Yamaha EF3000iSE - Inverter Generator - 3000 Maximum AC... User manual

SERVICE MANUAL
EF3000iSE
7WL-28197-E0
310140

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.
EF3000iSE
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st Edition, October 2002
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
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
4
New

INDEX
GENERAL
INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE
ELECTRICAL
SPECIFICATIONS

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
(For Canada) ............................................2-1
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS .................... 2-1
COVERS, PANELS, AND CAPS .............. 2-2
ENGINE .................................................... 2-3
ENGINE OIL LEAKAGE CHECKING .. 2-3
OIL LEVEL CHECKING .......................2-3
OIL REPLACEMENT ........................... 2-4
FUEL LEAKAGE .................................. 2-5
FUEL TANK FILTER ........................... 2-6
FUEL PIPE STRAINER ....................... 2-7
AIR FILTER ELEMENT .......................2-8
MUFFLER ............................................2-9
VALVE CLEARANCE
ADJUSTMENT ..................................2-10
AIR GAP BETWEEN TCI UNIT
AND FLYWHEEL MAGNETO ...........2-13
COMPRESSION PRESSURE ...........2-14
ENGINE SPEED (NO LOAD) ............2-16
ECONOMY ENGINE SPEED ............2-16
CHOKE CABLE .................................2-17
BREATHER HOSE ............................2-17
ELECTRICAL ......................................... 2-18
SPARK PLUG ................................... 2-18
MAIN SWITCH .................................. 2-19
ECONOMY SWITCH ........................ 2-20
PILOT LIGHT .................................... 2-20
OVERLOAD WARNING LIGHT ........ 2-20
DC CIRCUIT BREAKER ................... 2-21
DC CIRCUIT BREAKER
(120 V-60 Hz) .................................... 2-21
RECEPTACLE .................................. 2-22
AC SWITCH (NFB)
(120 V-60 Hz/23.5 A) ........................ 2-22
AC SWITCH (NFB)
(120 V-60 Hz/15 A) ........................... 2-23
FUSES .............................................. 2-23
BATTERY .......................................... 2-25
BATTERY TERMINAL ...................... 2-25
BATTERY ELECTROLYTE ............... 2-26
BATTERY CHARGING ..................... 2-29
CHAPTER 3.
ENGINE
PANELS AND COVERS .......................... 3-1
CONTROL PANEL ................................... 3-3
FUEL TANK AND CONTROL BOX ......... 3-5
AIR FILTER ASSEMBLY
AND CONTROL UNIT .............................. 3-7
120 V-60 Hz, 220 V-50 Hz .................. 3-7
AIR FILTER ASSEMBLY, CONTROL UNIT
AND NOISE FILTER ................................ 3-8
230 V-50 Hz ........................................ 3-8
RECOIL STARTER
AND FLYWHEEL MAGNETO .................. 3-9
RECOIL STARTER REMOVAL ........ 3-12
FLYWHEEL MAGNETO
REMOVAL ......................................... 3-12
FLYWHEEL MAGNETO
INSTALLATION ................................. 3-13
RECOIL STARTER
DISASSEMBLY ................................. 3-14
RECOIL STARTER INSPECTION .... 3-14
RECOIL STARTER ASSEMBLY ....... 3-15
ENGINE ASSEMBLY ............................. 3-17
CHASSIS AND CASTERS ..................... 3-18
MUFFLER .............................................. 3-19
MUFFLER INSTALLATION ............... 3-20

GENERATOR .........................................3-21
GENERATOR ASSEMBLY
REMOVAL .........................................3-22
GENERATOR ASSEMBLY
INSTALLATION .................................3-23
CYLINDER HEAD COVER
AND CYLINDER HEAD ..........................3-25
CYLINDER HEAD REMOVAL ...........3-26
PUSH ROD INSPECTION ................. 3-26
CYLINDER HEAD INSPECTION ......3-26
CYLINDER HEAD ASSEMBLY ......... 3-27
BREATHER HOSE ............................3-27
VALVE ....................................................3-28
VALVE AND VALVE SPRING
REMOVAL .........................................3-29
VALVE AND VALVE SPRING
INSPECTION .....................................3-29
LOCKER ARM INSPECTION ............3-30
VALVE SEAT INSPECTION .............. 3-31
VALVE LAPPING .............................. 3-32
VALVE AND VALVE SPRING
ASSEMBLY .......................................3-33
CRANKCASE COVER
AND CAMSHAFT ...................................3-34
CRANKCASE COVER REMOVAL ....3-35
CAMSHAFT INSPECTION ................3-35
VALVE LIFTER INSPECTION ........... 3-36
CAMSHAFT ASSEMBLY .................. 3-36
CRANKCASE COVER
INSPECTION .....................................3-36
CRANKCASE COVER
INSTALLATION .................................3-36
PISTON, CONNECTING ROD,
CRANKSHAFT AND CRANKCASE ...... 3-37
CRANKCASE (CYLINDER)
INSPECTION .....................................3-38
PISTON AND PISTON PIN
INSPECTION .....................................3-38
PISTON RING INSPECTION ............ 3-40
CRANKSHAFT INSPECTION ........... 3-41
CONNECTING ROD OIL
CLEARANCE INSPECTION .............. 3-42
PISTON RING
AND PISTON ASSEMBLY ................3-43
CRANKSHAFT ASSEMBLY ..............3-44
CARBURETOR ...................................... 3-45
FLOAT HEIGHT INSPECTION ......... 3-49
CHOKE CABLE INSTALLATION ...... 3-50
THROTTLE CONTROL MOTOR ...... 3-50
TROUBLESHOOTING ........................... 3-51
THROTTLE CONTROL SYSTEM ..... 3-56
CHAPTER 4.
ELECTRICAL
ELECTRICAL COMPONENTS ................ 4-1
120 V-60 Hz ........................................ 4-1
220 V-50 Hz ........................................ 4-2
230 V-50 Hz ........................................ 4-3
SWITCHES ............................................... 4-4
CHECKING SWITCH CONTINUITY ... 4-4
IGNITION SYSTEM .................................. 4-5
TROUBLESHOOTING CHART ........... 4-5
ELECTRIC STARTING SYSTEM ........... 4-11
TROUBLESHOOTING CHART ......... 4-11
STARTER MOTOR ........................... 4-14
CHARGING SYSTEM ............................ 4-17
TROUBLESHOOTING CHART ......... 4-17
GENERATOR SYSTEM ......................... 4-20
TROUBLESHOOTING CHART ......... 4-20
CHAPTER 5.
SPECIFICATIONS
GENERAL SPECIFICATIONS ................. 5-1
MAINTENANCE SPECIFICATIONS ........ 5-4
ENGINE .............................................. 5-4
GENERATOR AND ELECTRICAL ...... 5-7
LUBRICATION POINTS
AND LUBRICANT TYPES ....................... 5-8
TIGHTENING TORQUE ........................... 5-9
GENERAL TORQUE
SPECIFICATIONS ................................. 5-11
DEFINITION OF UNITS ......................... 5-11
WIRE ROUTING DIAGRAM ................... 5-12

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.
1
SWL1010T
SWL1020J
STARTING SERIAL NUMBER
NOTE:
Designs and specifications are subject to
change without notice.
Model Code Starting serial
number
120 V-60 Hz 7WL2 7WL-220101~
220 V-50 Hz 7WL3 7WL-330101~
230 V-50 Hz 7WL3 7WL-300101~
230 V-50 Hz 7WL3 7WL-350101~

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. The shape and part number used for the special tool
differ by country, so two types are provided. Refer to the list pro-
vided to avoid errors when placing an order.
NOTE:
•For USA and Canada, use part number starting with “YM-”, “YU-”
or “YS-”.
•For others, use part number starting with “90890-”.
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 available
This instrument is used for checking cylinder bore size and con-
dition.
SVU1160

1-5
GEN
INFO
SPECIAL TOOLS AND TESTERS
5. Inductive self-powered tachometer
1P/N. YU-8036-B
Engine tachometer
2P/N. 90890-03113
3P/N. 90793-80009
4P/N. 90793-80032
This instrument is used for reading engine r/min.
SWL1010
1
2
SWL1020
3
SWL1040
4
SWL1050
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
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-A, 90890-01701
This tool is necessary for holding the flywheel or rotor.
SVU1205

1-6
GEN
INFO
10.Rotor assembly holder
Commercially available
This tool is necessary for holding the rotor.
SWL1030
11.Rotor puller
1P/N. YU-33270-B
2P/N. 90890-01362
This tool is necessary for removing the flywheel.
SVU1210
1
SVU1220
2
12.Pocket tester
P/N. YU-03112-C, 90890-03112
This instrument is necessary for checking the electrical system.
SVU1230
13.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
14.MF Battery charging
Commercially available
This instrument is necessary for charging the electrical system.
SWL1060
SPECIAL TOOLS AND TESTERS

2-1
INSP
ADJ
INTRODUCTION/MAINTENANCE INTERVALS CHART (For Canada)/
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 (For Canada)
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.
ÈÉÊËÌÍ
Î
Item Remarks
Pre-Opera-
tion check
(daily)
Initial
1 month
or 20 Hr
Every
3 months
or 50 Hr
Every
6 months
or 100 Hr
Every
12 months
or 300 Hr
Ï*Spark Plug Check condition. Adjust gap and clean.
Replace if necessary. ●
Ð*Valve Clearance Check and adjust when engine is cold. ●
Ñ*Crankcase breather
system
Check breather hose for cracks or damage.
Replace if necessary. ●
Ò*Idle speed Check and adjust engine idle speed. ●
Ó*Exhaust System
ÔCheck for leakage.
Retighten or replace gasket if necessary. ●
ÕCheck muffler screen and spark arrester.
Clean/replace if necessary. ●
ÖEngine Oil
×Check oil level. ●
ØReplace. ●●
Ù*Air Filter Clean.
Replace if necessary. ●
ÚFuel Filter Clean fuel tank filter.
Replace if necessary. ●
ÛFuel Line Check fuel hose for crack or damage. Replace
if necessary. ●
Ü*Choke knob Check choke operation. ●
ÝCooling System Check for fan damage. ●
ÞStarting System
ßCheck recoil starter operation. ●
ÀCheck electric starter operation. ●
Á*Decarbonization More frequently if necessary. ●
+Generation Check the pilot light comes on. ●
,Fittings/Fasteners Check all fittings and fasteners.
Correct if necessary. ●

2-2
INSP
ADJ
COVERS, PANELS, AND CAPS
COVERS, PANELS, AND CAPS
NOTE:
•The EF3000iSE are equipped with soundproof covers and panels that cover the engine and
frame.
•To make periodic maintenance checks easy, remove the applicable cover or panel.
•For cover or panel removal and installation, refer to “PANELS AND COVERS”in CHAPTER 3.
1Cover 1 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
2Panel 1 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
3Cover 2 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
4Cover 3 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
5Cap 1
6Cap 2
7Panel 2
8Cover 4 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
9Cover 5 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
0Panel 3 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
ABattery bracket 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
BPanel 4
CCover 6 7.0 Nm (0.7 m ·kg, 5.1 ft ·lb)
7
1
2
5
6
9
0
A
B
3
4
8
C
Rear left view
Front right view
SWL2180T

2-3
INSP
ADJ
ENGINE
ENGINE OIL LEAKAGE CHECKING
1. Remove:
•Panel 2
•Panel 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Check the areas outside of the engine for
oil leakage.
Oil leakage →Replace the gasket, oil
seal, or O-ring.
3. Install:
•Panel 4
•Panel 2
Refer to “COVERS, PANELS, AND
CAPS”.
SWL2020J
OIL LEVEL CHECKING
1. Check:
•Oil level with oil level warning light 1
•Set the main switch to “START”“”
or set it to “ON”“”and pull the recoil
starter to check that the oil level warn-
ing light 1flashes.
Oil level warning light flashes →Add
oil.
Oil level warning light does not flash →
OK
2. Remove:
•Panel 2
Refer to “COVERS, PANELS, AND
CAPS”.
•Oil filler cap 1
3. Check:
•Check that the engine oil is at the spec-
ified level a.
Oil level checking steps:
•Place the generator 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.
SWL2010T
1
a
1
SWL2040J
ENGINE OIL LEAKAGE CHECKING/
OIL LEVEL CHECKING

2-4
INSP
ADJ
4. Install:
•Oil filler cap
•Panel 2
Refer to “COVERS, PANELS, AND
CAPS”.
NOTE:
Tighten the oil filler cap securely by hand.
OIL REPLACEMENT
1. Warm up the engine for several minutes.
2. Stop the engine.
3. Remove:
•Panel 2
•Cap 2
•Cap 1
Refer to “COVERS, PANELS, AND
CAPS”.
4. Place a receptacle under the engine.
5. Remove:
•Oil drain bolt 1
6. Tilt the engine to drain the oil completely.
7. Tighten:
•Oil drain bolt
T
R
.
.
Oil drain bolt:
17 Nm (1.7 m ·kg, 12 ft ·lb)
1
SWL2050J
8. Remove:
•Oil filler cap 1
9. 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)
1
SWL2060J
SVU2060
È
OIL LEVEL CHECKING/
OIL REPLACEMENT

2-5
INSP
ADJ
NOTE:
Recommended engine oil classification:
API Service “SE”or “SF”, if not available, “SD”.
ÈFor Canada
ÉExcept for Canada
10.Install:
•Oil filler cap
NOTE:
Tighten the oil filler cap securely by hand.
11.Install:
•Cap 1
•Cap 2
•Panel 2
Refer to “COVERS, PANELS, AND
CAPS”.
Recommended oil:
ÈSAE #30 or 10W-30
or 10W-40
ÉSAE #20 or 10W-30
or 10W-40
ÊSAE 10W or 10W-30
or 10W-40
SAE #40: Above 35 °C (95 °F)
Engine oil quantity:
0.6 L (0.53 Imp qt, 0.63 US qt)
SVW2070T
É
FUEL LEAKAGE
1. Remove:
•Cover 1
•Cover 5
•Cover 4
Refer to “COVERS, PANELS, AND
CAPS”.
2. Remove:
•Fuel tank bolts
Refer to “FUEL TANK AND CONTROL
BOX”in CHAPTER 3.
3. Slide the fuel tank to check for leakage.
CAUTION:
When sliding the fuel tank, be sure not to
extremely bend, twist, or pull the fuel
hoses.
OIL REPLACEMENT/
FUEL LEAKAGE

2-6
INSP
ADJ
4. Check:
•Leakage
Check at fuel tank, fuel cock, fuel
hoses, and carburetor.
CAUTION:
Replace the fuel hoses every four years.
5. Install:
•Fuel tank
Refer to “FUEL TANK AND CONTROL
BOX”in CHAPTER 3.
6. Install:
•Cover 4
•Cover 5
•Cover 1
Refer to “COVERS, PANELS, AND
CAPS”.
SWL2070J
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.
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.
1
2
SVU2080J
FUEL LEAKAGE/
FUEL TANK FILTER

2-7
INSP
ADJ
FUEL PIPE 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.
1. Drain the fuel.
2. Remove:
•Cover 1
•Cover 5
•Cover 4
Refer to “COVERS, PANELS, AND
CAPS”.
3. Remove:
•Fuel hose (fuel cock end)
•Fuel tank
Refer to “FUEL TANK AND CONTROL
BOX”in CHAPTER 3.
4. Remove:
•Fuel hose (fuel tank end)
•Fuel pipe strainer 1
5. Inspect:
•Fuel pipe strainer
Damage →Replace.
6. Clean:
•Fuel pipe strainer
NOTE:
Clean the fuel pipe strainer with solvent, and
then dry it thoroughly.
7. Install:
•Fuel pipe strainer
•Fuel hose (fuel tank end)
8. Install:
•Fuel tank
•Fuel hose (fuel cock end)
Refer to “FUEL TANK AND CONTROL
BOX”in CHAPTER 3.
9. Install:
•Cover 4
•Cover 5
•Cover 1
Refer to “COVERS, PANELS, AND
CAPS”.
1
SWL2080J
FUEL PIPE STRAINER

2-8
INSP
ADJ
AIR FILTER ELEMENT
1. Remove:
•Panel 4
•Cover 5
Refer to “COVERS, PANELS, AND
CAPS”.
2. Remove:
•Hooks 1
•Air filter element case 2
1
2
1
SWL2090J
3. Remove:
•Air filter element 1 1
•Air filter element 2 2
NOTE:
Remove air filter element 1 and air filter ele-
ment 2 as a set.
4. Inspect:
•Air filter elements
Damage →Replace.
5. Clean:
•Air filter element 1
Wash the air filter elements in kero-
sene.
NOTE:
Be sure to squeeze the excess kerosene out of
the air filter element 1.
6. Lubricate:
•Air filter element 1
Soak the air filter element 1 in a 2–4:1
mixture of kerosene and engine oil.
NOTE:
Be sure to squeeze the excess kerosene and
engine oil out of the air filter element 1.
CAUTION:
•Do not twist the air filter elements, other-
wise they can tear.
•Do not wash the air filter elements in gas-
oline or in acid, alkaline, or organic sol-
vents.
7. Install:
•Air filter element 1
•Air filter element 2
NOTE:
Insert air filter element 1 into air filter element
2, and then install them into the air filter case.
2
1
SVU2100J
SWL2110
AIR FILTER ELEMENT