Yamaha EF2200iS Service Manual
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Yamaha EF2200iS Service Manual

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SERVICE MANUAL
EF2200iS
7PC-F8197-E0

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Summary of Contents for Yamaha EF2200iS

  • Page 1 SERVICE MANUAL EF2200iS 7PC-F8197-E0...
  • Page 3 EF2200iS SERVICE MANUAL ©2019 by Yamaha Motor Powered Products Co., Ltd. 1st Edition, July 2019 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Powered Products Co., Ltd. is expressly prohibited.
  • Page 4 This manual was produced by the Yamaha Motor Powered Products Co., Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha generators should have a basic understanding of mechanics and the techniques to repair these types of generators.
  • Page 5 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. •...
  • Page 6 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every generator. SYMBOL DEFINITION SYMBOL DEFINITION 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: General Information

    INDEX GENERAL INFORMATION PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR ELECTRICAL TROUBLESHOOTING SPECIFICATIONS...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS AIR FILTER ELEMENT......2-15 GENERAL INFORMATION MUFFLER..........2-16 FUEL TANK STRAINER ......2-17 MACHINE IDENTIFICATION...... 1-1 FUEL COCK STRAINER .....2-18 SERIAL NUMBER ......... 1-1 BREATHER HOSE ......2-20 STARTING SERIAL NUMBER ....1-1 CYLINDER HEAD DECARBONIZATION......2-20 IMPORTANT INFORMATION ..... 1-1 ADJUSTING THE VALVE PREPARATION FOR REMOVAL AND CLEARANCE........2-21 DISASSEMBLY ........
  • Page 9 REMOVING THE CDI MAGNETO CHECKING THE CONNECTING AND FLYWHEEL ......... 3-11 ROD OIL CLEARANCE .......3-39 INSTALLING THE CDI MAGNETO INSTALLING THE PISTON AND AND FLYWHEEL ......... 3-12 PISTON RINGS ........3-40 INSTALLING THE CRANKSHAFT..3-41 GENERATOR ........... 3-14 REMOVING THE GENERATOR ROTOR AND STATOR ASSEMBLY..3-15 CARBURETOR INSTALLING THE GENERATOR ROTOR AND STATOR ASSEMBLY..
  • Page 10 CHECKING THE SUB COIL UPPER SIDE AND LEFT SIDE RESISTANCE........5-13 VIEW............7-18 CHECKING THE DC COIL AC CONTROL UNIT ........7-20 VOLTAGE ..........5-14 GENERATOR........7-22 CHECKING THE DC COIL UPPER SIDE AND AIR FILTER SIDE RESISTANCE........5-14 VIEW............7-24 CHECKING THE THROTTLE CARBURETOR AND AIR FILTER ..7-26 CONTROL SYSTEM ......

  • Page 11: Machine Identification

    GENERAL INFORMATION MACHINE IDENTIFICATION SERIAL NUMBER The serial number is printed on the label “1” affixed to the position of the generator as shown in the illustration. • The first three digits identify the model, and the remain- ing digits indicate the production number. •...
  • Page 12 IMPORTANT INFORMATION Oil, grease and seals Be sure to use genuine Yamaha oils, grease and sealers, or the equivalents. Expendable parts Always replace the gaskets, O-rings, cotter pins and cir- clips with new parts when servicing engine. Tightening torque Be sure to follow torque specifications. When tightening...

  • Page 13: All Replacement Parts

    • Make sure that the parts, move smoothly after each sec- tion of the machine is assembled. ALL REPLACEMENT PARTS We recommend the use of genuine Yamaha parts for all replacements. Use oil and/or grease, recommended by Yamaha, for assembly and adjustment.

  • Page 14: Basic Service Information

    BASIC SERVICE INFORMATION 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 termi- nal slots. Always insert the probes from the opposite end “a”...
  • Page 15 BASIC SERVICE INFORMATION Check: • Lead • Coupler • Connector Moisture  Dry with an air blower. Rust/stains  Connect and disconnect several times. Check: • All connections Loose connection  Connect properly. • If the pin “1” on the terminal is flattened, bend it up. •...
  • Page 16 BASIC SERVICE INFORMATION Check: • Continuity (with the digital circuit tester) Model 88 Multimeter with tachometer: YU-A1927 Digital circuit tester (CD732): 90890-03243 • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (4).

  • Page 17: Special Tools And Testers

    SPECIAL TOOLS AND TESTERS 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 prevent damage caused by the use of improper tools or improvised techniques. •...
  • Page 18 SPECIAL TOOLS AND TESTERS MEMO...

  • Page 19: Periodic Checks And Adjustments

    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 operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale.

  • Page 20: Periodic Maintenance/Lubrication Intervals

    *1····· Initial replacement of the engine oil is after one month or 20 hours of operation. *2····· 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 21 COVERS AND FUEL TANK COVERS AND FUEL TANK COVERS AND FUEL TANK (FOR EUROPE) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 7 N ・...

  • Page 22: Covers And Fuel Tank (For Australia, Korea And China)

    COVERS AND FUEL TANK COVERS AND FUEL TANK (FOR AUSTRALIA, KOREA AND CHINA) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 7 N ・...

  • Page 23: Rear Cover 2 And Fuel Tank

    COVERS AND FUEL TANK REAR COVER 2 AND FUEL TANK Order Job/Parts to remove Q’ty Remarks Removing the rear cover 2 and fuel tank Remove the parts in the order listed. Rear cover 2 Fuel tank It is recommended to remove the rear cover 2 and the fuel tank together without disassembling. The rear cover 2 is hard to detach from the fuel tank.

  • Page 24: Front Covers And Fuel Tank

    COVERS AND FUEL TANK FRONT COVERS AND FUEL TANK 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 1.8 N ・...
  • Page 25 COVERS AND FUEL TANK When removing covers, it is easier to work if you take into consideration the following points as nec- essary. 1. Loosen the clamp. 2. Remove the clamp. 3. Disconnect the 2 pin coupler. 4. Remove the clamp. 5.

  • Page 26: Removing The Covers And Fuel Tank

    COVERS AND FUEL TANK REMOVING THE COVERS AND FUEL TANK 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. Drain the remained fuel in the carburetor by turning the carburetor fuel drain cock “1”.

  • Page 27: Installing The Covers And Fuel Tank

    COVERS AND FUEL TANK Remove: • Screw “1” • Engine switch (together with fuel cock) “2” • Screw and ground (earth) lead “3” WARNING Take care not to rotate the engine switch to the “I” (RUN) position when you remove it. Remove: •...

  • Page 28: Periodic Maintenance

    PERIODIC MAINTENANCE Install: • Engine switch • Choke cable holder Install: • Recoil starter handle “1” 15–20 mm • Make a knot “a” on the starter rope “2”, and then untie (0.59–0.79 in) the knot “b” after assembling the recoil starter handle “1”. •...

  • Page 29: Engine Oil Level

    PERIODIC MAINTENANCE ENGINE OIL LEVEL Check: • Oil level warning light “1” a. Place the generator on a level surface. b. Turn the engine switch to “I” (RUN). c. Pull the recoil starter handle. d. Check that the oil level warning light flashes. Oil level warning light flashes ...

  • Page 30: Replacing The Engine Oil

    PERIODIC MAINTENANCE d. Check that the engine oil is at the specified level “a”. Add oil if necessary. Install: • Oil filler cap • Rear cover 1 (Refer to “COVERS AND FUEL TANK” on page 2-3) REPLACING THE ENGINE OIL Warm up the engine for several minutes, and then stop the engine.

  • Page 31: Fuel Leakage

    PERIODIC MAINTENANCE Recommended oil brand: YAMALUBE Available oil grade: API SE type or higher JASO MA or MB Available viscosity index: 10W-30 or 10W-40 Engine oil quantity: 0.4 L (0.42 US qt, 0.35 Imp.qt) Check: • Engine oil level (Refer to “ENGINE OIL LEVEL” on page 2-11) FUEL LEAKAGE Remove: •...

  • Page 32: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG WARNING Check and adjust the areas around the cylinder head after the engine has cooled down completely. Remove: • Rear cover 1 (Refer to “COVERS AND FUEL TANK” on page 2-3) • Access cap • Spark plug cap •...

  • Page 33: Air Filter Element

    PERIODIC MAINTENANCE Install: • Spark plug Spark plug: 20 N·m (2.0 kgf·m, 15 lb·ft) To prevent threads from being damaged, temporally tighten “a” the spark plug before tightening it to the speci- fied torque “b”. 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.

  • Page 34: Muffler

    PERIODIC MAINTENANCE NOTICE Do not wring out the element. This could cause it to tear. Install: • Air filter element • Air filter case cover • Air filter case cover screw Air filter case cover screw: 1.6 N·m (0.16 kgf·m, 1.2 lb·ft) •...

  • Page 35: Fuel Tank Strainer

    PERIODIC MAINTENANCE Remove: • Muffler (Refer to “MUFFLER” on page 3-4) Decarbonize: • Muffler Tap on the muffler in the area shown in the illustra- tion to loosen carbon buildup, and then shake it out from the end of the muffler. NOTICE Do not use a wire to clean, otherwise the noise damp- ing material may come out, and the damping effect...

  • Page 36: Fuel Cock Strainer

    PERIODIC MAINTENANCE Remove: • Fuel tank cap “1” • Fuel tank strainer “2” Check: • Fuel tank strainer Damage  Replace. Dirt/clog  Clean. Clean the fuel tank strainer with clean gasoline, and then dry it thoroughly. Install: • Fuel tank strainer •...
  • Page 37 PERIODIC MAINTENANCE Turn the engine switch to “ ” (STOP). Drain the fuel from the fuel tank completely. Remove: • Fuel hose “1” • Engine switch “2” (Refer to “REMOVING THE COVERS AND FUEL TANK” on page 2-8) NOTICE Fuel cock is a part integrated with the engine switch, so be careful to remove it.

  • Page 38: Breather Hose

    PERIODIC MAINTENANCE Install: • Fuel hose • Engine switch • Front cover 1 • Front cover 2 (Refer to “COVERS AND FUEL TANK” on page 2-3) BREATHER HOSE Remove: • Rear cover 1 • Rear cover 2 (Refer to “COVERS AND FUEL TANK” on page 2-3) Check: •...

  • Page 39: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE Install: • Cylinder head assembly (Refer to “INSTALLING THE CYLINDER HEAD ASSEMBLY” on page 3-20) Install: • Rear cover 2 • Rear cover 1 (Refer to “COVERS AND FUEL TANK” on page 2-3) ADJUSTING THE VALVE CLEARANCE Remove: •...
  • Page 40 PERIODIC MAINTENANCE Feeler gauge set: YU-26900-9 Thickness gauge: 90890-03268 Valve clearance (cold): Intake: 0.07–0.12 mm (0.0028–0.0047 in) Exhaust: 0.07–0.12 mm (0.0028–0.0047 in) Adjust: • Valve clearance Adjustment steps: a. Loosen the locknut “1”. b. Turn the adjuster “2” in or out to obtain the proper clearance.

  • Page 41: Measuring The Compression Pressure

    PERIODIC MAINTENANCE Cylinder head cover bolt: 11 N·m (1.1 kgf·m, 8.1 lb·ft) • Clip • Breather hose • Spark plug Spark plug: 20 N·m (2.0 kgf·m, 15 lb·ft) • Spark plug cap Install: • Rear cover 2 • Rear cover 1 (Refer to “COVERS AND FUEL TANK”...
  • Page 42 PERIODIC MAINTENANCE Measure: • Compression pressure Crank the engine until the needle stop rising on the compression gauge. Out of specification  Refer to the testing steps. Standard compression pressure: 800–950 kPa (8.0–9.5 kg/cm², 116–137.75 psi) WARNING To prevent sparking when cranking the engine, ground the high tension cord.

  • Page 43: Rated Engine Speed

    PERIODIC MAINTENANCE RATED ENGINE SPEED Attach: • Digital tachometer “1” Digital tachometer: YU-39951-B, 90890-06760 Operate the engine (with no load). Measure: • Rated engine speed Out of specification  Refer to “ENGINE SPEED DOES NOT INCREASE” on page 6-5 and “ENGINE SPEED IS UNEVEN”...

  • Page 44: Output Voltage

    PERIODIC MAINTENANCE OUTPUT VOLTAGE Operate the generator (with no load). Check: • Output indicator “1” No indicator comes on  Refer to “GENERATOR SYSTEM” on page 6-1. ENGINE SWITCH Check: • Engine switch “1” a. Turn the engine switch “1” to “I” (RUN) “2”. b.

  • Page 45: Boost Mode Switch

    PERIODIC MAINTENANCE Check after warming up the engine. • Economy control switch “1” a. Start the engine with no load. b. Turn the economy control switch “1” in the “ ”/ “ ” (OFF) position. A. For Europe and Korea B.

  • Page 46: Receptacle

    PERIODIC MAINTENANCE RECEPTACLE Check: • AC receptacle “1” Cracks/damage  Replace. Poor connection  Correct. A. For Europe and Korea B. For Australia and China ACCESSORY SOCKET Check: • Accessory socket “1” Cracks/damage  Replace. Poor connection  Correct. A. For Europe and Korea B.

  • Page 47: Multi-Function Led Meter

    PERIODIC MAINTENANCE MULTI-FUNCTION LED METER This generator has an integrated multi-function LED meter. Function Display Description Output indicator(s) come on according to the Power supply meter current power supply. Output indicator(s) flash according to the accu- Operating time meter mulated operation time. Overload indicator light comes on after output indicators come on, when an overload or some Overload warning...

  • Page 48: Power Supply Meter

    PERIODIC MAINTENANCE POWER SUPPLY METER Check: • Power supply display a. Start the engine. b. Connect any electric devices. c. Turn on any electric devices and check that the LED come on. OPERATING TIME METER Check: • Hour meter The accumulated operation time is displayed by output indicator lights “A”...

  • Page 49: Oil Warning

    PERIODIC MAINTENANCE Reduce the total wattage of connected electric devices within the rated output. Push the reset button for 3 seconds to release the power output stop. If you suspect overheating, stop the engine and check for clogging around the air inlet and control unit. The overload indicator light may come on for a few sec- onds at the first when using electric devices that require a large starting current, such as a compressor of a submers-...
  • Page 50 PERIODIC MAINTENANCE MEMO 2-32...

  • Page 51: Engine

    ENGINE CONTROL BOX 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the control box Remove the parts in the order listed. Front cover 1/2, rear cover 1/2, side cover Refer to “COVERS AND FUEL TANK”...

  • Page 52: Control Panel (For Europe And Korea)

    CONTROL BOX CONTROL PANEL (FOR EUROPE AND KOREA) 0.3 N ・ m (0.03 kgf ・ m, 0.22 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 1.3 N ・...
  • Page 53 CONTROL BOX CONTROL PANEL (FOR AUSTRALIA AND CHINA) 0.3 N ・ m (0.03 kgf ・ m, 0.22 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.37 lb ・ ft) 1.3 N ・...

  • Page 54: Muffler

    MUFFLER MUFFLER 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 7 N ・...

  • Page 55: Installing The Muffler

    MUFFLER INSTALLING THE MUFFLER Install: • Spark arrester “1” • Muffler screen “2” • Muffler cap “3” • Muffler band “4” • Muffler band bolt “5” Muffler band bolt: 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) A. Top view B. Side view •...

  • Page 56: Engine

    ENGINE ENGINE 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the engine Remove the parts in the order listed. Front cover 1/2, rear cover 1/2, side cover Refer to “COVERS AND FUEL TANK”...

  • Page 57: Recoil Starter, Flywheel And Cdi Magneto

    RECOIL STARTER, FLYWHEEL AND CDI MAGNETO RECOIL STARTER, FLYWHEEL AND CDI MAGNETO 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・...

  • Page 58: Recoil Starter

    RECOIL STARTER, FLYWHEEL AND CDI MAGNETO RECOIL STARTER 3.4 N ・ m (0.34 kgf ・ m, 2.5 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Disassembling the recoil starter Disassemble the parts in the order listed. Drive plate Drive pawl Spring Sheave drum Starter spring...

  • Page 59: Disassembling The Recoil Starter

    RECOIL STARTER, FLYWHEEL AND CDI MAGNETO DISASSEMBLING THE RECOIL STARTER Remove: • Recoil starter assembly Make a knot “a” at the end of the starter rope to prevent the rope from being retracted into the starter case. Remove: • Sheave drum “1” NOTICE Be sure to press down on the sheave drum, because the spring will spring out suddenly when it is removed...

  • Page 60: Assembling The Recoil Starter

    RECOIL STARTER, FLYWHEEL AND CDI MAGNETO ASSEMBLING THE RECOIL STARTER Install: • Starter spring “1” • Sheave drum “2” Engage starter spring outer hook “a” with groove “b” on the sheave drum “2”. Carefully wind the starter spring counter- clockwise and place it on the sheave drum “2”. Install: •...

  • Page 61: Removing The Cdi Magneto And Flywheel

    RECOIL STARTER, FLYWHEEL AND CDI MAGNETO Install: • Clip “1” • Drive plate “2” As illustrated, insert the projection of drive pawl and the projection of sheave drum into the groove of drive plate “2”, and install them. Install: • Drive plate screw “1” Drive plate screw: 3.4 N·m (0.34 kgf·m, 2.5 lb·ft) •...

  • Page 62: Installing The Cdi Magneto And Flywheel

    RECOIL STARTER, FLYWHEEL AND CDI MAGNETO Remove: • Flywheel “1” • Remove the flywheel “1” using the flywheel puller “2”, bolts “3”. • Fully tighten the tool holding bolts, making sure the tool body is parallel with the flywheel. If necessary, one bolt may be backed out slightly to level the tool body.
  • Page 63 RECOIL STARTER, FLYWHEEL AND CDI MAGNETO • Tighten the flywheel nut “1” using the sheave holder “2” to hold the flywheel. • When installing the flywheel, make sure the woodruff key is properly seated in the key way of the crankshaft. Primary clutch holder: YS-01880-A Sheave holder:...

  • Page 64: Generator

    GENERATOR GENERATOR 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 40 N ・...

  • Page 65: Removing The Generator Rotor And Stator Assembly

    GENERATOR REMOVING THE GENERATOR ROTOR AND STATOR ASSEMBLY Remove: • Rear end cover “1” NOTICE Remove carefully because the magnetic force of the generator rotor is very strong. Remove: • Stator assembly bolts “1” • Rear end cover “2” • Stator assembly “3” •...

  • Page 66: Installing The Generator Rotor And Stator Assembly

    GENERATOR Remove: • Generator fan “1” INSTALLING THE GENERATOR ROTOR AND STATOR ASSEMBLY Install: • Generator fan Generator fan bolt: 7 N·m (0.7 kgf·m, 5.2 lb·ft) Install: • Stator assembly “1” • Stator assembly bolts “2” Stator assembly bolt: 10 N·m (1.0 kgf·m, 7.4 lb·ft) Tighten: •...

  • Page 67: Cylinder Head Cover, Cylinder Head

    CYLINDER HEAD COVER, CYLINDER HEAD CYLINDER HEAD COVER, CYLINDER HEAD 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) 6 N ・...
  • Page 68 CYLINDER HEAD COVER, CYLINDER HEAD 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) 6 N ・...

  • Page 69: Checking The Push Rod

    CYLINDER HEAD COVER, CYLINDER HEAD CHECKING THE PUSH ROD Check: • Push rod runout Runout limit: 0.5 mm (0.02 in) Out of specifications  Replace. CHECKING THE CYLINDER HEAD Check: • Cylinder head combustion chamber Check the combustion chamber for carbon depos- its.

  • Page 70: Installing The Cylinder Head Assembly

    CYLINDER HEAD COVER, CYLINDER HEAD INSTALLING THE CYLINDER HEAD ASSEMBLY Install: • Cylinder head • Cylinder head bolts “1” to “4”. Tighten the bolts to the specified torque in two steps and in order from “1” to “4”. Cylinder head bolt: 1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft) 2nd: 11 N·m (1.1 kgf·m, 8.1 lb·ft) INSTALLING THE CYLINDER HEAD COVER...

  • Page 71: Valve

    VALVE VALVE 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the valve Remove the parts in the order listed. Refer to “CYLINDER HEAD COVER, CYLIN- Cylinder head DER HEAD” on page 3-17. Rocker arm shaft Locknut Adjuster...

  • Page 72: Removing The Valves And Valve Springs

    VALVE REMOVING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves, valve springs and related components. Remove: • Valve cotter “1” • Valve spring retainer “2” • Valve spring “3” • Valve “4” • Valve stem seal (Intake side only) Remove the parts using the valve spring compres- sor “5”.
  • Page 73 VALVE Out of specifications  Replace. Measure: • Valve stem runout Valve stem runout limit: 0.01 mm (0.0004 in) Out of specifications  Replace. The value is half of that indicated on the dial indicator gauge. Measure: • Valve spring free length “a” Valve spring free length (Intake): 26.5 mm (1.0433 in) Valve spring free length (Exhaust):...

  • Page 74: Checking The Rocker Arms

    VALVE Check: • Valve spring contact surface “a” More than 2/3 of the contact surface does not con- tact  Replace. CHECKING THE ROCKER ARMS Check: • Rocker arms Wear/damage/cracks  Replace. CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats.

  • Page 75: Valve Lapping

    VALVE Valve face contact width (Intake): 0.4–0.6 mm (0.0157–0.0236 in) Valve face contact width (Exhaust): 0.4–0.6 mm (0.0157–0.0236 in) Limit (Intake): 1.1 mm (0.043 in) Limit (Exhaust): 1.1 mm (0.043 in)  specification/rough/eccentric wear Replace. Measure: • Valve seat contact width “a” Make sure that the contact width along the entire valve seat is within specifications.

  • Page 76: Installing The Valves And Valve Springs

    VALVE NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide. After every lapping procedure, clean off the compound from the valve face and valve seat. INSTALLING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves, valve springs and related components.
  • Page 77 VALVE • When installing the valve stem seal, install it so that the outer spring “c” does not come off. • When “YI” is stamped on the stamped portion “d” of the valve, install the valve on the intake side of the cylinder head, and when “YE”...

  • Page 78: Crankcase Cover And Camshaft

    CRANKCASE COVER AND CAMSHAFT CRANKCASE COVER AND CAMSHAFT 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 10 N ・...
  • Page 79 CRANKCASE COVER AND CAMSHAFT 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 10 N ・...

  • Page 80: Checking The Camshaft

    CRANKCASE COVER AND CAMSHAFT CHECKING THE CAMSHAFT Check: • Camshaft Crack/damage/wear  Replace. Check: • Camshaft lobe dimensions “a” and “b” Camshaft lobe dimensions Lobe height “a” (Intake): 20.540 ± 0.05 mm (0.81 ± 0.002 in) Limit: 20.39 mm (0.802 in) Lobe height “a”...

  • Page 81: Checking The Valve Lifters

    CRANKCASE COVER AND CAMSHAFT Check: • Camshaft journal diameter “a” Camshaft journal diameter: 11.965–11.990 mm (0.4711–0.4720 in) Limit: 11.95 mm (0.4705 in) Out of specification  Replace. CHECKING THE VALVE LIFTERS Check: • Valve lifters Damage  Replace. CHECKING THE CRANKCASE COVER Check: •...

  • Page 82: Installing The Crankcase Cover

    CRANKCASE COVER AND CAMSHAFT INSTALLING THE CRANKCASE COVER Install: • Oil level switch “1” Oil level switch bolt: 10 N·m (1.0 kgf·m, 7.4 lb·ft) Pass the lead wire “a” of the oil level switch as shown. Install: • Oil level switch lead clamp “1” Oil level switch lead clamp bolt: 10 N·m (1.0 kgf·m, 7.4 lb·ft) Install:...

  • Page 83: Piston, Connecting Rod, Crankshaft And Crankcase

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the piston, connecting rod, Remove the parts in the order listed. crankshaft and crankcase Refer to “RECOIL STARTER, FLYWHEEL Recoil starter...
  • Page 84 PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE 9 N ・ m (0.9 kgf ・ m, 6.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Piston Piston ring set Bearing Oil seal Dowel pin Crankcase 3-34...

  • Page 85: Checking The Cylinder And Piston

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE CHECKING THE CYLINDER AND PISTON Check: • Piston wall • Cylinder wall Vertical scratches  Replace the cylinder, and replace the piston and piston rings as a set. Measure: • Cylinder warpage Measure the warpage on the contact surface of the cylin- der at six points using the straight edge and thickness gauge.

  • Page 86: Checking The Crankcase

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE c. Measure piston skirt diameter “P” with the micrometer. a = 10 mm (0.3937 in) from the piston bottom edge Piston diameter: 48.574–48.594 mm (1.9124–1.9131 in) Limit: 48.53 mm (1.9106 in) d. If out of specification, replace the piston and pis- ton rings as a set.

  • Page 87: Checking The Piston Rings

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE Measure: • Piston pin hole inside diameter “a” Out of specification  Replace. Piston pin hole inside diameter: 12.004–12.015 mm (0.4726–0.4730 in) Limit: 12.045 mm (0.4742 in) Measure: • Piston pin diameter “a” Out of specification  Replace. Piston pin diameter: 11.996–12.000 mm (0.4723–0.4724 in) Limit:...
  • Page 88 PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE Piston ring Top ring: Side clearance: 0.04–0.08 mm (0.0016–0.0031 in) Limit: 0.12 mm (0.0047 in) 2nd ring: Side clearance: 0.04–0.08 mm (0.0016–0.0031 in) Limit: 0.12 mm (0.0047 in) Install: • Piston ring (into the cylinder) Use the piston crown to level the piston ring near bottom of cylinder “a”, where cylinder wear is lowest.

  • Page 89: Checking The Crankshaft

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE CHECKING THE CRANKSHAFT Check: • Crankshaft sprocket “1” Crack/damage/wear  Replace the crankshaft. Measure: • Crankshaft runout limit Out of specification  Replace. Use a dial gauge. Dial indicator gauge: YU-A8428 Dial gauge: 90890-03097 Runout limit: 0.03 mm (0.0012 in) Measure:...

  • Page 90: Installing The Piston And Piston Rings

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE Install: • Connecting rod “1” • Connecting rod cap “2” Connecting rod cap bolt: 9 N·m (0.9 kgf·m, 6.6 lb·ft) Tighten the cap bolts so that the crankshaft does not move while the oil clearance is being measured. Remove: •...

  • Page 91: Installing The Crankshaft

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE Apply the engine oil to the inside of the connecting rod small end. Install: • Piston “1” • Piston pin “2” • Piston pin circlips “3” • Make sure that the “FWM” mark “a” on the connecting rod faces as shown.
  • Page 92 PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE Install: • Camshaft (Refer to “INSTALLING THE VALVE LIFTERS AND CAMSHAFT” on page 3-31) • Crankcase cover (Refer “INSTALLING CRANKCASE COVER” on page 3-32) 3-42...

  • Page 93: Carburetor

    CARBURETOR REMOVING THE CARBURETOR AND AIR FILTER 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 10 N ・...

  • Page 94: Disassembling The Carburetor

    DISASSEMBLING THE CARBURETOR DISASSEMBLING THE CARBURETOR 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 1.0 N ・ m (0.10 kgf ・ m, 0.73 lb ・ ft) 1.7 N ・ m (0.17 kgf ・ m, 1.3 lb ・ ft) 7 N ・...

  • Page 95: Installing The Throttle Control Motor

    DISASSEMBLING THE CARBURETOR INSTALLING THE THROTTLE CONTROL MOTOR Install: • Throttle control motor “1” NOTICE Do not turn the shaft “a” of the throttle control motor by hand. It may cause internal gear damage. • Install the shaft “a” of the throttle control motor by align- ing it with the groove “b”...
  • Page 96 DISASSEMBLING THE CARBURETOR Install: Install the choke cable holder to front cover 2. • Choke cable holder “1” • Screw “2” (Refer to “COVERS AND FUEL TANK” on page 2-3) Install: • Inner cable “1” Choke cable screw: 1.0 N·m (0.10 kgf·m, 0.73 lb·ft) Insert it until cap “a”...

  • Page 97: Fuel Pump

    FUEL PUMP FUEL PUMP 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Removing the fuel pump Remove the parts in the order listed. Fuel hose (engine switch side) Pulsar hose Fuel hose (carburetor side) Fuel pump...

  • Page 98: Checking The Fuel Pump

    FUEL PUMP CHECKING THE FUEL PUMP Check: • Fuel hose (engine switch side) “1” • Pulsar hose “2” • Fuel hose (carburetor side) “3” • Fuel pump “4” Cracks/damage  Replace. Check: • Fuel pump operation a. Connect the manual vacuum pump (Vacuum/ pressure pump gauge set) “1”...
  • Page 99 FUEL PUMP MEMO...

  • Page 100: Electrical

    ELECTRICAL CIRCUIT DIAGRAM (FOR EUROPE AND KOREA)
  • Page 101 CIRCUIT DIAGRAM 1. Generator 2. DC coil 3. AC sub coil 4. AC coil 5. AC/DC converter 6. Control box 7. Accessory socket 8. Twin Tech (parallel running terminal) 9. AC receptacle 10.Multi-function LED meter 11.Economy control switch 12.Boost mode switch/Reset button 13.Ground (Earth) terminal 14.Engine switch 15.Fuel cock ground (earth)

  • Page 102: (For Australia And China)

    CIRCUIT DIAGRAM (FOR AUSTRALIA AND CHINA)
  • Page 103 CIRCUIT DIAGRAM 1. Generator 2. DC coil 3. AC sub coil 4. AC coil 5. AC/DC converter 6. Control box 7. Accessory socket 8. Twin Tech (parallel running terminal) 9. AC receptacle 10.Multi-function LED meter 11.Economy control switch 12.Boost mode switch/Reset button 13.Ground (Earth) terminal 14.Engine switch 15.Fuel cock ground (earth)

  • Page 104: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1. Engine switch 2. CDI magneto 3. CDI unit/ignition coil 4. Oil level switch 5. AC/DC converter 6. Control unit 7. Spark plug 8. Generator assembly 9. Throttle control motor...

  • Page 105: Control Unit

    ELECTRICAL COMPONENTS CONTROL UNIT 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.95 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 7 N ・...

  • Page 106: Installing The Control Unit

    ELECTRICAL COMPONENTS INSTALLING THE CONTROL UNIT Install: • Control unit “1” Install control unit “1” inside of projection “a” of base mount “2”. CHECKING THE SWITCH CONTINUITY Check each switch for continuity with the tester. If the con- tinuity reading is incorrect, check the wiring connections O.L”...

  • Page 107: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS B. Disconnect the connector and check. CHECKING THE IGNITION SPARK GAP Check: • Engine oil level Insufficient  Add the engine oil. (Refer to “ENGINE OIL LEVEL” on page 2-11) Check: • Spark plug condition Wear/damage  Replace. (Refer to “SPARK PLUG”...

  • Page 108: Checking The Spark Plug Cap Resistance

    ELECTRICAL COMPONENTS CHECKING THE SPARK PLUG CAP RESISTANCE Remove: • Spark plug cap Check: • Spark plug cap resistance Out of specification  Replace the spark plug cap. Spark plug cap resistance: 3.75–6.25 k a. Remove the spark plug cap from the high tension cord.

  • Page 109: Checking The Cdi Magneto Resistance

    ELECTRICAL COMPONENTS a. Remove the ignition coil (CDI unit, ignition coil). b. Connect the digital circuit tester () to the sec- ondary terminal. Model 88 Multimeter with tachometer: YU-A1927 Digital circuit tester (CD732): 90890-03243 • Positive tester probe  High tension cord “1” •...

  • Page 110: Checking The Oil Level Switch

    ELECTRICAL COMPONENTS a. Connect the digital circuit tester () to the charge coil terminal. Model 88 Multimeter with tachometer: YU-A1927 Digital circuit tester (CD732): 90890-03243 • Positive tester probe  Red/White terminal “1” • Negative tester probe  Black terminal “2” b.

  • Page 111: Checking The Main Coil Ac Voltage

    ELECTRICAL COMPONENTS CHECKING THE MAIN COIL AC VOLTAGE Measure: • Main coil AC voltage Too low  Replace the generator rotor. Does not generate  Measure the main coil resis- tance. Main coil AC voltage: 326–488 V/4900 r/min a. Start the engine. b.

  • Page 112: Checking The Sub Coil Ac Voltage

    ELECTRICAL COMPONENTS CHECKING THE SUB COIL AC VOLTAGE Measure: • Sub coil AC voltage Within specification  Replace the control unit. Too low  Replace the generator rotor. Does not generate  Measure the sub coil resis- tance. Sub coil AC voltage: 16–24 V/4900 r/min a.

  • Page 113: Checking The Dc Coil Ac Voltage

    ELECTRICAL COMPONENTS CHECKING THE DC COIL AC VOLTAGE Measure: • DC coil “1” AC voltage Within specification  Replace the AC/DC con- verter. Too low  Replace the generator rotor. Does not generate  Measure the DC coil resis- tance. DC coil AC voltage: 29–43 V/4900 r/min a.

  • Page 114: Checking The Throttle Control System

    ELECTRICAL COMPONENTS CHECKING THE THROTTLE CONTROL SYSTEM Check: • AC output Weak/uneven  Refer to “GENERATOR SYSTEM” on page 6-1. Check: • Throttle control motor rotation Does not turns smoothly  Replace the throttle control motor. Measure: • Throttle control motor coil resistance Out of specification ...

  • Page 115: Checking The Multi-Function Led Meter

    ELECTRICAL COMPONENTS CHECKING THE MULTI-FUNCTION LED METER The overload indicator light on the multi-function LED meter comes on or flashes when an overload is detected, the inverter control unit overheats, or the AC output volt- age rises. Then the AC protector will trip, stopping power generation in order to protect the generator and any connected elec- tric devices.
  • Page 116 ELECTRICAL COMPONENTS MEMO 5-17...

  • Page 117: Troubleshooting

    TROUBLESHOOTING GENERATOR SYSTEM TROUBLESHOOTING WEAK OR NO AC CURRENT Checking procedures 1. Overload indicator light 5. Main coil AC voltage 2. Power supply meter 6. Main coil resistance 3. Throttle control system 7. Sub coil AC voltage 4. Wire harness 8.
  • Page 118 GENERATOR SYSTEM 4. Wire harness Checking steps Possible remedy Good  Proceed to step 5. Check the terminal of the connector for contamina- Contamination, rust or disconnection  Connect or tion, rust or disconnection. replace the connector or wire harness. 5.
  • Page 119 GENERATOR SYSTEM Model 88 Multimeter with tachometer: YU-A1927 Digital circuit tester (CD732): 90890-03243 1. Overload indicator light Checking steps Possible remedy Comes on  Refer to “OVERLOAD WARNING” on Check the overload indicator light comes on. page 2-30. Does not comes on  Proceed to step 2. 2.

  • Page 120: Engine Does Not Start

    ENGINE DOES NOT START ENGINE DOES NOT START IGNITION SYSTEM The ignition system fails to operate (no spark or intermittent spark). Checking steps Possible remedy Check the spark plug. Re-gap or replace the spark plug. (Refer to “SPARK PLUG” on page 2-14) Check the ignition spark gap.

  • Page 121: Engine Speed Does Not Increase

    OTHER TROUBLES ENGINE SPEED DOES NOT INCREASE Checking steps Possible remedy Check the spark plug for dirt and check the spark plug gap. Clean, adjust, or replace the spark plug. Check the air filter element for dirt. Clean. Clean or replace spark arrester, muffler Check spark arrester, muffler and air filter.

  • Page 122: Engine Speed Is Uneven

    OTHER TROUBLES ENGINE SPEED IS UNEVEN Checking steps Possible remedy Check the fuel level. Add the fuel if it is insufficient. Check if fuel has deteriorated. Replace the fuel. Check the spark plug for dirt and check the spark plug gap. Clean, adjust, or replace the spark plug. •...

  • Page 123: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Model name: EF2200iS Model code number: 7PC300 (For Europe) 7PC301 (For Australia) 7PC302 (For Korea) 7PC303 (For China) Dimensions: Overall length 555 mm (21.8 in) Overall width 300 mm (11.8 in) Overall height 470 mm (18.5 in) Dry weight 25 kg (55.1 lb)
  • Page 124 GENERAL SPECIFICATIONS Air filter system Semi-wet (urethane foam) Cooling system Air cooled Starting system Recoil starter Stopping system Misfire Rotating direction Clockwise (from flywheel) Governor type Electrical system Electrical: Ignition system Ignition timing (3000 r/min) BTDC 23 Spark plug type BPR6HS (NGK) Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
  • Page 125 GENERAL SPECIFICATIONS Rated engine speed 4900 r/min Economy control engine speed 3500 r/min Boost mode engine speed 5500 r/min Voltage stability Within ± 0.1 % Frequency stability Within ± 0.1 Hz Rotating speed control Throttle motor control type Wave distortion ratio Less than 2.5 % Number of phase Single phase...

  • Page 126: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Piston: Piston-to-cylinder clearance 0.020–0.035 mm (0.0008–0.0014 in) Limit 0.150 mm (0.0059 in) Piston diameter 48.574–48.594 mm (1.9124–1.9131 in) Limit 48.53 mm (1.9106 in) Measuring point (from piston 10 mm (0.3937 in) skirt bottom) Oversize 1st 48.85 mm (1.9232 in) 49.10 mm (1.9331 in) Piston pin hole inside diameter...
  • Page 127 MAINTENANCE SPECIFICATIONS Limit 48.620 mm (1.9142 in) Taper limit 0.05 mm (0.002 in) Warpage limit 0.05 mm (0.002 in) Crankshaft: Big end side clearance 0.1–0.3 mm (0.004–0.012 in) Limit 0.35 mm (0.014 in) Runout limit 0.03 mm (0.0012 in) Crank pin outside diameter 21.969–21.984 mm (0.8649–0.8655 in) Limit 21.939 mm (0.8637 in)
  • Page 128 MAINTENANCE SPECIFICATIONS Valve face contact width 0.4–0.6 mm (0.0157–0.0236 in) (Exhaust) Limit (Intake) 1.1 mm (0.043 in) Limit (Exhaust) 1.1 mm (0.043 in) Valve seat contact width 0.4–0.6 mm (0.0157–0.0236 in) (Intake) Valve seat contact width 0.4–0.6 mm (0.0157–0.0236 in) (Exhaust) Limit (Intake) 1.1 mm (0.043 in)

  • Page 129: Electrical

    MAINTENANCE SPECIFICATIONS Pilot air jet ø1.3 Pilot outlet ø0.8 Valve seat size ø1.2 232.5–267.5  at 25 C (77 F) Throttle control motor coil resis- tance ELECTRICAL Electrical: Ignition system Ignition timing (3000 r/min) BTDC 23 Ignition timing (5000 r/min) BTDC 33...
  • Page 130 TIGHTENING TORQUES TIGHTENING TORQUES Item Thread size Tightening torque M6  1.0 Exhaust pipe stud bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) M6  1.0 Intake manifold stud bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft) M6 ...
  • Page 131 TIGHTENING TORQUES Item Thread size Tightening torque Engine switch (fuel cock) knob — 0.9 N·m (0.09 kgf·m, 0.66 lb·ft) screw Engine switch screw — 0.9 N·m (0.09 kgf·m, 0.66 lb·ft) Control unit cover screw — 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Control panel screw —...

  • Page 132: Tightening Torques

    GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifi- cations for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached.

  • Page 133: Lubrication Points And Type Of Lubricants

    LUBRICATION POINTS AND TYPE OF LUBRICANTS LUBRICATION POINTS AND TYPE OF LUBRICANTS Part name Type of lubricant Oil seal lip Bearing Connecting rod big end Crank pin Crankshaft journal Crankshaft journal (recoil starter side) Connecting rod cap bolt Piston pin Piston Crankshaft gear teeth Valve stem...

  • Page 134: Wire Routing Diagram

    WIRE ROUTING DIAGRAM WIRE ROUTING DIAGRAM CONTROL PANEL AND CONTROL BOX (FOR EUROPE AND KOREA) 7-12...
  • Page 135 WIRE ROUTING DIAGRAM 1. Accessory socket 6. Terminal cap (For Europe) 2. Economy control switch 7. Ground (Earth) terminal 3. Multi-function LED meter 8. AC receptacle 4. Boost mode switch/Reset button 9. Control panel 5. Twin Tech (parallel running terminal) 10.Wire harness A.

  • Page 136: Control Panel And Control Box (For Australia And China)

    WIRE ROUTING DIAGRAM CONTROL PANEL AND CONTROL BOX (FOR AUSTRALIA AND CHINA) 7-14...
  • Page 137 WIRE ROUTING DIAGRAM 1. Accessory socket 6. Ground (Earth) terminal 2. Economy control switch 7. AC receptacle 3. Multi-function LED meter 8. Control panel 4. Boost mode switch/Reset button 9. Wire harness 5. Twin Tech (parallel running terminal) A. Put the washer between the resin nut and the control panel. B.

  • Page 138: Engine And Generator

    WIRE ROUTING DIAGRAM ENGINE AND GENERATOR 7-16...
  • Page 139 WIRE ROUTING DIAGRAM 1. Wire harness lead 2. Ignition coil lead A. Secure the wire harness leads and ignition coil leads in the location of white tape. B. Secure the wire harness leads and other leads in the location of white tape. C.

  • Page 140: Upper Side And Left Side View

    WIRE ROUTING DIAGRAM UPPER SIDE AND LEFT SIDE VIEW 7-18...
  • Page 141 WIRE ROUTING DIAGRAM 1. Throttle control motor lead 3. Wire harness 2. Generator output lead 4. Control unit A. Route the throttle control motor lead as shown in the illustration. B. Route the generator output lead as shown in the illustration. C.

  • Page 142: Control Unit

    WIRE ROUTING DIAGRAM CONTROL UNIT 7-20...
  • Page 143 WIRE ROUTING DIAGRAM 1. Control box assembly 6. 11-pole coupler 2. Wire harness 7. 2-pole coupler 3. AC/DC converter 8. 6-pole coupler 4. Throttle control motor lead 9. 2-pole coupler 5. Control unit 10.3-pole coupler A. Clamp the AC/DC converter leads together and insert them into the holes in the cover. B.

  • Page 144: Generator

    WIRE ROUTING DIAGRAM GENERATOR 7-22...
  • Page 145 WIRE ROUTING DIAGRAM 1. Clamp 4. Generator grommet 2. Generator assembly 5. Rear end cover 3. Generator fan A. Install within the range of 45. B. Wire harness routing position. C. Insert until it hits. 7-23...

  • Page 146: Upper Side And Air Filter Side View

    WIRE ROUTING DIAGRAM UPPER SIDE AND AIR FILTER SIDE VIEW 7-24...
  • Page 147 WIRE ROUTING DIAGRAM 1. Fuel tank bracket 5. Choke cable 2. Control unit cover 6. Choke knob 3. Grommet 7. Choke cable holder 4. Mount base complete 8. Throttle control motor cover A. Install the control unit cover only after wiring of the control unit is complete. B.

  • Page 148: Carburetor And Air Filter

    WIRE ROUTING DIAGRAM CARBURETOR AND AIR FILTER 7-26...
  • Page 149 WIRE ROUTING DIAGRAM 1. Gasket 8. Air filter element 2. Joint 9. Air filter case 3. Throttle control motor assembly 10.Air filter case cover 4. Damper 11.Air filter case joint 5. Carburetor assembly 12.Air filter case gasket 6. Crankcase 13.Pipe 1 7.

  • Page 150: Fuel Tank And Fuel Hoses

    WIRE ROUTING DIAGRAM FUEL TANK AND FUEL HOSES 7-28...
  • Page 151 WIRE ROUTING DIAGRAM 1. Fuel tank 8. Fuel hose (fuel cock to fuel pump) 2. Engine switch (together with fuel cock) 9. Drain hose (carburetor to carburetor fuel drain cock) 3. Screw 10.Clip 4. Clip 11.Fuel drain hose 5. Clip 12.Carburetor fuel drain cock assembly 6.
  • Page 152 WIRE ROUTING DIAGRAM 7-30...
  • Page 153 WIRE ROUTING DIAGRAM 1. Fuel tank 5. Engine switch (together with fuel cock) 2. Clip 6. Carburetor assembly 3. Fuel pump 7. Pulsar hose 4. Fuel hose (fuel cock to fuel pump) 8. Fuel hose (fuel pump to carburetor) A. White paint B.

  • Page 154: Oil Level Switch (Crankcase Cover) And Cdi Magneto

    WIRE ROUTING DIAGRAM OIL LEVEL SWITCH (CRANKCASE COVER) AND CDI MAGNETO 7-32...
  • Page 155 WIRE ROUTING DIAGRAM 1. CDI unit/ignition coil 5. CDI magneto 2. Spark plug cap seal 6. Oil level switch 3. Spark plug cap 7. Oil level switch lead clamp 4. Flywheel A. Twist the high tension cord in until it comes in contact with the spark plug cap. B.
  • Page 156 APPENDIX CIRCUIT DIAGRAM (FOR EUROPE AND KOREA)
  • Page 157 1. Generator 2. DC coil 3. AC sub coil 4. AC coil 5. AC/DC converter 6. Control box 7. Accessory socket 8. Twin Tech (parallel running terminal) 9. AC receptacle 10.Multi-function LED meter 11.Economy control switch 12.Boost mode switch/Reset button 13.Ground (Earth) terminal 14.Engine switch 15.Fuel cock ground (earth)
  • Page 158 (FOR AUSTRALIA AND CHINA)
  • Page 159 1. Generator 2. DC coil 3. AC sub coil 4. AC coil 5. AC/DC converter 6. Control box 7. Accessory socket 8. Twin Tech (parallel running terminal) 9. AC receptacle 10.Multi-function LED meter 11.Economy control switch 12.Boost mode switch/Reset button 13.Ground (Earth) terminal 14.Engine switch 15.Fuel cock ground (earth)
  • Page 160 MEMO...
  • Page 162 2019.09×1 !

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