Yamaha EF2800i - Inverter Generator User manual

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

FOREWORD
This manual was written by the Yamaha Motor
Company 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 under-
standing of the mechanical precepts and pro-
cedures 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 Company Ltd. is continually
striving to further improve all models manufac-
tured 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.
NOTE:
This Service Manual contains information
regarding periodic maintenance to the emis-
sion control system. Please read this material
carefully.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT
INFORMATION
This material is distinguished by the following
notation.
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
MANUAL FORMAT
The procedures in this manual are organized
in a sequential, step-by-step format. The infor-
mation has been compiled to provide the
mechanic with an easy to read, handy refer-
ence that contains comprehensive explana-
tions of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty
component will precede an arrow symbol and
the course of action required will follow the
symbol, e.g.,
•Bearings
Pitting/damage →Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams
before each disassembly section for ease in
identifying the correct disassembly and
assembly procedures.
EF2800i
SERVICE MANUAL
©2000 by Yamaha Motor
Corporation, U.S.A.
1st Edition, November 2000
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor
Corporation, U.S.A.
is expressly prohibited.
Printed in USA
LIT-19616-00-92
WARNING
CAUTION:

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1through 5are designed
as thumb tabs to indicate the chapter’s number
and content.
1General information
2Periodic inspections and adjustments
3Engine
4Electrical
5Specifications
Illustrated symbols 6through Bare used to
identify the specific tools and test equipment.
6Filling fluid
7Lubricant
8Special tool
9Tightening
0Wear limit, clearance
AEngine speed
BΩ, V, A
Illustrated symbols Cthrough Kin the
exploded diagram indicate the grades of lubri-
cant and the locations of the lubrication points.
CApply engine oil
DApply gear oil
EApply molybdenum disulfide oil
FApply wheel bearing grease
GApply lightweight lithium-soap base grease
HApply molybdenum disulfide grease
IApply a locking agent (LOCTITE®)
JApply Yamaha bond
KUse a new one
12
34
5
67
89
0A
B
CDE
FGH
IJK
GEN
INFO INSP
ADJ
ENG –+
ELEC
SPEC
T
R
.
.
EGM
BLS M
LT 4New

INDEX
GENERAL INFORMATION GEN
INFO 1
PERIODIC INSPECTIONS
AND ADJUSTMENTS INSP
ADJ 2
ENGINE ENG 3
ELECTRICAL ELEC 4
SPECIFICATIONS SPEC 5
–+

CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ....................1-1
SERIAL NUMBER ...............................1-1
STARTING SERIAL NUMBER ............1-1
IMPORTANT INFORMATION ..................1-2
PREPARATION FOR REMOVAL AND
DISASSEMBLY
CAUTION ON SERVICE .....................1-2
NOTES ON SERVICE .........................1-2
ALL REPLACEMENT PARTS .............1-3
GASKETS, OIL SEALS,
AND O-RINGS .....................................1-3
BEARINGS AND OIL SEALS ..............1-3
SPECIAL TOOLS AND TESTERS ...........1-4
CHAPTER 2.
PERIODIC INSPECTIONS AND
ADJUSTMENTS
INTRODUCTION .......................................2-1
MAINTENANCE INTERVALS CHART .....2-1
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS ....................2-1
ENGINE ....................................................2-2
ENGINE OIL LEAKAGE
CHECKING ..........................................2-2
OIL LEVEL CHECKING .......................2-2
OIL REPLACEMENT ...........................2-3
FUEL LEAKAGE ..................................2-4
FUEL COCK STRAINER
INSPECTION .......................................2-4
FUEL TANK FILTER ...........................2-5
AIR FILTER ELEMENT .......................2-6
MUFFLER ............................................2-7
VALVE CLEARANCE
ADJUSTMENT ....................................2-8
COMPRESSION PRESSURE ...........2-10
RATED ENGINE SPEED ..................2-11
BREATHER HOSE ............................2-11
ELECTRICAL ......................................... 2-12
SPARK PLUG ................................... 2-12
ENGINE SWITCH ............................. 2-13
ECONOMY SWITCH ........................ 2-13
PILOT LIGHT .................................... 2-13
RECEPTACLE .................................. 2-14
DC CIRCUIT BREAKER ................... 2-14
CHAPTER 3.
ENGINE
CONTROL PANEL ................................... 3-1
CONTROL BOX COVER AND
FUEL TANK ............................................. 3-3
MUFFLER AND AIR CLEANER .............. 3-4
BREATHER HOSE INSTALLATION ... 3-5
MUFFLER ASSEMBLY ....................... 3-5
CONTROL UNIT AND AC-CDI UNIT ....... 3-6
ENGINE .................................................... 3-7
CYLINDER HEAD COVER
AND CYLINDER HEAD ........................... 3-8
PUSH ROD INSPECTION ................ 3-10
CYLINDER HEAD INSPECTION ...... 3-10
CYLINDER HEAD ASSEMBLY ......... 3-11
BREATHER HOSE ASSEMBLY ....... 3-11
VALVE .................................................... 3-12
VALVE AND VALVE SPRING
REMOVAL ......................................... 3-13
VALVE AND VALVE SPRING
INSPECTION .................................... 3-13
VALVE AND VALVE SPRING
REMOVAL ......................................... 3-14
LOCKER ARM INSPECTION ........... 3-14
VALVE SEAT INSPECTION ............. 3-15
VALVE LAPPING .............................. 3-16
VALVE AND VALVE SPRING
ASSEMBLY ....................................... 3-17
RECOIL STARTER ................................ 3-18
RECOIL STARTER
DISASSEMBLY ................................. 3-20
RECOIL STARTER INSPECTION .... 3-20
RECOIL STARTER ASSEMBLY ....... 3-21

GENERATOR .........................................3-23
MAGNETO ROTOR AND STATOR
COIL ASSEMBLY REMOVAL ...........3-25
MAGNETO ROTOR AND STATOR
COIL ASSEMBLY INSTALLATION ...3-26
CRANKCASE COVER AND
CAMSHAFT ............................................3-28
CAMSHAFT INSPECTION ................3-29
VALVE LIFTER INSPECTION ...........3-30
CAMSHAFT ASSEMBLY ..................3-30
CRANKCASE COVER
INSPECTION .....................................3-30
CRANKCASE COVER
INSTALLATION .................................3-30
PISTON, CONNECTING ROD,
CRANKSHAFT AND CRANKCASE ......3-31
CRANKCASE (CYLINDER)
INSPECTION .....................................3-32
PISTON AND PISTON PIN
INSPECTION .....................................3-32
PISTON RING INSPECTION ............3-34
CRANKSHAFT INSPECTION ...........3-34
CONNECTING ROD OIL CLEARANCE IN-
SPECTION ........................................3-35
PISTON RING AND PISTON
ASSEMBLY .......................................3-36
CRANKSHAFT ASSEMBLY ..............3-37
CARBURETOR .......................................3-38
FLOAT HEIGHT INSPECTION .........3-40
CHOKE CABLE INSTALLATION ......3-41
THROTTLE CONTROL MOTOR .......3-41
TROUBLESHOOTING ............................3-42
THROTTLE CONTROL SYSTEM .....3-48
CHAPTER 4.
ELECTRICAL
ELECTRICAL COMPONENTS .................4-1
CIRCUIT DIAGRAM .................................4-2
SWITCHES ...............................................4-3
CHECKING SWITCH CONTINUITY ...4-3
IGNITION SYSTEM .................................. 4-4
TROUBLESHOOTING CHART ........... 4-4
GENERATOR SYSTEM ........................... 4-9
TROUBLESHOOTING CHART ........... 4-9
CHARGING SYSTEM ............................ 4-11
TROUBLESHOOTING ...................... 4-11
CHAPTER 5.
SPECIFICATIONS
GENERAL SPECIFICATIONS ................. 5-1
MAINTENANCE SPECIFICATIONS ........ 5-3
ENGINE .............................................. 5-3
GENERATOR AND ELECTRICAL ...... 5-6
TIGHTENING TORQUE ........................... 5-7
GENERAL TORQUE
SPECIFICATIONS ................................... 5-8
DEFINITION OF UNITS ........................... 5-8
WIRE ROUTING DIAGRAM ..................... 5-9
CONTROL BOX PANEL
AND BEHIND CONTROL BOX ........... 5-9
ENGINE AND GENERATOR ............ 5-10

1-1
GEN
INFO
MACHINE IDENTIFICATION
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.
SVU1010
SVU1020
STARTING SERIAL NUMBER
7VU-200101~
NOTE:
Designs and specifications are subject to
change without notice.
1

1-2
GEN
INFO
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
CAUTION ON SERVICE
1. Fire prevention
When servicing the engine, always keep the engine and yourself
away from fire.
SVU1030
NOTES ON SERVICE
1. Correct tools
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.
SVU1060
4. 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.
SVU1070
5. Notes on disassembly and assembly
a. Parts should be cleaned in solvent and blown dry with com-
pressed air after disassembly.
SVU1080
SVU1090
b. Contact surfaces of moving parts should be oiled when reas-
sembled.
c. Make sure that the parts, move smoothly after each section of
the machine is assembled.
SVU1100
IMPORTANT INFORMATION

1-3
GEN
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. All gaskets surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly.
Apply grease to the oil seal lips.
BEARINGS AND OIL SEALS
Install the bearing(s) 1and oil seal(s) 2with their manufacture’s
marks or numbers facing outward. (In other words, the stamped let-
ters must be on the side exposed to view.) When installing oil
seal(s), apply a light coating of light-weight lithium base grease to
the seal lip(s). Oil the bearings liberally when installing.
CAUTION:
Do not use compressed air to spin the bearings dry. This
causes damage to the bearing surfaces.
SVU1110
SVU1120
IMPORTANT INFORMATION

1-4
GEN
INFO
SPECIAL TOOLS AND TESTERS
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.
1. Piston ring compressor
P/N. YU-33294, 90890-05158
This tool is used to compress the piston rings when installing the
piston.
SVU1130
2. Valve spring compressor
P/N. YM-01253, 90890-01253
This tool is used to remove the valve springs.
SVU1140
3. Thickness gauge
P/N. YU-26900-9, 90890-03079
This gauge is used to adjust valve clearance, piston clearance
and piston ring end gap.
SVU1150
4. Cylinder gauge
Commercially obtainable
This instrument is used for checking cylinder bore size and con-
dition.
SVU1160
5. Inductive tachometer
P/N. YU-8036-A
Engine tachometer
P/N. 90890-03113
This instrument is used for reading engine r/min.
SVU1170
6. Compression gauge 1
P/N. YU-33223, 90890-03081
Adapter 2
P/N. YU-33223-3, 90890-04082
This gauge is used for checking engine compression.
SVU1180
7. Dial gauge
P/N. YU-03097, 90890-03097
This instrument is used for checking crankshaft side clearance.
SVU1190

1-5
GEN
INFO
SPECIAL TOOLS AND TESTERS
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
1P/N. YU-33270
2P/N. 90890-01362
This tool is necessary for removing the flywheel.
SVU1210
1
SVU1220
2
11.Pocket tester
P/N. YU-03112, 90890-03112
This instrument is necessary for checking the electrical system.
SVU1230
12.Dynamic spark tester 1
P/N. YM-34487
Ignition checker 2
P/N. 90890-06754
This instrument is necessary for checking the ignition system
components.
SVU1240
1
SVU1250
2

2-1
INSP
ADJ
INTRODUCTION/MAINTENANCE INTERVALS CHART/
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. 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 cleaner air but are also vital
to proper engine operation and maximum performance. In the following maintenance tables, the
services related to emissions control are indicated as “*” in the chart.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
*: Related to emission control system.
Item Remarks Pre-Opera- tion check
(daily)
Initial Every
1monthor
20 Hr 3 months or 50 Hr 6 months or 100 Hr 12months or 300 Hr
*Spark plug Check condition, adjust gap and clean.
Replace if necessary. ●
*Valve clearance Check and adjust when engine is cold. ●
*Crankcase breather
system Check breather hose for cracks or damage. Replace if necessary. ●
*Idle speed Check and adjust engine idle speed. ●
*Exhaust system
Check for leakage.
Retighten or replace gasket if necessary. ●
Check muffler screen and spark arrester.
Clean/replace if necessary. ●
Engine oil Check oil level. ●
Replace. ●●
*Air filter Clean. Replace if necessary. ●
Fuel filter Clean fuel cock and fuel tank filter.
Replace if necessary. ●
Fuel line Check fuel hose for cracks or damage.
Replace if necessary. ●
*Choke knob Check choke operation. ●
Cooling system Check for fan damage. ●
Starting system Check recoil starter operation. ●
*Decarbonization More frequently if necessary. ●
Fittings/fasteners Check all fittings and fasteners.
Correct if necessary. ●

2-2
INSP
ADJ
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
1. Check:
• Oil level with oil warning light 1
Check whether the oil warning light
flashes by operating the recoil starter.
Oil warning light flashes →Add oil.
Oil warning light does not flash →OK
ECON.
SW
AC OVER
LOAD
BATTERY
CHARGE
ONLY
12V10A
RESET 20A
OFF
DC
PROTECTOR
DC
1
SVU2020
2. Remove:
• Oil filler cap 1
3. Check:
• Check that the engine oil is at the spec-
ified level a.
Oil level checking steps:
• Place the engine on a level surface.
• Warm up the engine for several minutes.
• Stop the engine.
• Check that the engine oil is at the specified
level a. Add oil if necessary.
4. Install:
• Oil filler cap
SVU2030
ENGINE OIL LEAKAGE CHECKING/
OIL LEVEL CHECKING
2

2-3
INSP
ADJ
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:
• Oil drain bolt 1
T
R
.
.
Oil drain bolt:
17 Nm (1.7 m · kg, 12 ft · lb)
SVU2040
7. Remove:
• Oil filler cap 1
8. Fill:
NOTE:
Recommended engine oil classification:
API Service “SE” or “SF”, if not available, “SD”.
Recommended oil:
ÈYAMALUBE 4 (10W-30) or SAE
10W-30 type SE
ÉSAE #30
ÊSAE #20
ËSAE 10W
Engine oil quantity:
0.6 L (0.53 Imp qt, 0.63 US qt)
SVU2050
SVU2060
9. Install:
• Oil filler cap
OIL REPLACEMENT

2-4
INSP
ADJ
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” aposi-
tion, detach the strainer cup, and then
remove the debris from inside the cup.
2. Remove:
• Fuel cock cup 1
• Gasket 2
•Strainer
3
3. Inspect:
• Fuel cock cup
Dirt/debris →Clean.
• Gasket 2
Damage →Replace.
•Strainer
3
Dirt/debris→Clean.
NOTE:
Clean the cup with solvent, and then dry it
thoroughly.
SVU2080
4. Install:
•Strainer
• Gasket
• Fuel cock cup
CAUTION:
Securely install the strainer cup to prevent
fuel leaks.
T
R
.
.
Fuel cock cup:
1.3 Nm (0.13 m · kg, 0.94 ft · lb)
FUEL LEAKAGE/
FUEL COCK STRAINER INSPECTION

2-5
INSP
ADJ
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. Inspect:
• Fuel tank filter
Damage →Replace.
3. Clean:
• Fuel tank filter
NOTE:
Clean the fuel tank filter with solvent, and then
dry it thoroughly.
4. Install:
• Fuel tank filter
• Fuel tank cap
WARNING
Be sure the tank cap is tightened securely.
SVU2090
FUEL TANK FILTER

2-6
INSP
ADJ
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.
Oil the element and squeeze out the
excess oil.
CAUTION:
• Do not wring out the element: this could
cause it to tear.
• Do not wash the element in gasoline or in
acidic, alkalinic, or organic solvents.
SVU2120
4. Install:
• Air filter element
• Air filter case cover
•Screws
CAUTION:
The engine should never run without the
element, otherwise excessive piston and/or
cylinder wear may result.
AIR FILTER ELEMENT

2-7
INSP
ADJ
MUFFLER
1. Remove:
• Muffler
Refer to “MUFFLER AND AIR
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.
CAUTION:
Don’t use a wire to clean, otherwise the
noise damping material may come out, and
the damping effect may be reduced.
3. Decarbonize:
• Muffler screen
• Spark arrester
4. Install:
• Spark arrester
• Muffler screen
• Muffler cap
• Muffler band
• Muffler
Refer to “MUFFLER AND AIR
CLEANER” in CHAPTER 3.
SVU2140
SVU2150
MUFFLER