Honda EU10iT1 Manual
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Honda EU10iT1 Manual

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GENERATOR
SOME PARTS OF CHANGES
Applicable Information
EU10i
CHANGE LOCATION
The changed instructions are shown in
INVERTER UNIT REMOVAL/INSTALLATION
Remove the fuel tank (page 6-3).
• When installing, route the wire harness properly (page 2-8).
Honda Motor Co., Ltd.
Service Publication Office
.
RECTIFIER
INSPECTION: page 8-9
INVERTER MOUNTING
RUBBER B
INVERTER UNIT
Shop Manual News
Publication No.
62Z4000
BOLT (6 x 12 mm)
WATER PROOF SEAT
INVERTER MOUNTING
RUBBER A (2)
1
Power Equipment
News No.
Issue Date
P/P-388
Mar. 2014
Applicable Page
8-9, 8-10
2014.03

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Summary of Contents for Honda EU10iT1

  • Page 1 • When installing, route the wire harness properly (page 2-8). BOLT (6 x 12 mm) RECTIFIER INSPECTION: page 8-9 WATER PROOF SEAT INVERTER MOUNTING RUBBER B INVERTER MOUNTING RUBBER A (2) INVERTER UNIT Honda Motor Co., Ltd. 2014.03 Service Publication Office...
  • Page 2 GENERATOR REMOVAL/INSTALLATION Remove the shroud (page 13-3). BOLT (6 x 16 mm) COOLING FAN STARTER PULLEY WASHER (6 mm) NUT (10 mm) 27.5 N·m (2.8 kgf·m, 20 lbf·ft) (Threads and seating surface) BOLT (6 x 16 mm) (2) ROTOR COOLING FAN BOSS REMOVAL: page 8-11 INSTALLATION: page 8-12 BOLT (5 x 25 mm) (2)

  • Page 3: Service Information

    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 4: Table Of Contents

    dummyhead dummyhead 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 ROCKER ARM/CAMSHAFT CYLINDER BLOCK WIRING DIAGRAM INDEX...
  • Page 5 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 Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 6 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 7 dummyhead dummyhead 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 Automatic Voltage Regulator...
  • Page 8 dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 PERFORMANCE CURVE ····························· 1-5 SPECIFICATIONS ·········································1-2 DIMENSIONAL DRAWINGS························· 1-7...
  • Page 9 The engine serial number [1] is stamped on the cylinder barrel, and the frame serial number [2] is shown at the underside of the L. side cover. Refer to it when ordering parts or making technical inquiries. SPECIFICATIONS DIMENSIONS AND WEIGHTS Model EU10iT1 Type Except GW1 Description code EAAT Overall length 451 mm (17.8 in)
  • Page 10 SPECIFICATIONS GENERATOR Model EU10iT1 Description code SS0, SS1, SK1, LL0, LL1, LT, LB RR0, RR1 Type EAAT 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...
  • Page 11 SPECIFICATIONS CHARACTERISTICS Model EU10iT1 Type SS0, SS1, SK1, LL0, LL1, LT, LB RR0, RR1 Voltage variation Momentary 10% max. rate Average 6% max. Average time 3 sec. max. Voltage stability within ± 1% Frequency Momentary 1% max. variation rate Average 1% max.
  • Page 12 dummyhead dummyhead SPECIFICATIONS PERFORMANCE CURVE 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 CURVE LL0, LL1, LT, LB TYPES AC 130...
  • Page 13 dummyhead dummyhead SPECIFICATIONS G, B, F, W, GW1, U, RH, RG, CL TYPES AC 250 LOAD CURRENT (A) DC EXTERNAL CHARACTERISTIC CURVE With Eco-Throttle OFF DC 30 LOAD CURRENT (A) This DC output characteristic was measured under the condition with capacitors (100,000 μF) were connected in parallel.
  • Page 14 dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS Unit: mm (in) 242 (9.5) Except GW1 TYPE: 451 (17.8) GW1 TYPE: 456 (18.0)
  • Page 15 dummyhead dummyhead MEMO...
  • Page 16 dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 HOW TO READ CONNECTOR DRAWINGS ··················································· 2-7 TORQUE VALUES ········································2-3 CABLE/HARNESS ROUTING ······················ 2-8 LUBRICATION & SEAL POINT ····················2-5 TUBE ROUTING ········································· 2-17 TOOLS···························································2-6...
  • Page 17 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Unit: mm (in) Service Part Item Standard limit Engine Engine speed 4,000 – 6,000 min (rpm) – [Eco-Throttle OFF] [5,500 – 6,000 min (rpm)] Cylinder compression 0.42 MPa (4.3 kgf/cm , 61.2 psi)/ –...
  • Page 18 dummyhead dummyhead SERVICE INFORMATION Service Part Item Standard limit Valve guide Valve guide I.D. IN/EX 4.060 4.000 – 4.018 (0.1575 – 0.1582) (0.1598) Valve spring Free length IN/EX 23.7 (0.93) 22.8 (0.90) Camshaft Cam height IN/EX 26.972 27.772 – 28.172 (1.0934 – 1.1091) (1.0619) Camshaft roller bearing I.D.
  • Page 19 dummyhead dummyhead SERVICE INFORMATION FRAME TORQUE VALUES Torque values Item Thread Dia. (mm) N·m kgf·m lbf·ft Rotor nut M10 x 1.25 27.5 Fan cover stud bolt M5 x 0.8 Maintenance cover screw M6 x 1.0 0.23 Fuel pump self-tapping screw 0.08 Fuel valve self-tapping screw 0.14...
  • Page 20 dummyhead dummyhead SERVICE INFORMATION LUBRICATION & SEAL POINT Material Location Remarks Use molybdenum oil solution Piston outer surface and piston pin hole (mixture of the engine oil and Piston pin outer surface molybdenum grease in a ratio Piston ring entire surface of 1:1) Cylinder inner surface Crankshaft pin...
  • Page 21 dummyhead dummyhead SERVICE INFORMATION TOOLS Attachment, 24 x 26 mm Pilot, 17 mm Driver 07746-0010700 07746-0040400 07749-0010000 Flywheel puller Cleaning brush Float level gauge 07935-8050004 07998-VA20100 07401-0010000...
  • Page 22 dummyhead dummyhead SERVICE INFORMATION 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 23 dummyhead dummyhead SERVICE INFORMATION CABLE/HARNESS ROUTING THROTTLE CONTROL MOTOR WIRE 4P CONNECTOR INSTALLATION: After installing the motor cover, set WIRE SIDE against the clamp of the throttle control motor base securely. CLAMP (AIR INTAKE JOINT) IGNITION COIL HARNESS PRIMARY WIRE CLIP 2P CONNECTOR ENGINE STOP...
  • Page 24 dummyhead dummyhead SERVICE INFORMATION CABLE CLIP HIGH TENSION WIRE GENERATOR WIRE HARNESS HIGH TENSION WIRE INSTALLATION: INSTALLATION: Route the wire harness Set in the groove of the fan cover. so it does not contact Secure with cable clip. with the engine bed edge, and clamp it at white tape position.
  • Page 25 dummyhead dummyhead SERVICE INFORMATION LT, RH, LL0, LL1, RR0, RR1, SS0, SS1 TYPES: CONTROL PANEL (LT, LL0, LL1 types only) (Except LT, LL0, LL1 types) SUB WIRE HARNESS CONTROL PANEL GENERATOR WIRE HARNESS WIRE HARNESS 3P CONNECTOR 10P CONNECTOR GENERATOR WIRE CONTROL PANEL HARNESS SIDE WIRE HARNESS SIDE...
  • Page 26 dummyhead dummyhead SERVICE INFORMATION U TYPE: CONTROL PANEL SUB WIRE HARNESS GENERATOR WIRE HARNESS CONTROL PANEL WIRE HARNESS 3P CONNECTOR GENERATOR WIRE 10P CONNECTOR HARNESS SIDE CONTROL PANEL WIRE HARNESS SIDE Install the generator wire harness as shown. Install the ground wire as close CONTROL PANEL to the back of the control panel WIRE HARNESS...
  • Page 27 dummyhead dummyhead SERVICE INFORMATION LT, LL0, LL1 TYPES: Terminal Terminal Terminal Terminal Wire color Wire color Wire color Wire color number number number number – Bl/Bu Bl/R Bl/Bu – G/Bl RH, PRO, RR1 TYPE: RH, RR0, RR1 TYPES: Terminal Terminal Terminal Terminal Wire color...
  • Page 28 dummyhead dummyhead SERVICE INFORMATION U TYPE: Terminal Terminal Terminal Terminal Wire color Wire color Wire color Wire color number number number number Bl/R – Bl/Bu Bl/Bu – Wire color G/Bl LB TYPE: Terminal Terminal Terminal Terminal Wire color Wire color Wire color Wire color number...
  • Page 29 dummyhead dummyhead SERVICE INFORMATION SB TYPE: Terminal Terminal Terminal Terminal Wire color Wire color Wire color Wire color number number number number Bl/R – Bl/Bu Bl/Bu – G/Bl RH, PRO, RR1 TYPE: SS0, SS1, SK1 TYPES: SS0, SS1 TYPES: Terminal Terminal Terminal Terminal...
  • Page 30 dummyhead dummyhead SERVICE INFORMATION G, GW1, CL, RG, B, F, W TYPES: B TYPE: Terminal Terminal Terminal Terminal Wire color Wire color Wire color Wire color number number number number Bl/R – Bl/Bu Bl/Bu – Wire color G/Bl G, GW1, CL, RG TYPES: F, W TYPES: Terminal Terminal...
  • Page 31 dummyhead dummyhead SERVICE INFORMATION 8P CONNECTOR CONTROL PANEL WIRE HARNESS CONTROL PANEL WIRE HARNESS SIDE 4P CONNECTOR Except SS0, SS1, SK1, GENERATOR WIRE RECTIFIER SB TYPES: HARNESS SIDE 2P CONNECTOR SUB WIRE 4P CONNECTOR HARNESS THROTTLE CONTROL SS0, SS1, SK1, SB SIDE MOTOR WIRE SIDE TYPES:...
  • Page 32 dummyhead dummyhead SERVICE INFORMATION TUBE ROUTING FUEL TUBE (PUMP TO CARBURETOR) INSTALLATION: Pass through the hole in the fan cover. BREATHER TUBE DRAIN TUBE INSTALLATION: Set in the groove in the cover securely. DRAIN TUBE AIR VENT TUBE ENGINE TUBE SIDE CLAMP DIAPHRAGM TUBE...
  • Page 33 dummyhead dummyhead MEMO...

  • Page 34: Maintenance

    dummytext 3. MAINTENANCE TOOL ·····························································3-2 SPARK ARRESTER CLEANING·················· 3-6 MAINTENANCE SCHEDULE························3-2 VALVE CLEARANCE CHECK/ ADJUSTMENT ·············································· 3-6 ENGINE OIL LEVEL CHECK ························3-3 COMBUSTION CHAMBER CLEANING ······· 3-7 AIR CLEANER CHECK/CLEANING ·············3-4 FUEL TANK AND FILTER CLEANING ········ 3-7 SPARK PLUG CHECK/ADJUSTMENT/ REPLACEMENT············································3-5 FUEL TUBE INSPECTION····························...
  • Page 35 dummyhead dummyhead MAINTENANCE TOOL MAINTENANCE Cleaning brush 07998-VA20100 MAINTENANCE SCHEDULE ITEM Perform at every REGULAR SERVICE PERIOD (2) Refer indicated month or First Every Every Every operating hour interval, Each use month 3 months 6 months 2 year or page whichever comes first.
  • Page 36 dummyhead dummyhead MAINTENANCE ENGINE OIL LEVEL CHECK LEVEL CHECK Remove the maintenance cover (page 5-2). Place the engine on a level surface. Remove the oil filler cap [1] and check the oil level [2]. If the oil level is low, fill with the recommended oil to the upper level of the oil filler neck.
  • Page 37 dummyhead dummyhead MAINTENANCE AIR CLEANER CHECK/CLEANING Remove the maintenance cover (page 5-2). Disengaged the locking tab [1] by pushing it, and remove the air cleaner cover [2]. Remove the air cleaner element [3] from the air cleaner cover. Clean the air cleaner element in warm soapy water [1], rinse, and allow to dry thoroughly, or clean with a high flash point solvent and allow to dry.
  • Page 38 dummyhead dummyhead MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT/ REPLACEMENT If the engine has been running, the engine will be very hot. Allow it to cool before proceeding. Remove the plug cover [1]. Clean any dirt from around the spark plug. Disconnect the spark plug cap [1], and use a spark plug wrench [2] to remove the spark plug [3].
  • Page 39 dummyhead dummyhead MAINTENANCE SPARK ARRESTER CLEANING The engine and muffler become very hot during operation, and they remain hot for a while after operation. Be sure that the engine is cool before servicing the spark arrester. Remove the muffler (page 12-2). Clean the carbon deposits from the spark arrester screen with a wire brush.
  • Page 40 dummyhead dummyhead MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the piston/connecting rod assembly (page 15- Prepare a cylinder of a thick paper or equivalent material [1], which diameter is as large as the inner wall of the cylinder, and insert the paper into the cylinder. Attach the special tool to an electric drill and clean any carbon deposits from the combustion chamber.
  • Page 41 dummyhead dummyhead MAINTENANCE FUEL TUBE INSPECTION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Remove the side cover (page 5-3). Check the fuel tubes [1] for damage, fuel leakage, corrosion, and other abnormalities.
  • Page 42 dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING···················4-2 ENGINE SPEED DOES NOT INCREASE OR STABILIZE ··················································· 4-4 HARD STARTING ·········································4-2 ENGINE OIL LEVEL IS LOW, BUT ENGINE DOES NOT STOP ········································ 4-5 ENGINE STARTS BUT THEN STALLS········4-3...

  • Page 43: Troubleshooting

    dummyhead dummyhead TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Check that the connectors are connected securely. • Check for sufficient fresh fuel in the fuel tank. • Read the circuit tester's operation instructions carefully, and observe the instructions during inspection. HARD STARTING Check the engine oil level (page 3-3).
  • Page 44 dummyhead dummyhead TROUBLESHOOTING ENGINE STARTS BUT THEN STALLS Abnormal Check for blockage of the fuel filter (page 3-7). Clean the fuel filter or replace if necessary (page 6-3). Normal Abnormal Check for blockage of the fuel pump or diaphragm Replace the fuel pump or diaphragm tube (pages tube (pages 5-5 and 13-3).
  • Page 45 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED DOES NOT INCREASE OR STABILIZE Contaminated Check the air cleaner (page 3-4). Clean the air cleaner or replace if necessary (page 3-5). contaminated Abnormal Check the valve clearance (page 3-6). Adjust the valve clearance (page 3-6). Normal Abnormal Check for blockage in the main jet of the...
  • Page 46 dummyhead dummyhead TROUBLESHOOTING ENGINE OIL LEVEL IS LOW, BUT ENGINE DOES NOT STOP Check the following at the engine on a level surface. Drain the engine oil. Perform the spark test (page 9-6). No light Pull the recoil starter grip and check the Oil Alert Replace the ignition control module if necessary indicator light on the control panel.
  • Page 47 dummyhead dummyhead MEMO...

  • Page 48: Cover

    dummytext 5. COVER MAINTENANCE COVER REMOVAL/ SIDE COVER REMOVAL/ INSTALLATION·············································5-2 INSTALLATION ············································ 5-3 FRONT COVER REMOVAL/ L. SIDE COVER DISASSEMBLY/ INSTALLATION·············································5-2 ASSEMBLY ··················································· 5-5 MUFFLER PROTECTOR REMOVAL/ INSTALLATION·············································5-2...
  • Page 49 dummyhead dummyhead COVER MAINTENANCE COVER REMOVAL/ COVER INSTALLATION Loosen the screw [1] and remove the maintenance cover [2]. To install the maintenance cover, set it on the L. side cover by aligning the tabs with the holes. Tighten the maintenance cover screw to the specified torque.
  • Page 50 dummyhead dummyhead COVER SIDE COVER REMOVAL/ INSTALLATION REMOVAL Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Drain the fuel from the fuel tank and carburetor.
  • Page 51 dummyhead dummyhead COVER INSTALLATION Before installing, check the wire and tube routing in the L. side cover (page 2-8). Connect the 2P connector and bind it with the cable tie. Connect the fuel tube to the fuel tank. Connect the fuel tube and diaphragm tube to the fuel pump.
  • Page 52 dummyhead dummyhead COVER L. SIDE COVER DISASSEMBLY/ ASSEMBLY Remove the L. side cover (page 5-3). • When installing, route the wire properly (page 2-8). L. SIDE COVER FUEL PUMP Do not remove the pump unless it is replaced. Replace the fuel pump if foreign material or ENGINE SWITCH KNOB water has accumulated in the tank.
  • Page 53 dummyhead dummyhead MEMO...

  • Page 54: Fuel System

    dummytext 6. FUEL SYSTEM TOOL ·····························································6-2 CARBURETOR DISASSEMBLY/ ASSEMBLY ··················································· 6-6 FUEL TANK DISASSEMBLY/ASSEMBLY···6-3 FLOAT LEVEL HEIGHT INSPECTION········· 6-7 AIR CLEANER REMOVAL/ INSTALLATION·············································6-4 PILOT SCREW REPLACEMENT ················· 6-7 CARBURETOR REMOVAL/ INSTALLATION·············································6-5...
  • Page 55 dummyhead dummyhead FUEL SYSTEM TOOL FUEL SYSTEM Float level gauge 07401-0010000...
  • Page 56 dummyhead dummyhead FUEL SYSTEM FUEL TANK 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. Remove the side covers (page 5-3).
  • Page 57 dummyhead dummyhead FUEL SYSTEM AIR CLEANER REMOVAL/INSTALLATION Remove the maintenance cover (page 5-2). AIR CLEANER ELEMENT Push COVER SEAL A COVER SEAL B AIR CLEANER RUBBER INSTALLATION: AIR CLEANER COVER Install firmly into the tabs [1] of the air cleaner case. INSTALLATION: Be sure that there is no clearance between seals A [1] and B [2].
  • Page 58 dummyhead dummyhead 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. Loosen the drain screw to drain the carburetor thoroughly before removal. Remove the maintenance cover (page 5-2).
  • Page 59 dummyhead dummyhead 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. Remove the throttle control motor (page 7-4). PILOT JET CARBURETOR BODY ASSEMBLY:...
  • Page 60 dummyhead dummyhead FUEL SYSTEM THROTTLE STOP SCREW Install the throttle stop screw [1] after installing the pilot jet. Install so that the throttle valve is fully closed and the screw end does not come out of the bracket. FLOAT LEVEL HEIGHT INSPECTION Place the carburetor in the position shown, and measure the distance between the float top [1] and carburetor body [2] when the float just contacts the seat...
  • Page 61 dummyhead dummyhead FUEL SYSTEM Apply LOCTITE ® 638, or equivalent to the inside of the limiter cap [1], and then install the cap so its stop [2] prevents pilot screw from being turned counterclockwise. Be careful to avoid turning the pilot screw while installing the limiter cap.

  • Page 62: Governor System

    dummytext 7. GOVERNOR SYSTEM THROTTLE CONTROL SYSTEM Eco-Throttle SWITCH INSPECTION ··········· 7-5 TROUBLESHOOTING···································7-2 THROTTLE CONTROL MOTOR THROTTLE CONTROL MOTOR REMOVAL/ INSPECTION················································· 7-5 INSTALLATION·············································7-4...
  • Page 63 dummyhead dummyhead GOVERNOR SYSTEM THROTTLE CONTROL SYSTEM TROUBLESHOOTING GOVERNOR SYSTEM Engine Speed is Too High, Unstable Abnormal Check the AC output. Perform "GENERATOR TROUBLESHOOTING" (page 8-3). Normal Perform "ENGINE SPEED DOES NOT INCREASE OR STABILIZE" (page 4-4). Normal Inspect the throttle control motor (page 7-5). Abnormal Faulty throttle control motor.
  • Page 64 dummyhead dummyhead 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 Check the AC output.
  • Page 65 dummyhead dummyhead 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 6-5).
  • Page 66 dummyhead dummyhead GOVERNOR SYSTEM Eco-Throttle SWITCH INSPECTION Remove the control panel (page 8-6). Disconnect the connectors from the Eco-Throttle switch. Check for continuity between the Eco-Throttle switch terminals. There must be no continuity with the switch turned ON, and continuity with the switch turned OFF. THROTTLE CONTROL MOTOR INSPECTION Remove the carburetor (page 6-5).
  • Page 67 dummyhead dummyhead MEMO...

  • Page 68: Generator/Charging System

    dummytext 8. GENERATOR/CHARGING SYSTEM TOOL ·····························································8-2 INVERTER UNIT REMOVAL/ INSTALLATION ············································ 8-9 GENERATOR TROUBLESHOOTING···········8-3 RECTIFIER INSPECTION ····························· 8-9 CONTROL PANEL REMOVAL/ INSTALLATION·············································8-6 GENERATOR REMOVAL/ INSTALLATION ·········································· 8-10 CONTROL PANEL DISASSEMBLY/ ASSEMBLY ···················································8-7 GENERATOR INSPECTION ······················· 8-13...
  • Page 69 dummyhead dummyhead GENERATOR/CHARGING SYSTEM TOOL GENERATOR/CHARGING SYSTEM Flywheel puller 07935-8050004...
  • Page 70 dummyhead dummyhead GENERATOR/CHARGING SYSTEM GENERATOR TROUBLESHOOTING No or low AC output Check that the output indicator (green) is ON. Go to page 8-4 Check that the engine speed is normal. Abnormal Perform "THROTTLE CONTROL SYSTEM Engine speed: 5,500 – 6,000 min (rpm) with Eco- TROUBLESHOOTING"...
  • Page 71 dummyhead dummyhead GENERATOR/CHARGING SYSTEM From page 8-3 Start the engine and check the overload indicator Disconnect the load, and restart the engine and light (red) ON. recheck the AC output. Abnormal Stop the engine and check the AC receptacle Replace the AC receptacle (page 8-7). (page 8-8).
  • Page 72 dummyhead dummyhead GENERATOR/CHARGING SYSTEM No DC output Check that the engine speed is normal. Abnormal Perform "THROTTLE CONTROL SYSTEM Engine speed: 5,500 – 6,000 min (rpm) with Eco- TROUBLESHOOTING" (page 7-2). Throttle switch OFF. Normal Abnormal Stop the engine and check the DC receptacle Replace the DC receptacle (page 8-7).
  • Page 73 dummyhead dummyhead GENERATOR/CHARGING SYSTEM CONTROL PANEL REMOVAL/INSTALLATION Remove the front cover (page 5-2). • When installing, route the wire harness properly (page 2-8). LL1 TYPE shown: DC OUTPUT TERMINAL REMOVAL: Install a small screwdriver or equivalent tool into the groove and pull out the wire. AC OUTPUT TERMINAL REMOVAL: INSTALLATION:...
  • Page 74 dummyhead dummyhead GENERATOR/CHARGING SYSTEM CONTROL PANEL DISASSEMBLY/ASSEMBLY Remove the control panel (page 8-6) • When installing, route the wire harness properly (page 2-8). U TYPE: F, B, W, G, GW1, CL, SB, LB TYPES: RG, SK1 TYPES: NUT (4 mm) (4) SCREW (4 mm) (4) SCREW NUT (4 mm) (4)
  • Page 75 dummyhead dummyhead GENERATOR/CHARGING SYSTEM AC RECEPTACLE INSPECTION Connect both terminals of the receptacle with a jumper LL1 type shown: wire to short. There must be continuity between the lead wire terminals. LL0, LL1, LT, RR0, RR1, RH, SS0, SS1 types: There must be continuity between the ground terminal of the receptacle and the receptacle installation fitting.
  • Page 76 dummyhead dummyhead GENERATOR/CHARGING SYSTEM INVERTER UNIT REMOVAL/INSTALLATION Remove the fuel tank (page 6-3). • When installing, route the wire harness properly (page 2-8). BOLT (6 x 12 mm) WATER PROOF SEAT RECTIFIER INSPECTION: page 8-9 INVERTER MOUNTING RUBBER B INVERTER UNIT INVERTER MOUNTING RUBBER A (2) RECTIFIER INSPECTION...
  • Page 77 dummyhead dummyhead GENERATOR/CHARGING SYSTEM GENERATOR REMOVAL/INSTALLATION Remove the shroud (page 13-3). BOLT (6 x 16 mm) COOLING FAN STARTER PULLEY WASHER (6 mm) NUT (10 mm) 27.5 N·m (2.8 kgf·m, 20 lbf·ft) (Threads and seating surface) ROTOR BOLT (6 x 16 mm) (2) COOLING FAN BOSS REMOVAL: page 8-11 INSTALLATION: page 8-12...
  • Page 78 dummyhead dummyhead GENERATOR/CHARGING SYSTEM ROTOR REMOVAL • Do not strike any part of the rotor when removing it. The rotor may be damaged. Hold the rotor [1] with a commercially available strap wrench [2]. Remove the following parts: – Bolt (6 x 16 mm) [3] –...
  • Page 79 dummyhead dummyhead GENERATOR/CHARGING SYSTEM ROTOR INSTALLATION Clean any oil from the tapered portions of the rotor and crankshaft. Check for any foreign material attracted to the inside of the rotor before installation. Install the rotor [1] by aligning the key slot with the woodruff key on the crankshaft.
  • Page 80 dummyhead dummyhead GENERATOR/CHARGING SYSTEM GENERATOR INSPECTION MAIN WINDING Remove the control panel (page 8-6). Disconnect the generator wire harness 5P connector from the inverter unit. Measure the resistance between the terminals of the connector according to the table below. Terminal number Resistance 1 –...
  • Page 81 dummyhead dummyhead GENERATOR/CHARGING SYSTEM DC WINDING Remove the inverter unit (page 8-9). Measure the resistance between the terminals of the connector according to the table below. Terminal number Resistance 3 – 4 0.1 – 0.2 Ω 8-14...

  • Page 82: Ignition System

    dummytext 9. IGNITION SYSTEM IGNITION SYSTEM IGNITION PULSE GENERATOR TROUBLESHOOTING···································9-2 INSPECTION················································· 9-6 IGNITION COIL/IGNITION PULSE IGNITION COIL INSPECTION ······················ 9-6 GENERATOR/FAN COVER REMOVAL/ INSTALLATION·············································9-4 IGNITION CONTROL MODULE INSPECTION················································· 9-8 SPARK TEST ················································9-6...
  • Page 83 dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING IGNITION SYSTEM Engine does not start with sufficient oil in the crankcase Sparks Perform the spark test (page 9-6). Replace the spark plug (page 3-5). No spark Lights Pull the recoil starter grip and check the Oil Alert Check the oil level switch (page 11-4).
  • Page 84 dummyhead dummyhead IGNITION SYSTEM From page 9-2 Abnormal Replace the ignition coil (page 9-4). Check the ignition coil (page 9-6). Normal Abnormal Check the ignition control module (page 9-8). Replace the ignition control module (page 8-7). Normal Check the control wire harness, generator wire harness and ignition coil ground wire. CONTROL WIRE HARNESS IGNITION COIL GROUND WIRE Bl/Bu...
  • Page 85 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL/IGNITION PULSE GENERATOR/FAN COVER REMOVAL/ INSTALLATION Remove the following: – Air intake joint (page 6-5) – Inverter unit (page 8-9) • When installing, route the tube properly (page 2-17). STUD BOLT B 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft) SPARK PLUG CAP COLLAR STUD BOLT A (2)
  • Page 86 dummyhead dummyhead IGNITION SYSTEM FAN COVER DISASSEMBLY/ ASSEMBLY Remove the following: – Air cleaner (page 6-4) – Recoil starter (page 10-2) REFLECTOR SET COLLAR (3) FAN COVER FAN COVER COLLAR (3) IGNITION PULSE GENERATOR AIR GAP ADJUSTMENT Insert a feeler gauge [1] between the ignition pulse generator [2] and the rotor projection [3].
  • Page 87 dummyhead dummyhead IGNITION SYSTEM SPARK TEST Never hold the high-tension cord with wet hands while performing this test. Check for the following before conducting the spark test. – Faulty spark plug – Loose spark plug cap – Water in the spark plug cap (leaking ignition coil secondary voltage) Remove the plug cover (page 3-5), and disconnect the spark plug cap [1].
  • Page 88 dummyhead dummyhead IGNITION SYSTEM SECONDARY SIDE Measure the resistance of the secondary coil by attaching one ohmmeter probe to the spark plug cap and the other to the ignition coil ground terminal RESISTANCE: 12 – 21 kΩ If measured resistance is out of specification, replace the ignition coil.
  • Page 89 dummyhead dummyhead IGNITION SYSTEM IGNITION CONTROL MODULE INSPECTION Remove the control panel (page 8-6). Do not disconnect the connector and Disconnect the 10P connector from the ignition terminal during control module. inspection. Turn the engine stop switch to the ON position. Test the wire harness according to the table below.

  • Page 90: Starting System

    dummytext 10. STARTING SYSTEM RECOIL STARTER REMOVAL/ RECOIL STARTER DISASSEMBLY/ INSTALLATION···········································10-2 ASSEMBLY ················································· 10-3 RECOIL STARTER INSPECTION ·············· 10-6 10-1...
  • Page 91 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER REMOVAL/INSTALLATION STARTING SYSTEM Remove the inverter unit (page 8-9). RECOIL STARTER BOLT (5 x 10 mm) (3) 4.8 N·m (0.49 kgf·m, 3.5 lbf·ft) 10-2...
  • Page 92 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER DISASSEMBLY/ASSEMBLY • Wear gloves and eye protection. • During disassembly, take care not to allow the return spring to come out from the spring cover. DISASSEMBLY Remove the recoil starter (page 10-2). SET SCREW SWINGARM COLLAR FRICTION SPRING SWINGARM (2)
  • Page 93 dummyhead dummyhead STARTING SYSTEM ASSEMBLY • Wear gloves and eye protection. • During disassembly, take care not to allow the return spring to come out from the spring cover. Pass the starter rope [1] through the rope hole [2] in the 15 –...
  • Page 94 dummyhead dummyhead STARTING SYSTEM Pass the starter rope [1] through the cutout [2] in the starter reel [3], and turn the starter reel approximately 3 turns in the direction of the arrows to preload the spring. Make sure that the rope grommet [1] is in place. Pass the rope [2] through the grommet, starter rope guide [3], starter grip [4] and grip cover [5].
  • Page 95 dummyhead dummyhead STARTING SYSTEM Install the friction spring [1]. Insert the swingarms [2] into the grooves [3] in the starter reel, and set the collar so the projections [4] are positioned between the projections [5] of the starter reel. Install the set screw [6] and tighten it. Install the grip cover [7] into the starter grip [8].

  • Page 96: Other Electrical

    dummytext 11. OTHER ELECTRICAL COMPONENT LOCATION ··························11-2 OIL LEVEL SWITCH INSPECTION ············ 11-4 OIL LEVEL SWITCH REMOVAL/ ENGINE STOP SWITCH INSPECTION ······ 11-4 INSTALLATION···········································11-3 11-1...

  • Page 97: Component Location

    dummyhead dummyhead OTHER ELECTRICAL COMPONENT LOCATION OTHER ELECTRICAL OIL LEVEL SWITCH ENGINE STOP SWITCH 11-2...
  • Page 98 dummyhead dummyhead OTHER ELECTRICAL OIL LEVEL SWITCH REMOVAL/INSTALLATION Remove the shroud (page 13-3). GENERATOR WIRE HARNESS O-RING (34.6 x 2.5 mm) (Entire surface) OIL LEVEL SWITCH INSPECTION: page 11-4 BOLT (5 x 14 mm) (3) 11-3...

  • Page 99: Oil Level Switch Inspection

    dummyhead dummyhead OTHER ELECTRICAL OIL LEVEL SWITCH INSPECTION Remove the oil level switch (page 11-3). Check continuity between the oil level switch wire connector and ground terminal The oil level switch is normal if there is no continuity with the switch set upside down. There must be continuity between the wires with the switch set right side up.

  • Page 100: Muffler

    dummytext 12. MUFFLER MUFFLER REMOVAL/INSTALLATION······12-2 12-1...
  • Page 101 dummyhead dummyhead 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. Allow it to cool before proceeding. Remove the muffler protector (page 5-2).

  • Page 102: Generator/Engine Removal/Installation

    dummytext 13. GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE REMOVAL/ SHROUD REMOVAL/INSTALLATION ······· 13-3 INSTALLATION···········································13-2 13-1...
  • Page 103 dummyhead dummyhead GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE REMOVAL/INSTALLATION Remove the inverter unit (page 8-9). WASHER (4) ENGINE BED INSULATOR (4) ENGINE BED GENERATOR WIRE HARNESS INSTALLATION: When installing, route the wire properly (page 2-8). BOLT (6 x 16 mm) (3) BOLT (5 x 8 mm) 2.3 N·m (0.23 kgf·m, 17 lbf·ft) INSULATOR COLLAR A (2)
  • Page 104 dummyhead dummyhead GENERATOR/ENGINE REMOVAL/INSTALLATION SHROUD REMOVAL/INSTALLATION Remove the following: – Fan cover (page 9-4) – Engine bed (page 13-2) • When installing, route the tubes properly (page 2-8). L. SHROUD SHROUD INSULATOR (2) INSULATOR COLLAR D WASHER (2) CARBURETOR INSULATOR HARNESS CLIP INSULATOR GASKET INSTALLATION:...

  • Page 105: Installation

    dummyhead dummyhead GENERATOR/ENGINE REMOVAL/INSTALLATION EXHAUST MANIFOLD REMOVAL/ INSTALLATION Remove the muffler (page 12-2). Remove the two bolts (5 x 20 mm) [1], exhaust manifold [2] and gasket [3]. Remove the carbon deposits inside of the exhaust manifold. Install a new gasket and exhaust manifold, then install and tighten the two bolts (5 x 20 mm) securely.

  • Page 106: Rocker Arm/Camshaft

    dummytext 14. ROCKER ARM/CAMSHAFT HEAD COVER/ROCKER ARM/PUSH ROD CYLINDER COMPRESSION CHECK········· 14-6 REMOVAL/INSTALLATION························14-2 CRANKCASE SIDE COVER/CAMSHAFT/ ROCKER ARM/PUSH ROD VALVE LIFTER/CYLINDER BLOCK INSPECTION ···············································14-3 INSPECTION··············································· 14-7 CRANKCASE SIDE COVER/CAMSHAFT/ AIR INTAKE JOINT STUD BOLT VALVE LIFTER REMOVAL/ REPLACEMENT ········································· 14-9 INSTALLATION···········································14-5 14-1...

  • Page 107: Head Cover/Rocker Arm/Push Rod Removal/Installation

    dummyhead dummyhead ROCKER ARM/CAMSHAFT HEAD COVER/ROCKER ARM/PUSH ROD REMOVAL/INSTALLATION ROCKER ARM/CAMSHAFT Remove the following: – Ignition coil/ignition pulse generator/fan cover (page 9-4) – Shroud (page 13-3) HEAD COVER REMOVAL: When removing the head cover, pry off slowly at each corner of the cover. BOLT (5 x 12 mm) (4) 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft) INSTALLATION:...

  • Page 108: Rocker Arm/Push Rod

    dummyhead dummyhead ROCKER ARM/CAMSHAFT HEAD COVER INSTALLATION Clean the mating surfaces of the head cover and cylinder block [1] with a degreasing detergent or a clean shop towel. Apply a bead Φ1.5 – 2.0 mm (Φ0.06 – 0.08 in) of liquid sealant (Threebond ®...
  • Page 109 dummyhead dummyhead ROCKER ARM/CAMSHAFT ROCKER ARM ROLLER JOURNAL I.D. Measure the rocker arm roller journal I.D. STANDARD: 4.000 – 4.018 mm (0.1575 – 0.1582 in) SERVICE LIMIT: 4.050 mm (0.1594 in) If the measurement is more than the service limit, replace the cylinder block.

  • Page 110: Crankcase Side Cover/Camshaft/ Valve Lifter Removal

    dummyhead dummyhead ROCKER ARM/CAMSHAFT CRANKCASE SIDE COVER/ CAMSHAFT/VALVE LIFTER REMOVAL/ INSTALLATION Remove the following: – Exhaust manifold (page 13-4) – Head cover/rocker arm/push rod (page 14-2) CRANKCASE SIDE COVER REMOVAL: Insert a screwdriver or equivalent tool into the recess at the positions shown, and remove the crankcase side cover.

  • Page 111: Installation

    dummyhead dummyhead ROCKER ARM/CAMSHAFT CAMSHAFT INSTALLATION Install the camshaft [1] by aligning the alignment mark [2] on the camshaft with the timing mark [3] on the crankshaft [4]. CRANKCASE SIDE COVER INSTALLATION Clean the mating surfaces of the side cover and cylinder block [1] with a degreasing detergent or a clean shop towel.

  • Page 112: Crankcase Side Cover/Camshaft/ Valve Lifter/Cylinder Block

    dummyhead dummyhead ROCKER ARM/CAMSHAFT CRANKCASE SIDE COVER/ CAMSHAFT/VALVE LIFTER/CYLINDER BLOCK INSPECTION CAMSHAFT ROLLER JOURNAL I.D. CRANKCASE SIDE COVER SIDE Measure the camshaft roller journal I.D. of the crankcase side cover. STANDARD: 5.000 – 5.018 mm (0.1968 – 0.1976 in) SERVICE LIMIT: 5.050 mm (0.1988 in) If the measurement is more than the service limit, replace the crankcase side cover.
  • Page 113 dummyhead dummyhead ROCKER ARM/CAMSHAFT CAMSHAFT ROLLER O.D. Measure the camshaft roller O.D. STANDARD: 4.990 – 5.000 mm (0.1965 – 0.1969 in) SERVICE LIMIT: 4.950 mm (0.1949 in) If the measurement is less than the service limit, replace the camshaft roller. CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft.

  • Page 114: Air Intake Joint Stud Bolt

    dummyhead dummyhead ROCKER ARM/CAMSHAFT VALVE LIFTER SIDE Measure the valve lifter roller journal I.D. of the valve lifter. STANDARD: 5.005 – 5.025 mm (0.1970 – 0.2012 in) SERVICE LIMIT: 5.050 mm (0.1988 in) If the measurement is more than the service limit, replace the valve lifter.
  • Page 115 dummyhead dummyhead MEMO...

  • Page 116: Cylinder Block

    dummytext 15. CYLINDER BLOCK TOOLS·························································15-2 PISTON/CONNECTING ROD DISASSEMBLY/ASSEMBLY ······················ 15-7 OIL CASE/CRANKSHAFT/PISTON REMOVAL/INSTALLATION························15-3 CYLINDER BLOCK/PISTON/CONNECTING ROD/CRANKSHAFT/VALVE INSPECTION··············································· 15-8 VALVE/VALVE SPRING REMOVAL/ INSTALLATION···········································15-6 CRANKSHAFT OIL SEAL REPLACEMENT ······································· 15-14 15-1...
  • Page 117 dummyhead dummyhead CYLINDER BLOCK TOOLS CYLINDER BLOCK Attachment, 24 x 26 mm Pilot, 17 mm Driver 07746-0010700 07746-0040400 07749-0010000 15-2...
  • Page 118 dummyhead dummyhead CYLINDER BLOCK OIL CASE/CRANKSHAFT/PISTON REMOVAL/INSTALLATION Remove the following: – Generator (page 8-10) – Crankcase side cover/camshaft/valve lifter (page 14-5) OIL FILLER CAP OIL CASE (Oil seal lips) REMOVAL: OIL CHECK RUBBER Insert a screwdriver into the recess at the positions shown, and remove the oil case.
  • Page 119 dummyhead dummyhead CYLINDER BLOCK OIL CASE INSTALLATION Clean the mating surfaces of the oil case and cylinder block [1] with a degreasing detergent or a clean shop towel. Install the two dowel pin (6 x 15 mm) into the cylinder block (page 15-3).
  • Page 120 dummyhead dummyhead CYLINDER BLOCK CONNECTING ROD CAP INSTALLATION Install by aligning the alignment marks [1] on the connecting rod big end and the cap. Install with the oil dipper [2] facing the rotor side. 15-5...
  • Page 121 dummyhead dummyhead CYLINDER BLOCK VALVE/VALVE SPRING REMOVAL/INSTALLATION Remove the oil case/crankshaft/piston/connecting rod assembly (page 15-3). VALVE SPRING RETAINER (2) REMOVAL: Push down and slide the valve spring retainer [1] to the side so that the valve stem [2] slips through the hole at the side of the valve spring retainer.
  • Page 122 dummyhead dummyhead CYLINDER BLOCK PISTON/CONNECTING ROD DISASSEMBLY/ASSEMBLY Remove the piston/connecting rod assembly (page 15-3). MARK (TOP/SECOND RING) TOP RING (CHROME FACE) 120° 120° 120° SECOND RING OIL RING (COMBINATION MARK 10 mm (Entire surface) RING) (0.4 in) PISTON RINGS ASSEMBLY: To install the oil ring, install the spacer [1] first, and then install 10 mm the side rails [2].
  • Page 123 dummyhead dummyhead CYLINDER BLOCK CYLINDER BLOCK/PISTON/ CONNECTING ROD/CRANKSHAFT/ VALVE INSPECTION COMBUSTION CHAMBER Check the combustion chamber [1] for damage. If the combustion chamber is dirty, clean the combustion chamber (page 3-7). 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°...
  • Page 124 dummyhead dummyhead CYLINDER BLOCK PISTON-TO-CYLINDER CLEARANCE Subtract the piston skirt O.D. from the cylinder sleeve I.D. to obtain the piston-to-cylinder clearance. Except GW1 TYPE: STANDARD: 0.010 – 0.045 mm (0.0004 – 0.0018 in) SERVICE LIMIT: 0.120 mm (0.0047 in) GW1 TYPE: STANDARD: 0.010 –...
  • Page 125 dummyhead dummyhead CYLINDER BLOCK PISTON RING SIDE CLEARANCE Measure the clearance between each piston ring and ring groove of the piston using feeler gauge. STANDARD: Top: 0.015 – 0.050 mm (0.0006 – 0.0020 in) Second: 0.015 – 0.050 mm (0.0006 – 0.0020 in) SERVICE LIMIT: Top: 0.12 mm (0.005 in)
  • Page 126 dummyhead dummyhead CYLINDER BLOCK CONNECTING ROD BIG END SIDE CLEARANCE Measure the clearance between the connecting rod big end and crankshaft using a feeler gauge. STANDARD: 0.1 – 0.6 mm (0.004 – 0.024 in) SERVICE LIMIT: 0.8 mm (0.031 in) If the measurement is more than the service limit, replace the connecting rod (page 15-7) and recheck the clearance.
  • Page 127 dummyhead dummyhead CYLINDER BLOCK CRANKPIN O.D. Measure the crankpin O.D. of the crankshaft. STANDARD: 14.973 – 14.984 mm (0.5895 – 0.5899 in) SERVICE LIMIT: 14.940 mm (0.5882 in) If the measurement is less than the service limit, replace the crankshaft. CONNECTING ROD BIG END OIL CLEARANCE Clean all oil from the crankpin and connecting rod big...
  • Page 128 dummyhead dummyhead CYLINDER BLOCK VALVE STEM O.D. Inspect each valve for bending or abnormal stem wear. If necessary, replace the valve. Measure and record each valve stem O.D. STANDARD: IN: 3.970 – 3.985 mm (0.1563 – 0.1569 in) EX: 3.935 – 3.950 mm (0.1549 – 0.1555 in) SERVICE LIMIT: IN: 3.900 mm (0.1535 in) EX: 3.880 mm (0.1528 in)
  • Page 129 dummyhead dummyhead CYLINDER BLOCK CRANKSHAFT OIL SEAL REPLACEMENT Remove the oil seal [1]. 0.7 – 1.7 mm Drive a new oil seal into the cylinder block using the (0.03 – 0.06 in) special tools as shown. TOOLS Driver [2] 07749-0010000 Attachment, 24 x 26 mm [3] 07746-0010700 Pilot, 17 mm [4]...

  • Page 130: Wiring Diagram

    dummytext 16. WIRING DIAGRAM HOW TO READ A WIRING DIAGRAM & WIRING DIAGRAM ····································· 16-3 RELATED INFORMATION··························16-2 16-1...
  • Page 131 dummyhead dummyhead WIRING DIAGRAM HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAM The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a...
  • Page 132 dummyhead dummyhead WIRING DIAGRAM WIRING DIAGRAM LL0, LL1, LT TYPES: 16-3...
  • Page 133 dummyhead dummyhead WIRING DIAGRAM RR0, RR1, RH, U TYPES: 16-4...
  • Page 134 dummyhead dummyhead WIRING DIAGRAM G, GW1, CL, RG, B, F, W TYPES: 16-5...
  • Page 135 dummyhead dummyhead WIRING DIAGRAM LB TYPE: 16-6...
  • Page 136 dummyhead dummyhead WIRING DIAGRAM SB TYPE: 16-7...
  • Page 137 dummyhead dummyhead WIRING DIAGRAM SS0, SS1, SK1 TYPES: 16-8...

  • Page 138: Index

    INDEX dummytext INDEX AIR CLEANER CHECK/CLEANING ·······························3-4 MUFFLER REMOVAL/INSTALLATION························ 12-2 AIR CLEANER REMOVAL/INSTALLATION ···················6-4 OIL CASE/CRANKSHAFT/PISTON REMOVAL/ AIR INTAKE JOINT STUD BOLT REPLACEMENT······14-9 INSTALLATION ···························································· 15-3 BEFORE TROUBLESHOOTING ····································4-2 OIL LEVEL SWITCH INSPECTION······························ 11-4 CABLE/HARNESS ROUTING ········································2-8 OIL LEVEL SWITCH REMOVAL/INSTALLATION ······· 11-3 CARBURETOR DISASSEMBLY/ASSEMBLY ················6-6 PERFORMANCE CURVE ··············································...

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