Yamaha EF2800i Service Manual
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Yamaha EF2800i Service Manual

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SERVICE MANUAL
EF2800i
LIT-19616-00-92
7VU-28197-10
310115

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  • Page 1 SERVICE MANUAL EF2800i LIT-19616-00-92 7VU-28197-10 310115...
  • Page 3 FOREWORD HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor PARTICULARLY IMPORTANT Company primarily for use by Yamaha dealers INFORMATION and their qualified mechanics. It is not possible This material is distinguished by the following to put an entire mechanic’s education into one notation.
  • Page 4 D Apply gear oil E Apply molybdenum disulfide oil F Apply wheel bearing grease G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease I Apply a locking agent (LOCTITE ® J Apply Yamaha bond K Use a new one...
  • Page 5 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTIONS INSP AND ADJUSTMENTS ENGINE – ELECTRICAL ELEC SPECIFICATIONS SPEC...

  • Page 6: Table Of Contents

    CHAPTER 1. ELECTRICAL ......... 2-12 SPARK PLUG ........2-12 GENERAL INFORMATION ENGINE SWITCH ......2-13 ECONOMY SWITCH ......2-13 MACHINE IDENTIFICATION ....1-1 PILOT LIGHT ........2-13 SERIAL NUMBER ....... 1-1 RECEPTACLE ........2-14 STARTING SERIAL NUMBER .... 1-1 DC CIRCUIT BREAKER ....2-14 IMPORTANT INFORMATION ....
  • Page 7 GENERATOR ......... 3-23 IGNITION SYSTEM ........4-4 MAGNETO ROTOR AND STATOR TROUBLESHOOTING CHART ... 4-4 COIL ASSEMBLY REMOVAL ... 3-25 MAGNETO ROTOR AND STATOR GENERATOR SYSTEM ......4-9 COIL ASSEMBLY INSTALLATION ... 3-26 TROUBLESHOOTING CHART ... 4-9 CRANKCASE COVER AND CHARGING SYSTEM ......

  • Page 9: Chapter 1. General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION SERIAL NUMBER The serial number is printed on a label 1 which is affixed to the generator as shown. NOTE: The first three characters of this number are for model identification, the remaining digits SVU1010 are the unit production number.

  • Page 10: Important Information

    Be sure to use the correct special tool for the job to guard against damage. SVU1040 2. Oil, grease and seals Be sure to use genuine Yamaha oils, grease and sealers, or the equivalents. SVU1050 3. Expendable parts Always replace the gaskets, O-rings, cotter pins and circlips with new parts when servicing engine.

  • Page 11: All Replacement Parts

    IMPORTANT INFORMATION INFO ALL REPLACEMENT PARTS We recommend the use of genuine Yamaha parts for all replace- ments. Use oil and/or grease, recommended by Yamaha, for assembly and adjustment. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled.

  • Page 12: Special Tools And Testers

    SPECIAL TOOLS AND TESTERS 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 pre- vent damage caused by the use of improper tools or improvised techniques.
  • Page 13 SPECIAL TOOLS AND TESTERS INFO 8. Piston pin puller P/N. YU-01304, 90890-01304 This tool is used to remove the piston pin. SVU1200 9. Sheave holder P/N. YS-01880, 90890-01701 This tool is necessary for holding the flywheel. SVU1205 10.Rotor puller 1 P/N. YU-33270 2 P/N.

  • Page 14: Periodic Inspections And Adjustments

    INTRODUCTION/MAINTENANCE INTERVALS CHART/ INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale.

  • Page 15: Engine

    ENGINE OIL LEAKAGE CHECKING/ INSP OIL LEVEL CHECKING ENGINE ENGINE OIL LEAKAGE CHECKING 1. Check the areas outside of the engine for oil leakage. Oil leakage → Replace the gasket, oil seal, or O-ring. SVU2010 OIL LEVEL CHECKING ECON. 1. Check: 12V10A •...

  • Page 16: Oil Replacement

    INSP OIL REPLACEMENT OIL REPLACEMENT 1. Warm up the engine for several minutes. 2. Stop the engine. 3. Place a receptacle under the engine. 4. Remove: • Oil filler cap 5. Tilt the engine to drain the oil completely. 6. Tighten: •...

  • Page 17: Fuel Leakage

    FUEL LEAKAGE/ INSP FUEL COCK STRAINER INSPECTION FUEL LEAKAGE 1. Check: • Leakage Check at fuel tank, fuel cock, fuel hose, and carburetor. CAUTION: Replace hose every four years. SVU2070 FUEL COCK STRAINER INSPECTION 1. Turn the fuel cock to the “OFF” a posi- tion, detach the strainer cup, and then remove the debris from inside the cup.

  • Page 18: Fuel Tank Filter

    INSP FUEL TANK FILTER FUEL TANK FILTER WARNING Do not smoke, and keep away form open flames, sparks, or any other source of fire when handling or in the vicinity of fuel. 1. Remove: • Fuel tank cap 1 • Fuel tank filter 2 2.

  • Page 19: Air Filter Element

    INSP AIR FILTER ELEMENT AIR FILTER ELEMENT 1. Remove: • Screws 1 • Air filter case cover 2 SVU2100 2. Remove: • Air filter element 1 SVU2110 3. Inspect: • Element Damage → Replace. Clogging → Wash the element in a sol- vent, and then dry it thoroughly.

  • Page 20: Muffler

    INSP MUFFLER MUFFLER 1. Remove: • Muffler Refer “MUFFLER CLEANER” in CHAPTER 3. • Muffler band 1 • Muffler cap 2 • Muffler screen 3 • Spark arrester 4 SVU2130 2. Decarbonize: • Muffler Tap on the muffler in the area shown in the illustration to loosen carbon buildup, and then shake it out of the end of the muffler.

  • Page 21: Valve Clearance Adjustment

    INSP VALVE CLEARANCE ADJUSTMENT VALVE CLEARANCE ADJUSTMENT 1. Remove: • Breather hose 1 • Spark plug cap 2 • Cylinder head cover 3 • Spark plug 4 SVU2160 2. Gently operate the starter rope to bring SVU2170 the piston to the top-dead-center of its compression stroke (when the screw- driver inserted into the spark plug hole reaches the highest position).
  • Page 22 INSP VALVE CLEARANCE ADJUSTMENT 4. Adjust: • Valve clearance Adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 in or out to obtain the proper clearance. Adjuster Valve clearance SVU2200 Turn in Decrease Turn out Increase • Tighten the locknut 1. Locknut: 10 Nm (1.0 m ·...

  • Page 23: Compression Pressure

    INSP COMPRESSION PRESSURE COMPRESSION PRESSURE NOTE: Measure the compression after checking and adjusting the valve clearance. 1. Warm up the engine for several minutes. 2. Remove: • Spark plug 3. Connect: • Compression gauge 1 • Adapter 2 Compression gauge: YU-33223, 90890-03081 Adapter: YU-33223-3, 90890-04082...

  • Page 24: Rated Engine Speed

    COMPRESSION PRESSURE/ INSP RATED ENGINE SPEED/BREATHER HOSE Testing steps (above maximum level): • Check the cylinder head, valve surfaces, and piston crown for carbon deposits. 5. Install: • Spark plug Spark plug: 18 Nm (1.8 m · kg, 13 ft · lb) RATED ENGINE SPEED 1.

  • Page 25: Electrical

    INSP SPARK PLUG ELECTRICAL SPARK PLUG WARNING Inspect and adjust the areas around the cylinder head after the engine has cooled down completely. CAUTION: Before removing the spark plug, use com- pressed air to clean the cylinder head cover to prevent dirt from falling into the engine.

  • Page 26: Engine Switch

    SPARK PLUG/ENGINE SWITCH/ INSP ECONOMY SWITCH/PILOT LIGHT 4. Tighten: • Spark plug Spark plug: 18 Nm (1.8 m · kg, 13 ft · lb) NOTE: To prevent thread damage, finger tighten a the spark plug before tightening it to the speci- fied torque b.

  • Page 27: Receptacle

    INSP RECEPTACLE/DC CIRCUIT BREAKER RECEPTACLE 1. Check: 12V10A • AC receptacles (20 A) 1 AC RESET METHOD: ENGINE PAUSE • AC receptacle (30 A) 2 BATTERY • DC receptacle (12 V, 10 A) 3 CHARGE ONLY RESET Cracks/damage → Replace. Poor connection →...

  • Page 29: Chapter 3. Engine

    CONTROL PANEL ENGINE CONTROL PANEL SVU3010 Order Job name/Part name Q’ty Remarks Control panel assembly removal Remove the parts in the order listed below. Control panel assembly Wire harness Disconnect all couplers and lead wires. Ground terminal For installation, reverse the removal pro- cedure.
  • Page 30 CONTROL PANEL SVU3010 Order Job name/Part name Q’ty Remarks Control panel disassembly Remove the parts in the order listed below. Control panel Engine switch Economy switch Oil warning light Pilot light Over load warning light DC circuit breaker assembly AC receptacle (20 A) AC receptacle (30 A) DC receptacle (12 V-10 A) For assembly, reverse the disassembly...

  • Page 31: Control Box Cover And Fuel Tank

    CONTROL BOX COVER AND FUEL TANK CONTROL BOX COVER AND FUEL TANK 7 Nm (0.7 m · kg, 5.1 ft · lb) SVU3020 Order Job name/Part name Q’ty Remarks Control box cover and fuel tank Remove the parts in the order listed removal below.

  • Page 32: Muffler And Air Cleaner

    MUFFLER AND AIR CLEANER MUFFLER AND AIR CLEANER 2 Nm (0.2 m · kg, 1.4 ft · lb) 4 Nm (0.4 m · kg, 2.9 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb) 16 Nm (1.6 m ·...

  • Page 33: Breather Hose Installation

    MUFFLER AND AIR CLEANER BREATHER HOSE INSTALLATION 1. Install: • Breather hose 1 • Air filter case 2 NOTE: Contact the end of the breather hose 1 to the stopper a of the air filter case 2. SVU3040 MUFFLER ASSEMBLY 1.

  • Page 34: Control Unit And Ac-Cdi Unit

    CONTROL UNIT AND AC-CDI UNIT CONTROL UNIT AND AC-CDI UNIT 2 Nm (0.2 m · kg, 1.4 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb) SVU3080 Order Job name/Part name Q’ty Remarks Control unit AC-CDI unit Remove the parts in the order listed removal...

  • Page 35: Engine

    ENGINE ENGINE 7 Nm (0.7 m · kg, 5.1 ft · lb) 16 Nm (1.6 m · kg, 11 ft · lb) SVU3090 Order Job name/Part name Q’ty Remarks Engine removal Remove the parts in the order listed below. Engine oil Refer to “OIL REPLACEMENT”...

  • Page 36: Cylinder Head Cover And Cylinder Head

    CYLINDER HEAD COVER AND CYLINDER HEAD CYLINDER HEAD COVER AND CYLINDER HEAD SVU3090 Order Job name/Part name Q’ty Remarks Cylinder head cover and cylinder Remove the parts in the order listed head removal below. Control box cover and fuel tank assembly Refer to “CONTROL BOX COVER AND FUEL TANK”.
  • Page 37 CYLINDER HEAD COVER AND CYLINDER HEAD SVU3090 Order Job name/Part name Q’ty Remarks Dowel pin Push rod For installation, reverse the removal procedure.

  • Page 38: Push Rod Inspection

    CYLINDER HEAD COVER AND CYLINDER HEAD PUSH ROD INSPECTION 1. Measure: • Push rod runout Runout limit: 0.5 mm (0.02 in) Out of specification → Replace. SVU3110 CYLINDER HEAD INSPECTION 1. Inspect: • Cylinder head combustion chamber Check the combustion chamber for car- bon deposits Carbon deposits →...

  • Page 39: Cylinder Head Assembly

    CYLINDER HEAD COVER AND CYLINDER HEAD CYLINDER HEAD ASSEMBLY 1. Install: • Cylinder head bolts 1 to 4. NOTE: Tighten the bolts to the specified torque in two steps and in order from 1 to 4. Cylinder head bolts: SVU3140 20 Nm (2.0 m ·...

  • Page 40: Valve

    VALVE VALVE SVU3160 Order Job name/Part name Q’ty Remarks Valve removal Remove the parts in the order listed below. Cylinder head assembly Refer to “CYLINDER HEAD COVER AND CYLINDER HEAD”. Lock nut Adjuster Locker arm Valve cotter Valve spring retainer Valve spring Valve (intake) Valve (exhaust)

  • Page 41: Valve And Valve Spring Removal

    VALVE VALVE AND VALVE SPRING REMOVAL 1. Remove: • Valve cotter 1 • Valve spring retainer 2 • Valve spring 3 • Valve 4 Remove the parts using the valve spring compressor 5. NOTE: SVU3170 Do not compress the spring more than neces- sary.

  • Page 42: Locker Arm Inspection

    VALVE 3. Measure: • Valve stem runout Runout limit: 0.01 mm (0.0004 in) Out of specification → Replace. NOTE: The value is half of that indicated on the dial gauge. SVU3200 4. Measure: • Valve spring free length a Valve spring free length: Intake and exhaust: 26.5 mm (1.04 in) Limit: 25.0 mm (0.98 in)

  • Page 43: Valve Seat Inspection

    VALVE VALVE SEAT INSPECTION 1. Remove carbon deposits from the valve face and valve seat. 2. Apply small amount coarse mechanic's blueing dye (Dykem) to the valve face. 3. Insert the vale into the valve guide and use a valve lapper to contact the valve face with the valve seat.

  • Page 44: Valve Lapping

    VALVE 6. Remove the carbon deposits on the valve face a and valve seat. • Valve face contact seat width b • Valve margin thickness c Apply a small amount of coarse mechanic’s blueing dye (Dykem) to the valve seat. Press the valve through the valve guide and onto the valve seat to make a clear impression.

  • Page 45: Valve And Valve Spring Assembly

    VALVE VALVE AND VALVE SPRING ASSEMBLY 1. Install: • Valve 1 • Valve spring 2 • Valve spring retainer 3 • Valve cotter 4 Apply a small amount of molybdenum disulfide oil to the valve stem and use the valve spring compressor 5 to SVU3290 install the parts.

  • Page 46: Recoil Starter

    RECOIL STARTER RECOIL STARTER 7 Nm (0.7 m · kg, 5.1 ft · lb) 2.3 Nm (0.23 m · kg, 1.7 ft · lb) SVU3300 Order Job name/Part name Q’ty Remarks Recoil starter removal Remove the parts in the order listed below.
  • Page 47 RECOIL STARTER 5 Nm (0.5 m · kg, 3.6 ft · lb) SVU3310 Order Job name/Part name Q’ty Remarks Recoil starter disassembly Remove the parts in the order listed below. Starter handle Bolt Drive plate Clip Drive pawl Spring Sheave drum Starter spring Starter case For assembly, reverse the disassembly...

  • Page 48: Recoil Starter Disassembly

    RECOIL STARTER RECOIL STARTER DISASSEMBLY 1. Remove: • Starter handle 1 NOTE: Make a knot a at the end of the starter rope to prevent the rope from being retracted into the starter case. Then, undo the knot b at the starter handle to the remove starter handle 1.

  • Page 49: Recoil Starter Assembly

    RECOIL STARTER RECOIL STARTER ASSEMBLY 1. Install: • Starter spring 1 • Sheave drum 2 NOTE: Engage starter spring outer hook a with groove b marked “R” on the sheave drum 2. Carefully wind the spring counterclockwise and place it on the sheave drum 2. SVU3370 2.
  • Page 50 RECOIL STARTER 5. Install: SVU3410 • Bolt 1 After tightening the bolt, place starter rope 2 in the cutout a in the sheave drum, and wind it counterclockwise four turns. NOTE: SVU3420 Make a knot b at the end of the starter rope to prevent the rope from being retracted into the recoil starter case.

  • Page 51: Generator

    GENERATOR GENERATOR 4 Nm (0.4 m · kg, 2.9 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb) 65 Nm (6.5 m · kg, 47 ft · lb) SVU3430 Order Job name/Part name...
  • Page 52 GENERATOR 4 Nm (0.4 m · kg, 2.9 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb) 65 Nm (6.5 m · kg, 47 ft · lb) SVU3430 Order Job name/Part name...

  • Page 53: Magneto Rotor And Stator Coil Assembly Removal

    GENERATOR MAGNETO ROTOR AND STATOR COIL ASSEMBLY REMOVAL CAUTION: The magnetic force of the magneto rotor is very strong. Therefore, be sure to remove the magneto rotor and stator coil assembly together as a set, otherwise they may be damaged. 1.

  • Page 54: Magneto Rotor And Stator Coil Assembly Installation

    GENERATOR 4. Remove: • Magneto rotor 1 NOTE: • Remove the magneto rotor 1 together with the stator coil assembly using the magneto rotor puller 2. • Fully tighten the tool holding bolts, making sure the tool body is parallel with the mag- neto rotor.
  • Page 55 GENERATOR CAUTION: Be sure to remove any oil or grease from the tapered portion of the magneto rotor using a cloth dampened with thinner. NOTE: When installing the magneto rotor, make sure the woodruff key is properly seated in the key way of the crankshaft.

  • Page 56: Crankcase Cover And Camshaft

    CRANKCASE COVER AND CAMSHAFT CRANKCASE COVER AND CAMSHAFT SVU3490 Order Job name/Part name Q’ty Remarks Crankcase cover camshaft Remove the parts in the order listed removal below. Engine assembly Refer to “ENGINE”. Cylinder head assembly Refer to “CYLINDER HEAD COVER AND CYLINDER HEAD”.

  • Page 57: Camshaft Inspection

    CRANKCASE COVER AND CAMSHAFT CAMSHAFT INSPECTION 1. Inspect: • Camshaft Damage → Replace. SVU3500 2. Measure: • Cam lobes length a and b Out of specifications → Replace. Cam lobes length: a: 26.9 ± 0.05 mm Intake (1.06 ± 0.002 in) b: 22.0 ±...

  • Page 58: Valve Lifter Inspection

    CRANKCASE COVER AND CAMSHAFT VALVE LIFTER INSPECTION 1. Inspect: • Valve lifter Damage → Replace. SVU3540 CAMSHAFT ASSEMBLY 1. Install: • Camshaft 1 CAUTION: Be sure to align the hole a of camshaft gear with the crankshaft gear mark b. SVU3550 CRANKCASE COVER INSPECTION 1.

  • Page 59: Piston, Connecting Rod, Crankshaft And Crankcase

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE SVU3580 Order Job name/Part name Q’ty Remarks Piston, connecting rod, crankshaft Remove the parts in order listed. and crankcase removal Engine assembly Refer to “ENGINE”. Cylinder head assembly Refer to “CYLINDER HEAD COVER AND CYLINDER HEAD”.

  • Page 60: Crankcase (Cylinder) Inspection

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE CRANKCASE (CYLINDER) INSPECTION 1. Measure: • Cylinder inside diameter NOTE: Take side to side a and front to back b mea- surements at each of the three locations A, B, C (total of six measurements), and then find the average of the measurements.
  • Page 61 PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE 2. Measure: • Piston clearance Out of specification → Rebore or replace cylinder and replace piston and piston rings. Piston clearance: 0.015 ~ 0.040 mm (0.00059 ~ 0.00157 in) Piston clearance = Cylinder inside diameter – Piston skirt diameter 3.

  • Page 62: Piston Ring Inspection

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE PISTON RING INSPECTION 1. Measure: • Piston ring end gap Out of specification → Replace. NOTE: Insert the piston ring 1 into the cylinder, and push it approximately 5 mm (0.2 in) into the cylin- der.

  • Page 63: Connecting Rod Oil Clearance Inspection

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE 2. Inspect: • Crankshaft gear 1 Wear/damage → Replace. SVU3680 3. Measure: • Crank pin outside diameter a Wear/damage → Replace. Use a micrometer. Out of specification → Replace. Crank pin outside diameter: 28.0 mm (1.102 in) Wear limit: 27.9 mm (1.098 in) SVU3690...

  • Page 64: Piston Ring And Piston Assembly

    • Piston 1 • Piston pin 2 • Piston pin circlip 3 NOTE: • Make sure that the “YAMAHA” mark a on the connecting rod faces toward the crank- case cover. ” mark b on the pis- • Make sure that the “...

  • Page 65: Crankshaft Assembly

    NOTE: ” mark a on the pis- • Make sure that the “ ton head faces toward the push rod. • Make sure that the “YAMAHA” mark b on the connecting rod faces toward the crank- case cover. 4. Install: •...

  • Page 66: Carburetor

    CARBURETOR CARBURETOR SVU3790 Order Job name/Part name Q’ty Remarks Carburetor removal Remove the parts in the order listed below. Air cleaner assembly Refer to “MUFFLER AND AIR CLEANER”. Choke knob Choke cable Fuel hose Throttle control motor cover Throttle control motor coupler Carburetor assembly Gasket Carburetor joint...
  • Page 67 CARBURETOR SVU3800 Order Job name/Part name Q’ty Remarks Carburetor disassembly Remove the parts in the order listed below. Throttle control motor assembly Throttle controller bracket Bracket Bolt Gasket Drain screw Float chamber Gasket Float pin Float Needle valve Main nozzle Main jet Pilot jet For assembly, reverse the disassembly...

  • Page 68: Float Height Inspection

    CARBURETOR FLOAT HEIGHT INSPECTION 1. Measure: • Float height Out of specification → Replace. NOTE: Lift up the float height so that the tip of the float valve lightly contacts the float arm, and then measure the float height a. (This measure- ment should be made with the gasket SVU3810 removed.)

  • Page 69: Choke Cable Installation

    CARBURETOR CHOKE CABLE INSTALLATION 1. Inspect: • Choke knob 1 NOTE: Push the choke knob 1 entirely in before installing it to the frame. 2. Install • Casing cap (choke cable) 2 NOTE: Place the choke knob casing cap against the stay 3.

  • Page 70: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ENGINE DOES NOT START Check that the oil warning Check connections between oil warning Replace oil warning light turns ON by pulling the unit and oil level switch. light, oil warning starter rope. unit, or oil level DOSE NOT switch.
  • Page 71 TROUBLESHOOTING Check carburetor for clogged passages or fuel overflow. GOOD NO GOOD Clean. Measure valve clearance. OUT OF GOOD SPECIFICA- Adjust. TION Check compression using compression gauge. OUT OF SPECIFICA- GOOD TION Check valve face and valve seat for wear. Resurface or GOOD WEAR...
  • Page 72 TROUBLESHOOTING ENGINE STARTS BUT STALLS Check fuel level. SUFFI- INSUFFI- Add. CIENT CIENT Check if fuel cock is clogged. GOOD NO GOOD Clean. Check if fuel hose is clogged. GOOD NO GOOD Clean. • Check carburetor • Tighten the carbu- retaining nuts are loose.
  • Page 73 TROUBLESHOOTING ENGINE SPEED DOES NOT INCREASE Check if the electric equipment consumes too much wattage for this generator. GOOD TOO MUCH Use a generator with a larger capacity. Check air filter element for dirt. GOOD NOT GOOD Clean. Check spark plug for dirt and check spark plug gap.
  • Page 74 TROUBLESHOOTING ENGINE SPEED IS UNEVEN Check fuel level. SUFFICIENT INSUFFICIENT Add. Check if fuel is deteriorated. GOOD NO GOOD Replace. Check if fuel cock is clogged. GOOD NO GOOD Clean. Check spark plug for dirt and check spark plug gap. GOOD NO GOOD Clean or adjust.
  • Page 75 TROUBLESHOOTING Check valve face and valve seat for wear. GOOD WEAR Resurface or replace. Check if there is seizure or wear on piston, piston ring, or cylinder. SEIZURE OR GOOD Rebore or replace. WEAR Check the condition of the throttle control system.

  • Page 76: Throttle Control System

    TROUBLESHOOTING THROTTLE CONTROL SYSTEM ENGINE DOES NOT START, ENGINE STARTS BUT STALLS, ENGINE SPEED DOES NOT INCREASE, OR ENGINE SPEED IS UNEVEN. Check AC output. GOOD NO GOOD Refer to “GENERATOR SYSTEM” in CHAPTER 4. Rotate the shaft of the throttle control motor to check if it turns smoothly with slight resistance.
  • Page 77 TROUBLESHOOTING With no load, engine speed does not increase when economy control switch is set to “OFF”. With no load, engine speed does not decrease when economy control switch is set to “ON”. With load, engine speed does not increase when economy control switch is set to “ON”. Check AC output.

  • Page 78: Chapter 4. Electrical

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS Control unit Engine switch Economy switch Oil warning unit AC receptacle (20 A) AC receptacle (30 A) Ground terminal Overload warning light (Red) Pilot light (Green) Oil warning light (Red) SVU4010 Oil level switch DC circuit breaker Spark plug Throttle control motor...

  • Page 79: Circuit Diagram

    – ELEC CIRCUIT DIAGRAM...

  • Page 80: Switches

    – ELEC SWITCHES SWITCHES CHECKING SWITCH CONTINUITY Use a tester to check the terminals for continu- ity. If the continuity is faulty at any point, replace the switch. Pocket tester: YU-03112, 90890-03112 NOTE: • Set the pocket tester to “0” before starting a test.

  • Page 81: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING CHART NO SPARK OR WEAK SPARK Inspection steps: 1. Spark plug 6. Pulser coil resistance 2. Ignition spark gap 7. Engine switch 3. Spark plug cap 8. Oil level switch 4. Ignition coil resistance 9.
  • Page 82 – ELEC IGNITION SYSTEM • Turn the crankshaft and measure the igni- tion spark gap a. Minimum spark gap: MEETS SPECIFICATION 6 mm (0.24 in) OUT OF SPECIFICATION OR NO SPARK The ignition system is good. 3. Spark plug cap NOTE: •...
  • Page 83 – ELEC IGNITION SYSTEM C0NTINUITY 2) Secondary coil resistance • Connect the pocket tester (Ω × 1) to the secondary terminal. Tester (+) lead → High-tension cord 1 Tester (–) lead → Black terminal 2 SVU4090 Secondary coil resistance: OUT OF SPECIFICATION 6.7 kΩ...
  • Page 84 – ELEC IGNITION SYSTEM C0NTINUITY 7. Engine switch • Disconnect the engine switch coupler in the control box. • Turn the engine stop switch to “ON” a, and then check the engine stop switch for SVU4120 continuity. • Connect the pocket tester (Ω × 1k) to the engine switch terminal.
  • Page 85 – ELEC IGNITION SYSTEM C0NTINUITY 9. Wire harness DISCONNECTED • Check the terminal of the connector for contamination, rust, or disconnection. GOOD Correct or replace the connector. Replace the magneto rotor. GOOD Replace the AC-CDI unit.

  • Page 86: Generator System

    – ELEC GENERATOR SYSTEM GENERATOR SYSTEM TROUBLESHOOTING CHART WEAK OR NO AC CURRENT Start the engine. Disconnect the overloaded electric device. Check the overload warning light. TURNS ON DOES NOT TURN ON DOES NOT TURN ON TURNS ON Start the engine. Check the AC output indicator.
  • Page 87 – ELEC GENERATOR SYSTEM Sub coil AC voltage inspection Magnetic force is weak. Start the engine. Measure the voltage between the Orange leads of the sub coil 1 Replace the magneto rotor. Sub coil resistance inspection Stop the engine. Measure the resistance between the Orange to Orange lead.

  • Page 88: Charging System

    – ELEC CHARGING SYSTEM CHARGING SYSTEM TROUBLESHOOTING NO DC CURRENT NOTE: • Choose a battery which meets the following specifications for testing. Recommended battery capacity: Minimum: 12 V, 40 Ah Maximum: 12 V, 120 Ah • Use the following special tool(s) for troubleshooting. Inductive tachometer: Pocket tester: YU-8036-A...
  • Page 89 – ELEC CHARGING SYSTEM LESS THAN 14.0 V R × 1 3. DC charge coil resistance • Disconnect the DC charge coil 1 leads. • Connect the pocket tester. • Measure the DC charge coil resistance. SVU4210 DC charge coil resistance OUT OF SPECIFICATION Blue-Blue: 0.06 ~ 1.00 Ω...

  • Page 90: Chapter 5. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Unit EF2800i Model code number 7VU2 Dimensions: Overall length mm (in) 487 (19.2) Overall width mm (in) 395 (15.6) Overall height mm (in) 425 (16.7) Dry weight kg (lb) 29 (63.8) Engine: Engine type...
  • Page 91 SPEC GENERAL SPECIFICATIONS Unit EF2800i Voltage fluctuation Instantaneous Less than 20% Settling Less than 3% Settling time Less than 5 sec AC output Rated voltage Frequency Rated output Rated current 20.8 Safety device type Electronic no fuse breaker Circuit breaker (No fuse breaker)

  • Page 92: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Unit EF2800i Piston: mm (in) Piston clearance 0.015 ~ 0.040 (0.00059 ~ 0.00157) <Limit> 0.100 (0.0039) Piston skirt “D” 66.0 (2.598) <Limit> 65.9 (2.594) Measuring point “H” 10.0 (0.4) Oversize 1st 66.25 (2.6083) 66.50 (2.6181) Piston pin hole inside diameter 16.002 ~ 16.013 (0.6300 ~ 0.6304)
  • Page 93 SPEC MAINTENANCE SPECIFICATIONS Unit EF2800i Crankshaft: mm (in) Big end side clearance “A” 0.20 ~ 0.60 (0.008 ~ 0.024) <Limit> 0.75 (0.029) Runout “B” <Limit> 0.04 (0.0016) Crank pin diameter “C” 28.0 (1.102) <Limit> 27.9 (1.098) Connecting rod: mm (in) Small end diameter “A”...
  • Page 94 SPEC MAINTENANCE SPECIFICATIONS Unit EF2800i Push rod: mm (in) Runout limit 0.5 (0.02) Valve spring: mm (in) Free length 26.5 (1.04) 26.5 (1.04) <Limit> 25.0 (0.98) 25.0 (0.98) Set length 21.6 (0.85) 21.6 (0.85) Set force 4.5 kg (9.9 lb) 4.5 kg (9.9 lb)

  • Page 95: Generator And Electrical

    SPEC MAINTENANCE SPECIFICATIONS GENERATOR AND ELECTRICAL Unit EF2800i Generator: Main coil AC voltage (3 phase) (V/r/min) 130 ~ 160/2,800 (With the throttle control motor coupler dis- connected) Sub coil AC voltage (single phase)(V/r/min) 13.5 ~ 23.0/2,800 (With the throttle control motor coupler dis-...

  • Page 96: Tightening Torque

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE Tightening torque Item Tread size Nm (m·kg, ft·lb) M14 × 1.25 Spark plug 18 (1.8, 13) M6 × 1.0 Cylinder head cover 10 (1.0, 7.2) M8 ×1.25 Cylinder head 20 (2.0, 14) M10 × 1.25 Oil drain bolt 17 (1.7, 12) M8 ×...

  • Page 97: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE Tightening torque Tread size SPECIFICATIONS m·kg ft·lb This chart specifies torque for standard fasten- ers with standard I.S.O. pitch treads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book.

  • Page 98: Wire Routing Diagram

    SPEC WIRE ROUTING DIAGRAM WIRE ROUTING DIAGRAM CONTROL BOX PANEL AND BEHIND CONTROL BOX È Black lead with red tape mark É Black/White and Yellow leads with tape mark ECON. Ê Ground terminal 12V10A AC RESET METHOD: ENGINE PAUSE COLOR CODE BATTERY CHARGE ONLY...

  • Page 99: Engine And Generator

    SPEC WIRE ROUTING DIAGRAM ENGINE AND GENERATOR Ê Connect the coupler, and then store them in the 1 Ground terminal 2 Control unit space located above the control unit. Ë Coupler storage space 3 AC-CDI unit Ì Connect the lead wires, and then fasten them 4 Rectifier with a clamp.
  • Page 100 SPEC WIRE ROUTING DIAGRAM È Install the spark plug cap. 1 Spark plug cap É Route the oil level switch lead as shown. 2 Oil level switch Ê Pass the leads through the hole, install and 3 Pulser coil 4 Ground terminal tighten the clamp, and then insert it in the grom- 5 Ignition coil met into the hole.
  • Page 102 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN USA...
  • Page 103 CIRCUIT DIAGRAM 1 Main coil 0 DC charge coil I AC-CDI unit 2 Sub coil (AC control) A Economy switch J Pulser coil 3 Charge coil (Ignition source) B Over load warning light K Throttle control motor 4 Generator assembly C Engine switch L Rectifier 5 Control unit...

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