Yamaha EH63 Manuals

Manuals and User Guides for Yamaha EH63. We have 1 Yamaha EH63 manual available for free PDF download: Service Manual

Yamaha EH63 Service Manual (194 pages)

Brand: Yamaha | Category: Engine | Size: 25.08 MB

Table of Contents
8
General Information
13
Machine Identification
13
Serial Number
13
Dimensions
14
Dimension Chart for P.t.o
14
Top
16
Mounting Base
16
Left Side
17
Front
17
Rear
18
Important Information
19
Preparation for Removal and Disassembly
19
Caution on Service
19
Notes on Service
19
All Replacement Parts
20
Gaskets, Oil Seals, and O-Rings
20
Bearings and Oil Seals
21
Basic Service Information
21
Electrical System
21
Special Tools and Testers
25
Periodic Checks and Adjustments
27
Introduction
27
Maintenance Intervals Chart
27
Periodic Maintenance/Lubrication Intervals
27
Periodic Maintenance
29
Spark Plugs
30
Fuel Leakage
30
Fuel Filter
30
Engine Oil Leakage
31
Engine Oil Level
31
Replacing the Engine Oil
32
Oil Cooler (Eh72A/Eh72B/Eh72K)
34
Air Filter Element
34
Muffler
36
Breather Hose
37
Cylinder Head Decarbonization
37
Adjusting the Valve Clearance
38
Engine Speed (Eh63K/Eh64A/ Eh64K/Eh65A/Eh65B)
40
Engine Speed (Eh72A/Eh72B/Eh72K)
42
Fittings and Fasteners
44
Engine
45
Engine Inspection
45
Measuring the Compression Pressure
45
Air Filter
47
Eh63K/Eh64A/Eh64K/Eh65A/Eh65B
47
Eh72A/Eh72B/Eh72K
48
Muffler
49
Eh63K/Eh72B/Eh72K
49
Eh64K
50
Eh65B
51
Eh65A/Eh72A
52
Installing the Muffler
53
Oil Cooler and Oil Filter
54
Removing the Oil Cooler (Eh72A/Eh72B/Eh72K)
55
Checking the Oil Cooler (Eh72A/Eh72B/Eh72K)
55
Installing the Oil Cooler (Eh72A/Eh72B/Eh72K)
55
Rectifier/Regulator
57
Case and Fan
58
Removing the Case and Fan
59
Checking the Case and Fan
59
Installing the Case and Fan
60
Cylinder Covers
61
Cylinder Cover 1 and Cylinder Cover 2
61
Cylinder Cover 3
62
Tci Units, Flywheel and Stator Coil Assembly
63
Tci Units
63
Flywheel and Stator Coil Assembly
64
Removing the Flywheel and Stator Coil Assembly
65
Checking the Flywheel and Stator Coil Assembly
66
Installing the Flywheel and Stator Coil Assembly
66
Installing the Tci Units
67
Engine Switch and Oil Warning Light (Equipped Models Only)
69
Cylinder Head Covers, Cylinder Heads
70
Cylinder Head #1
70
Cylinder Head #2
73
Checking the Rocker Arms
76
Removing the Cylinder Heads
76
Checking the Cylinder Heads
76
Installing the Cylinder Head Assemblies
77
Valves
78
Cylinder Head #1
78
Cylinder Head #2
79
Removing the Valves and Valve Springs
80
Checking the Valves and Valve Springs
80
Checking the Valve Seats
82
Valve Lapping
83
Installing the Valves and Valve Springs
84
Oil Pump
85
Disassembling the Oil Pump
86
Checking the Oil Pump
86
Assembling the Oil Pump
86
Pistons, Camshaft, Crankcase, and Crankshaft
88
Crankcase Cover
88
Camshaft
89
Pistons and Crankshaft
90
Crankcase
91
Checking the Relief Valve
92
Assembling the Relief Valve
92
Checking the Oil Pump Strainer
92
Assembling the Oil Pump Strainer
92
Removing the Flyweight Shaft Assembly and Governor Fork
92
Disassembling the Flyweight Shaft Assembly
93
Checking the Flyweight Shaft Assembly
93
Assembling the Flyweight Shaft Assembly
94
Installing the Flyweight Shaft Assembly and Governor Fork
94
Removing the Camshaft and Valve Lifters
95
Checking the Camshaft
95
Checking the Valve Lifters
97
Installing the Valve Lifters and Camshaft
97
Checking the Crankcase Cover
97
Installing the Crankcase Cover
98
Checking the Cylinders and Pistons
98
Checking the Crankcase
100
Checking the Piston Pins
100
Checking the Piston Rings
101
Checking the Crankshaft
102
Checking the Connecting Rods Oil Clearance
102
Installing the Pistons and Piston Rings
103
Installing the Crankshaft
104
Selecting the Crankshaft Shim
106
Fuel
109
Fuel Pump
109
Eh63K/Eh64A/Eh64K/Eh65A/Eh65B
109
Eh72A/Eh72B/Eh72K
110
Checking the Fuel Pump
111
Carburetor Assembly
112
Removing the Carburetor (Eh63K/Eh64A/Eh64K/Eh65A/Eh65B)
112
Disassembling the Carburetor (Eh64A/Eh65B)
113
Disassembling the Carburetor (Eh63K/Eh64K/Eh65A)
115
Removing the Carburetor (Eh72A/Eh72B/Eh72K)
117
Disassembling the Carburetor (Eh72A/Eh72B/Eh72K)
118
Removing the Carburetor Assembly
119
Checking the Carburetor
119
Installing the Carburetor Assembly
120
Adjusting the Governor
121
Intake Manifold
122
Eh63K/Eh64A/Eh64K/Eh65A/Eh65B
122
Eh72A/Eh72B/Eh72K
123
Removing the Intake Manifold
124
Checking the Intake Manifold
124
Installing the Intake Manifold
124
Electrical
126
Circuit Diagram
126
Electrical Components
128
Checking the Switch Continuity
130
Checking the Oil Pressure Switch
130
Checking the Ignition Spark Gap
131
Checking the Air Gap
132
Checking the Ignition Coil (Tci Unit, Primary) Resistance
132
Checking the Ignition Coil (Tci Unit, Secondary) Resistance
132
Checking the Engine Switch (Equipped Models Only)
133
Checking the Starter Motor Operation
133
Checking the Wire Harness
134
Electric Starting System
135
Removing the Starter Motor
135
Charging System
136
Checking the Stator Coil Assembly
136
Checking the Rectifier/Regulator
136
Troubleshooting
139
Engine Does Not Start
139
Electric Starting System
140
Engine Starts but Stalls
140
Engine Speed Does Not Increase
141
Engine Speed Is Uneven
142
The Battery (Option) Is Not Charged
142
Governor Operation
143
Specifications
145
General Specifications
145
Maintenance Specifications
147
Engine
147
Electrical
151
Tightening Torques
154
General Torque Specifications
154
Lubrication Points and Type of Lubricants
155
Wire Routing Diagram
156
Fuel Pump and Fuel Hose (Eh63K)
156
Fuel Pump and Fuel Hose (Eh64A)
157
Fuel Pump and Fuel Hose (Eh64K, Except for Kor)
158
Fuel Pump and Fuel Hose (Eh64K, for Kor)
159
Fuel Pump and Fuel Hose (Eh65A)
160
Fuel Pump and Fuel Hose (Eh65B)
161
Fuel Pump and Fuel Hose (Eh72A)
162
Fuel Pump and Fuel Hose (Eh72B, for Sea/Eh72K, for Chn)
163
Fuel Pump and Fuel Hose (Eh72K, Except for Chn)
164
Air Filter, Carburetor and Fuel Hose (Eh63K/Eh64A/Eh64K, Except for Kor)
165
Air Filter, Carburetor and Fuel Hose (Eh64K, for Kor/Eh65A/Eh65B)
166
Air Filter, Carburetor and Fuel Hose (Eh72A/Eh72B/Eh72K)
167
Carburetor and Intake Manifold (Eh64A/Eh64K, Except for Kor)
168
Carburetor and Intake Manifold (Eh64K, for Kor/Eh65A/Eh65B)
169
Carburetor and Intake Manifold (Eh72A/Eh72B/Eh72K)
170
Tci Unit (Eh63K)
171
Tci Unit (Eh64A)
172
Tci Unit (Eh64K, Except for Kor)
173
Tci Unit (Eh64K, for Kor)
174
Tci Unit (Eh65A)
175
Tci Unit (Eh65B)
176
Tci Unit (Eh72A)
177
Tci Unit (Eh72B, for Sea/Eh72K, for Chn)
178
Tci Unit (Eh72K, Except for Chn)
179
Rectifier/Regulator and Starter Motor (Eh63K)
180
Rectifier/Regulator and Starter Motor (Eh64A)
181
Rectifier/Regulator and Starter Motor (Eh64K, Except for Kor)
182
Rectifier/Regulator and Starter Motor (Eh64K, for Kor)
183
Rectifier/Regulator and Starter Motor (Eh65A)
184
Rectifier/Regulator and Starter Motor (Eh65B)
185
Rectifier/Regulator and Starter Motor (Eh72A)
186
Rectifier/Regulator and Starter Motor (Eh72B, for Sea/Eh72K, for Chn)
187
Rectifier/Regulator and Starter Motor (Eh72K, Except for Chn)
188

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