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

Transcription

1 SERVICE MANUAL EF7000 EF7000E EF700 EF700E EF700DE 7P6-F897-E0

2

3 FOREWORD This Service Manual has been prepared to introduce service procedure and data for the EF7000/EF7000E/EF700/EF700E/ EF700DE. For complete information on service procedure of the engine, it is necessary to use following Service Manual: MZ SERIES ENGINE SERVICE MANUAL: 7VB-F897-E0 This manual was written by the Yamaha Motor Powered Products Co., Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha generators have a basic understanding of the mechanical precepts and procedures inherent to generator repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Powered Products Co., Ltd. is continually striving to further improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the machine or other property. TIP A TIP provides key information to make procedures easier or clearer. EF7000/EF7000E/EF700/EF700E/ EF700DE SERVICE MANUAL 04 by Yamaha Motor Powered Products Co., Ltd. st Edition, May 04 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Powered Products Co., Ltd. is expressly prohibited.

4 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 9 The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page. 9 Sub-section titles appear in smaller print than the section title. 9 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section 3. 9 Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step 4. 9 Symbols indicate parts to be lubricated or replaced 5. Refer to ILLUSTRATED SYMBOLS. 9 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 6. This step explains removal procedure only. For installation, reverse the steps. 9 Jobs requiring more information (such as special tools and technical data) are described sequentially 7. PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT ENG PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT ENG 3 PISTON, CAMSHAFT AND CRANKSHAFT Nm (.0 m á kgf, 4 ft á lbf) 7 a b d c REMOVING THE BALANCER SHAFT, CAMSHAFT, AND VALVE LIFTER. Remove: 9 Balancer shaft TIP Remove the balancer shaft when the balancer shaft gear mark a and the crankshaft gear mark b are aligned.. Remove: 9 Camshaft TIP 7 6 Remove the camshaft when the camshaft gear mark c and the crankshaft gear mark d are aligned Remove: 9 Intake valve lifter 9 Exhaust valve lifter Order Job/Parts to remove Q ty Remarks Removing the piston, camshaft and Remove the parts in the order listed. crankshaft Crankcase Refer to CRANKCASE on 3-8. CHECKING THE BALANCER SHAFT. Check: 9 Balancer gear teeth 9 Balancer shaft Wear/damage Replace. Balancer shaft Camshaft 3 Valve lifter 4 Connecting rod cap 5 Crankshaft 6 Connecting rod 7 Piston pin circlip 8 Piston pin 9 Piston 0 Piston ring set

5 .. ILLUSTRATED SYMBOLS (Refer to the illustration) SYMBOL DEFINITION SYMBOL DEFINITION General information Periodic checks and adjustments Engine Carburetor Electrical Troubleshooting Specifications Filling fluid Lubricant Special tool T R Tightening torque Wear limit, clearance Engine speed Electrical data Replace the part with a new one. LS Lithium-soap base grease M Molybdenum disulfide grease E Engine oil M Molybdenum disulfide oil LT Apply locking agent (LOCTITE )

6

7 INDEX GENERAL INFORMATION PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR ELECTRICAL TROUBLESHOOTING SPECIFICATIONS GEN INFO CHK ADJ ENG CARB ELEC TRBL SPEC

8 CHAPTER. GENERAL INFORMATION MODEL VARIATIONS...- MACHINE IDENTIFICATION...- SERIAL NUMBER...- IMPORTANT INFORMATION...-3 PREPARATION FOR REMOVAL AND DISASSEMBLY CAUTION ON SERVICE...-3 NOTES ON SERVICE...-3 ALL REPLACEMENT PARTS...-4 GASKETS, OIL SEALS, AND O-RINGS...-4 BEARINGS AND OIL SEALS...-4 BASIC SERVICE INFORMATION...-5 ELECTRICAL SYSTEM...-5 SPECIAL TOOLS AND TESTERS...-8 CHAPTER. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION...- MAINTENANCE INTERVALS CHART...- PERIODIC MAINTENANCE/ LUBRICATION INTERVALS...- PERIODIC MAINTENANCE...-3 SPARK PLUG...-3 FUEL LEAKAGE...-5 ENGINE OIL LEAKAGE...-5 ENGINE OIL LEVEL...-5 REPLACING THE ENGINE OIL...-6 AIR FILTER ELEMENT...-7 MUFFLER...-8 FUEL TANK FILTER...-0 FUEL COCK STRAINER...- BREATHER HOSE...- CYLINDER HEAD DECARBONIZATION...- ADJUSTING THE VALVE CLEARANCE...- ADJUSTING THE ENGINE SPEED (Except for EF7000/EF700)...-5 ADJUSTING THE ENGINE SPEED (For EF7000/EF700)...-6 RECOIL STARTER...-7 FITTINGS AND FASTENERS...-7 CHAPTER 3. ENGINE CONTROL BOX...3- EF700DE...3- Except for EF700DE INSTALLING THE CONTROL BOX AIR FILTER FUEL TANK, CANISTER CHECKING THE CANISTER (For EF700DE CAN) MUFFLER INSTALLING THE MUFFLER...3- ENGINE...3- GENERATOR REMOVING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY INSTALLING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT CRANKCASE PISTON, CAMSHAFT AND CRANKSHAFT REMOVING THE BALANCER SHAFT, CAMSHAFT, AND VALVE LIFTER...3- CHECKING THE BALANCER SHAFT...3- INSTALLING THE VALVE LIFTER, BALANCER SHAFT, AND CAMSHAFT...3- INSTALLING THE CRANKCASE COVER...3-

9 HANDLE AND WHEELS (FOR EF700DE CAN) INSTALLING THE HANDLE INSTALLING THE WHEELS CHAPTER 4. CARBURETOR REMOVING THE CARBURETOR...4- DISASSEMBLING THE CARBURETOR EF7000/EF EF7000E/EF700E/EF700DE CHECKING THE FUEL CUT SOLENOID VALVE CHAPTER 5. ELECTRICAL ELECTRICAL COMPONENTS...5- EF7000 (CHN)...5- EF7000E (CHN)...5- EF700 (SEA/AFR/RUS)...5- EF700E (Except for OCE)...5- EF700E (OCE) EF700DE (Except for CAN) EF700DE (CAN) CIRCUIT DIAGRAM EF7000/EF EF7000E/EF700E EF700DE (Except for CAN) EF700DE (CAN) CONTROL PANEL EF7000/EF EF7000E/EF700E (Except for OCE) EF700E (OCE)...5- EF700DE (Except for CAN) EF700DE (CAN) BATTERY (EF7000E/EF700E/EF700DE) CHECKING AND CHARGING THE BATTERY FUSE (EF7000E/EF700E/EF700DE) CHECKING THE FUSE SWITCHES CHECKING THE SWITCH CONTINUITY IGNITION SYSTEM TROUBLESHOOTING CHART ELECTRIC STARTING SYSTEM (EF7000E/EF700E/EF700DE) TROUBLESHOOTING CHART REMOVING THE STARTER MOTOR DISASSEMBLING THE STARTER MOTOR CHECKING THE BRUSH ASSEMBLING THE STARTER MOTOR CHARGING SYSTEM (EF7000E/EF700E/EF700DE) TROUBLESHOOTING CHART GENERATOR SYSTEM TROUBLESHOOTING CHART ECONOMY CONTROL SYSTEM (EF7000E/EF700E/EF700DE) ECONOMY CONTROL SOLENOID INSTALLING THE ECONOMY CONTROL SOLENOID ECONOMY CONTROL SYSTEM DIAGRAM TROUBLESHOOTING CHART CHAPTER 6. TROUBLESHOOTING ENGINE...6- CHAPTER 7. SPECIFICATIONS GENERAL SPECIFICATIONS...7- MAINTENANCE SPECIFICATIONS ENGINE ELECTRICAL GENERATOR...7-8

10 TIGHTENING TORQUES GENERAL TORQUE SPECIFICATIONS...7- LUBRICATION POINTS AND TYPE OF LUBRICANTS WIRE ROUTING DIAGRAM CONTROL PANEL AND CONTROL BOX (EF7000/EF700) CONTROL PANEL AND CONTROL BOX (EF7000E/EF700E) CONTROL PANEL AND CONTROL BOX (Except for EF700DE CAN) CONTROL PANEL AND CONTROL BOX (For EF700DE CAN) BACK SIDE AND LEFT SIDE VIEW (For EF700DE CAN)...7- UPPER SIDE VIEW (EF7000E/EF700E/EF700DE) UPPER SIDE VIEW (EF7000/EF700) ENGINE GENERATOR (EF7000/EF7000E/ EF700/EF700E) GENERATOR (Except for EF700DE CAN) GENERATOR (For EF700DE CAN)...7-8

11 MODEL VARIATIONS MODEL VARIATIONS GENERAL INFORMATION GEN INFO Model code number 7P6 7P63 Model name EF700DE EF700DE EF700DE EF700 EF700E EF700E EF7000 EF7000E EF700 EF700E Starting serial number* 7P P P P P P P P P P Voltage/Frequency 0/40 V-60 Hz 0/40 V-60 Hz 0/40 V-60 Hz 0 V-50 Hz 0 V-50 Hz 30 V-50 Hz 0 V-50 Hz 0 V-50 Hz 0 V-50 Hz 0 V-50 Hz Destination CSA/SEA CAN SAU SEA/AFR OCE CHN RUS 0 A 50 V 0 A 50 V 5 A 50 V 0 A 50 V 0 A 50 V 0 A 50 V 0 A 50 V 5 A 5 V 30 A 5 V 30 A 50 V/5 V 5 A 5 V 30 A 5 V 30 A 50 V/5 V 5 A 5 V 30 A 5 V 30 A 50 V/5 V AC receptacle Starter motor Dual voltage Voltage/hour meter Oil warning light Economy control system Auto choke Fuel level gauge AVR Fuel cut solenoid valve Two wheel kit P 3 P P P P P P P P Remote control kit P P P P P P P Battery CSA : Central South America SEA : South East Asia CAN : Canada SAU : Saudi Arabia AFR : Africa OCE : Oceania CHN : China RUS : Russia 3 : Equipped : Not equipped P : Optional parts * : Serial number location (Refer to MACHINE IDENTIFICATION on -) -

12 A MACHINE IDENTIFICATION GEN INFO MACHINE IDENTIFICATION SERIAL NUMBER The serial number is printed on the label affixed to the position of the generator as shown in the illustration. B A For EF700DE CAN B Except for EF700DE CAN TIP 9 The first three digits identify the model, and the remaining digits indicates the production number. 9 Designs and specifications are subject to change without notice. -

13 SVU030 IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY CAUTION ON SERVICE. Fire prevention When servicing the engine, always keep the engine and yourself away from fire. NOTES ON SERVICE. Correct tools Be sure to use the correct special tool for the job to guard against damage. SVU040. Oil, grease and seals Be sure to use genuine Yamaha oils, grease and sealers, or the equivalents. SVU Expendable parts Always replace the gaskets, O-rings, cotter pins and circlips with new parts when servicing engine. SVU060 SVU Tightening torque Be sure to follow torque specifications. When tightening bolts, nuts or screws, start with the largest-diameter fastener and work from an inner position to an outer position in a crisscross pattern. 5. Notes on disassembly and assembly a. Parts should be cleaned in solvent and blown dry with compressed air after disassembly. SVU080 SVU090 b. Contact surfaces of moving parts should be oiled when reassembled. c. Make sure that the parts, move smoothly after each section of the machine is assembled. SVU00-3

14 IMPORTANT INFORMATION GEN INFO ALL REPLACEMENT PARTS We recommend the use of genuine Yamaha parts for all replacements. Use oil and/or grease, recommended by Yamaha, for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gaskets surfaces, oil seal lips, and O-rings must be cleaned.. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. SVU0 BEARINGS AND OIL SEALS Install the bearing(s) and oil seal(s) with their manufacture s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. NOTICE Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. SVU0-4

15 BASIC SERVICE INFORMATION GEN INFO BASIC SERVICE INFORMATION ELECTRICAL SYSTEM Checking the electrical system a TIP Before checking the electrical system, make sure that the battery voltage is at least V. NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end a of the coupler, taking care not to loosen or damage the leads. Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc.. Disconnect: 9 Lead 9 Coupler 9 Connector NOTICE 9 When disconnecting a coupler, release the coupler lock, hold both sections of the coupler securely, and then disconnect the coupler. 9 There are many types of coupler locks; therefore, be sure to check the type of coupler lock before disconnecting the coupler. NOTICE When disconnecting a connector, do not pull the leads. Hold both sections of the connector securely, and then disconnect the connector. -5

16 BASIC SERVICE INFORMATION GEN INFO. Check: 9 Lead 9 Coupler 9 Connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Connect: 9 Lead 9 Coupler 9 Connector TIP 9 When connecting a coupler or connector, push both sections of the coupler or connector together until they are connected securely. 9 Make sure all connections are tight. 4. Check: 9 Continuity (with the pocket tester) Analog pocket tester: YU-03-C Pocket tester: TIP 9 If there is no continuity, clean the terminals. 9 When checking the wire harness, perform steps () to (3). 9 Make sure to check the connector and coupler of the TCI unit/ CDI unit when replacing the TCI unit/cdi unit. 9 As a quick remedy, use a contact revitalizer available at most part stores. -6

17 BASIC SERVICE INFORMATION GEN INFO NOTICE For waterproof couplers, never insert the tester leads directly into the coupler. When performing any checks using a waterproof coupler, use the specified test harness or a suitable commercially available test harness. 5. Check: 9 Resistance Analog pocket tester: YU-03-C Pocket tester: TIP The resistance values shown were obtained at the standard measuring temperature of 0 C (68 F). If the measuring temperature is not 0 C (68 F), the specified measuring conditions will be shown. Intake air temperature sensor resistance: kw at 0 C (3 F) W at 80 C (76 F) -7

18 SPECIAL TOOLS AND TESTERS GEN INFO SPECIAL TOOLS AND TESTERS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. TIP 9 For U.S.A. and Canada, use part number starting with YM-, YU-, or ACC-. 9 For others, use part number starting with Feeler gauge set P/N. YU Thickness gauge P/N This gauge is used to adjust valve clearance, piston clearance and piston ring end gap.. Cylinder gauge Commercially obtainable This instrument is used for checking cylinder bore size and condition. SVU60 3. Digital tachometer P/N. YU-3995-B, This tool is needed for observing engine r/min. 4. Engine compression tester P/N. YU-333 Compression gauge P/N This tool is used for checking engine compression. 5. Extension P/N This tool is used for checking engine compression. -8

19 SVU90 SPECIAL TOOLS AND TESTERS GEN INFO 6. Dial indicator gauge P/N. YU-A848 Dial gauge P/N This instrument is used for checking crankshaft side clearance. SVU30 7. Analog pocket tester P/N. YU-03-C Pocket tester P/N This instrument is necessary for checking the electrical system. 8. Oppama pet-4000 spark checker P/N. YM Ignition checker P/N This instrument is necessary for checking the ignition system components. 9. Primary clutch holder P/N. YS-0880-A Sheave holder P/N This tool is necessary for holding the flywheel. YM-A5970 ø8 ø9 ø0 ø3 ø4 0. Six piece tappet set P/N. YM-A5970 Tappet adjusting tool P/N This tool is used to adjust the valve clearances mm SVU0. Heavy duty puller P/N. YU-3370-B Flywheel puller P/N This tool is necessary for removing the flywheel. -9

20 SPECIAL TOOLS AND TESTERS. Valve spring compressor P/N This tool is used to remove the valve springs. GEN INFO 3. Piston ring compressor P/N. YM-08037, This tool is used to compress the piston rings when installing the piston. 4. Rotor shock puller assy. P/N. YU-047, This tool is used to remove the rotor assembly. M4XP.5 5. Rotor puller attachment (M4 P.5) P/N. YU-379, This tool is used to remove the rotor assembly. -0

21 - GEN INFO

22 INTRODUCTION/MAINTENANCE INTERVALS CHART/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter. MAINTENANCE INTERVALS CHART Proper periodic maintenance is important. Especially important are the maintenance services related to emissions control. These controls not only function to ensure air filter but are also vital to proper engine operation and maximum performance. PERIODIC MAINTENANCE/LUBRICATION INTERVALS Item Routine Preoperation Every 6 months months check or 00 Hr or 300 Hr Spark plug Check condition. Clean and replace if necessary. Fuel Check fuel level and leakage. Check fuel hose for cracks or damage. Fuel hose Replace if necessary. Engine oil Check oil level in engine. Replace. (*) Air filter element Check condition. Clean. (*) Muffler screen Check condition. Clean and replace if necessary. Fuel tank filter Clean and replace if necessary. Fuel strainer Clean and replace if necessary. Check breather hose for cracks or Crankcase breather damage. hose Replace if necessary. Cylinder head Decarbonize cylinder head. More frequently if necessary. After every 500 Hrs. Valve clearance Check and adjust valve clearance. Idle speed Check and adjust idle speed. Recoil starter Check recoil starter for damage. Fittings/fasteners Check all fittings and fasteners. Correct if necessary. The point where abnormality was recognized by use. -

23 PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ * Initial replacement of the engine oil is after one month or 0 hours of operation. * The air filter element needs to be cleaned more frequently when using in unusually wet or dusty areas. Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. -

24 PERIODIC MAINTENANCE CHK ADJ PERIODIC MAINTENANCE SPARK PLUG WARNING Check and adjust the areas around the cylinder head after the engine has cooled down completely.. Remove: 9 Spark plug cap 9 Spark plug NOTICE Before removing the spark plug, use compressed air to clean the cylinder head cover to prevent dirt from falling into the engine.. Check: 9 Spark plug type Not correct Replace a Spark plug type: BPR4ES (NGK) 9 Electrode Wear/damage Replace. 9 Insulator color Not normal Replace. -3

25 PERIODIC MAINTENANCE CHK ADJ 3. Measure: 9 Spark plug gap a Use a wire gauge or thickness gauge. Out of specification Regap. If necessary, clean the spark plug with a spark plug cleaner. Feeler gauge set: YU Thickness gauge: Spark plug gap: mm ( in) TIP Before installing the spark plug, clean the gasket surface and plug surface. b a 4. Install: 9 Spark plug 0 Nm (.0 m kgf, 4 ft lbf) TIP To prevent threads from being damaged, temporally tighten a the spark plug before tightening it to the specified torque b. -4

26 PERIODIC MAINTENANCE CHK ADJ FUEL LEAKAGE. Check: 9 Leakage Check at fuel tank, fuel cock, fuel hose, and carburetor. NOTICE Replace fuel hose every four years. ENGINE OIL LEAKAGE. Place the generator on a level surface.. Check the areas outside of the engine for oil leakage. Oil leakage Replace the gasket, oil seal, or O-ring. ENGINE OIL LEVEL. Check: 9 Oil level with the oil warning light Check whether the oil warning light comes on by operating the recoil starter or turn the engine switch. Oil warning light comes on Add oil. Oil warning light does not comes on OK a. Remove: 9 Oil filler cap 3. Check: 9 Check that engine oil is at the specified level a. Oil level checking steps: a. Place the engine on a level surface. b. Warm up the engine for several minutes. c. Stop the engine. d. Remove the oil filler cap. e. Check that engine oil is at the specified level a. Add oil if necessary. 4. Install: 9 Oil filler cap -5

27 3 PERIODIC MAINTENANCE CHK ADJ REPLACING THE ENGINE OIL. Warm up the engine for several minutes, and then stop the engine.. Remove: 9 Oil filler cap 9 Oil drain bolt 9 Oil drain bolt gasket 3 3. Drain: 9 Engine oil Place the oil pan under the engine and drain the engine oil. 4. Install: 9 Oil drain bolt gasket 3 9 Oil drain bolt 7 Nm (.7 m kgf, 0 ft lbf) 0 C 5 C å YAMALUBE 4 (0W-40) SAE 0W ç SAE #0 SAE #30 3 F 80 F 5. Fill: 9 Engine oil Make sure to fill with the recommended engine oil from the oil filler hole in the crankcase. Recommended engine oil: A YAMALUBE 4 (0W-40), SAE 0W-30 or 0W-40 B SAE #30 C SAE #0 D SAE 0W Recommended engine oil grade: API Service SE type or higher Engine oil quantity:. L (.6 US qt, 0.97 Imp qt) 6. Check: 9 Engine oil level (Refer to ENGINE OIL LEVEL on -5) 7. Install: 9 Oil filler cap -6

28 PERIODIC MAINTENANCE CHK ADJ AIR FILTER ELEMENT NOTICE Be sure not to run the engine without air filter element. Otherwise this can result in excessive piston and/or cylinder wear. 3. Remove: 9 Air filter cover screws 9 Air filter cover. Remove: 9 Air filter element 3 3. Check: 9 Air filter element Damage Replace. Clogged Wash the element with solvent, and then dry it thoroughly. Oil the element and squeeze out the excess oil. WARNING Do not wash the element with gasoline or with acidic, alkalic, or organic solvents. NOTICE Do not wring out the element. This could cause it to tear. 4. Install: 9 Air filter element 9 Air filter cover 9 Air filter cover screws.6 Nm (0.6 m kgf,. ft lbf) -7

29 PERIODIC MAINTENANCE CHK ADJ MUFFLER WARNING The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during check or repair.. Remove: 9 Muffler cover bolts 9 Muffler cover. Remove: 9 Muffler band 9 Muffler cap 9 Muffler screen 3 9 Washer Remove: 9 Muffler (Refer to MUFFLER on 3-0) -8

30 PERIODIC MAINTENANCE CHK ADJ 4. Decarbonize: 9 Muffler Tap on the muffler in the area shown in the illustration to loosen carbon buildup, and then shake it out from the end of the muffler. NOTICE Do not use a wire to clean, otherwise the noise damping material may come out, and the damping effect may be reduced. 5. Decarbonize: 9 Muffler screen NOTICE When cleaning with a wire brush, use it softly to avoid damage or scratch the muffler screen. 6. Install: 9 Muffler (Refer to MUFFLER on 3-0) 9 Washer 9 Muffler screen 9 Muffler cap 9 Muffler band 9 Muffler cover 9 Muffler cover bolts.0 Nm (0.0 m kgf,.4 ft lbf) Nm (. m kgf, 8.7 ft lbf) -9

31 PERIODIC MAINTENANCE CHK ADJ FUEL TANK FILTER WARNING Do not smoke, and keep away from open flames, sparks, or any other source of fire when handling or in the vicinity of fuel.. Remove: 9 Fuel tank cap 9 Fuel tank filter. Check: 9 Fuel tank filter Damage Replace. Dirt/clog Clean. TIP Clean the fuel tank filter with clean gasoline, and then dry it thoroughly. 3. Install: 9 Fuel tank filter 9 Fuel tank cap WARNING Make sure that the fuel tank cap is tightened securely. -0

32 PERIODIC MAINTENANCE CHK ADJ 3 FUEL COCK STRAINER WARNING Do not smoke, and keep away from open flames, sparks, or any other source of fire when handling or in the vicinity of fuel.. Turn the fuel cock lever to the OFF position.. Remove: 9 Strainer cup 9 Gasket 9 Fuel cock strainer 3 3. Check: 9 Fuel cock strainer Damage Replace. Dirt/clog Clean. TIP Clean the fuel cock strainer with clean gasoline, and then dry it thoroughly. 4. Install: 9 Fuel cock strainer 9 Gasket 9 Strainer cup.3 Nm (0.3 m kgf, 0.94 ft lbf) WARNING Make sure that the strainer cup is tightened securely. -

33 PERIODIC MAINTENANCE CHK ADJ BREATHER HOSE. Check: 9 Breather hose Crack/damage Replace. Poor connection Correct. CYLINDER HEAD DECARBONIZATION. Remove: 9 Cylinder head (Refer to CYLINDER HEAD COVER, CYLINDER HEAD in 7VB-F897-E0 chapter 3). Eliminate: 9 Carbon deposits (Refer to CHECKING THE CYLINDER HEAD in 7VB-F897-E0 chapter 3) 3. Install: 9 Cylinder head (Refer to INSTALLING THE CYLINDER HEAD ASSEMBLY in 7VB-F897-E0 chapter 3) ADJUSTING THE VALVE CLEARANCE. Remove: 9 Spark plug cap 9 Spark plug 4 3 NOTICE Before removing the spark plug, use compressed air to clean the cylinder head cover to prevent dirt from falling into the engine.. Remove: 9 Breather hose 3 9 Cylinder head cover 4 9 Cylinder head cover gasket -

34 PERIODIC MAINTENANCE CHK ADJ 3. Pull the recoil starter slowly, and then set the piston at TDC (top-dead-center) on the compression stroke. TIP Check the piston position by inserting a screw driver into the spark plug hole. 4. Measure: 9 Valve clearance (Between the rocker arm and valve stem end) Out of specification Adjust. TIP Valve clearance must be measured when the engine has cooled down enough to be touched. Feeler gauge set: YU Thickness gauge: Valve clearance: Intake valve (cold): mm ( in) Exhaust valve (cold): mm ( in) -3

35 PERIODIC MAINTENANCE CHK ADJ 3 5. Adjust: 9 Valve clearance Adjustment steps: a. Loosen the locknuts and insert the 0.07 mm (0.008 in) thickness gauge between the rocker arm and the valve tip. b. Using the tappet adjusting tool turn the adjuster 3 in or out to obtain the proper valve clearance. Move the thickness gauge up and down to check for the proper resistance. Six piece tappet set: YM-A5970 Tappet adjusting tool: Feeler gauge set: YU Thickness gauge: Adjuster Turn clockwise Turn counterclockwise Valve clearance Decrease Increase c. Tighten the locknuts. 7 Nm (0.7 m kgf, 5. ft lbf) 6. Install: 9 Cylinder head cover gasket 9 Cylinder head cover 9 Breather hose 9 Spark plug 9 Spark plug cap Nm (. m kgf, 8.0 ft lbf) 0 Nm (.0 m kgf, 4 ft lbf) -4

36 PERIODIC MAINTENANCE CHK ADJ ADJUSTING THE ENGINE SPEED (Except for EF7000/EF700). Warm up the engine for a few minutes.. Attach: 9 Digital tachometer Digital tachometer: YU-3995-B, Measure: 9 Economy control engine speed and engine speed (with no load) Out of specification Adjust Economy control engine speed (with no load): r/min Engine speed (with no load): r/min 4. Adjust: 9 Economy control engine speed Adjustment steps: a. Turn the economy control switch to I (ON). b. Turn the adjusting screw to obtain the proper engine speed. a b 9 Engine speed Adjustment steps: a. Turn the economy control switch to 3 (OFF). b. Turn the adjusting screw to obtain the proper engine speed. Turn to a The engine speed decreases. Turn to b The engine speed increases. -5

37 PERIODIC MAINTENANCE CHK ADJ ADJUSTING THE ENGINE SPEED (For EF7000/EF700). Warm up the engine for a few minutes.. Attach: 9 Digital tachometer Digital tachometer: YU-3995-B, Measure: 9 Engine speed (with no load) Out of specification Adjust Engine speed (with no load): r/min a b 4. Adjust: 9 Engine speed Adjustment step: a. Turn the adjusting screw to obtain the proper engine speed. Turn to a The engine speed decreases. Turn to b The engine speed increases. -6

38 PERIODIC MAINTENANCE CHK ADJ RECOIL STARTER. Check: 9 Recoil starter operate smoothly Rough movement Replace the defective part(s). (Refer to RECOIL STARTER in 7VB-F897-E0 chapter 3) FITTINGS AND FASTENERS. Check: 9 All fittings and fasteners Looseness Tighten. Rough movement Replace the defective part(s). Damage/pitting Replace. -7

39 CONTROL BOX ENG ENGINE For complete information about procedures for engine maintenance, it is necessary to refer to the MZ SERIES ENGINE SERVICE MANUAL 7VB-F897-E0. CONTROL BOX EF700DE 3.8 Nm (0.38 m á kgf,.8 ft á lbf) Nm (0.7 m á kgf, 5. ft á lbf) Nm (0.7 m á kgf, 5. ft á lbf) Order Job/Parts to remove Q ty Remarks Removing the control box Remove the parts in the order listed. Negative battery lead Disconnect. Carrier frame Refer to HANDLE AND WHEELS (FOR EF700DE CAN) on 3-3. Fuel tank Refer to FUEL TANK, CANISTER on 3-7. Generator cover Control box 3 Ground lead 4 Stator assembly (main coil) lead 3 5 Stator assembly (sub coil) coupler 6 Exciter field coil coupler 3-

40 CONTROL BOX ENG 3.8 Nm (0.38 m á kgf,.8 ft á lbf) 7 Nm (0.7 m á kgf, 5. ft á lbf) Nm (0.7 m á kgf, 5. ft á lbf) Order Job/Parts to remove Q ty Remarks 7 Economy control solenoid lead connector 8 Oil level switch lead connector 9 TCI unit lead connector 0 Starter relay lead connector Charging coil lead connector Auto choke lead connector 3 Fuel cut solenoid valve lead connector 4 Positive battery lead connector 3-

41 CONTROL BOX ENG Except for EF700DE 3.8 Nm (0.38 m á kgf,.8 ft á lbf) Nm (0.7 m á kgf, 5. ft á lbf) Nm (0.7 m á kgf, 5. ft á lbf) Order Job/Parts to remove Q ty Remarks Removing the control box Remove the parts in the order listed. Negative battery lead Disconnect. EF7000E/EF700E Fuel tank Refer to FUEL TANK, CANISTER on 3-7. Generator cover Control box 3 Ground lead 4 Stator assembly (main coil) lead 5 Stator assembly (sub coil) coupler 6 Exciter field coil coupler 7 Economy control solenoid lead connector EF7000E/EF700E 3-3

42 CONTROL BOX ENG 3.8 Nm (0.38 m á kgf,.8 ft á lbf) 7 Nm (0.7 m á kgf, 5. ft á lbf) Nm (0.7 m á kgf, 5. ft á lbf) Order Job/Parts to remove Q ty Remarks 8 Oil level switch lead connector 9 TCI unit lead connector 0 Starter relay lead connector EF7000E/EF700E Charging coil lead connector Auto choke lead connector EF7000E/EF700E 3 Fuel cut solenoid valve lead connector 4 Positive battery lead connector EF7000E/EF700E 3-4

43 CONTROL BOX ENG b INSTALLING THE CONTROL BOX. Install: 9 Control box 9 Control box bolts 9 Control box nuts 7 Nm (0.7 m kgf, 5. ft lbf) a A A Behind the control box c TIP 9 Install the a portion of the control box to the frame b at both sides. 9 When installing the grommet c, make sure that it is facing direction shown in the illustration. 3-5

44 AIR FILTER ENG AIR FILTER 6 Nm (. m á kgf, 8.0 ft á lbf) Nm (.0 m á kgf, 7. ft á lbf).6 Nm (0.6 m á kgf,. ft á lbf) Order Job/Parts to remove Q ty Remarks Removing the air filter Remove the parts in the order listed. Air filter cover Air filter element 3 Element fitting plate 4 Plate 5 Air filter case 6 Breather hose 7 Gasket 3-6

45 FUEL TANK, CANISTER ENG FUEL TANK, CANISTER Nm (0.7 m á kgf, 5. ft á lbf) Nm (.6 m á kgf, ft á lbf) 7 Nm (0.7 m á kgf, 5. ft á lbf) 0.8 Nm (0.08 m á kgf, 0.58 ft á lbf).3 Nm (0.3 m á kgf, 0.94 ft á lbf) 5 7 Order Job/Parts to remove Q ty Remarks Removing the fuel tank, canister Remove the parts in the order listed. Carrier frame Refer to HANDLE AND WHEELS (FOR EF700DE CAN) on 3-3. Control box Refer to CONTROL BOX on 3-. Fuel hose Turn the fuel cock lever to the OFF position. Clip 3 Pipe 4 Pipe 3 5 Canister For EF700DE CAN 6 Pipe 4 7 Canister bracket 8 Member 9 Fuel tank 0 Locating damper 3-7

46 FUEL TANK, CANISTER ENG 3 7 Nm (0.7 m á kgf, 5. ft á lbf) 6 Nm (.6 m á kgf, ft á lbf) Nm (0.7 m á kgf, 5. ft á lbf) Nm (0.3 m á kgf, 0.94 ft á lbf) 0.8 Nm (0.08 m á kgf, 0.58 ft á lbf) Order Job/Parts to remove Q ty Remarks Fuel tank cap Fuel tank filter 3 Fuel level gauge 4 Fuel cock 5 Strainer cup 6 Gasket 7 Fuel cock strainer 8 Gasket 9 O-ring 3-8

47 FUEL TANK, CANISTER ENG CHECKING THE CANISTER (For EF700DE CAN). Check: 9 Pipes Cracks/damage Replace. Poor connection Correct. 9 Canister Cracks/damage Replace. 3-9

48 MUFFLER ENG MUFFLER 6 Nm (.6 m kgf, ft lbf) 6 Nm (.6 m kgf, ft lbf) Nm (0.0 m kgf,.4 ft lbf) Nm (. m kgf, 8.7 ft lbf) Order Job/Parts to remove Q ty Remarks Removing the muffler Remove the parts in the order listed. Muffler cover Muffler damper 3 Muffler band 4 Muffler cap 5 Muffler screen 6 Washer 7 Muffler 8 Exhaust gasket 3-0

49 MUFFLER ENG INSTALLING THE MUFFLER. Install: 9 Exhaust gasket 9 Muffler assembly 9 Exhaust nuts 9 Muffler bolt 3 9 Muffler bolt 4 TIP Temporarily tighten the nuts, and bolts 3, 4 until just comes in contact with the surface.. Tighten: 9 Exhaust nuts 9 Muffler bolt 3 9 Muffler bolt 4 6 Nm (.6 m kgf, ft lbf) TIP Tighten the nuts and bolts to the specified torque in order of exhaust nuts, muffler bolt 3 and muffler bolt Install: 9 Muffler damper 9 Muffler cover 5 Nm (. m kgf, 8.7 ft lbf) 3-

50 ENGINE ENG ENGINE 3 3 Nm (3. m á kgf, 3 ft á lbf) 3 Nm (3. m á kgf, 3 ft á lbf) 0 Nm (.0 m á kgf, 7. ft á lbf) Order Job/Parts to remove Q ty Remarks Removing the engine Remove the parts in the order listed. Engine oil Drain. Refer to REPLACING THE ENGINE OIL on -6. Handle and wheels Refer to HANDLE AND WHEELS (FOR EF700DE CAN) on 3-3. Control box Refer to CONTROL BOX on 3-. Fuel tank/canister Refer to FUEL TANK, CANISTER on 3-7. Air filter Refer to AIR FILTER on 3-6. Muffler Refer to MUFFLER on 3-0. Battery Refer to BATTERY (EF7000E/ EF700E/EF700DE) on 5-8. Ground lead For EF700DE CAN Engine mounting nut 4 3 Engine assembly 3-

51 GENERATOR ENG GENERATOR 4.5 Nm (0.45 m kgf, 3.3 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) Nm (4. m kgf, 30 ft lbf) Nm (0.38 m kgf,.8 ft lbf) 0 Nm (.0 m kgf, 7. ft lbf) 3.8 Nm (0.38 m kgf,.8 ft lbf) 7 Nm (0.7 m kgf, 5. ft lbf) Order Job/Parts to remove Q ty Remarks Removing the generator Remove the parts in the order listed. Handle and wheels Refer to HANDLE AND WHEELS (FOR EF700DE CAN) on 3-3. Control box Refer to CONTROL BOX on 3-. Air filter Refer to AIR FILTER on 3-6. Muffler Refer to MUFFLER on 3-0. Fuel tank Refer to FUEL TANK, CANISTER on 3-7. Engine assembly Refer to ENGINE on 3-. Recoil starter Refer to RECOIL STARTER in 7VB-F897-E0 chapter 3. Rear frame Put a support under the crankcase. Exciter field coil 3 Stator cover 4 Stator assembly 3-3

52 GENERATOR ENG 4.5 Nm (0.45 m kgf, 3.3 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) Nm (4. m kgf, 30 ft lbf) 3.8 Nm (0.38 m kgf,.8 ft lbf) 0 Nm (.0 m kgf, 7. ft lbf) 3.8 Nm (0.38 m kgf,.8 ft lbf) 7 Nm (0.7 m kgf, 5. ft lbf) Order Job/Parts to remove Q ty Remarks 5 Rotor assembly 6 Generator fan A For EF700DE B Except for EF700DE 3-4

53 GENERATOR ENG REMOVING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY. Remove: 9 Rear frame TIP To remove the rear frame, strike it with a rubber hammer, since the bearing may be stuck in the frame.. Remove: 9 Stator cover 9 Stator assembly NOTICE Do not drop or damage the stator assembly. 3. Remove: 9 Exciter field coil screws 9 Exciter field coil 3-5

54 GENERATOR ENG 4. Remove: 9 Recoil starter 9 Rotor assembly bolt TIP Attach the sheave holder to hold the flywheel 3. Primary clutch holder: YS-0880-A Sheave holder: Assemble the special tools: 9 Rotor shock puller assy 9 Rotor puller attachment Rotor shock puller assy.: YU-047, Rotor puller attachment (M4.5): YU-379, Remove: 9 Rotor assembly NOTICE Do not drop or damage the rotor assembly. TIP Remove the rotor assembly using the rotor shock puller assy. 3-6

55 GENERATOR ENG INSTALLING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY. Install: 9 Rotor assembly. Tighten: 9 Rotor assembly bolt 4 Nm (4. m kgf, 30 ft lbf) TIP Tighten the rotor assembly bolt by attaching the sheave holder to hold the flywheel 3. 3 Primary clutch holder: YS-0880-A Sheave holder: a b 3. Install: 9 Stator assembly 9 Stator cover TIP Align the projection a on the stator assembly with the slot b on the crankcase cover. b a 4. Install: 9 Rear frame 0 Nm (.0 m kgf, 7. ft lbf) TIP 9 Align the pin a on the rotor bearing with the slot b on the rear frame. 9 Align the projection c on the stator assembly with the slot d on the rear frame. d c 3-7

56 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT ENG PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT CRANKCASE 7 Nm (0.7 m kgf, 5. ft lbf) 7 Nm (.7 m kgf, 0 ft lbf) Nm (.7 m kgf, 0 ft lbf) Nm (.0 m kgf, 7. ft lbf) 0 Nm (.0 m kgf, 7. ft lbf) st nd Nm (. m kgf, 8.7 ft lbf) 30 Nm (3.0 m kgf, ft lbf) Order Job/Parts to remove Q ty Remarks Removing the crankcase Remove the parts in the order listed. Engine assembly Refer to ENGINE on 3-. Generator assembly Refer to GENERATOR on 3-3. Cylinder head assembly Refer to CYLINDER HEAD COVER, CYLINDER HEAD in 7VB-F897-E0 chapter 3. Flywheel Refer to FLYWHEEL in 7VB-F897-E0 chapter 3. Crankcase cover Oil filler cap 3 Gasket 4 Dowel pin 5 Clamp 6 Oil level switch 3-8

57 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT ENG 7 Nm (0.7 m kgf, 5. ft lbf) 0 7 Nm (.7 m kgf, 0 ft lbf) Nm (.7 m kgf, 0 ft lbf) 0 Nm (.0 m kgf, 7. ft lbf) 0 Nm (.0 m kgf, 7. ft lbf) st nd Nm (. m kgf, 8.7 ft lbf) 30 Nm (3.0 m kgf, ft lbf) Order Job/Parts to remove Q ty Remarks 7 Flyweight shaft assembly 8 Clip 9 Governor shaft 0 Negative battery lead EF7000E/EF700E/EF700DE 3-9

58 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT ENG PISTON, CAMSHAFT AND CRANKSHAFT Nm (.0 m á kgf, 4 ft á lbf) Order Job/Parts to remove Q ty Remarks Removing the piston, camshaft and Remove the parts in the order listed. crankshaft Crankcase Refer to CRANKCASE on 3-8. Balancer shaft Camshaft 3 Valve lifter 4 Connecting rod cap 5 Crankshaft 6 Connecting rod 7 Piston pin circlip 8 Piston pin 9 Piston 0 Piston ring set 3-0

59 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT ENG a d c REMOVING THE BALANCER SHAFT, CAMSHAFT, AND VALVE LIFTER. Remove: 9 Balancer shaft b TIP Remove the balancer shaft when the balancer shaft gear mark a and the crankshaft gear mark b are aligned.. Remove: 9 Camshaft TIP Remove the camshaft when the camshaft gear mark c and the crankshaft gear mark d are aligned. 3. Remove: 9 Intake valve lifter 9 Exhaust valve lifter CHECKING THE BALANCER SHAFT. Check: 9 Balancer gear teeth 9 Balancer shaft Wear/damage Replace. 3-

60 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT ENG INSTALLING THE VALVE LIFTER, BALANCER SHAFT, AND CAMSHAFT. Install: 9 Intake valve lifter 9 Exhaust valve lifter a. Install: 9 Balancer shaft NOTICE Be sure to align the balancer shaft gear mark a with the crankshaft gear mark b. b 3. Install: 9 Camshaft NOTICE Be sure to align the camshaft gear mark a with the crankshaft gear mark b. b a INSTALLING THE CRANKCASE COVER. Install: 9 Crankcase cover 9 Crankcase cover bolts to 8 TIP Tighten the bolts to the specified torque in two stages and in order from to 8. st: Nm (. m kgf, 8.7 ft lbf) nd: 30 Nm (3.0 m kgf, ft lbf) 3-

61 HANDLE AND WHEELS (FOR EF700DE CAN) ENG HANDLE AND WHEELS (FOR EF700DE CAN) 7 Nm (0.7 m kgf, 5. ft lbf) 6 Nm (.6 m kgf, ft lbf) Nm (.6 m kgf, ft lbf) 6 Nm (.6 m kgf, ft lbf) Nm (.6 m kgf, ft lbf) Nm (.6 m kgf, ft lbf) Order Job/Parts to remove Q ty Remarks Removing the handle and wheels Remove the parts in the order listed. Wheel axle frame TIP Cotter pin Lift the generator 0 cm (7.87 in) off 3 Washer the ground using a winch or other suitable 4 Wheel lifting device. 5 Main stand 6 Handle 7 Locating damper 8 Bracket handle 9 Sleeve 0 Plate 4 Collar Lock lever 3 Washer 3-3

62 HANDLE AND WHEELS (FOR EF700DE CAN) ENG 7 Nm (0.7 m kgf, 5. ft lbf) Nm (.6 m kgf, ft lbf) 6 Nm (.6 m kgf, ft lbf) 6 Nm (.6 m kgf, ft lbf) 8 6 Nm (.6 m kgf, ft lbf) 6 Nm (.6 m kgf, ft lbf) Order Job/Parts to remove Q ty Remarks 4 Stopper 5 Plate 6 Damper 7 Engine hanger 8 Carrier frame 3-4

63 HANDLE AND WHEELS (FOR EF700DE CAN) ENG 3 3 INSTALLING THE HANDLE. Install: 9 Engine hanger 9 Carrier frame 9 Engine hanger bolts 3 6 Nm (.6 m kgf, ft lbf) TIP 9 Fasten the engine hanger to the carrier frame with the engine hanger bolts 3. 9 Match the punch marks a as shown in the illustration. a 3. Install: 9 Damper 9 Plate 9 Stopper 3 9 Stopper bolt 4 7 Nm (0.7 m kgf, 5. ft lbf) 4 TIP Install the damper and plate into the stopper 3, and tightly fasten it to carrier frame with the stopper bolt

64 HANDLE AND WHEELS (FOR EF700DE CAN) ENG Install: 9 Lock lever bolt 9 Washer 9 Collar 3 9 Lock lever 4 9 Lock lever nut 5 6 Nm (.6 m kgf, ft lbf) 4 7 TIP 9 Insert the lock lever bolt into the carrier frame 6, and then put the washer, collar 3, and lock lever 4 in this order, and tighten the lock lever nut 5. 9 Make sure that the collar 3 is placed into the washer. 9 Lock lever pin should be above stopper Install: 9 Carrier frame 9 Plate 9 Plate bolts 3 6 Nm (.6 m kgf, ft lbf) a 0 cm (3.94 in) 3 a TIP 9 Place the carrier frame 0 cm (3.94 in) from the end of generator body. 9 Place the carrier frame assembled to this point on the generator body, and then fasten the plate to the carrier frame with the plate bolts

65 HANDLE AND WHEELS (FOR EF700DE CAN) ENG 5. Install: 9 Sleeve TIP Install the sleeve on the generator frame. 6. Install: 9 Bracket handle TIP Install the bracket handle to the sleeve. 7. Install: 9 Locating damper TIP Install the locating damper on the sleeve Install: 9 Handle 9 Handle bolts 6 Nm (.6 m kgf, ft lbf) TIP 9 Place the handle on the carrier frame, and then fasten with the handle bolts. 9 Lock the handle into position with the lock lever

66 HANDLE AND WHEELS (FOR EF700DE CAN) ENG INSTALLING THE WHEELS. Install: 9 Main stand 9 Main stand bolts 9 Main stand nuts 3 6 Nm (.6 m kgf, ft lbf) 3 3 TIP 9 Lift the generator 0 cm (7.87 in) off the ground using a winch or other suitable lifting device. 9 Fasten the main stand to the left side of the generator frame as viewed when looking at the control panel with the main stand bolts and nuts Install: 9 Wheels 9 Wheel axle frame TIP 9 Install the wheels into wheel axle frame. 9 Make sure the installation direction a of the wheels are correct. a 3-8

67 HANDLE AND WHEELS (FOR EF700DE CAN) ENG 3. Install: 9 Washers 9 Cotter pins TIP 9 Install the washers into wheel axle. 9 Insert cotter pins into wheel axle frame, and then bend as shown in the illustration Install: 9 Wheel axle frame 9 Wheel axle frame bolts 9 Wheel axle frame nuts 3 6 Nm (.6 m kgf, ft lbf) TIP Fasten the wheel axle frame to the generator frame with the wheel axle frame bolts and nuts

68 REMOVING THE CARBURETOR CARB CARBURETOR For complete information about procedures for carburetor maintenance, it is necessary to refer to the MZ SERIES ENGINE SERVICE MANUAL 7VB-F897-E0. REMOVING THE CARBURETOR 3 3 Order Job/Parts to remove Q ty Remarks Removing the carburetor Remove the parts in the order listed. Negative battery lead Turn the fuel cock lever to the OFF position. Disconnect. EF7000E/EF700E/EF700DE Carrier frame Refer to HANDLE AND WHEELS (FOR EF700DE CAN) on 3-3. Fuel tank Refer to FUEL TANK, CANISTER on 3-7. Air filter Refer to AIR FILTER on 3-6. Fuel cut solenoid valve lead Auto choke lead EF7000E/EF700E/EF700DE 3 Carburetor assembly 4-

69 REMOVING THE CARBURETOR CARB Order Job/Parts to remove Q ty Remarks 4 Link rod/spring / 5 Gasket 6 Joint 7 Gasket A EF7000/EF700 4-

70 DISASSEMBLING THE CARBURETOR CARB DISASSEMBLING THE CARBURETOR EF7000/EF Nm (0.07 m kgf, 0.5 ft lbf) 3.5 Nm (0.35 m kgf,.5 ft lbf) w 9.0 Nm (0.0 m kgf, 0.7 ft lbf) 0 8 q Nm (0.5 m kgf,.8 ft lbf) 4.0 Nm (0.40 m kgf,.9 ft lbf) 0.7 Nm (0.07 m kgf, 0.5 ft lbf) 7 Nm (0.7 m kgf, 5. ft lbf) Order Job/Parts to remove Q ty Remarks Disassembling the carburetor Disassemble the parts in the order listed. Drain screw Main jet holder 3 O-ring 4 Gasket 5 Main jet 6 Float chamber 7 Gasket 8 Main nozzle 9 Needle assembly 0 Float pin q Float w Cap Except for EF700 SEA/AFR 4-3

71 DISASSEMBLING THE CARBURETOR CARB 0.7 Nm (0.07 m kgf, 0.5 ft lbf) 3.5 Nm (0.35 m kgf,.5 ft lbf) t e r.0 Nm (0.0 m kgf, 0.7 ft lbf).5 Nm (0.5 m kgf,.8 ft lbf) 4.0 Nm (0.40 m kgf,.9 ft lbf) 0.7 Nm (0.07 m kgf, 0.5 ft lbf) 7 Nm (0.7 m kgf, 5. ft lbf) Order Job/Parts to remove Q ty Remarks e Pilot adjusting screw/spring / -/ turns out. (Except for EF700 SEA/AFR) turns out. (For EF700 SEA/AFR) r Throttle screw/spring / t Pilot jet/o-ring / 4-4

72 DISASSEMBLING THE CARBURETOR CARB EF7000E/EF700E/EF700DE 0.7 Nm (0.07 m kgf, 0.5 ft lbf) 3.5 Nm (0.35 m kgf,.5 ft lbf) w e q 6.0 Nm (0.0 m kgf, 0.7 ft lbf).5 Nm (0.5 m kgf,.8 ft lbf) 4.0 Nm (0.40 m kgf,.9 ft lbf) Nm (0.07 m kgf, 0.5 ft lbf) 7 Nm (0.7 m kgf, 5. ft lbf) Order Job/Parts to remove Q ty Remarks Disassembling the carburetor Disassemble the parts in the order listed. Drain screw Main jet holder 3 O-ring 4 Gasket 5 Main jet 6 Float chamber 7 Gasket 8 Main nozzle 9 Needle assembly 0 Float pin q Float w Cap e Pilot adjusting screw/spring / -/ turns out. 4-5

73 DISASSEMBLING THE CARBURETOR CARB 0.7 Nm (0.07 m kgf, 0.5 ft lbf) t u y 3.5 Nm (0.35 m kgf,.5 ft lbf) r.0 Nm (0.0 m kgf, 0.7 ft lbf).5 Nm (0.5 m kgf,.8 ft lbf) 4.0 Nm (0.40 m kgf,.9 ft lbf) 0.7 Nm (0.07 m kgf, 0.5 ft lbf) 7 Nm (0.7 m kgf, 5. ft lbf) Order Job/Parts to remove Q ty Remarks r Throttle screw/spring / t Pilot jet/o-ring / y Plate u Choke solenoid assembly 4-6

74 DISASSEMBLING THE CARBURETOR CARB W CHECKING THE FUEL CUT SOLENOID VALVE. Check: 9 Fuel cut solenoid valve Connect the pocket tester (W ). Measure the fuel cut solenoid valve resistance. Fuel cut solenoid valve resistance: 9 W ± 0 % Analog pocket tester: YU-03-C Pocket tester: Out of specification Replace. Check: 9 Fuel cut solenoid valve operation Check whether the sound of the valve operation can be heard when the V power from the battery is supplied to the lead of the fuel cut solenoid valve. Battery positive Blue/Red Battery negative Blue/White No sound heard Replace. Operation sound heard Check the rectifier. TIP Use a fully charged battery. 3. Remove: 9 Panel cover (Refer to CONTROL PANEL on 5-8) 9 Rectifier 4-7

75 DISASSEMBLING THE CARBURETOR CARB Check: 9 Rectifier Connect the pocket tester (W ). Check for continuity between the terminals. 3 Rectifier continuity: Tester ( ) Tester lead 3 4 (+) lead 3 4 Replace if any faults are found. 4-8

76 ELECTRICAL COMPONENTS ELEC ELECTRICAL For complete information about procedures for electrical maintenance, it is necessary to refer to the MZ SERIES ENGINE SERVICE MANUAL 7VB-F897-E0. A q ELECTRICAL COMPONENTS Control box Oil warning unit 3 Rectifier 4 Economy control solenoid (EF7000E/EF700E/EF700DE) 5 Economy control unit (EF7000E/EF700E/EF700DE) 6 Spark plug 7 AVR (Automatic Voltage Regulator) 8 Stator and rotor assembly 9 Battery (EF7000E/EF700E/EF700DE) 0 TCI unit q Starter motor (EF7000E/EF700E/EF700DE) A For EF700DE CAN B Except for EF700DE CAN B q

77 ELECTRICAL COMPONENTS ELEC EF7000 (CHN) EF7000 (CHN) Oil warning light Engine switch 3 Voltage/hour meter 4 AC receptacle 5 AC switch (N.F.B.) EF7000E (CHN) EF7000E (CHN) Oil warning light Economy control switch 3 Engine switch 4 Voltage/hour meter 5 AC receptacle 6 AC switch (N.F.B.) EF700 (SEA/AFR/RUS) EF700 (SEA/AFR/RUS) Oil warning light Engine switch 3 Voltage/hour meter 4 AC receptacle 5 AC switch (N.F.B.) 5 EF700E (Except for OCE) EF700E (Except for OCE) Oil warning light Economy control switch 3 Engine switch 4 Voltage/hour meter 5 AC receptacle 6 AC switch (N.F.B.) 5-

78 ELECTRICAL COMPONENTS ELEC EF700E (OCE) EF700E (OCE) Oil warning light Economy control switch 3 Engine switch 4 Voltage/hour meter 5 AC receptacle 6 AC switch (N.F.B.) EF700DE (Except for CAN) EF700DE (Except for CAN) Oil warning light Economy control switch 3 Engine switch 4 Voltage/hour meter 5 AC receptacle 6 AC switch (N.F.B.) EF700DE (CAN) EF700DE (CAN) Oil warning light Economy control switch 3 Engine switch 4 Voltage/hour meter 5 AC receptacle 6 AC switch (N.F.B.)

79 CIRCUIT DIAGRAM ELEC CIRCUIT DIAGRAM EF7000/EF700 i d s Generator Rotor assembly 3 Exciter field coil 4 Sub coil 5 Main coil 6 Stator assembly 7 Control box 8 Voltage/hour meter 9 AC switch (N.F.B.) a p o 0 AC receptacle q Rectifier w Engine switch e Voltage adjuster r Condenser t AVR (Automatic Voltage Regulator) y Oil warning unit u Oil warning light i Engine o Fuel cut solenoid valve p Charging coil a TCI unit s Spark plug d Oil level switch 8 Color code B Black Br Brown G Green L Blue Lg Light green O Orange R Red W White 9 u 0 0 r e t y w Y Yellow B/W Black/White G/R Green/Red G/Y Green/Yellow L/R Blue/Red L/W Blue/White R/G Red/Green q 5-4

80 CIRCUIT DIAGRAM ELEC EF7000E/EF700E d Generator Rotor assembly 3 Exciter field coil 4 Sub coil 5 Main coil 6 Stator assembly 7 Control box 8 Voltage/hour meter 9 AC switch (N.F.B.) c x f j z ; k g l h 0 AC receptacle q Engine switch w Rectifier e Remote control terminal r Fuse t Rectifier/regulator y Voltage adjuster u Condenser i AVR (Automatic Voltage Regulator) o Oil warning unit p Economy control unit a Oil warning light s Economy control switch d Engine f Economy control solenoid g Starter relay h Starter motor j Auto choke k Fuel cut solenoid valve s 0 0 l Battery ; Charging coil z TCI unit x Spark plug c Oil level switch p 8 a 9 å 0 0 u i y t o r A Except for OCE B For OCE Color code B Black Br Brown G Green L Blue Lg Light green O Orange R Red W White Y Yellow q e w B/W Black/White G/R Green/Red G/Y Green/Yellow L/R Blue/Red L/W Blue/White R/B Red/Black R/G Red/Green R/W Red/White 5-5