Honda EU30i Manual
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How to use this manual
A Few Words About Safety
How to use this manual
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and precau-
tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda EU30i

  • Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2: Table Of Contents

    CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER FUEL SYSTEM GOVERNOR SYSTEM GENERATOR/CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL MUFFLER GENERATOR/ENGINE REMOVAL/INSTALLATION CYLINDER HEAD CYLINDER BLOCK TECHNICAL FEATURES WIRING DIAGRAMS INDEX...
  • Page 3 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Mo- tor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 4 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
  • Page 5 How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery Bottom Dead Center...
  • Page 6: Specifications

    1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 PERFORMANCE CURVES··························· 1-5 SPECIFICATIONS ·········································1-2 DIMENSIONAL DRAWINGS························· 1-8...
  • Page 7 Refer to it when ordering parts or making technical inquiries. ENGINE SERIAL NUMBER FRAME SERIAL NUMBER SPECIFICATIONS DIMENSIONS AND WEIGHTS Model EU30i EU3000i Type GW, G, G8, F, IT, S, S8, SK, R, U, L, LT, RH, RG Description code EAVJ Overall length 622 mm (24.5 in)
  • Page 8 SPECIFICATIONS GENERATOR Model EU3000i EU30i Type Description code EAVJ Generator type Multi–electrode field rotation type Generator structure Self–ventilation, drip–proof type Excitation Self–excitation Voltage regulation system PWM (Pulse width modulation) Phase Single phase Rotating direction Clockwise (Viewed from the generator) Rated output...
  • Page 9 SPECIFICATIONS CHARACTERISTICS Model EU3000i EU30i Type Voltage variation Momentary 10% max. rate Average 6% max. Average time 3 sec. max. Voltage stability ± 1% max. Frequency varia- Momentary 1% max. tion rate Average 1% max. Average time 1 sec. max.
  • Page 10 SPECIFICATIONS PERFORMANCE CURVES The curve shows performance of the generator under average conditions. Performance may vary to some degree depending on ambient temperature and humidity. The output voltage will be higher than usual when the generator is still cold, immediately after the engine starts. AC EXTERNAL CHARACTERISTIC CURVES GW, G, G8, F, IT, RG, RH TYPE AC 250...
  • Page 11 SPECIFICATIONS U TYPE AC 255 LOAD CURRENT (A) C, L, LT TYPE AC 135 LOAD CURRENT (A)
  • Page 12 SPECIFICATIONS DC EXTERNAL CHARACTERISTIC CURVE DC 30 LOAD CURRENT (A) *This DC output characteristic was measured with the condition that condensers (200,000 μF) were parallel-connected.
  • Page 13 SPECIFICATIONS DIMENSIONAL DRAWINGS Unit: mm (in) 379 (14.9) 468 (18.4) 445 (17.5) 622 (24.5)
  • Page 14: Service Information

    2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-5 TORQUE VALUES ········································2-3 CABLE/HARNESS ROUTING ······················ 2-7 LUBRICATION & SEAL POINT ····················2-4...
  • Page 15 SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Unit: mm (in) Part Item Standard Service limit Engine Engine speed Eco–Throttle OFF 3,600 ± 100 min (rpm) – Cylinder compression 0.42 MPa – (4.3 kgf/cm , 61 psi) at 600 min (rpm) Cylinder Sleeve I.D.
  • Page 16 SERVICE INFORMATION GENERATOR Service Part Item Terminals Standard limit 0.6 – 1.1 Ω 2 – 3 – 0.6 – 1.1 Ω AC coil resistance 2 – 4 – 0.6 – 1.1 Ω 3 – 4 – Stator 0.4 – 0.7 Ω Sub coil resistance 1 –...
  • Page 17 SERVICE INFORMATION Torque values Item Thread dia. (mm) N·m kgf·m lbf·ft Engine switch base screw M5 (Screw) 0.14 Engine switch knob screw M5 x 0.8 0.23 Cock cable nut Control panel bolt M6 x 1.0 0.95 Inverter bolt M6 x 1.0 0.95 Fuel tank bracket bolt M6 x 1.0...
  • Page 18 SERVICE INFORMATION TOOLS Float level gauge Sliding hammer weight Bearing driver attachment, 37×40 07401-0010000 07741-0010201 07746-0010200 Bearing driver attachment, 52×55 Pilot, 25 Driver handle, 15×135L 07746-0010400 07746-0040600 07749-0010000 Seat cutter, 24.5 Seat cutter, 27.5 Flat cutter, 25 07780-0010100 07780-0010200 07780-0012000 Flat cutter, 28 Interior cutter, 30 Cutter holder, 5.5...
  • Page 19 SERVICE INFORMATION Flywheel puller set Bearing remover shaft set 25 Valve guide driver, 5.0x9.4 07935-8050004 07936-ZV10100 07942-8920000 Valve guide reamer, 5.510 07984-2000001...
  • Page 20 SERVICE INFORMATION CABLE/HARNESS ROUTING ALL TYPES CABLE TIE C WHITE TAPE Clamp the indicator wire CABLE CLAMP F harness as shown. Cut the band end as shown. INDICATOR WIRE HARNESS Push the indicator 0 - 5 mm wire harness into the (0 - 0.2 in) groove beside the FRONT...
  • Page 21 SERVICE INFORMATION HARNESS BAND CLIP COUPLER CLIP RECTIFIER HARNESS BAND CLIP GENERATOR WIRE HARNESS CONTROL WIRE HARNESS Terminal Terminal Wire color Wire color number number Y/G (*1), G (*2) Terminal Terminal Wire color Wire color number number G/Bl Bl/R R/W (*3) Generator wire harness side Rectifier side Terminal...
  • Page 22 SERVICE INFORMATION CONTROL WIRE HARNESS GENERATOR WIRE HARNESS GND1 CONTROL WIRE HARNESS THROTTLE CONTROL MOTOR SUB HARNESS Terminal Terminal Wire color Wire color number number Bl/R G/Bl Generator wire harness side Control wire harness side Bl/Bu Y/G (*1), G (*2) Y/G (*1), G (*2) Control wire harness side Terminal...
  • Page 23 SERVICE INFORMATION Terminal Wire color number INVERTER UNIT CONTROL WIRE HARNESS ENGINE STOP SWITCH Terminal Wire color number Control wire harness side Bl/R Terminal Wire color number Bl/R Engine stop switch side Black Brown Yellow Orange Bu Blue Lb Light blue Green Lg Light green Pink...
  • Page 24 SERVICE INFORMATION HARNESS BAND CLIP GENERATOR WIRE HARNESS IGNITION PULSE GENARATOR HARNESS BAND CLIP Terminal Wire color number CYLINDER HEAD COVER FAN COVER SEAL CLAMP IGNITION COIL HIGH TENSION CORD LOWER SHROUD CORD GROMMET GENERATOR WIRE Black Brown HARNESS Yellow Orange Bu Blue Lb Light blue...
  • Page 25 SERVICE INFORMATION GENERATOR WIRE OIL LEVEL SWITCH HARNESS HARNESS BAND CLIP CRANKCASE COVER FRONT FRAME Terminal Wire color number BREATHER TUBE SPARK PLUG CAP FAN COVER SEAL CLAMP HIGH TENSION CORD IGNITION COIL Black Brown Yellow Orange Bu Blue Lb Light blue GENERATOR WIRE Green Lg Light green...
  • Page 26 SERVICE INFORMATION CHOKE CABLE BREATHER TUBE FAN COVER GUIDE FAN COVER GUIDE CLAMP TUBE CLIP (B10) AIR INTAKE JOINT FUEL COCK TUBE FUEL TANK FRONT FRAME 8 mm WIRE BRACKET CLAMP CLAMP TUBE CLIP (B12) COCK CABLE FUEL TANK TUBE BREATHER TUBE FUEL TANK TUBE CLIP (B12)
  • Page 27 SERVICE INFORMATION G, G8, GW, F TYPES IGNITION CONTROL MODULE AC RECEPTACLE (16A-250V) (WHITE TAPE) (WHITE TAPE) PARALLEL OPERATION OUTLET TERMINAL CORD DC RECEPTACLE (WHITE TAPE) AC CIRCUIT PROTECTOR (16A) GND3 COUPLER CLIP GND2 TERMINAL CORD CABLE TIE AC CIRCUIT CONTROL WIRE WHITE TAPE PROTECTOR (16A)
  • Page 28 SERVICE INFORMATION IT TYPE IGNITION CONTROL MODULE AC RECEPTACLE TERMINAL (16A-240V) CORD PARALLEL OPERATION OUTLET AC CIRCUIT PROTECTOR (16A) DC RECEPTACLE GND3 COUPLER CLIP GND2 CABLE TIE CONTROL WIRE WHITE TAPE HARNESS Terminal Wire color number Terminal Wire coior number GND2 Control wire harness side Bl/Bu...
  • Page 29 SERVICE INFORMATION L, LT TYPES IGNITION CONTROL AC RECEPTACLE MODULE (30A-125V) AC RECEPTACLE (20A-125V) PARALLEL OPERATION OUTLET (WHITE TAPE) (WHITE TAPE) DC RECEPTACLE (WHITE TAPE) GND3 COUPLER CLIP WHITE TAPE GND2 CONTROL WIRE HARNESS CABLE TIE Terminal Terminal Wire color Wire coior number number...
  • Page 30 SERVICE INFORMATION R, RH, S, S8 TYPES IGNITION CONTROL MODULE AC RECEPTACLE (20A-250V) (WHITE TAPE) AC RECEPTACLE (20A-250V) PARALLEL OPERATION OUTLET (WHITE TAPE) DC RECEPTACLE (WHITE TAPE) GND3 COUPLER CLIP GND2 WHITE TAPE CONTROL WIRE HARNESS CABLE TIE Terminal Wire color number Terminal Wire coior...
  • Page 31 SERVICE INFORMATION RG, SK TYPES AC RECEPTACLE IGNITION CONTROL (16A-250V) MODULE (WHITE TAPE) AC RECEPTACLE (16A-250V) PARALLEL OPERATION OUTLET (WHITE TAPE) (WHITE TAPE) DC RECEPTACLE GND3 COUPLER CLIP WHITE TAPE GND2 CONTROL WIRE HARNESS CABLE TIE Terminal Wire color Terminal number Wire coior number...
  • Page 32 SERVICE INFORMATION U TYPE AC RECEPTACLE IGNITION CONTROL (15A-250V) MODULE (WHITE TAPE) AC RECEPTACLE (15A-250V) PARALLEL OPERATION OUTLET (WHITE TAPE) (WHITE TAPE) DC RECEPTACLE GND3 COUPLER CLIP WHITE TAPE GND2 CABLE TIE CONTROL WIRE HARNESS Terminal Wire color number Terminal Wire coior number GND2...
  • Page 33 SERVICE INFORMATION C TYPE AC RECEPTACLE AC RECEPTACLE (30A-125V) (20A-125V) AC CIRCUIT AC CIRCUIT IGNITION CONTROL PROTECTOR (30A) PROTECTOR (20A) MODULE SUB CORD A SUB CORD A (WHITE TAPE) DC RECEPTACLE AC CIRCUIT PROTECTOR (20A) BREATHER HEATER SUB CORD GND3 CABLE TIE GND2 COUPLER CLIP...
  • Page 34 SERVICE INFORMATION WITHOUT C TYPE THROTTLE CONTROL MOTOR Route the throttle control motor wire sub harness as shown. THROTTLE CONTROL MOTOR AIR INTAKE JOINT SUB HARNESS CHOKE CABLE (Page 2-9) HARNESS CLIP RESONATOR COVER CLAMP HARNESS CLIP THROTTLE CONTROL MOTOR HARNESS BAND CLIP SUB HARNESS Terminal...
  • Page 35 SERVICE INFORMATION C TYPE ONLY THROTTLE CONTOROL MOTOR Route the throttle control motor wire sub harness as shown. THROTTLE CONTOROL MOTOR SUB HARNESS THROTTLE CONTROL MOTOR RESONATOR SUB HARNESS COVER CLAMP BREATHER HEATER HARNESS BAND Cut the band end as shown. (Page 2-9) HARNESS BAND CLIP HARNESS CLIP...
  • Page 36 SERVICE INFORMATION BREATHER TUBE INSULATOR BREATHER TUBE C BREATHER TUBE A BREATHER HEATER INSULATOR BREATHER TUBE C BREATHER TUBE BREATHER HEATER INSULATOR B BREATHER TUBE A BREATHER HEATER INSULATOR BREATHER TUBE B AIR INTAKE JOINT AIR INTAKE JOINT INSULATOR 2-23...
  • Page 37 MEMO...
  • Page 38: Maintenance

    3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 SPARK ARRESTER CLEANING·················· 3-7 ENGINE OIL LEVEL CHECK ························3-3 VALVE CLEARANCE CHECK/ADJUSTMENT ································ 3-7 ENGINE OIL CHANGE··································3-3 COMBUSTION CHAMBER CLEANING ······· 3-9 AIR CLEANER CHECK/CLEANING ·············3-4 FUEL TANK & FILTER CLEANING ············· 3-9 SPARK PLUG CHECK/ADJUSTMENT ········3-5 FUEL TUBE CHECK ···································...
  • Page 39 (2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to Honda shop manual for service procedures. (3) For commercial use, log hours of operation to determine proper maintenance intervals.
  • Page 40 MAINTENANCE ENGINE OIL LEVEL CHECK Place the generator on a level surface. Open the oil maintenance cover (1). Remove the oil filler cap (2), and wipe the oil level gauge clean. Insert the oil filler cap without screwing it into the oil filler neck (3).
  • Page 41 MAINTENANCE Remove the oil filler cap (1) and the drain plug bolt (2) and drain the oil into the suitable container (3). Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation.
  • Page 42 MAINTENANCE Clean the elements in warm soapy water (1), rinse and allow to dry thoroughly, or clean with a high flash point solvent and allow to dry. Squeeze Wash Dip the elements in clean engine oil (2) and squeeze firmly out all the excess oil.
  • Page 43 MAINTENANCE Visually inspect the spark plug. Replace the plug if the insulator (1) is cracked or chipped. Remove carbon or other deposits with wire brush. Check the sealing washer (2) for damage. Replace the spark plug if the sealing washer is damaged (page 3-6).
  • Page 44 MAINTENANCE SPARK ARRESTER CLEANING The engine and muffler become very hot during op- eration, and they remain hot for a while after oper- ation. Be sure that the engine is cool before servicing the spark arrester. Remove the muffler protector cover (page 3-5). Remove the 4 x 6 mm tapping screw (1) and spark arrester (2) from the muffler (3).
  • Page 45 MAINTENANCE Set the piston near the top dead center of the cylinder compression stroke (both valves fully closed) by pulling the recoil starter slowly. When the piston is near the top dead center of the compression stroke, the mark (1) on the starter pulley will align with the mark (2) on the fan cover.
  • Page 46 MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder head (page 14-3). Clean any carbon deposits from the combustion chamber (1). FUEL TANK & FILTER CLEANING Gasoline is highly flammable and explosive.You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. •...
  • Page 47 MAINTENANCE FUEL TUBE CHECK Gasoline is highly flammable and explosive.You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the fuel tank cap and fuel filter (page 5-7), and then drain the fuel.
  • Page 48: Troubleshooting

    4. TROUBLESHOOTING HARD STARTING ·········································4-2 ENGINE OIL LEVEL IS LOW, BUT ENGINE DOES NOT STOP ·················· 4-6 ENGINE STARTS BUT THEN STALLS········4-4 ENGINE SPEED DOES NOT INCREASE OR STABILIZE ························· 4-7...
  • Page 49 TROUBLESHOOTING HARD STARTING TROUBLESHOOTING If case of hard starting after reassembly, check the throttle lever is moved to the open position. Check the engine oil level (page 3-3). Add recommended engine oil to the proper level Is it normal? and restart the engine. Light comes on Pull the recoil starter grip and check the oil alert Replace the oil level switch (page 11-2).
  • Page 50 TROUBLESHOOTING From page 4-2 No spark or weak spark Perform the spark test (page 9-6). Perform "No Spark at Spark Plug" troubleshooting (page 9-2). Good spark High cylinder compression Check for carbon deposits in the combustion Check the cylinder compression (page 14-5). chamber (page 14-3).
  • Page 51 TROUBLESHOOTING ENGINE STARTS BUT THEN STALLS Light comes on Check whether the overload indicator is ON when Go to page 4-5 the engine stops. No light Check the fuel. Is it fresh? Drain the fuel tank and carburetor and refill with fresh fuel.
  • Page 52 TROUBLESHOOTING From page 4-4 Abnormal Remove obstruction. Remove all loads from the generator. Verify that the cooling air duct is not blocked and that the generator is not placed near a wall. Normal Abnormal Replace or repair the control wire harness Check the harness connecting the receptacles (page 8-13).
  • Page 53 TROUBLESHOOTING ENGINE OIL LEVEL IS LOW, BUT ENGINE DOES NOT STOP Light comes on Drain the engine oil. Check the ignition control module line and ignition Remove the spark plug cap. control module (page 9-7 and 8). Replace the Pull the recoil starter grip and check the oil alert spark unit, if no abnormalities are is found.
  • Page 54 TROUBLESHOOTING ENGINE SPEED DOES NOT INCREASE OR STABILIZE Clogged Check the air cleaner element (page 3-4). Clean the air cleaner element (page 3-4). Not clogged Not fully open Turn the engine switch knob to the ON position, Adjust the choke cable (page 6-19). and confirm if the choke lever is fully opened.
  • Page 55 TROUBLESHOOTING From page 4-7 Abnormal Adjust the ignition pulse generator air gap (page Check the ignition pulse generator air gap 9-6). (page 9-6). Normal Abnormal Replace the ignition pulse generator (page 9-5). Check the ignition pulse generator resistance (page 9-7). Normal Perform the throttle control system troubleshooting (page 7-2).
  • Page 56 5. COVER CARRY HANDLE CARRY HANDLE HOLDER REMOVAL/INSTALLATION··························5-2 REMOVAL/INSTALLATION ······················· 5-11 FRONT COVER UNDER COVER REMOVAL/INSTALLATION··························5-3 REMOVAL/INSTALLATION ······················· 5-12 REAR COVER FRONT COVER REMOVAL/INSTALLATION··························5-4 DISASSEMBLY/ASSEMBLY ······················ 5-13 SIDE COVER REAR COVER REMOVAL/INSTALLATION··························5-7 DISASSEMBLY/ASSEMBLY ······················ 5-14 RIGHT SHROUD RIGHT SHROUD REMOVAL/INSTALLATION··························5-8 DISASSEMBLY/ASSEMBLY ······················...
  • Page 57 COVER CARRY HANDLE REMOVAL/ COVER INSTALLATION UPPER CARRY GRIP INSTALLATION: Install the upper carry grip, noting the direction as shown. RIGHT CARRY HANDLE SIDE RIGHT CARRY HANDLE LEFT CARRY HANDLE SIDE LEFT CARRY HANDLE NUT (2) LOWER CARRY GRIP PAN SCREW (6 x 12 mm) 9 N·m (0.9 kgf·m, 6.5 lbf·ft) PLAIN WASHER (2) SOCKET BOLT (6 x 32 mm) (2)
  • Page 58 COVER FRONT COVER REMOVAL/ INSTALLATION KNOB CAP INSTALLATION: Install the knob cap to the engine stop switch knob. KNOB CAP SPECIAL SCREW (6 x 12 mm) (2) 4.4 N·m (0.45 kgf·m, 3.3 lbf·ft) CARRY HANDLE COVER HANDLE COVER SEAL KNOB SCREW (5 x 27.5 mm) 2.3 N·m (0.23 kgf·m, 1.7 lbf·ft) ENGINE SWITCH KNOB...
  • Page 59 COVER REAR COVER REMOVAL/ INSTALLATION MUFFLER PROTECTOR COVER SPECIAL SCREW (6 x 15 mm) (5) 4.4 N·m (0.45 kgf·m, 3.3 lbf·ft) TANK MOUNT RUBBER A SPECIAL SCREW (6 x 16 mm) 2.3 N·m (0.23 kgf·m, 1.7 lbf·ft) WASHER (2) AIR INTAKE JOINT AIR CLEANER TUBE CLIP (2) RESONATOR TUBE...
  • Page 60 COVER REMOVAL Disconnect the resonator tube (1) upper side from rear cover assembly (2). Remove the resonator tube from the under cover (3). Loosen the hose clamp screw (1). Disconnect the air cleaner connecting tube (2) from the air intake joint (3). Remove the five special screws (1) and rear cover assembly (2) as shown.
  • Page 61 COVER Install the air cleaner connecting tube (1) to the air intake joint (2). Tighten the hose clamp screw (3) to the specified torque. TORQUE: 0.7 N·m (0.07 kgf·m, 0.5 lbf·ft) Connect the bottom of the resonator tube (1), aligning the projection with the groove (2) of the under cover.
  • Page 62: Cover

    COVER SIDE COVER REMOVAL/ INSTALLATION Remove the following parts: – Front cover (page 5-3) – Rear cover (page 5-4) SIDE COVER UPPER SEAL A OIL MAINTENANCE FUEL TANK CAP RIGHT SIDE COVER DISASSEMBLY/ASSEMBLY: COVER Page 6-12 SIDE COVER UPPER SEAL B OIL MAINTENANCE SIDE COVER CAP COVER SEAL...
  • Page 63 COVER RIGHT SHROUD REMOVAL/ INSTALLATION Remove the control panel (page 8-8). RIGHT SHROUD ASSEMBLY INSTALLATION: Install the right shroud by aligning the tabs with the slots of the left shroud. To mating RIGHT SHROUD CASE CLAMP (5) INSTALLATION: After installing the right shroud, install the case clamps to Slot the grooves of the right/left shroud as shown.
  • Page 64 COVER FRONT FRAME/CENTER FRAME/ HANDLE BASE REMOVAL/ INSTALLATION Remove the following parts: – Carry handle (page 5-2) – Right shroud (page 5-8) – Engine switch/control (page 6-10) REAR GUARD BRACKET CENTER FRAME / LEFT SHROUD FRONT FRAME REMOVAL / INSTALLATION: INSTALLATION: INSTALLATION: Install the center frame, rear guard...
  • Page 65 COVER WHEEL REMOVAL/INSTALLATION WHEEL SHAFT FLANGE BOLT (8 x 16 mm) (4) WHEEL WASHER (14.2 mm) (2) E-RING (12 mm) (2) WHEEL CAP INSTALLATION: Install the E-ring to the wheel shaft, noting the installation REMOVAL: direction as shown. Insert a screwdriver or equivalent tool into the groove as shown, and remove the wheel cap.
  • Page 66 COVER CARRY HANDLE HOLDER REMOVAL/ INSTALLATION FRICTION SETTING WASHER B INSTALLATION: Align the tabs with groove of the handle base. HANDLE HOLDER SHAFT GROOVE RIGHT HANDLE HOLDER PAN SCREW (6 x 12 mm) 9 N·m (0.9 kgf·m, 6.5 lbf·ft) FRICTION SPRING (4) INSTALLATION: Install the friction spring as shown.
  • Page 67 COVER UNDER COVER REMOVAL/ INSTALLATION Remove the following parts: – Wheel (page 5-10) – Resonator (page 6-11) – Generator/engine (page 13-2) UNDER COVER TAPE SPECIAL NUT (6 mm) (4) LEFT REAR GRIP PLATE RIGHT REAR GRIP PLATE UNDER COVER DISCHARGE GUARD STOPPER COLLAR A (4) FLANGE BOLT (6 x 14 mm) (4) HARNESS CLIP (2)
  • Page 68 COVER FRONT COVER DISASSEMBLY/ ASSEMBLY ECO-THROTTLE SWITCH CABLE CLAMP F INSTALLATION: Install the ECO-Throttle switch to the front cover with the MARK positioned upwards. TAPPING SCREW (5 x 12 mm) (2) MARK 1.2 N·m (0.12 kgf·m, 0.9 lbf·ft) (UPPER SIDE) INDICATOR WIRE HARNESS CABLE CLAMP F...
  • Page 69 COVER REAR COVER DISASSEMBLY/ ASSEMBLY REAR COVER ASSEMBLY: Install the rear cover shroud seal, rear cover upper seal, rear cover lower seal, and rear cover intake seal as shown. REAR COVER REAR COVER SHROUD SEAL UPPER SEAL REAR COVER REAR COVER LOWER SEAL INTAKE SEAL AIR CLEANER TUBE ASSEMBLY...
  • Page 70 COVER RIGHT SHROUD DISASSEMBLY/ ASSEMBLY RIGHT SHROUD ASSEMBLY: Bend the insulator bind clip as shown. INSULATOR BIND CLIP RIGHT SHROUD RIGHT INSULATOR SHROUD SEAL INSULATOR BIND CLIP RIGHT SHROUD INSULATOR INSULATOR BIND CLIP (9) RIGHT SHROUD SEAL 5-15...
  • Page 71 COVER LEFT SHROUD/CENTER FRAME DISASSEMBLY/ASSEMBLY CENTER FRAME LEFT SHROUD SEAL LEFT SHROUD SEAL A INSULATOR BIND CLIP (7) LEFT SHROUD INSULATOR SPECIAL BOLT (6 mm) STOPPER RUBBER STOPPER BRACKET CENTER FRAME TAPE LEFT SHROUD DISASSEMBLY: LEFT SHROUD Remove the tabs and bosses from the BOSS center frame in numbered order as shown.
  • Page 72 COVER FRONT FRAME DISASSEMBLY/ ASSEMBLY FRONT FRAME SEAL FRONT FRAME CENTER MAT FRONT FRAME TAPE FRONT FRAME SEAL (LEFT SHROUD) WIRE HARNESS CLIP (25 mm) (2) SCREW GROMMET SPRING NUT (2) FRONT FRAME ASSEMBLY: Install the front frame seal, front frame seal (left shroud), front frame center mat, and front frame tape as shown. FRONT FRAME SEAL FRONT FRAME SEAL FRONT FRAME...
  • Page 73 MEMO...
  • Page 74: Fuel System

    6. FUEL SYSTEM TOOLS···························································6-2 AIR INTAKE JOINT DISASSEMBLY/ASSEMBLY ······················ 6-14 BREATHER SYSTEM TROUBLESHOOTING···································6-3 CARBURETOR DISASSEMBLY/ASSEMBLY ······················ 6-15 AIR CLEANER REMOVAL/INSTALLATION··························6-4 ENGINE SWITCH/CONTROL DISASSEMBLY/ASSEMBLY ······················ 6-16 FUEL TANK REMOVAL/INSTALLATION ····6-5 COCK CABLE ADJUSTMENT ··················· 6-19 BREATHER HEATER REMOVAL/ INSTALLATION (C TYPE ONLY) ·················6-7 CHOKE CABLE ADJUSTMENT ·················...
  • Page 75 FUEL SYSTEM TOOLS FUEL SYSTEM Float level gauge 07401-0010000...
  • Page 76 FUEL SYSTEM BREATHER SYSTEM TROUBLESHOOTING With breather heater type only Push the AC circuit breaker ON. Is the AC Circuit breaker ON? Perform the "Non or Low AC Output" Start the engine and check for 120V AC at the AC troubleshooting (page 8-3).
  • Page 77 FUEL SYSTEM AIR CLEANER REMOVAL/ INSTALLATION REAR COVER INSTALLATION: Install the air cleaner cover seal C as shown. AIR CLEANER COVER SEAL C AIR CLEANER COVER SEAL C AIR CLEANER ELEMENT CLEANING: page 3-4 SPECIAL SCREW (6 x 16 mm) 2.3 N·m (0.23 kgf·m, 1.7 lbf·ft) OUTER FILTER CLEANING: page 3-4...
  • Page 78 FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION WITHOUT C TYPE Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the side cover (page 5-7).
  • Page 79 FUEL SYSTEM C TYPE ONLY Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the side cover (page 5-7). After installing the fuel cock, be sure to adjust the cock cable securely (page 6-19).
  • Page 80 FUEL SYSTEM BREATHER HEATER REMOVAL/ INSTALLATION (C TYPE ONLY) REMOVAL Remove the fuel tank (page 6-5). After installing the air intake joint, be sure to adjust the choke cable (page 6-19). BREATHER TUBE A BREATHER HEATER BREATHER TUBE INSULATOR INSPECTION: Page 6-23 BREATHER TUBE INSULATOR B BREATHER TUBE C...
  • Page 81 FUEL SYSTEM INSTALLATION After installing breather heater tube C (1) and breather heater B (2) to the breather heater (3), install the breather heater in the breather heater insulator (4). Install the breather tube insulator (1) to breather tube A (2) so that the white marking (3) of the breather tube A is faced upwards and the cutout (4) of the breather tube insulator comes down.
  • Page 82 FUEL SYSTEM CARBURETOR REMOVAL/ INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the fuel tank (page 6-5). After installing the air intake joint, be sure to adjust the choke cable (page 6-19).
  • Page 83 FUEL SYSTEM ENGINE SWITCH/CONTROL REMOVAL/ INSTALLATION Remove the following parts: – Fuel tank (page 6-5) – Control panel (page 8-8) After installing the engine switch/control, be sure to adjust the choke cable (page 6-19). CHOKE SPRING PAN SCREW (4 x 6 mm) CHOKE CABLE HOLDER 2.3 N·m (0.23 kgf·m, 1.7 lbf·ft)
  • Page 84 FUEL SYSTEM RESONATOR CASE REMOVAL/ INSTALLATION Remove the generator/engine (page 13-2). RESONATOR COVER TAPPING SCREW (5 x 25 mm) 1.4 N·m (0.14 kgf·m, 1 lbf.ft) TAPPING SCREW (5 x 30 mm) (3) 2.8 N·m (0.28 kgf·m, 2 lbf.ft) RESONATOR SEAL B HOLE BOSS RESONATOR SEAL A...
  • Page 85 FUEL SYSTEM FUEL TANK CAP DISASSEMBLY/ ASSEMBLY BREATHER VALVE O-RING (13.8 x 2.4 mm) TANK CAP FUEL CAP BREATHER SPONGE FUEL CAP PACKING INSTALLATION: Clean the sponge with water and neutral detergent and allow it to dry before installation. FUEL CAP INNER FUEL CAP SPRING WASHER (6 mm) LOCK PIN (6 mm)
  • Page 86 FUEL SYSTEM FUEL TANK DISASSEMBLY/ ASSEMBLY (C TYPE ONLY) FUEL TANK TANK MOUNT RUBBER A ASSEMBLY: ASSEMBLY: Insert the projection of the fuel tank into the tank mount rubber A Install the tank mount rubber A to the tank and tank cover rubber B securely. cover rubber B as shown.
  • Page 87 FUEL SYSTEM AIR INTAKE JOINT DISASSEMBLY/ ASSEMBLY SPECIAL SCREW (6 x 12 mm) PAN SCREW (4 x 6 mm) 1.5 N·m (0.15 kgf·m, 1.7 lbf·ft) CHOKE CABLE HOLDER CHOKE LEVER PLAIN WASHER (6 mm) PLAIN WASHER (6 mm) E-RING (5 mm) SPECIAL NUT (6 mm) ASSEMBLY: AIR INTAKE JOINT...
  • Page 88 FUEL SYSTEM CARBURETOR DISASSEMBLY/ ASSEMBLY Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. To prevent serious eye injury, always wear safety goggles or other eye protection when using com- pressed air.
  • Page 89 FUEL SYSTEM ENGINE SWITCH/CONTROL DISASSEMBLY/ASSEMBLY DISASSEMBLY TAPPING SCREW (5 x 25 mm) (2) TAPPING SCREW (3 x 10 mm) (2) 0.8 N·m (0.08 kgf·m, 0.59 lbf.ft) 0.18 N·m (0.018 kgf·m, 0.13 lbf.ft) ENGINE STOP SWITCH INSPECTIONT: Page 11-3 PLAIN WASHER (8 mm) (2) PLAIN WASHER (5 mm) (2) CHOKE CABLE ADJUSTMENT: Page 6-19...
  • Page 90 FUEL SYSTEM ASSEMBLY As shown in the diagram, route the cock cable (1) and the choke cable (2) through the engine switch base (3) and fasten the cock cable bracket (4) and choke cable bracket (5) with two 5 x 16 mm tapping screws (6). TORQUE: 1.4 N·m (0.14 kgf·m, 1 lbf·ft) Install the choke cable (1) and choke cable spring (2) to the choke arm (3).
  • Page 91 FUEL SYSTEM Install the switch cam tension plate (1) to the engine switch base (2). Install the switch cam tension spring (3) as shown. Install the engine stop switch (1) to the engine switch base (2) with two 3 x 10 mm tapping screws (3). TORQUE: 0.18 N·m (0.018 kgf·m, 0.13 lbf·ft) Install the two 8 mm washers (1), engine switch plate (2), and two 5 mm washers (3) in the order shown to the...
  • Page 92 FUEL SYSTEM COCK CABLE ADJUSTMENT Remove the control panel (page 8-8). Install the engine switch knob (1) to the engine switch cam (2). Turn the engine switch knob to OFF. Confirm that the engine switch knob is in the horizontal position and that the projection of the switch cam tension plate (3) is placed in the groove (4) of the engine switch cam.
  • Page 93 FUEL SYSTEM Switch the engine switch knob (1) to CHOKE. Confirm that the choke cable (2) is pulled to the direction shown by the choke arm (3). Confirm that the projection of the switch cam tension plate (4) is placed in the groove (5) of the engine switch cam.
  • Page 94 Check the container for instructions. If you are in doubt, do not use these products to clean a Honda carburetor. • High air pressure may damage the carburetor. Use low air pressure (0.2 MPa (30 psi) or less) when cleaning passages and ports.
  • Page 95 FUEL SYSTEM FLOAT VALVE Check for a worn float valve (1) and valve seat (2) contamination. CLEAN REPLACE PILOT SCREW REPLACEMENT The limiter cap is an emission-related part. Leave the pilot screw (1) and limiter cap (2) in place during carburetor cleaning. Remove only if necessary for repair of the carburetor.
  • Page 96 FUEL SYSTEM Apply LOCTITE 638 to the inside (1) of the limiter cap (2), and then install the cap so its stop prevents the pilot screw (3) from being turned counterclockwise. Be careful to avoid turning the pilot screw while installing the limiter cap.
  • Page 97 MEMO...
  • Page 98: Governor System

    7. GOVERNOR SYSTEM THROTTLE CONTROL SYSTEM ECO-THROTTLE SWITCH TROUBLESHOOTING···································7-2 INSPECTION················································· 7-6 THROTTLE CONTROL MOTOR THROTTLE CONTROL MOTOR REMOVAL/INSTALLATION··························7-5 INSPECTION················································· 7-6...
  • Page 99 GOVERNOR SYSTEM THROTTLE CONTROL SYSTEM GOVERNOR SYSTEM TROUBLESHOOTING Engine Speed is Too High, Too Low, Unstable Abnormal Check the AC output. Perform generator system troubleshooting following the instruction of "No or Low AC output" (page 8-3). Normal Perform engine troubleshooting following the instruction of "Engine Speed Does Not Increase or Stabilize troubleshooting"...
  • Page 100 GOVERNOR SYSTEM Engine Speed Does Not Increase With ECO Throttle System OFF Under No Load Engine Speed Does Not Decrease With ECO Throttle System ON Under No Load Engine Speed Does Not Increase by Connecting Load With ECO Throttle System ON Abnormal Perform generator system troubleshooting Check the AC output.
  • Page 101 GOVERNOR SYSTEM From page 7-3 Abnormal Replace or repair the control wire harness (page Check the harness connecting the throttle control 8-13). motor sub harness and inverter unit for open or short circuit and for proper connection. CONTROL WIRE HARNESS Viewed from terminal side Normal Replace the inverter unit (page 8-7).
  • Page 102 GOVERNOR SYSTEM THROTTLE CONTROL MOTOR REMOVAL/INSTALLATION Gasoline is highly flammable and explosive.You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the carburetor (page 6-9). THROTTLE CONTROL MOTOR SCREW-WASHER (3 x 8 mm) (2) SCREW-WASHER (4 x 10 mm) (2)
  • Page 103 GOVERNOR SYSTEM ECO THROTTLE SWITCH INSPECTION Remove the front cover (page 5-3). Check for continuity between the switch terminals. Switch position Terminal C5 - C6 No continuity Continuity THROTTLE SWITCH THROTTLE CONTROL MOTOR INSPECTION Remove the throttle control motor (page 7-5). Measure the resistance between the terminals.
  • Page 104: Generator/Charging System

    8. GENERATOR/CHARGING SYSTEM TOOLS···························································8-2 CONTROL PANEL DISASSEMBLY/ASSEMBLY ······················ 8-13 GENERATOR SYSTEM TROUBLESHOOTING···································8-3 INVERTER UNIT INSPECTION ·················· 8-27 INVERTER UNIT RECTIFIER INSPECTION ··························· 8-28 REMOVAL/INSTALLATION··························8-7 PARALLEL OPERATION OUTLET CONTROL PANEL INSPECTION··············································· 8-28 REMOVAL/INSTALLATION··························8-8 AC CIRCUIT PROTECTOR GENERATOR INSPECTION··············································· 8-28 REMOVAL/INSTALLATION························8-10 GENERATOR INSPECTION ······················· 8-29...
  • Page 105 GENERATOR/CHARGING SYSTEM TOOLS GENERATOR/CHARGING SYSTEM Flywheel puller set 07935-8050004...
  • Page 106 GENERATOR/CHARGING SYSTEM GENERATOR SYSTEM TROUBLESHOOTING No or Low AC Output Either or both lights ON Go to page 8-4 When the engine running check whether the output indicator and the overload indicator lights are ON. Both lights OFF Abnormal Check the engine speed at no load. Check the ECO throttle switch, and if no problem Specified engine speed:3,600 ±...
  • Page 107 GENERATOR/CHARGING SYSTEM From page 8-3 Light is ON Check whether the overload indicator light (red) is Disconnect the AC receptacle. Verify that the cooling air duct is not blocked and the generator is not placed near a wall. Correct the above problems, and restart the engine.
  • Page 108 GENERATOR/CHARGING SYSTEM No DC Output Abnormal Check the ECO throttle switch, and if no problem Check the engine speed at no load. can be found, perform Throttle Control System Specified engine speed:3,600 ± 100 rpm (ECO throttle switch OFF) troubleshooting (page 7-2 and 3). Normal Abnormal Replace the DC receptacle (page 8-13).
  • Page 109 GENERATOR/CHARGING SYSTEM From page 8-5 Abnormal Replace or repair the generator wire harness Check the harness connecting the generator and (page 8-10). rectifier for an open or short circuit and for proper connection. GENERATOR WIRE HARNESS Viewed from terminal side Normal Replace the stator (page 8-10).
  • Page 110 GENERATOR/CHARGING SYSTEM INVERTER UNIT REMOVAL/ INSTALLATION Remove the front cover (page 5-3). INVERTER UNIT RUBBER INVERTER JONIT COLLAR INVERTER MOUNT RUBBER (2) WASHER BOLT (6 x 25 mm) 9.3 N·m (0.95 kgf·m, 6.9 lbf·ft) INVERTER UNIT...
  • Page 111 GENERATOR/CHARGING SYSTEM CONTROL PANEL REMOVAL/ INSTALLATION WITHOUT C TYPE Remove the following parts: – Side cover (page 5-7) – Inverter unit (page 8-7) CONTROL PANEL BOLT (6 x 57 mm) (2) BOLT (6 x 10 mm) (2) 9.3 N·m (0.95 kgf·m, 6.9 lbf·ft) GND1 TAPPING SCREW (5 x 16 mm) (2)
  • Page 112 GENERATOR/CHARGING SYSTEM C TYPE ONLY Remove the following parts: – Side cover (page 5-7) – Inverter unit (page 8-7) CONTROL PANEL BOLT (6 x 57 mm) (2) BOLT (6 x 10 mm) (2) 9.3 N·m (0.95 kgf·m, 6.9 lbf·ft) GND1 TAPPING SCREW (5 x 16 mm) (2) 1.4 N·m (0.14 kgf·m, 1 lbf·ft) RECTIFIER...
  • Page 113 GENERATOR/CHARGING SYSTEM GENERATOR REMOVAL/ INSTALLATION REMOVAL Remove the fan cover guide assembly (page 13-3). SPECIAL WOODRUFF KEY STATOR COLLAR (SHORT) STATOR COLLAR GENERATOR WIRE HARNESS (LONG) STATOR COLLAR (SHORT) SOCKET BOLT (6 x 57 mm) (4) 11 N·m (1.1 kgf·m, 8 lbf·ft) STATOR ROTOR...
  • Page 114 GENERATOR/CHARGING SYSTEM INSTALLATION Install the stator collars on the stator (1) as shown. • Do not interchange the double notched collars (2) with the single notched collars (3). • Connect the generator wire harness connectors to the three terminal side (4) as shown. Clean off oil or grease from the crankshaft taper and rotor tapered hole.
  • Page 115 GENERATOR/CHARGING SYSTEM Note that the magnetic force of the rotor is very strong. Take care not to pinch your fingers during installa- tion. Check for any foreign material attached to the inside (1) of the rotor before installation. Install the rotor by aligning the key groove (2) with the woodruff key (3) on the crankshaft (4).
  • Page 116 GENERATOR/CHARGING SYSTEM CONTROL PANEL DISASSEMBLY/ ASSEMBLY G, G8, GW, F TYPES LOCATION Remove the control panel (page 8-8). CONTROL WIRE HARNESS COUPLER CLIP TERMINAL CORD AC CIRCUIT PROTECTOR (16A) (2) FLANGE NUT CABLE TIE (4 mm) (8) PAN SCREW (5 x 16 mm) FLAT SCREW (4 x 12 mm) (8) HARNESS...
  • Page 117 GENERATOR/CHARGING SYSTEM HARNESS CONNECTION AC RECEPTACLE IGNITION CONTROL (16A-250V) MODULE PARALLEL OPERATION (WHITE TAPE) OUTLET (WHITE TAPE) TERMINAL CORD DC RECEPTACLE (WHITE TAPE) AC CIRCUIT PROTECTOR (16A) GND3 COUPLER CLIP GND2 TERMINAL CORD WHITE TAPE AC CIRCUIT CONTROL WIRE PROTECTOR (16A) HARNESS CABLE TIE Clamp the taping...
  • Page 118 GENERATOR/CHARGING SYSTEM IT TYPE LOCATION Remove the control panel (page 8-8). AC CIRCUIT PROTECTOR (16A) COUPLER CLIP CONTROL WIRE HARNESS TERMINAL CORD CONSENT SET PLATE CABLE TIE PAN SCREW (5 x 16 mm) SCREW-WASHER (5 x 16 mm) (4) HARNESS BAND CLIP CONTROL PANEL...
  • Page 119 GENERATOR/CHARGING SYSTEM HARNESS CONNECTION AC RECEPTACLE IGNITION CONTROL (16A-240V) TERMINAL CORD MODULE PARALLEL OPERATION OUTLET AC CIRCUIT PROTECTOR (16A) DC RECEPTACLE GND3 COUPLER CLIP WHITE TAPE GND2 CABLE TIE CONTROL WIRE Clamp the taping HARNESS position as shown. Terminal Terminal Wire color Wire color number...
  • Page 120 GENERATOR/CHARGING SYSTEM L, LT TYPES LOCATION Remove the control panel (page 8-8). FLANGE NUT (4 mm) (2) FLANGE NUT (4 mm) (2) AC RECEPTACLE CONTROL WIRE HARNESS (20A-125V) COUPLER CLIP AC RECEPTACLE (30A-125V) SCREW (3) SCREW (3) CABLE TIE PAN SCREW (5 x 12 mm) HARNESS BAND CLIP...
  • Page 121 GENERATOR/CHARGING SYSTEM HARNESS CONNECTION AC RECEPTACLE IGNITION CONTROL (30A-125V) MODULE AC RECEPTACLE (20A-125V) (WHITE TAPE) PARALLEL OPERATION OUTLET (WHITE TAPE) (WHITE TAPE) DC RECEPTACLE GND3 COUPLER CLIP WHITE TAPE GND2 CABLE TIE CONTROL WIRE HARNESS Clamp the taping position as shown. Terminal Terminal Wire color...
  • Page 122 GENERATOR/CHARGING SYSTEM R, RH, S, S8 TYPES LOCATION Remove the control panel (page 8-8). CONTROL WIRE HARNESS COUPLER CLIP FLANGE NUT AC RECEPTACLE (20A-250V) (4 mm) (4) SCREW (6) CABLE TIE PAN SCREW (5 x 12 mm) HARNESS BAND CLIP PAN SCREW (5 x 13 mm) (2) IGNITION CONTROL...
  • Page 123 GENERATOR/CHARGING SYSTEM HARNESS CONNECTION AC RECEPTACLE IGNITION CONTROL (20A-250V) MODULE (WHITE TAPE) AC RECEPTACLE PARALLEL OPERATION (20A-250V) OUTLET (WHITE TAPE) DC RECEPTACLE (WHITE TAPE) GND3 COUPLER CLIP WHITE TAPE GND2 CABLE TIE Clamp the taping CONTROL WIRE HARNESS position as shown. Terminal Terminal Wire color...
  • Page 124 GENERATOR/CHARGING SYSTEM RG, SK TYPES LOCATION Remove the control panel (page 8-8). COUPLER CLIP CONTROL WIRE HARNESS FLANGE NUT (4 mm) (8) CONTROL PANEL PACKING (2) CABLE AC RECEPTACLE (16A-250V) (2) FLAT SCREW (4 x 12 mm) (8) PAN SCREW (5 x 12 mm) HARNESS BAND CLIP...
  • Page 125 GENERATOR/CHARGING SYSTEM HARNESS CONNECTION AC RECEPTACLE IGNITION CONTROL (16A-250V) MODULE (WHITE TAPE) (WHITE TAPE) PARALLEL OPERATION OUTLET AC RECEPTACLE (16A-250V) (WHITE TAPE) DC RECEPTACLE GND3 COUPLER CLIP WHITE TAPE GND2 CABLE TIE Clamp the taping CONTROL WIRE HARNESS position as shown. Terminal Wire color Terminal...
  • Page 126 GENERATOR/CHARGING SYSTEM U TYPE LOCATION Remove the control panel (page 8-8). CONTROL WIRE HARNESS COUPLER CLIP FLANGE NUT (4 mm) (8) CONTROL PANEL CABLE AC RECEPTACLE (15A-250V) (2) FLAT SCREW PAN SCREW (4 x 20 mm) (8) (5 x 12 mm) HARNESS BAND CLIP PAN SCREW...
  • Page 127 GENERATOR/CHARGING SYSTEM HARNESS CONNECTION IGNITION CONTROL AC RECEPTACLE MODULE (15A-250V) (WHITE TAPE) PARALLEL OPERATION OUTLET AC RECEPTACLE (15A-250V) (WHITE TAPE) DC RECEPTACLE (WHITE TAPE) GND3 COUPLER CLIP WHITE TAPE GND2 CABLE TIE Clamp the taping CONTROL WIRE HARNESS position as shown. Terminal Terminal Wire color...
  • Page 128 GENERATOR/CHARGING SYSTEM C TYPE LOCATION Remove the control panel (page 8-8). AC CIRCUIT PROTECTOR (20A) AC CIRCUIT PROTECTOR (30A) AC RECEPTACLE AC RECEPTACLE (20A-125V) (30A-125V) FLANGE NUT SUB CORD A (4 mm) (4) SCREW (5) CABLE TIE CABLE TIE C CONTROL WIRE HARNESS CONTROL PANEL...
  • Page 129 GENERATOR/CHARGING SYSTEM HARNESS CONNECTION AC RECEPTACLE AC RECEPTACLE (20A-125V) (30A-125V) AC CIRCUIT AC CIRCUIT PROTECTOR (30A) PROTECTOR (20A) SUB CORD A SUB CORD A IGNITION CONTROL MODULE (WHITE TAPE) DC RECEPTACLE AC CIRCUIT PROTECTOR (20A) SUB CORD WHITE TAPE GND3 GND2 COUPLER CLIP CABLE TIE C...
  • Page 130 GENERATOR/CHARGING SYSTEM INVERTER UNIT INSPECTION Remove the inverter unit (page 8-7). Check for continuity between the terminals using a Viewed from terminal side tester with diode measuring function according to the tables below. • Set the tester to the mark position and perform this inspection.
  • Page 131 GENERATOR/CHARGING SYSTEM RECTIFIER INSPECTION Check for continuity between the terminals according to the table below. • Some testers have reverse polarity. (+)Tester probe Connector Connector Terminal Continuity Continuity Continuity Continuity Continuity PARALLEL OPERATION OUTLET INSPECTION There must be continuity between the outlet and terminal.
  • Page 132 GENERATOR/CHARGING SYSTEM GENERATOR INSPECTION Remove the inverter unit (page 8-7). Measure the resistance between the terminals of the according to the table below. Termi- Resis- Con- Coil tance nector number (Ω) 2 - 3 0.6 - 1.1 MAIN 3 - 4 0.6 - 1.1 2 - 4 0.6 - 1.1...
  • Page 133 MEMO...
  • Page 134: Ignition System

    9. IGNITION SYSTEM IGNITION SYSTEM IGNITION PULSE GENERATOR TROUBLESHOOTING···································9-2 INSPECTION················································· 9-7 IGNITION COIL/IGNITION PULSE IGNITION COIL INSPECTION ······················ 9-7 GENERATOR REMOVAL/INSTALLATION··························9-5 IGNITION CONTROL MODULE LINE INSPECTION················································· 9-7 IGNITION PULSE GENERATOR AIR GAP ADJUSTMENT···············································9-6 IGNITION CONTROL MODULE INSPECTION················································· 9-8 SPARK TEST ················································9-6...
  • Page 135 IGNITION SYSTEM IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING No Spark at Spark Plug Good spark Perform spark test using a new spark plug (page Previous spark plug was faulty. 9-6). No spark Abnormal Replace the engine stop switch (page 6-16). Check the engine stop switch (page 11-3). Normal Check the ignition pulse generator air gap Adjust the ignition pulse generator air gap (page...
  • Page 136 IGNITION SYSTEM From page 9-2 Replace or repair the generator wire harness Check the harness connecting the ignition coil Abnormal (page 8-10) and/or control wire harness (page and ignition control module for open or short 8-13). circuit and for proper connection. CONTROL WIRE HARNESS Viewed from terminal side B l/ R...
  • Page 137 IGNITION SYSTEM From page 9-3 Abnormal Replace the stator (page 8-10). Check the exciter coil resistance (page 8-29). Normal Abnormal Replace the ignition control module (page 8-13). Check the ignition control module (page 9-8). Normal Good spark Replace the ignition coil (page 9-5). Perform the spark test again using a new ignition coil (page 9-6).
  • Page 138 IGNITION SYSTEM IGNITION COIL/IGNITION PULSE GENERATOR REMOVAL/ INSTALLATION Remove the fan cover guide assembly (page 13-3). UPPER SHROUD INSTALLATION: ·Install the upper shroud projection into the cylinder head cover as shown. ·Clamp the generator wire harness to the hook of the upper shroud as shown. STICK OUT STICK OUT HOOK...
  • Page 139 IGNITION SYSTEM IGNITION PULSE GENERATOR AIR GAP ADJUSTMENT Remove the fan cover (page 13-3). Insert an appropriate feeler gauge (1) between the ignition pulse generator (2) and projecting part (3) of the rotor. Air gap (at rotor): 0.3 - 0.7 mm (0.01 - 0.03 in) Push the ignition pulse generator firmly against the rotor and tighten the two 6 x 23 mm flange bolts (4).
  • Page 140 IGNITION SYSTEM IGNITION PULSE GENERATOR INSPECTION Measure the resistance between the terminal (1) and the ignition pulse generator base (2). 294 - 359 Ω (20°C/68°F) Resistance: IGNITION COIL INSPECTION PRIMARY SIDE Measure the resistance of the primary coil by attaching the ohmmeter leads to the ignition coil terminal and the iron core.
  • Page 141 IGNITION SYSTEM IGNITION CONTROL MODULE INSPECTION Remove the control panel (page 8-8). Check for continuity between the terminals according to the table below. • Some testers have reverse polarity. Unit: Ω Terminal number – 1k – 50k 1k – 50k 20k –...
  • Page 142: Starting System

    10. STARTING SYSTEM RECOIL STARTER/FAN COVER RECOIL STARTER ROPE REMOVAL/INSTALLATION························10-2 REPLACEMENT ········································· 10-3 RECOIL STARTER INSPECTION ·············· 10-4 10-1...
  • Page 143 STARTING SYSTEM RECOIL STARTER/FAN COVER STARTING SYSTEM REMOVAL/INSTALLATION Remove the side cover (page 5-7). RECOIL STARTER BOLT (6 x 20 mm) (3) STARTER ROPE GUIDE TAPPING SCREW (5 x 16 mm) (2) 1.2 N·m (0.12 kgf·m, 0.9 lbf·ft) 10-2...
  • Page 144 STARTING SYSTEM RECOIL STARTER ROPE REPLACEMENT Pull the starter grip (1) until the starter rope is completely pulled out. To prevent the starter reel from rewinding, hold the starter reel (1) and starter case (2) with a band or equivalent material (3) as shown. Untie the knots (4) of the starter rope (5) at the starter grip side and the starter reel side, and remove the Hold...
  • Page 145 STARTING SYSTEM Route the starter rope (1) to the starter case (2), starter reel (3), rope guide (4), starter grip (5), and grip cover (6). Tie knots at the ends of the starter rope. Remove the band (7). Install the grip cover to the recoil starter grip. Check the recoil starter operation.
  • Page 146: Other Electrical

    11. OTHER ELECTRICAL OIL LEVEL SWITCH OIL LEVEL SWITCH INSPECTION ············ 11-3 REMOVAL/INSTALLATION························11-2 ENGINE STOP SWITCH INSPECTION ······ 11-3 11-1...
  • Page 147 OTHER ELECTRICAL OIL LEVEL SWITCH REMOVAL/ OTHER ELECTRICAL INSTALLATION Remove the crankshaft (page 15-4). CYLINDER BARREL OIL LEVEL SWITCH JOINT NUT (10 mm) OIL LEVEL SWITCH 10 N·m (1.0 kgf·m, 7 lbf·ft) BOLT (6 x 12 mm) (2) O-RING (14 mm) INSTALLATION: Install firmly in the groove.
  • Page 148 OTHER ELECTRICAL OIL LEVEL SWITCH INSPECTION Check continuity between the oil level switch (1) lead and switch body with an ohmmeter. Check the float by dipping the switch into a container of oil. The ohmmeter reading should go from continuity to no continuity as the switch is lowered into the oil.
  • Page 149 MEMO...
  • Page 150: Muffler

    12. MUFFLER MUFFLER REMOVAL/INSTALLATION······12-2 12-1...
  • Page 151 MUFFLER MUFFLER REMOVAL/INSTALLATION MUFFLER The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Al- low it to cool before proceeding. Remove the right shroud (page 5-8). TAPPING SCREW (4 x 6 mm) (Equipped type only) 2.2 N.m (0.22 kgf·m, 1.6 lbf·ft)
  • Page 152: Generator/Engine Removal/Installation

    13. GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE FAN COVER GUIDE REMOVAL/INSTALLATION························13-2 DISASSEMBLY/ASSEMBLY ······················ 13-4 FAN COVER/FAN COVER GUIDE REMOVAL/INSTALLATION························13-3 13-1...
  • Page 153 GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE REMOVAL/ INSTALLATION Remove the following parts: – Carburetor (page 6-9) – Front frame/Center frame/handle base (page 5-9) FLANGE NUT (8 mm) (4) 24 N·m (2.4 kgf·m, 18 lbf·ft) GENERATOR/ENGINE LEFT FRONT MOUNT RUBBER (ENGINE SIDE) INSTALLATION: After installing the washer, install the left front mount rubber, aligning the...
  • Page 154 GENERATOR/ENGINE REMOVAL/INSTALLATION FAN COVER/FAN COVER GUIDE REMOVAL/INSTALLATION Remove the following parts: – Muffler (page 12-2) – Generator/engine (page 13-2) FAN COVER GUIDE ASSEMBLY FAN COVER BRACKET REMOVAL: INSTALLATION: Remove the rubber grommet of the stator. Install the fan cover bracket, aligning the cutout with the tab of the fan cover guide INSTALLATION: assembly.
  • Page 155 GENERATOR/ENGINE REMOVAL/INSTALLATION FAN COVER GUIDE DISASSEMBLY/ ASSEMBLY ASSEMBLY: Be sure that the fan cover seal is set securely. FAN COVER SEAL FAN COVER SEAL FAN COVER GUIDE FAN COVER GUIDE ASSEMBLY: Be sure that the fan cover seal is set securely. FAN COVER SEAL ASSEMBLY: FAN COVER SEAL...
  • Page 156: Cylinder Head

    14. CYLINDER HEAD TOOLS·························································14-2 CYLINDER HEAD/VALVES INSPECTION··············································· 14-5 CYLINDER HEAD REMOVAL/INSTALLATION························14-3 VALVE GUIDE REPLACEMENT ················ 14-8 CYLINDER HEAD VALVE GUIDE REAMING ·························· 14-9 DISASSEMBLY/ASSEMBLY ······················14-4 VALVE SEAT RECONDITIONING·············· 14-9 14-1...
  • Page 157 CYLINDER HEAD TOOLS CYLINDER HEAD Seat cutter, 24.5 Seat cutter, 27.5 Flat cutter, 25 07780-0010100 07780-0010200 07780-0012000 Flat cutter, 28 Interior cutter, 30 Cutter holder, 5.5 07780-0012100 07780-0014000 07781-0010101 Valve guide driver, 5.0x9.4 Valve guide reamer, 5.510 07942-8920000 07984-2000001 14-2...
  • Page 158 CYLINDER HEAD CYLINDER HEAD REMOVAL/ INSTALLATION Remove the fan cover guide assembly (page 13-3). CYLINDER HEAD REMOVAL/INSTALLATION: Before installing the cylinder head, remove any (Apply to the threads carbon deposits from the combustion chamber, and inspect the valve seats. and seating surface) After installing the cylinder head, measure the BOLT (8 x 60 mm) (4) cylinder compression.
  • Page 159 CYLINDER HEAD CYLINDER HEAD DISASSEMBLY/ ASSEMBLY Remove the cylinder head (page 14-3). VALVE SPRING RETAINER DISASSEMBLY: EXHAUST VALVE VALVE STEM Push down and slide the valve spring retainer to ASSEMBLY: the side so that the valve stem slips through the Do not interchange with the hole at side of the valve spring retainer.
  • Page 160 CYLINDER HEAD CYLINDER HEAD/VALVES INSPECTION CYLINDER COMPRESSION CHECK Warm the engine to normal operating temperature. Turn the engine switch knob to the OFF position, and then remove the drain screw to drain the carburetor. Remove the spark plug cap from the spark plug. Remove the spark plug using a spark plug wrench.
  • Page 161 CYLINDER HEAD VALVE GUIDE I.D. Ream the valve guide (1) to remove any carbon deposits before measuring. TOOL: Valve guide reamer, 5.510 (2) 07984-2000001 COMBUSTION CHAMBER SIDE: Turn the special tool (Valve guide reamer) clockwise, never counterclockwise. Continue to rotate the special tool while removing it from the valve guide.
  • Page 162 CYLINDER HEAD VALVE SPRING FREE LENGTH Measure the free length of the valve spring. STANDARD: 30.5 mm (1.20 in) SERVICE LIMIT: 29.0 mm (1.14 in) If the measured length is less than the service limit, replace the valve spring (page 14-4). VALVE SPRING PERPENDICULARITY Measure the valve spring perpendicularity.
  • Page 163 CYLINDER HEAD VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Use a hot plate or oven to heat the cylinder head evenly to 150°C (300°F). To avoid burns, use heavy gloves when handling the heated cylinder head.
  • Page 164 CYLINDER HEAD VALVE GUIDE REAMING For best results, be sure the cylinder head is at room temperature before reaming valve guides (1). Coat the reamer and valve guide with cutting oil. Rotate the reamer clockwise through the valve guide the full length of the reamer (2). COMBUSTION TOOL: CHAMBER SIDE...
  • Page 165 CYLINDER HEAD The 32° cutter removes material from the top edge CONTACT TO STANDARD (contact too high). TOOLS: Cutter holder, 5.5 07781-0010101 Flat cutter, 25 07780-0012000 Flat cutter, 28 07780-0012100 VALVE FACE The 60° cutter removes material from the bottom edge (contact too low).
  • Page 166: Cylinder Block

    15. CYLINDER BLOCK TOOLS·························································15-2 CRANKCASE COVER/CYLINDER BARREL/ PISTON/CONNECTING ROD/CRANKSHAFT/ CAMSHAFT INSPECTION·························· 15-6 CRANKCASE COVER REMOVAL/INSTALLATION························15-3 CRANKSHAFT BEARING REPLACEMENT (CRANKCASE COVER SIDE) ·················· 15-12 CRANKSHAFT/PISTON REMOVAL/INSTALLATION························15-4 CRANKSHAFT BEARING/OIL SEAL REPLACEMENT PISTON DISASSEMBLY/ASSEMBLY········15-5 (CYLINDER BARREL SIDE)····················· 15-13 15-1...
  • Page 167: Tools

    CYLINDER BLOCK TOOLS CYLINDER BLOCK Sliding hammer weight Bearing driver attachment, 37×40 Bearing driver attachment, 52×55 07741-0010201 07746-0010200 07746-0010400 Pilot, 25 Driver handle, 15×135L Bearing remover shaft set 25 07746-0040600 07749-0010000 07936-ZV10100 15-2...
  • Page 168: Crankcase Cover Removal/Installation

    CYLINDER BLOCK CRANKCASE COVER REMOVAL/ INSTALLATION Remove the fan cover guide assembly (page 13-3). DOWEL PIN (2) CRANKCASE COVER PACKING CRANKCASE COVER OIL FILLER CAP PACKING BOLT (8 x 32 mm) (6) OIL FILLER CAP DRAIN PLUG WASHER 24 N·m (2.4 kgf·m, 18 lbf·ft) (10.2 mm) DRAIN PLUG BOLT 18 N·m (1.8 kgf·m, 13 lbf·ft)
  • Page 169: Crankshaft/Piston Removal/Installation

    CYLINDER BLOCK CRANKSHAFT/PISTON REMOVAL/ INSTALLATION Remove the following parts: – Cylinder head (page 14-3) – Crankcase cover (page 15-3) PISTON ASSEMBLY INSTALLATION: PISTON Install the piston assembly in the cylinder barrel assembly with the mark on the piston head toward the push rod hole of the cylinder head.
  • Page 170: Piston Disassembly/Assembly

    CYLINDER BLOCK PISTON DISASSEMBLY/ASSEMBLY Remove the crankshaft (page 15-4). MARK (TOP/ PISTON RINGS SECOND RING) ASSEMBLY: Be sure that the top ring and second rings are not interchanged. Install the top ring and second ring on the piston TOP RING with the maker mark side facing up.
  • Page 171: Crankcase Cover/Cylinder Barrel/Piston/Connecting Rod/ Crankshaft/Camshaft Inspection

    CYLINDER BLOCK CRANKCASE COVER/CYLINDER BARREL/PISTON/CONNECTING ROD/ CRANKSHAFT/CAMSHAFT INSPECTION CAMSHAFT HOLDER I.D. CRNKCASE COVER SIDE Measure the camshaft holder I.D. of the crankcase cover. STANDARD: 14.000 – 14.018 mm (0.5512 – 0.5519 in) SERVICE LIMIT: 14.048 mm (0.5531 in) If the measurement is more than the service limit, replace the crankcase cover (page 15-3).
  • Page 172 CYLINDER BLOCK PISTON SKIRT O.D. Measure and record the piston O.D. at a point 10 mm (0.4 in) from the bottom of the skirt and 90 degrees to the piston pin bore. STANDARD: 67.965 – 67.985 mm (2.6758 – 2.6766 in) SERVICE LIMIT: 67.845 mm (2.6711 in) If the measurement is less than the service limit, 90°...
  • Page 173 CYLINDER BLOCK PISTON PIN O.D. Measure and record the piston pin O.D. at three points (both ends and middle). Take the minimum reading to determine piston pin O.D. STANDARD: 17.994 – 18.000 mm (0.7084 – 0.7087 in) SERVICE LIMIT: 17.954 mm (0.7068 in) If the measurement is less than the service limit, replace the piston pin (page 15-5).
  • Page 174 CYLINDER BLOCK PISTON RING END GAP Before inspection, check whether the cylinder sleeve I.D. is within the specification (page 15-6). Measure each piston ring (1) end gap using a feeler gauge. STANDARD: 0.200 - 0.350 mm (0.0079 - 0.0138 in) Second 0.350 - 0.500 mm (0.0138 - 0.0197 in)
  • Page 175 CYLINDER BLOCK CONNECTING ROD BIG END OIL CLEARANCE Clean all oil from the crank pin and connecting rod big end surface. Place a piece of plastigauge on the crank pin, install the connecting rod and the connecting rod cap, and tighten the two connecting rod bolts (1) to the specified torque.
  • Page 176 CYLINDER BLOCK CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft. STANDARD: IN: 27.600 - 27.800 mm (1.0866 - 1.0945 in) EX: 27.647 - 27.847 mm (1.0885 - 1.0963 in) SERVICE LIMIT: IN: 27.45 mm (1.081 in) EX: 27.50 mm (1.083 in) If the measurement is less than the service limit, replace the camshaft (page 15-4).
  • Page 177: Crankshaft Bearing Replacement (Crankcase Cover Side)

    CYLINDER BLOCK CRANKSHAFT BEARING REPLACEMENT (CRANKCASE COVER SIDE) LOCATION CRANKSHAFT BEARING (6205) CRANKSHAFT BEARING (6205) Remove the crankcase cover (page 15-3). Pull out the radial ball bearing (1) using the special tools. TOOLS: Bearing remover shaft set, 07936-ZV10100 25 (2) Sliding hammer weight (3) 07741-0010201 Apply oil to the circumference of a new bearing (1).
  • Page 178: Crankshaft Bearing/Oil Seal Replacement (Cylinder Barrel Side)

    CYLINDER BLOCK CRANKSHAFT BEARING/OIL SEAL REPLACEMENT (CYLINDER BARREL SIDE) LOCATION CRANKSHAFT BEARING (6205) CRANKSHAFT OIL SEAL (25 x 41 x 6 mm) CRANKSHAFT BEARING (6205) Remove the crankshaft, crankshaft oil seal (page 15-4). Drive out the radial ball bearing. Apply oil to the circumference of a new bearing (1). Drive the radial ball bearing until it is fully seated on the end using the special tools.
  • Page 179 MEMO...
  • Page 180: Technical Features

    16. TECHNICAL FEATURES FRAME MADE OF MAGNESIUM ···············16-2 INDICATOR ················································· 16-3 16-1...
  • Page 181 TECHNICAL FEATURES FRAME MADE OF MAGNESIUM TECHNICAL FEATURES OUTLINE The space between the stow-away handle and large-sized wheel consists of a frame made of magnesium and resin. It has achieved a highly efficient cooling air path by dividing the zones into cooling zones and hot zone by taking advantages of the T shaped frame.
  • Page 182 TECHNICAL FEATURES INDICATOR OUTPUT INDICATOR (GREEN) The green LED output indicator has a simplified hour meter function, and it blinks when starting the engine, depending on the cumulative operating hours. After completing the blinking at engine start, it turns on/off depending on the power generating status of the inverter. <Blinking pattern of the hour meter when starting the engine>...
  • Page 183 TECHNICAL FEATURES <Output indicator status by power generating status> OUTPUT INDICATOR (GREEN) ON/OFF INDICATOR Assy. OUTPUT INDICATOR Condition of generator (GREEN) Generating power Stop generating power OVERLOAD INDICATOR (RED) The red LED overload indicator turns on when an overloaded condition of the generator is detected, or when an error is detected. When a malfunction in the inverter is detected, it will blink.
  • Page 184 TECHNICAL FEATURES <Blinking when malfunction has been detected> OVERLOAD INDICATOR (RED) BLINK/OFF INDICATOR Assy. Blinking cycle: 250ms 250ms OVERLOAD INDICATOR Condition of generator (RED) Detecting malfunctions Blinking Other than above * “Detecting malfunction” indicates that it is detecting either of the following; SCR short circuit, diode short circuit, engine over-rev, A/D input malfunction, EEPROM error, or CPU control error.
  • Page 185 MEMO...
  • Page 186: Wiring Diagrams

    17. WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & WIRING DIAGRAMS ··································· 17-4 RELATED INFORMATION··························17-2 17-1...
  • Page 187 WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAMS The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins and the shape of terminal (male or female). Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are shown for the dedicated connectors.
  • Page 188 WIRING DIAGRAMS HOW TO READ WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a male or female terminal. TERMINAL No. INVERTER UNIT M A I N ( U ) M A I N ( V ) A C 1 A C 2 M A I N ( W )
  • Page 189 WIRING DIAGRAMS WIRING DIAGRAMS F, G, G8, GW, IT TYPES 17-4...
  • Page 190 WIRING DIAGRAMS R, RG, RH, S, S8, SK TYPES 17-5...
  • Page 191 WIRING DIAGRAMS U TYPE 17-6...
  • Page 192 WIRING DIAGRAMS C, L, LT TYPES 17-7...
  • Page 193 MEMO...
  • Page 194: Index

    INDEX INDEX AC CIRCUIT PROTECTOR INSPECTION ···················8-28 GENARATOR SYSTEM TROUBLESHOOTING ············ 8-3 AIR CLEANER CHECK/CLEANING ·······························3-4 GENERATOR INSPECTION ········································ 8-29 AIR CLEANER REMOVAL/INSTALLATION ···················6-4 GENERATOR REMOVAL/INSTALLATION·················· 8-10 AIR INTAKE JOINT DISASSEMBLY/ASSEMBLY ········6-14 GENERATOR/ENGINE BREATHER HEATER INSPECTION REMOVAL/INSTALLATION·········································· 13-2 (C TYPE ONLY) ····························································6-23 HARD STARTING ··························································...

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