Yamaha EF7000 User manual

SERVICE MANUAL
EF7000
EF7000E
EF7200
EF7200E
EF7200DE
7P6-F8197-E0
2014_05×1 !
7P6-F8197-E0_cover.indd 1 2014/05/29 15:46:41

2
3
5
6
1
8
7
9
9 9 9
9
00
0
q
e
t
y
i
u
o
p
f
d
g
h
j
k
l
;
z
x
c
s
a
w
4
r
1 Generator 2 Rotorassembly 3 Exciterfieldcoil 4 Subcoil 5 Maincoil 6 Statorassembly 7 Controlbox 8 Voltage/hourmeter 9 ACswitch(N.F.B.)
0 ACreceptacle q Engineswitch w Rectifier e Remotecontrolterminal r Fuse t Rectifier/regulator y Voltageadjuster u Condenser
i AVR(AutomaticVoltage
Regulator)
o Oilwarningunit p Economycontrolunit a Oilwarninglight s Economycontrolswitch d Engine f Economycontrolsolenoid g Starterrelay
h Startermotor j Autochoke k Fuelcutsolenoidvalve l Battery ; Chargingcoil z TCIunit x Sparkplug c Oillevelswitch
Color code B   Black Br   Brown G   Green L   Blue Lg  Lightgreen O   Orange R   Red W   White
EF7200DE (CAN)
2014 CIRCUIT DIAGRAM
Y   Yellow B/W Black/White G/R Green/Red G/Y  Green/Yellow L/R  Blue/Red L/W Blue/White R/B  Red/Black R/G Red/Green R/W Red/White
7P6-F8197-E0_cover.indd 2 2014/05/29 15:46:42

FOREWORD
This Service Manual has been prepared to
introduce service procedure and data for the
EF7000/EF7000E/EF7200/EF7200E/
EF7200DE.
For complete information on service proce-
dure of the engine, it is necessary to use fol-
lowing Service Manual:
MZ SERIES ENGINE SERVICE MANUAL:
7VB-F8197-E0
This manual was written by the Yamaha Motor
Powered Products Co., Ltd. primarily for use
by Yamaha dealers and their qualified
mechanics. It is not possible to put an entire
mechanic’s education into one manual, so it is
assumed that persons using this book to per-
form maintenance and repairs on Yamaha
generators have a basic understanding of the
mechanical precepts and procedures inherent
to generator repair technology. Without such
knowledge, attempted repairs or service to
this model may render it unfit for use and/or
unsafe.
Yamaha Motor Powered Products Co., Ltd. is
continually striving to further improve all mod-
els manufactured by Yamaha. Modifications
and significant changes in specifications or
procedures will be forwarded to all Authorized
Yamaha dealers and will, where applicable,
appear in future editions of this manual.
EF7000/EF7000E/EF7200/EF7200E/
EF7200DE
SERVICE MANUAL
©2014 by Yamaha Motor Powered
Products Co., Ltd.
1st Edition, May 2014
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor
Powered Products Co., Ltd.
is expressly prohibited.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT
INFORMATION
Particularly important information is distin-
guished in this manual by the following nota-
tions.
This is the safety alert symbol. It is used to
alert you to potential personal injury haz-
ards. Obey all safety messages that follow
this symbol to avoid possible injury or
death.
WARNING
A WARNING indicates a hazardous situa-
tion which, if not avoided, could result in
death or serious injury.
NOTICE
A NOTICE indicates special precautions
that must be taken to avoid damage to the
machine or other property.
TIP
A TIP provides key information to make proce-
dures easier or clearer.

HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic.
Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check
procedures are laid out with the individual steps in sequential order.
9The manual is divided into chapters and each chapter is divided into sections. The current sec-
tion title is shown at the top of each page 1.
9Sub-section titles appear in smaller print than the section title 2.
9To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section 3.
9Numbers are given in the order of the jobs in the exploded diagram. A number indicates a dis-
assembly step 4.
9Symbols indicate parts to be lubricated or replaced 5.
Refer to “ILLUSTRATED SYMBOLS”.
9A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. 6. This step explains removal procedure only. For installation, reverse
the steps.
9Jobs requiring more information (such as special tools and technical data) are described
sequentially 7.
3-20
ENG
PISTON, CAMSHAFT, CRANKCASE, AND
CRANKSHAFT
1
2
3
3
4
5
6
7
7
8
9
10
20 Nm (2.0 m á kgf, 14 ft á lbf)
Order Job/Parts to remove Q’ty Remarks
Removing the piston, camshaft and
crankshaft
Remove the parts in the order listed.
Crankcase Refer to “CRANKCASE” on 3-18.
1 Balancer shaft 1
2 Camshaft 1
3 Valve lifter 2
4 Connecting rod cap 1
5 Crankshaft 1
6 Connecting rod 1
7 Piston pin circlip 2
8 Piston pin 1
9 Piston 1
10 Piston ring set 1
PISTON, CAMSHAFT AND CRANKSHAFT
3-21
ENG
PISTON, CAMSHAFT, CRANKCASE, AND
CRANKSHAFT
REMOVING THE BALANCER SHAFT,
CAMSHAFT, AND VALVE LIFTER
1. Remove:
9 Balancer shaft 1
TIP
Remove the balancer shaft 1 when the bal-
ancer shaft gear mark a and the crankshaft
gear mark b are aligned.
2. Remove:
9 Camshaft 2
TIP
Remove the camshaft 2 when the camshaft
gear mark c and the crankshaft gear mark d
are aligned.
3. Remove:
9 Intake valve lifter
9 Exhaust valve lifter
CHECKING THE BALANCER SHAFT
1. Check:
9 Balancer gear teeth
9 Balancer shaft
Wear/damage → Replace.
21 b
a
c
d
1
3
4
5
6
7
2

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

INDEX
GENERAL INFORMATION GEN
INFO
PERIODIC CHECKS
AND ADJUSTMENTS CHK
ADJ
ENGINE ENG
CARBURETOR
ELECTRICAL
TROUBLESHOOTING
CARB
ELEC
TRBL
SPECIFICATIONS
SPEC
1
2
3
4
5
6
7

CHAPTER 1.
GENERAL INFORMATION
MODEL VARIATIONS ................................1-1
MACHINE IDENTIFICATION .....................1-2
SERIAL NUMBER ................................1-2
IMPORTANT INFORMATION ....................1-3
PREPARATION FOR REMOVAL
AND DISASSEMBLY CAUTION
ON SERVICE ........................................1-3
NOTES ON SERVICE...........................1-3
ALL REPLACEMENT PARTS ...............1-4
GASKETS, OIL SEALS, AND
O-RINGS ...............................................1-4
BEARINGS AND OIL SEALS ...............1-4
BASIC SERVICE INFORMATION ..............1-5
ELECTRICAL SYSTEM ........................1-5
SPECIAL TOOLS AND TESTERS .............1-8
CHAPTER 2.
PERIODIC CHECKS AND
ADJUSTMENTS
INTRODUCTION ........................................2-1
MAINTENANCE INTERVALS CHART ......2-1
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS ......................2-1
PERIODIC MAINTENANCE ......................2-3
SPARK PLUG .......................................2-3
FUEL LEAKAGE ...................................2-5
ENGINE OIL LEAKAGE .......................2-5
ENGINE OIL LEVEL .............................2-5
REPLACING THE ENGINE OIL ...........2-6
AIR FILTER ELEMENT .........................2-7
MUFFLER .............................................2-8
FUEL TANK FILTER ............................2-10
FUEL COCK STRAINER ....................2-11
BREATHER HOSE..............................2-12
CYLINDER HEAD
DECARBONIZATION ..........................2-12
ADJUSTING THE VALVE
CLEARANCE ......................................2-12
ADJUSTING THE ENGINE SPEED
(Except for EF7000/EF7200) ..............2-15
ADJUSTING THE ENGINE SPEED
(For EF7000/EF7200) .........................2-16
RECOIL STARTER .............................2-17
FITTINGS AND FASTENERS ............2-17
CHAPTER 3.
ENGINE
CONTROL BOX .........................................3-1
EF7200DE ............................................3-1
Except for EF7200DE ...........................3-3
INSTALLING THE CONTROL BOX ......3-5
AIR FILTER ................................................3-6
FUEL TANK, CANISTER ...........................3-7
CHECKING THE CANISTER
(For EF7200DE CAN) ...........................3-9
MUFFLER ................................................3-10
INSTALLING THE MUFFLER .............3-11
ENGINE ....................................................3-12
GENERATOR ...........................................3-13
REMOVING THE STATOR
ASSEMBLY AND ROTOR
ASSEMBLY .........................................3-15
INSTALLING THE STATOR
ASSEMBLY AND ROTOR
ASSEMBLY .........................................3-17
PISTON, CAMSHAFT, CRANKCASE,
AND CRANKSHAFT ................................3-18
CRANKCASE ......................................3-18
PISTON, CAMSHAFT AND
CRANKSHAFT ....................................3-20
REMOVING THE BALANCER
SHAFT, CAMSHAFT, AND VALVE
LIFTER ................................................3-21
CHECKING THE BALANCER
SHAFT ................................................3-21
INSTALLING THE VALVE LIFTER,
BALANCER SHAFT, AND
CAMSHAFT ........................................3-22
INSTALLING THE CRANKCASE
COVER ...............................................3-22

HANDLE AND WHEELS
(FOR EF7200DE CAN) ............................3-23
INSTALLING THE HANDLE ................3-25
INSTALLING THE WHEELS ...............3-28
CHAPTER 4.
CARBURETOR
REMOVING THE CARBURETOR ..............4-1
DISASSEMBLING THE CARBURETOR ...4-3
EF7000/EF7200 ....................................4-3
EF7000E/EF7200E/EF7200DE ............4-5
CHECKING THE FUEL CUT
SOLENOID VALVE ................................4-7
CHAPTER 5.
ELECTRICAL
ELECTRICAL COMPONENTS ..................5-1
EF7000 (CHN) ......................................5-2
EF7000E (CHN) ....................................5-2
EF7200 (SEA/AFR/RUS) ......................5-2
EF7200E (Except for OCE) ..................5-2
EF7200E (OCE) ....................................5-3
EF7200DE (Except for CAN) ................5-3
EF7200DE (CAN) .................................5-3
CIRCUIT DIAGRAM ...................................5-4
EF7000/EF7200 ....................................5-4
EF7000E/EF7200E ...............................5-5
EF7200DE (Except for CAN) ................5-6
EF7200DE (CAN) .................................5-7
CONTROL PANEL .....................................5-8
EF7000/EF7200 ....................................5-8
EF7000E/EF7200E
(Except for OCE) ................................5-10
EF7200E (OCE) ..................................5-12
EF7200DE (Except for CAN) ..............5-14
EF7200DE (CAN) ...............................5-16
BATTERY
(EF7000E/EF7200E/EF7200DE) ..............5-18
CHECKING AND CHARGING THE
BATTERY ............................................5-19
FUSE (EF7000E/EF7200E/EF7200DE) ...5-26
CHECKING THE FUSE ......................5-26
SWITCHES ...............................................5-28
CHECKING THE SWITCH
CONTINUITY .....................................5-28
IGNITION SYSTEM ..................................5-29
TROUBLESHOOTING CHART ...........5-29
ELECTRIC STARTING SYSTEM
(EF7000E/EF7200E/EF7200DE) ..............5-35
TROUBLESHOOTING CHART ...........5-35
REMOVING THE STARTER
MOTOR ...............................................5-37
DISASSEMBLING THE STARTER
MOTOR ...............................................5-38
CHECKING THE BRUSH ...................5-39
ASSEMBLING THE STARTER
MOTOR ...............................................5-39
CHARGING SYSTEM
(EF7000E/EF7200E/EF7200DE) ..............5-40
TROUBLESHOOTING CHART ...........5-40
GENERATOR SYSTEM ...........................5-43
TROUBLESHOOTING CHART ...........5-43
ECONOMY CONTROL SYSTEM
(EF7000E/EF7200E/EF7200DE) ..............5-54
ECONOMY CONTROL SOLENOID ...5-54
INSTALLING THE ECONOMY
CONTROL SOLENOID .......................5-55
ECONOMY CONTROL SYSTEM
DIAGRAM ...........................................5-56
TROUBLESHOOTING CHART ...........5-57
CHAPTER 6.
TROUBLESHOOTING
ENGINE ......................................................6-1
CHAPTER 7.
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................7-1
MAINTENANCE SPECIFICATIONS ..........7-4
ENGINE ................................................7-4
ELECTRICAL ........................................7-7
GENERATOR ........................................7-8

TIGHTENING TORQUES .........................7-10
GENERAL TORQUE
SPECIFICATIONS ....................................7-12
LUBRICATION POINTS AND TYPE OF
LUBRICANTS ..........................................7-13
WIRE ROUTING DIAGRAM ....................7-14
CONTROL PANEL AND CONTROL
BOX (EF7000/EF7200) .......................7-14
CONTROL PANEL AND CONTROL
BOX (EF7000E/EF7200E) ..................7-16
CONTROL PANEL AND CONTROL
BOX (Except for EF7200DE CAN)......7-18
CONTROL PANEL AND CONTROL
BOX (For EF7200DE CAN) ................7-20
BACK SIDE AND LEFT SIDE VIEW
(For EF7200DE CAN) .........................7-22
UPPER SIDE VIEW
(EF7000E/EF7200E/EF7200DE) ........7-23
UPPER SIDE VIEW
(EF7000/EF7200) ...............................7-24
ENGINE ..............................................7-25
GENERATOR (EF7000/EF7000E/
EF7200/EF7200E) ..............................7-26
GENERATOR
(Except for EF7200DE CAN) ..............7-27
GENERATOR
(For EF7200DE CAN) .........................7-28

1-1
GEN
INFO
MODEL VARIATIONS
GENERAL INFORMATION
MODEL VARIATIONS
Model code number 7P62 7P63 Model name EF7200DE EF7200DE EF7200DE EF7200 EF7200E EF7200E EF7000 EF7000E EF7200 EF7200E Starting serial number*
7P6-4000101– 7P6-4030101– 7P6-4040101– 7P6-0300101– 7P6-0360101– 7P6-5000101– 7P6-5010101– 7P6-5110101– 7P6-5130101– 7P6-5140101–
Voltage/Frequency
120/240 V-60 Hz 120/240 V-60 Hz 120/240 V-60 Hz
220
V-50
Hz 220
V-50
Hz 230
V-50
Hz 220
V-50
Hz 220
V-50
Hz 220
V-50
Hz 220
V-50
Hz
Destination CSA/SEA CAN SAU SEA/AFR OCE CHN RUS AC receptacle
15 A 125 V×2 30 A 125 V×1
30 A
250 V/125 V×1
15 A 125 V×2 30 A 125 V×1
30 A
250 V/125 V×1
15 A 125 V×2 30 A 125 V×1
30 A
250 V/125 V×1
20 A 250 V×2 20 A 250 V×2 15 A 250 V×2 20 A 250 V×2 20 A 250 V×2 20 A 250 V×2 20 A 250 V×2
Starter motor 333—33—3—3 Dual voltage 333——————— Voltage/hour meter 3333333333 Oil warning light 3333333333 Economy control system 333—33—3—3 Auto choke 333—33—3—3 Fuel level gauge 3333333333 AVR
3333333333
Fuel cut solenoid valve 3333333333 Two wheel kit P3PPPPPPPP Remote control kit P P P—P P—P—P Battery 333—33—3—3
CSA : Central South America SEA : South East Asia CAN : Canada SAU : Saudi Arabia AFR : Africa OCE : Oceania CHN : China RUS : Russia 3 : Equipped — : Not equipped P : Optional parts * : Serial number location (Refer to “MACHINE IDENTIFICATION” on 1-2)
1

1-2
GEN
INFO
MACHINE IDENTIFICATION
MACHINE IDENTIFICATION
SERIAL NUMBER
The serial number is printed on the label 1
affixed to the position 2 of the generator as
shown in the illustration.
A For EF7200DE CAN
B Except for EF7200DE CAN
TIP
9 The first three digits identify the model, and
the remaining digits indicates the production
number.
9 Designs and specifications are subject to
change without notice.
1
2
1
2
A
B

1-3
GEN
INFO
IMPORTANT INFORMATION
SVU1030
SVU1040
SVU1050
SVU1060
SVU1070
SVU1080
SVU1090
SVU1100
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
CAUTION ON SERVICE
1. Fire prevention
When servicing the engine, always keep the engine and your-
self away from fire.
NOTES ON SERVICE
1. Correct tools
Be sure to use the correct special tool for the job to guard
against damage.
2. Oil, grease and seals
Be sure to use genuine Yamaha oils, grease and sealers, or the
equivalents.
3. Expendable parts
Always replace the gaskets, O-rings, cotter pins and circlips with
new parts when servicing engine.
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 pat-
tern.
5. Notes on disassembly and assembly
a. Parts should be cleaned in solvent and blown dry with com-
pressed air after disassembly.
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.

1-4
GEN
INFO
IMPORTANT INFORMATION
SVU1110
SVU1120
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) 1 and oil seal(s) 2 with their manufacture’s
marks or numbers facing outward. (In other words, the stamped
letters must be on the side exposed to view.) When installing oil
seal(s), apply a light coating of lightweight lithium base grease to
the seal lip(s). Oil the bearings liberally when installing.
NOTICE
Do not use compressed air to spin the bearings dry. This
causes damage to the bearing surfaces.

1-5
GEN
INFO
BASIC SERVICE INFORMATION
BASIC SERVICE INFORMATION
ELECTRICAL SYSTEM
Checking the electrical system
TIP
Before checking the electrical system, make sure that the battery
voltage is at least 12 V.
NOTICE
Never insert the tester probes into the coupler terminal slots.
Always insert the probes from the opposite end a of the cou-
pler, taking care not to loosen or damage the leads.
a
Checking the connections
Check the leads, couplers, and connectors for stains, rust, mois-
ture, etc.
1. Disconnect:
9 Lead
9 Coupler
9 Connector
NOTICE
9 When disconnecting a coupler, release the coupler lock,
hold both sections of the coupler securely, and then dis-
connect the coupler.
9 There are many types of coupler locks;
therefore, be sure to check the type of coupler lock before
disconnecting the coupler.
NOTICE
When disconnecting a connector, do not pull the leads. Hold
both sections of the connector securely, and then disconnect
the connector.

1-6
GEN
INFO
BASIC SERVICE INFORMATION
2. Check:
9 Lead
9 Coupler
9 Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
3. Connect:
9 Lead
9 Coupler
9 Connector
TIP
9 When connecting a coupler or connector, push both sections of
the coupler or connector together until they are connected
securely.
9 Make sure all connections are tight.
4. Check:
9 Continuity
(with the pocket tester)
Analog pocket tester:
YU-03112-C
Pocket tester:
90890-03112
TIP
9 If there is no continuity, clean the terminals.
9 When checking the wire harness, perform steps (1) to (3).
9 Make sure to check the connector and coupler of the TCI unit/
CDI unit when replacing the TCI unit/CDI unit.
9 As a quick remedy, use a contact revitalizer available at most
part stores.

1-7
GEN
INFO
BASIC SERVICE INFORMATION
NOTICE
For waterproof couplers, never insert the tester leads directly
into the coupler. When performing any checks using a water-
proof coupler, use the specified test harness or a suitable
commercially available test harness.
5. Check:
9 Resistance
Analog pocket tester:
YU-03112-C
Pocket tester:
90890-03112
TIP
The resistance values shown were obtained at the standard meas-
uring temperature of 20 °C (68 °F). If the measuring temperature
is not 20 °C (68 °F), the specified measuring conditions will be
shown.
Intake air temperature sensor
resistance:
5.40–6.60 kW at 0 °C (32 °F)
290–390 W at 80 °C (176 °F)

1-8
GEN
INFO
SPECIAL TOOLS AND TESTERS
SVU1160
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.
TIP
9 For U.S.A. and Canada, use part number starting with “YM-”,
“YU-”, or “ACC-”.
9 For others, use part number starting with “90890-”.
1. Feeler gauge set
P/N. YU-26900-9
Thickness gauge
P/N. 90890-03180
This gauge is used to adjust valve clearance, piston clearance
and piston ring end gap.
2. Cylinder gauge
Commercially obtainable
This instrument is used for checking cylinder bore size and
condition.
3. Digital tachometer
P/N. YU-39951-B, 90890-06760
This tool is needed for observing engine r/min.
4. Engine compression tester
P/N. YU-33223
Compression gauge
P/N. 90890-03081
This tool is used for checking engine compression.
5. Extension
P/N. 90890-04082
This tool is used for checking engine compression.

1-9
GEN
INFO
SPECIAL TOOLS AND TESTERS
ø9ø8 ø10
ø3 ø4
YM-A5970
9. Primary clutch holder
P/N. YS-01880-A
Sheave holder
P/N. 90890-01701
This tool is necessary for holding the ywheel.
10. Six piece tappet set
P/N. YM-A5970
Tappet adjusting tool
P/N. 90890-01311
This tool is used to adjust the valve clearances.
90890-01311
3mm
SVU1220
11. Heavy duty puller
P/N. YU-33270-B
Flywheel puller
P/N. 90890-01362
This tool is necessary for removing the ywheel.
SVU1230
7. Analog pocket tester
P/N. YU-03112-C
Pocket tester
P/N. 90890-03112
This instrument is necessary for checking the electrical system.
8. Oppama pet-4000 spark checker
P/N. YM-34487
Ignition checker
P/N. 90890-06754
This instrument is necessary for checking the ignition system
components.
SVU1190
6. Dial indicator gauge
P/N. YU-A8428
Dial gauge
P/N. 90890-03097
This instrument is used for checking crankshaft side clearance.

1-10
GEN
INFO
12. Valve spring compressor
P/N. 90890-01253
This tool is used to remove the valve springs.
13. Piston ring compressor
P/N. YM-08037, 90890-05158
This tool is used to compress the piston rings when installing
the piston.
SPECIAL TOOLS AND TESTERS
14. Rotor shock puller assy.
P/N. YU-1047, 90890-01259
This tool is used to remove the rotor assembly.
15. Rotor puller attachment (M14 × P1.25)
P/N. YU-1379, 90890-01379
This tool is used to remove the rotor assembly.
M14XP1.25