Yamaha EF2400iS Service Manual
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Yamaha EF2400iS Service Manual

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SERVICE MANUAL
EF2400iS
7CF-28197-E0
331153

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  • Page 1 SERVICE MANUAL EF2400iS 7CF-28197-E0 331153...
  • 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 to put an entire mechanic’s education into one...
  • Page 4 Apply gear oil u Apply molybdenum disulfide oil i Apply wheel bearing grease o Apply lightweight lithium-soap base grease p Apply molybdenum disulfide grease a Apply a locking agent (LOCTITE ® s Apply Yamaha bond d Use a new one...
  • Page 5 INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE CARBURETOR ELECTRICAL TROUBLESHOOTING SPECIFICATIONS...

  • Page 6: Table Of Contents

    CHAPTER 1. ENGINE SWITCH ......2-16 RECEPTACLE ........2-17 GENERAL INFORMATION AC SWITCH (NFB For CANADA) ..2-17 DC SWITCH (NFB For CANADA) ..2-18 MACHINE IDENTIFICATION ....1-1 DC CIRCUIT BREAKER ....2-20 SERIAL NUMBER ......1-1 STARTING SERIAL NUMBER ... 1-1 CHAPTER 3.
  • Page 7 VALVE AND VALVE SPRING IGNITION SYSTEM ......... 5-6 INSPECTION ........3-26 TROUBLESHOOTING CHART ..5-6 LOCKER ARM INSPECTION ....3-27 GENERATOR SYSTEM ......5-10 VALVE SEAT INSPECTION ..... 3-28 TROUBLESHOOTING CHART ..5-10 VALVE LAPPING ......3-29 VALVE AND VALVE SPRING CHAPTER 6.

  • Page 8: 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 are the unit production number.

  • Page 9: 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 10: 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 11: 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 12 SPECIAL TOOLS AND TESTERS INFO 7. Rotor puller 1 P/N. YU-33270 2 a P/N. 90890-01362 b P/N. 90890-01355 (M6) This tool is necessary for removing the magneto rotor. SVU1210 SVU1220 8. Pocket tester P/N. YU-03112, 90890-03112 This instrument is necessary for checking the electrical system. SVU1230 9.

  • 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 INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS ∂ Initial ´ Every ç Pre- Operation ƒ 1 © 3 ˙ 6 ˆ 12 å Item ∫ Remarks check month months months months (daily) or 20 Hr or 50 Hr or 100 Hr or 300 Hr 13.

  • Page 16: Covers And Fuel Tank

    INSP COVERS AND FUEL TANK COVERS AND FUEL TANK å 7 Nm (0.7 m · kg, 5.1 ft · lb) 1.3 Nm (0.13 m · kg, 1.0 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb) 7CF3010E Order Job name...

  • Page 17: Engine

    ENGINE OIL LEAKAGE CHECKING/ INSP OIL LEVEL CHECKING ENGINE ENGINE OIL LEAKAGE CHECKING 1. Open the oil filer cover. 2. Check the areas outside of the engine for oil leakage. Oil leakage → Replace the gasket, oil seal, or O-ring. OIL LEVEL CHECKING 1.

  • Page 18: Oil Replacement

    INSP OIL REPLACEMENT OIL REPLACEMENT 1. Warm up the engine for several minutes. 2. Stop the engine and place the stable blocks as shown. 3. Remove: 9 Rubber cover 1 4. Place the oil pan under the engine, and then to drain the oil completely. 5.

  • Page 19: Fuel Leakage

    FUEL LEAKAGE/ INSP FUEL TANK FILTER FUEL LEAKAGE 1. Remove: 9 Rear cover 9 Side cover right Refer to “COVERS AND FUEL TANK”. 2. Check: 9 Leakage Check at fuel tank, fuel cock, fuel hose, and carburetor. Replace hose every four years. FUEL TANK FILTER Do not smoke, and keep away form open flames, sparks, or any other source of fire...

  • Page 20: Fuel Tank Strainer

    INSP FUEL TANK STRAINER FUEL TANK STRAINER 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: 9 Feel cock lever 9 Rear cover 9 Fuel tank cap 9 Top cover 9 Side cover right...

  • Page 21: Air Cleaner Element

    INSP AIR CLEANER ELEMENT AIR CLEANER ELEMENT The engine should never run without the element, otherwise excessive piston and/or cylinder wear may result. 1. Remove: 9 Side cover right SCH2100 9 Rear cover Refer to “COVERS AND FUEL TANK”. 9 Screw 1 9 Air cleaner case cap 2 2.

  • Page 22: Muffler

    INSP MUFFLER MUFFLER 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 inspection or repair. 1.
  • Page 23 INSP MUFFLER 3. Decarbonize: 9 Muffler screen 9 Spark arrester When cleaning, use the wire brush lightly to avoid damaging or scratching of the muffler screen and spark arrester. SCF2150 4. Install: 9 Spark arrester 9 Muffler screen 9 Muffler cap 9 Muffler band 9 Muffler Refer to “MUFFLER AND AIR CLEAN-...

  • Page 24: Valve Clearance Adjustment

    INSP VALVE CLEARANCE ADJUSTMENT VALVE CLEARANCE ADJUSTMENT 1. Remove: 9 Rear cover Refer to “COVERS AND FUEL TANK”. 2. Remove: 9 Spark plug cap 1 9 Spark plug 2 9 Breather hose 3 9 Cylinder head cover 4 3. Gently operate the starter rope to bring the piston to the top-dead-center of its SCF2160 compression stroke (when the screwdriv-...
  • Page 25 VALVE CLEARANCE ADJUSTMENT/ INSP COMPRESSION PRESSURE 5. Adjust: 9 Valve clearance Adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 in or out to obtain the proper clearance. • Tighten the locknut 1. SCF2200 use hexagonal wrench. Adjuster Valve clearance Turn in...

  • Page 26: Compression Pressure

    INSP COMPRESSION PRESSURE 4. Connect: 9 Compression gauge 1 9 Adapter 2 Compression gauge: YU-33223, 90890-03081 Adapter: YU-33223-3, 90890-04082 SCF2220 5. Measure: 9 Compression To measure the compression, pull the recoil starter until the needle stops ris- ing on the compression gauge. Standard compression pressure: 820 ~880 kPa (8.2 ~8.8 kg/cm...

  • Page 27: Rated Engine Speed

    INSP RATED ENGINE SPEED/BREATHER HOSE RATED ENGINE SPEED 1. Remove: 9 Rear cover Refer to “COVERS AND FUEL TANK”. 2. Connect: 9 Inductive tachometer 1 Inductive tachometer: YU-8036-A SCF2230 Engine tachometer: 90890-03113 3. Inspect: Rated engine speed Specified engine speed → OK Out of specification →...

  • Page 28: Electrical

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

  • Page 29: Engine Switch

    INSP SPARK PLUG/ENGINE SWITCH 5. Tighten: • Spark plug NOTE: To prevent thread damage, temporally tighten a the spark plug before tightening it to the specified torque b. Spark plug: 18 Nm (1.8 m · kg, 13 ft · lb) 6.

  • Page 30: Receptacle

    INSP RECEPTACLE RECEPTACLE 230 V/50 Hz, 220V/60Hz 1. Check: 9 AC receptacles 1 9 DC receptacle 2 Cracks/damage → Replace. Poor connection → Correct. 1 : 8.7 A 2 : 12 V, 8 A For GERMANY 1 : 9.1 A 2 : 12 V, 8 A 120 V/60 Hz For KOREA...

  • Page 31: Ac Switch (Nfb For Canada)

    INSP AC SWITCH (NFB For CANADA) AC SWITCH (NFB For CANADA) 1. Set the AC switch (NFB) 1 to the “ON” a position. 2. Connect the pocket tester (AC 120 V) to the AC receptacle and check the AC switch (NFB) for continuity. No continuity →...

  • Page 32: Dc Switch (Nfb For Canada)

    INSP DC SWITCH (NFB For CANADA) DC SWITCH (For CANADA) 1. Check: 9 DC switch Checking steps: 9 Set the DC switch 1 to the position of “ON” a. 9 Connect the pocket tester (DC 20 V). Pocket tester: YU-03112, 90890-03112 Digital circuit tester: 90890-03174 9 Start the engine.

  • Page 33: Dc Circuit Breaker

    INSP DC CIRCUIT BREAKER DC CIRCUIT BREAKER 230 V/50 Hz, 1. Check: 220V/60Hz 9 DC circuit breaker Checking steps: 9 Press the reset button 1 to the position of “RESET” a. 9 Connect the pocket tester (DC 20 V). Pocket tester: YU-03112, 90890-03112 Digital circuit tester: 230 V/50 Hz...

  • Page 34: Chapter 3. Engine

    CONTROL BOX ENGINE CONTROL BOX CONTROL BOX DISASSEMBLY 230 V/50 Hz (For GERMANY) 120 V/60 Hz (For CANADA) 2 12 230 V/50 Hz (For AUSTRALIA) 220 V/60 Hz (For KOREA) 12 8 7CF3021E Order Job name Q’ty Remarks Control box disassembly Remove the parts in the order listed below.
  • Page 35 CONTROL BOX 230 V/50 Hz (For GERMANY) 120 V/60 Hz (For CANADA) 2 12 230 V/50 Hz (For AUSTRALIA) 220 V/60 Hz (For KOREA) 12 8 7CF3021E Order Job name Q’ty Remarks Speed limiter Disconnect. Earth terminal Disconnect. Noise filter For GERMANY AC switch (NFB) For CANADA...

  • Page 36: Control Box Assembly

    CONTROL BOX CONTROL BOX ASSEMBLY 1 Install: 9 Control box 1 NOTE: Insert the rid of control box to the frame 2.

  • Page 37: Engine

    ENGINE ENGINE 16 Nm (1.6 m · kg, 12 ft · lb) å 16 Nm (1.6 m · kg, 12 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb) 7CF3031E Order Job name Q’ty Remarks Engine removal Remove the parts in the order listed below.

  • Page 38: Recoil Starter

    RECOIL STARTER RECOIL STARTER 7 Nm (0.7 m · kg, 5.1 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb) 7CF3040E Order Job name Q’ty Remarks Recoil starter removal Remove the parts in the order listed below.

  • Page 39: Recoil Starter Disassembly

    RECOIL STARTER AND ROTOR RECOIL STARTER DISASSEMBLY 5 Nm (0.5 m · kg, 3.6 ft · lb) 7CF3050E Order Job name Q’ty Remarks Recoil starter disassembly Remove the parts in the order listed below. Bolt Drive plate Clip Drive pawl Spring Sheave drum Starter spring...

  • Page 40: Recoil Starter Inspection

    RECOIL STARTER AND ROTOR RECOIL STARTER DISASSEMBLY 1. Remove: 9 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 41: Recoil Starter Assembly

    RECOIL STARTER AND ROTOR RECOIL STARTER ASSEMBLY 1. Install: 9 Starter spring 1 9 Sheave drum 2 install the swing arm to the collar. NOTE: Engage starter spring outer hook a with groove b marked “R” on the sheave drum 2. SCF3370 Carefully wind the spring counterclockwise and place it on the sheave drum 2.
  • Page 42 RECOIL STARTER AND ROTOR 5. Install: 9 Bolt 1 5 Nm (0.5 m · kg, 3.6 ft · lb) After tightening the bolt, place starter rope 2 in the cut-out a in the sheave drum, and wind it counterclockwise four turns.

  • Page 43: Ignition Coil And Rotor

    IGNITION COIL AND ROTOR IGNITION COIL AND ROTOR 7 Nm (0.7 m · kg, 5.1 ft · lb) 65 Nm (6.5 m · kg, 47 ft · lb) 7CF3070E Order Job name Q’ty Remarks Ignition coil and rotor removal Remove the parts in the order listed below.

  • Page 44: Ignition Coil And Rotor Removal

    IGNITION COIL AND ROTOR IGNITION COIL AND ROTOR REMOVAL 1. Remove: 9 Ignition coil 9 Rotor nut 1 use the sheave holder 2. Sheave holder: YS-01880, 90890-01701 2. Remove: 9 Rotor 1 use the rotor puller 2, bolt 3. Rotor puller: YU-33270, 2 90890-03162 3 90890-01355 (M6) IGNITION COIL AND ROTOR INSTALLA-...
  • Page 45 RECOIL STARTER AND ROTOR 2. Install: 9 Ignition coil 10 Nm (1.0 m · kg, 7.2 ft · lb) 3. Inspection: 9 Air gap inspect the clearance between the magneto on the rotor and ignition coil. Air gap: 0.5 ± 0.1 mm (0.02 ±...

  • Page 46: Muffler And Air Cleaner

    MUFFLER AND AIR CLEANER MUFFLER AND AIR CLEANER 1.2 Nm (0.12 m · kg, 0.9 ft · lb) 2 Nm (0.2 m · kg, 1.5 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb) 4 Nm (0.4 m ·...
  • Page 47 MUFFLER AND AIR CLEANER 1.2 Nm (0.12 m · kg, 0.9 ft · lb) 2 Nm (0.2 m · kg, 1.5 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb) 4 Nm (0.4 m ·...

  • Page 48: Breather Hose Installation

    MUFFLER AND AIR CLEANER BREATHER HOSE INSTALLATION 1. Install: 9 Breather hose 1 9 Air filter case 2 NOTE: Contact the end of the breather hose 1 to the stopper a of the air filter case 2. SCF3040 MUFFLER ASSEMBLY 1.

  • Page 49: Generator

    GENERATOR GENERATOR 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) 7 Nm (0.7 m · kg, 5.1 ft · lb) 1.2 Nm (0.12 m ·...
  • Page 50 GENERATOR 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) 7 Nm (0.7 m · kg, 5.1 ft · lb) 1.2 Nm (0.12 m ·...

  • Page 51: Magneto Rotor And Stator Coil Assembly Removal

    GENERATOR MAGNETO ROTOR AND STATOR COIL ASSEMBLY REMOVAL 1. Remove: 9 Magneto rotor nut 1 NOTE: Attach the sheave holder 2 to hold the rotor. Sheave holder: YS-01880, 90890-01701 2. Remove: 9 Stator coil assembly bolts 1 9 Tubes NOTE: Turn the magneto rotor until the stator coil assembly bolts are visible through the holes in the rotor, and then remove the bolts.

  • Page 52: Magneto Rotor And Stator Coil Assembly Installation

    GENERATOR 4. Remove: 9 Cover 1 NOTE: Remove the cover 1, and then disconnect the stator coil couplers. MAGNETO ROTOR AND STATOR COIL ASSEMBLY INSTALLATION 1. Install: 9 Cover 1 NOTE: Connect the stator coil couplers, before install the cover 1. 2.
  • Page 53 GENERATOR 3. Install: 9 Tubes 9 Stator coil assembly bolts 1 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Turn the magneto rotor until the stator coil assembly bolts are visible though the holes in the rotor, and then remove the bolts 1. 4.

  • Page 54: Cylinder Head Cover And Cylinder Head

    CYLINDER HEAD COVER AND CYLINDER HEAD CYLINDER HEAD COVER AND CYLINDER HEAD 20 Nm (2.0 m · kg, 14 ft · lb) 18 Nm (1.8 m · kg, 13 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb) 7CF3009E Order Job name...
  • Page 55 CYLINDER HEAD COVER AND CYLINDER HEAD 20 Nm (2.0 m · kg, 14 ft · lb) 18 Nm (1.8 m · kg, 13 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb) 7CF3009E Order Job name Q’ty Remarks Breather hose...

  • Page 56: Push Rod Inspection

    CYLINDER HEAD COVER AND CYLINDER HEAD PUSH ROD INSPECTION 1. Inspect: 9 Push rod runout Runout limit: 0.5 mm (0.02 in) Out of specifications → Replace. CYLINDER HEAD INSPECTION 1. Inspect: 9 Cylinder head combustion chamber Check the combustion chamber for car- bon deposits Carbon deposits →...

  • Page 57: Cylinder Head Assembly

    CYLINDER HEAD COVER AND CYLINDER HEAD CYLINDER HEAD ASSEMBLY 1. Inspect: 9 Cylinder head bolts 1 to 4. 20 Nm (2.0 m · kg, 14 ft · lb) NOTE: Tighten the bolts to the specified torque in two steps and in order from 1 to 4. SCF3140 BREATHER HOSE ASSEMBLY 1.

  • Page 58: Valve

    VALVE VALVE 10 Nm (1.0 m · kg, 7.2 ft · lb) 7CF30100E Order Job name Q’ty Remarks Valve removal Remove the parts in the order listed below. Cylinder head Refer to “CYLINDER HEAD” section. Lock nut Adjuster Rocker arm Valve cotter Spring retainer Spring...

  • Page 59: Valve And Valve Spring Removal

    VALVE VALVE AND VALVE SPRING REMOVAL 1. Remove: 9 Valve cotter 1 9 Valve spring retainer 2 9 Valve spring 3 9 Valve 4 Remove the parts using the valve spring compressor 5. NOTE: Do not compress the spring more than neces- sary.

  • Page 60: Locker Arm Inspection

    VALVE 3. Measure: 9 Valve stem runout Runout limit: 0.01 mm (0.0004 in) Out of specifications → Replace. NOTE: The value is half of that indicated on the dial gauge. 4. Measure: 9 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 61: Valve Seat Inspection

    VALVE VALVE SEAT INSPECTION 1. Remove carbon deposits from the valve face and valve seat. 2. Apply a small amount of coarse mechan- ic'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 62: Valve Lapping

    VALVE 6. Remove the carbon deposits on the valve face a and valve seat. 9 Valve face contact seat width b 9 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 63: Valve And Valve Spring Assembly

    VALVE VALVE AND VALVE SPRING ASSEMBLY 1. Install: 9 Valve 1 9 Valve spring 2 9 Valve spring retainer 3 9 Valve cotter 4 Apply a small amount of molybdenum disulfide oil to the valve stem and use the valve spring compressor 5 to install the parts.

  • Page 64: Crankcase Cover And Camshaft

    CRANKCASE COVER AND CAMSHAFT CRANKCASE COVER AND CAMSHAFT 10 Nm (1.0 m · kg, 7.2 ft · lb) 17 Nm (1.7 m · kg, 12 ft · lb) 22 Nm (2.2 m · kg, 16 ft · lb) 7CF30110E Order Job name Q’ty Remarks...
  • Page 65 CRANKCASE COVER AND CAMSHAFT 10 Nm (1.0 m · kg, 7.2 ft · lb) 17 Nm (1.7 m · kg, 12 ft · lb) 22 Nm (2.2 m · kg, 16 ft · lb) 7CF30110E Order Job name Q’ty Remarks Valve lifter For installation, reverse the removal procedure.

  • Page 66: Camshaft Inspection

    CRANKCASE COVER AND CAMSHAFT CAMSHAFT INSPECTION 1. Inspect: 9 Camshaft Crack/damage/wear → Replace. 2. Inspect: 9 Cam lobes length a and b Cam lobes length: Intake a: 26.9 ± 0.05 mm (1.06 ± 0.002 in) b: 22.0 ± 0.05 mm (0.87 ±...

  • Page 67: Valve Lifter Inspection

    CRANKCASE COVER AND CAMSHAFT VALVE LIFTER INSPECTION 1. Inspect: 9 Valve lifter Damage → Replace. CAMSHAFT ASSEMBLY 1. Install: 9 Camshaft 1 Be sure to align the hole a of camshaft gear with the crankshaft gear mark b. SCF3550 CRANKCASE COVER INSPECTION 1.

  • Page 68: Piston, Connecting Rod, Crankshaft And Crankcase

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE 12 Nm (1.2 m · kg, 8.7 ft · lb) 7CF30120E Order Job name Q’ty Remarks Piston, connecting rod, crankshaft Remove the parts in the order listed and crankcase removal below.

  • Page 69: Cylinder Inspection

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE CYLINDER INSPECTION 1. Measure: 9 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 70 PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE 2. Measure: 9 Piston clearance Out of specifications → Rebore or replace cylinder and replace piston and piston rings. Piston clearance: 0.015 ~ 0.040 mm (0.0006 ~ 0.00157 in) Piston clearance = Cylinder inside diameter - Piston skirt diameter 3.

  • Page 71: Piston Ring Inspection

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE PISTON RING INSPECTION 1. Measure: 9 Piston ring end gap Out of specification → Replace. NOTE: Insert the piston ring 1 into the cylinder, and push it approximately a 5 mm (0.2 in) into the cylinder.

  • Page 72: Crankshaft Inspection

    PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE CRANKSHAFT INSPECTION 1. Measure: 9 Crankshaft runout limit use a dial gauge Out of specification → Replace. Runout limit: 0.04 mm (0.0016 in) SVU3670 2. Inspect: 9 Crankshaft sprocket 1 Crack/damage/wear → Replace the crankshaft.

  • Page 73: Piston And Piston Ring Installation

    9 Piston pin 2 9 Piston pin circlip 3 SCF3730 NOTE: 9 Make sure that the “YAMAHA” mark a on the connecting rod faces toward the crank- case cover. 9 Make sure that the “∇” mark b on the pis- ton head faces toward the push rod.

  • Page 74: Crankshaft Assembly

    NOTE: mark a on the Make sure that the “∇” pis-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: 9 Crankshaft 9 Connecting rod cap 12 Nm (1.2 m ·...

  • Page 76: Chapter 4. Carburetor

    CARB CARBURETOR CARBURETOR CARBURETOR 1 Nm (0.1 m · kg, 0.7 ft · lb) 3 Nm (0.3 m · kg, 2.2 ft · lb) 7CF4010E Order Job name Q’ty Remarks Carburetor removal Remove the parts in the order listed below. Rear cover and right side cover Refer to “COVERS”...

  • Page 77: Carburetor Disassembly

    CARB CARBURETOR CARBURETOR DISASSEMBLY 2 Nm (0.2 m · kg, 1.4 ft · lb) 2 Nm (0.2 m · kg, 1.4 ft · lb) 1 Nm (0.1 m · kg, 0.7 ft · lb) 2 Nm (0.2 m · kg, 1.4 ft · lb) 1 Nm (0.1 m ·...
  • Page 78 CARB CARBURETOR 2 Nm (0.2 m · kg, 1.4 ft · lb) 2 Nm (0.2 m · kg, 1.4 ft · lb) 1 Nm (0.1 m · kg, 0.7 ft · lb) 2 Nm (0.2 m · kg, 1.4 ft · lb) 1 Nm (0.1 m ·...

  • Page 79: Float Height Inspection

    CARB CARBURETOR FLOAT HEIGHT INSPECTION 1. Measure: 9 Float height Out of specification → Replace. NOTE: 9 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 mea- surement should be made with the gasket removed.) 9 Do not adjustable the float height.

  • Page 80: Throttle Control Motor

    CARB CARBURETOR THROTTLE CONTROL MOTOR 1. Install: 9 Throttle control motor 1 NOTE: 9 Install the shaft a of the throttle control motor by aligning it with the groove b of the throttle shaft. 9 Install the throttle valve, and then make sure that is moves smoothly.

  • Page 82: Chapter 5. Electrical

    ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 Engine switch 2 Speed limiter 3 Oil warning light (Red) 4 Pilot light (Green) 5 Overload warning light (Red) 6 AC receptacle 7 DC circuit breaker 8 DC receptacle 9 Ground terminal 0 TCI unit q Control unit assembly w Rectifier e Generator assembly...
  • Page 83 ELEC CIRCUIT DIAGRAM...

  • Page 84: Circuit Diagram

    ELEC CIRCUIT DIAGRAM...
  • Page 85 ELEC CIRCUIT DIAGRAM...

  • Page 86: 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: 9 Set the pocket tester to “0” before starting a test.

  • Page 87: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING CHART NO SPARK OR WEAK SPARK Inspection steps: 1. Spark plug 6. Engine switch 2. Ignition spark gap 7. Oil level switch 3. Spark plug cap 8. Wire harness 4. Ignition coil resistance 5. Air gap NOTE: 9 Remove the following part(s) before troubleshooting.
  • Page 88 ELEC IGNITION SYSTEM Minimum spark gap: 6 mm (0.24 in) OUT OF MEETS SPECIFICATION SPECIFICATION OR NO SPARK The ignition system is good. 3. Spark plug cap NOTE: 9 Remove the spark plug cap. 9 Do not pull out the plug cap from the high- 9 Connect the pocket tester (Ω...
  • Page 89 ELEC IGNITION SYSTEM 2) Secondary coil resistance 9 Connect the pocket tester (Ω × 1k) to the secondary terminal. Tester (+) lead → High-tension cord 1 Tester (–) lead → Ground terminal 2 Secondary coil resistance: 6.8 kΩ Ω ± 20% at 20 °C (68 °F) OUT OF MEETS SPECIFICATION...
  • Page 90 ELEC IGNITION SYSTEM å ∫ 7. Oil level switch 9 Remove the oil level switch from the bottom of the crankcase. Refer to “CRANKSHAFT2, CAMSHAFT AND ROCKER ARM” in CHAPTER 3. 9 Connect the pocket tester to the oil level switch for continuity.

  • Page 91: Generator System

    ELEC GENERATOR SYSTEM GENERATOR SYSTEM TROUBLESHOOTING CHART WEAK OR NO AC CURRENT Start the engine. Check the overload warning light. Check the overload warning light. LIGHT ON DOES NOT LIGHT ON DOES NOT LIGHT ON LIGHT ON Start the engine. Check the pilot light.
  • Page 92 ELEC GENERATOR SYSTEM Magnetic force is weak. Sub coil AC voltage inspection 9 Connect the White leads of the sub coil 1. 9 Start the engine, then measure the voltage. (Tester Replace the magneto rotor. range: AC120V) Sub coil resistance inspection 9 Stop the engine.
  • Page 93 ELEC GENERATOR SYSTEM TROUBLESHOOTING CHART WEAK OR NO DC CURRENT No load engine speed inspection. 9 Operate the engine with no load. Check the throttle control system. Refer to “THROTTLE CONTROL SYSTEM” in 2,600 r/min CHAPTER 6. GOOD OUT OF SPECIFICATION Check the DC circuit breaker.

  • Page 94: Troubleshooting

    TRBL ENGINE TROUBLE SHOOTING ENGINE ENGINE DOES NOT START Check connections between oil warning unit Replace oil Check that the oil warn- and oil level switch. warning ing light turns ON by GOOD NO GOOD light, oil pulling the starter rope. warning DOSE NOT LIGHT ON...
  • Page 95 TRBL ENGINE Check carburetor clogged passages or fuel overflow. GOOD NOT GOOD Replace. Measure valve clear- ance. OUT OF Adjust. GOOD SPECIFICATION Check compression using compression gauge. OUT OF GOOD SPECIFICATION Check valve face and valve seat for wear. Resurface GOOD WEAR or replace.
  • Page 96 TRBL ENGINE 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. 9 Tighten the 9 Check carburetor carburetor retaining nuts...
  • Page 97 TRBL ENGINE ENGINE SPEED DOES NOT INCREASE Check if the electric equipment consumes too much wattage for this generator. Use a generator with a larger capacity. GOOD TOO MUCH Check air filter element for dirt. GOOD NO GOOD Clean. Check spark plug for dirt and check spark plug gap. GOOD NO GOOD Clean or adjust.
  • Page 98 TRBL ENGINE ENGINE SPEED IS UNEVEN Check fuel level. Add. SUFFICIENT INSUFFICIENT Check if fuel is deteriorated. GOOD NO GOOD Replace fuel. Check if fuel tank cap is clogged. GOOD NO GOOD Replace. Check if fuel cock is clogged. GOOD NO GOOD Clean.

  • Page 99: Throttle Control System

    TRBL THROTTLE CONTROL SYSTEM THROTTLE CONTROL SYSTEM ENGINE DOES NOT START, ENGINE STARTS BUT STALLS, ENGINE SPEED DOES NOT INCREASE, OR ENGINE SPEED IS UNEVEN. Check AC output. Refer to “GENERATOR SYSTEM” in GOOD NO GOOD CHAPTER 5. Rotate the shaft of the throttle control motor to check if it turns smoothly with slight resistance.

  • Page 100: Chapter 7. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS å Unit EF2400iS ∫ Model code number 7CF2/7CF3 ç Dimensions: ∂ Overall length mm (in) 527 (20.7) ´ Overall width mm (in) 419 (16.5) ƒ Overall height mm (in) 461 (18.1) © Dry weight kg (lb) 33 (72.8) (For GERMANY)
  • Page 101 SPEC GENERAL SPECIFICATIONS å Unit EF2400iS ∫ Frequency variation ç Instantaneous ∂ Less than 1 % ´ Settling ƒ Less than 0.1 % © Settling time ˙ Less than 1 sec ˆ Voltage fluctuation ∆ Instantaneous ˚ Less than 20 % ¬...

  • Page 102: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE å Unit ∫ Standard ç Limit ∂ Piston: mm (in) ´ Piston clearance 0.015 ~ 0.040 (0.0006 ∼ 0.0016) 0.1 (0.004) ƒ Piston skirt “ D ” 66.0 (2.598) 65.9 (2.594) © Measuring point “ H ” •••...
  • Page 103 SPEC MAINTENANCE SPECIFICATIONS å Unit ∫ Standard ç Limit ∂ Camshaft: mm (in) ´ Camshaft outside diameter ƒ Cam dimension “ A ” 26.9 ±0.05 26.68 ±0.05 (1.06 ±0.002) (1.05 ±0.002) “ B ” 22.0 ±0.05 22.03 ±0.05 (0.87 ±0.002) (0.87 ±0.002) ©...
  • Page 104 SPEC MAINTENANCE SPECIFICATIONS å Unit ∫ Standard ç Limit ∂ Carburetor: mm (in) ´ Type / manufacture ••• BV20-15 / MIKUNI ••• ƒ I.D.mark 7CF 10 ••• © Bore size Ø 15 (0.5906) ••• ˙ Main jet #86.3 ••• ˆ Main air jet Ø...

  • Page 105: Generator And Electrical

    SPEC MAINTENANCE SPECIFICATIONS GENERATOR AND ELECTRICAL å Unit ∫ Standard ç Limit ∂ Generator: ••• ´ Main coil AC voltage (3 phase) (V/r/min) 175 ~ 225 / 2,600 ƒ (With the throttle control motor coupler disconnected) ••• © Sub coil AC voltage (single phase) (V/r/min) 13.0 ~ 18.0 / 2,600 ˙...

  • Page 106: Tightening Torque

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE Tightening torque å Item ∫ Thread size ç 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) M7 × 1.0 ƒ Connecting rod cap 12 (1.2, 8.7) M5 ×...

  • Page 107: General Torque Specifications

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

  • Page 108: Lubrication Point And Type Of Lubricants

    SPEC LUBRICATION POINT AND TYPE OF LUBRICANTS LUBRICATION POINT AND TYPE OF LUBRICANTS å Part name ∫ Type of lubricants ç Oil seal lip (All) ∂ Lithium-soap base grease ´ Connecting rod big end ƒ Engine oil © Crank pin ˙...

  • Page 109: Wire Routing Diagram

    SPEC WIRE ROUTING DIAGRAM WIRE ROUTING DIAGRAM CONTROL BOX PANEL AND BEHIND CONTROL BOX 1 Engine switch å Clamp with white tape. COLOR CODE 2 DC switch (NFB) ∫ Be sure to fully pushed, when B ..Black 3 Oil warning light (Red) Br ..Brown install the choke cable to the 4 Pilot light (Green)
  • Page 110 SPEC WIRE ROUTING DIAGRAM 1 Engine switch å Clamp with white tape. COLOR CODE 2 Oil warning light (Red) ∫ Be sure to fully pushed, when B ..Black 3 Pilot light (Green) Br ..Brown install the choke cable to the 4 DC circuit breaker G..Green carburetor.
  • Page 111 SPEC WIRE ROUTING DIAGRAM 1 Engine switch å Clamp with white tape. COLOR CODE 2 Oil warning light (Red) ∫ Be sure to fully pushed, when B ..Black 3 Pilot light (Green) Br ..Brown install the choke cable to the 4 DC circuit braker G..Green carburetor.
  • Page 112 SPEC WIRE ROUTING DIAGRAM 1 Engine switch å Clamp with white tape. COLOR CODE 2 Oil warning light (Red) ∫ Be sure to fully pushed, when B ..Black 3 Pilot light (Green) Br ..Brown install the choke cable to the 4 DC circuit braker G..Green carburetor.

  • Page 113: Engine And Generator

    SPEC WIRE ROUTING DIAGRAM ENGINE AND GENERATOR å Install the ground lead as shown in illustration 45°. 1 Control unit 2 Throttle control motor lead 3 Throttle control motor 4 TCI unit lead 5 Stator coil lead 6 Control unit lead 7 Rectifier 8 Noise filter (For GERMANY) å...
  • Page 114 SPEC WIRE ROUTING DIAGRAM 1 Control unit å Pass through the throttle control motor lead under 2 Throttle control motor lead the Red and Brown lead. 3 Throttle control motor ∫ To throttle control motor. 4 Oil level gauge lead ç...
  • Page 115 SPEC WIRE ROUTING DIAGRAM 1 Throttle control motor å Put in completely the cable cap to the clamp. 2 Clamp ∫ Be sure to fully-pushed position, when install the 3 Choke cable choke cable to the carburetor. 4 Choke knob ç...
  • Page 116 SPEC WIRE ROUTING DIAGRAM 1 Spark plug cap å Install the plug cap as shown. 2 Oil level gauge lead ∫ Pass through the hole on the crankcase. 3 TCI unit lead ç Through out the hole on the crank case. 4 Fan case ∂...
  • Page 117 SPEC WIRE ROUTING DIAGRAM 1 Carburetor assembly å Install the fuel hose, visible the white paint on the 2 Air vent hose fuel hose between the fan case and air cleaner. 3 Fuel hose ∫ Pass the air vent hose onto the fuel hose. 4 Air cleaner case ç...
  • Page 120 YAMAHA MOTOR CO.,LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2005. 06 x 1...

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