OF LUBRICANTS LUBRICATION POINTS AND TYPE OF LUBRICANTS Part name Type of lubricant Oil seal lip Governor shaft oil seal lip Bearing Connecting rod big end Crank pin Crankshaft journal Connecting rod cap bolt Piston pin Piston Balancer shaft journal Balancer shaft gear teeth...

  • Page 158: Wire Routing Diagram

    SPEC WIRE ROUTING DIAGRAM WIRE ROUTING DIAGRAM CONTROL PANEL AND CONTROL BOX (EF7000/EF7200) 1 Oil warning light e Ground (earth) terminal G Pay attention to the polarity when connecting the lead to 2 Engine switch r Panel cover the condenser.
  • Page 159 SPEC WIRE ROUTING DIAGRAM Color code M To generator 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 7-15...

  • Page 160: Control Panel And Control Box (Ef7000E/Ef7200E)

    SPEC WIRE ROUTING DIAGRAM CONTROL PANEL AND CONTROL BOX (EF7000E/EF7200E) 1 Oil warning light t Wire harness H Connect the condenser lead coupler as shown in the illus- 2 Economy control switch y Ground (earth) terminal tration, paying attention to 3 Engine switch u Panel cover polarity.
  • Page 161 SPEC WIRE ROUTING DIAGRAM Color code M Make sure that the pawls are properly engaged on both B ..Black sides of the panel cover. Br ..Brown N Behind the control box O ..Orange O To engine R ..Red P To generator W ..White Y ..Yellow B/W ..Black/White...

  • Page 162: Control Panel And Control Box (Except For Ef7200De Can)

    SPEC WIRE ROUTING DIAGRAM CONTROL PANEL AND CONTROL BOX (Except for EF7200DE CAN) 1 Oil warning light t Wire harness F Connect the condenser lead coupler as shown in the illus- 2 Economy control switch y Ground (earth) terminal tration, paying attention to 3 Engine switch u Sub-wire harness polarity.
  • Page 163 SPEC WIRE ROUTING DIAGRAM Color code K Pay attention to the polarity when connecting the lead to B ..Black the condenser. Br ..Brown L Install the lead between the L..Blue screw and plate. O ..Orange M Behind the control box R ..Red N To engine W ..White...

  • Page 164: Control Panel And Control Box (For Ef7200De Can)

    SPEC WIRE ROUTING DIAGRAM CONTROL PANEL AND CONTROL BOX (For EF7200DE CAN) 1 Oil warning light t Economy control unit E 30°–45° 2 Economy control switch y Wire harness F Identification tape (White) 3 Engine switch u Ground (earth) terminal G Connect the condenser lead coupler as shown in the illus- 4 Voltage/hour meter...
  • Page 165 SPEC WIRE ROUTING DIAGRAM Color code L Make sure that the pawls are properly engaged on both B ..Black sides of the panel cover. Br ..Brown M Install the lead between the L..Blue screw and plate. O ..Orange N Behind the control box R ..Red O To engine W ..White...

  • Page 166: Back Side And Left Side View

    SPEC WIRE ROUTING DIAGRAM BACK SIDE AND LEFT SIDE VIEW (For EF7200DE CAN) 1 Washers A Install the washer within the 5th ball of the chain. 2 Fuel tank cap 3 Fuel tank filter B Install the washer within the 20th ball of the chain.

  • Page 167: Upper Side View

    SPEC WIRE ROUTING DIAGRAM UPPER SIDE VIEW (EF7000E/EF7200E/EF7200DE) Color code B ..Black 1 Auto choke lead connector e Oil level switch lead connector G ..Green 2 Clamp r Economy control solenoid lead L..Blue connector 3 Starter relay lead connector O ..Orange 4 TCI unit lead connector t Starter motor R ..Red...
  • Page 168 SPEC WIRE ROUTING DIAGRAM UPPER SIDE VIEW (EF7000/EF7200) Color code B ..Black 1 Fuel cut solenoid valve lead A Avoid contact of the lead with L..Blue connector the muffler and governor arm O ..Orange by making an adjustment with 2 Clamp B/W ..Black/White...
  • Page 169 SPEC WIRE ROUTING DIAGRAM ENGINE 1 Oil level switch lead A Install the grommet so that it G Adjust the TCI unit air gap contact with the gray tube. between to 0.4–0.6 mm 2 Clamp (0.0157–0.0236 in) on both 3 Oil level switch B Route the oil level switch lead as shown.
  • Page 170 SPEC WIRE ROUTING DIAGRAM GENERATOR (EF7000/EF7000E/EF7200/EF7200E) Color code Br ..Brown 1 Terminal A Details of the stator assembly R ..Red lead installation. 2 Wire harness (stator assembly W ..White lead) B Details of the stator assembly lead coupler installation. 3 Wire harness (exciter field coil...
  • Page 171 SPEC WIRE ROUTING DIAGRAM GENERATOR (Except for EF7200DE CAN) Color code Br ..Brown 1 Terminal A Details of the stator assembly L..Blue lead installation. 2 Wire harness (stator assembly R ..Red lead) B Details of the stator assembly W ..White lead coupler installation.
  • Page 172 SPEC WIRE ROUTING DIAGRAM GENERATOR (For EF7200DE CAN) Color code Br ..Brown 1 Terminal w Stator assembly (main coil) L..Blue lead 2 Wire harness (stator assembly R ..Red lead) W ..White 3 Lead A Details of the stator assembly lead installation. 4 Wire harness (exciter field coil lead) B Details of the stator assembly...
  • Page 174 EF7000/EF7200 2014 CIRCUIT DIAGRAM...
  • Page 175 EF7000E/EF7200E 2014 CIRCUIT DIAGRAM...
  • Page 176 EF7200DE (Except for CAN) 2014 CIRCUIT DIAGRAM...
  • Page 177 EF7200DE (CAN) 2014 CIRCUIT DIAGRAM...
  • Page 178 2014_05×1 !

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Ef7000eEf7200Ef7200eEf7200de

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