Yamaha YP20G User manual

Water Pump
YP20G
YP30G
OWNER’S MANUAL
LIT-19626-01-35 9CB-28199-11
2007 901 ×1 !
070001102
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AE00012
IDENTIFICATION NUMBER RECORDS
Record your Primary I.D., and serial num-
bers in the spaces provided, to assist you
in ordering spare parts from a Yamaha
dealer.
Also record and keep these I.D. numbers
in a separate place in case your machine
is stolen.
AE00011
MACHINE IDENTIFICATION
The machine serial number is stamped in
the location as shown.
NOTE:
The first three digits of these numbers are
for model identification; the remaining dig-
its are the unit production number. Keep a
record of these numbers for reference
when ordering parts from a Yamaha deal-
er.
AE00002
INTRODUCTION
Congratulations on your purchase of your new Yamaha.
This manual will provide you with a good basic understanding of the operation and
maintenance of this machine.
If you have any questions regarding the operation or maintenance of your machine,
please consult a Yamaha dealer.
PRI-I.D. NUMBER:
PRI-I.D.
CODE SERIAL No.
YP20G/YP30G
OWNER’S MANUAL
© 2007 by Yamaha Motor Corporation, U.S.A.
2nd Edition, January 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-19626-01-35
MODEL
-----------------
-----------------
-----------------
-----------------
-----------------
--------------
792-028b
AE00022
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NOTE:
9Yamaha continually seeks advance-
ments in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your engine and this manual. If there
is any question concerning this manu-
al, please consult your Yamaha deal-
er.
9This manual should be considered a
permanent part of this engine and
should remain with this engine when
resold.
AE00032
w
PLEASE READ AND UNDERSTAND
THIS MANUAL COMPLETELY BEFORE
OPERATING THE MACHINE.
Particularly important information is distin-
guished in this manual by the following
notations.
-
The Safety Alert Symbol means ATTEN-
TION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
w
Failure to follow WARNING instructions
could result in severe injury or death to
the engine operator, a bystander, or a
person inspecting or repairing the engine.
cC
A CAUTION indicates special precautions
that must be taken to avoid damage to the
engine.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
851-005
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AE00041
CONTENTS
WATER PUMP LIMITED
WARRANTY ..........................................1
LOCATION OF IMPORTANT
LABELS.................................................3
SAFETY INFORMATION.......................4
EXHAUST FUMES ARE
POISONOUS ......................................4
FUEL IS HIGHLY FLAMMABLE
AND POISONOUS .............................4
ENGINE AND MUFFLER MAY BE
HOT ....................................................4
CONTROL FUNCTION..........................6
DESCRIPTION ...................................6
WATER HOSE INSTALLATION .........7
OIL WARNING SYSTEM....................7
ENGINE SWITCH...............................8
THROTTLE LEVER ............................8
PRE-OPERATION CHECK ...................9
FUEL...................................................9
ENGINE OIL .....................................10
WATER PRIMING ............................10
OPERATION ....................................12
STARTING THE ENGINE.................12
STOPPING THE ENGINE ................13
DRAIN OF WATER AFTER USE .....14
PERIODIC MAINTENANCE ................15
MAINTENANCE CHART ..................15
SPARK PLUG INSPECTION............16
CARBURETOR ADJUSTMENT .......16
WATER LEAKAGE CHECK .............16
ENGINE OIL REPLACEMENT .........17
AIR FILTER ......................................18
FUEL COCK .....................................19
FUEL TANK FILTER.........................19
MUFFLER SCREEN AND SPARK
ARRESTER ......................................20
TROUBLESHOOTING.........................22
STORAGE ...........................................24
DRAIN THE FUEL ............................24
ENGINE ............................................24
EXHAUST EMISSION CONTROL
SYSTEM AND COMPONENTS...........25
SPECIFICATIONS ...............................26
DIMENSIONS ...................................26
ENGINE ............................................26
PUMP ...............................................26
WIRING DIAGRAM..............................27
RUBBER MOUNT INSTALLATION ....28
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– 1 –
Yamaha Motor Corporation, U.S.A. hereby war-
rants that new Yamaha water pumps pur-
chased from an authorized Yamaha water
pump dealer in the continental United States
will be free from defects in material and work-
manship for the period of time stated herein,
subject to certain stated limitations.
THE PERIOD OF WARRANTY for Yamaha
water pumps shall be one year from the date
of purchase.
DURING THE PERIOD OF WARRANTY any
authorized Yamaha water pump dealer will
provide:
1. Free of charge, the replacement of any part
adjudged defective by Yamaha due to faulty
workmanship or material from the factory.
Parts used in warranty repairs will be war-
ranted for the balance of the water pump’s
warranty period. All parts replaced under
warranty become property of Yamaha Motor
Corporation, U.S.A.
2. Any repairs made necessary by faulty work-
manship or material from the factory.
GENERAL EXCLUSIONS from this warranty
shall include any failures caused by:
a. Installation of parts or accessories that are
not qualitatively equivalent to genuine
Yamaha parts.
b. Abnormal strain, neglect, or abuse.
c. Lack of proper maintenance.
d. Accident or collision damage.
e. (Trash type pump) pumping any liquid other
than muddy or dirty water.
f. (General type pump) pumping any liquid
other than clean or cloudy water.
SPECIFIC EXCLUSIONS from this warranty
shall include parts replaced due to normal
wear or routine maintenance.
THE CUSTOMER’S RESPONSIBILITY under this
warranty shall be to:
1. Operate and maintain the water pump as
specified in the appropriate Owner’s
Manual, and
2. Give notice to an authorized Yamaha water
pump dealer of any and all apparent defects
within ten (10) days after discovery, and
make the unit available at that time for
inspection and repairs at such dealer’s place
of business.
WARRANTY TRANSFER; To transfer the war-
ranty from the original purchaser to any subse-
quent purchaser(s), it is imperative that the
unit be inspected and registered for warranty
by an authorized Yamaha water pump dealer.
In order for this warranty to remain in effect,
this inspection and registration must take
place within (10) days after transfer.
A reasonable dealer-imposed fee may be
charged for the inspection. In no case will the
warranty be extended beyond the original peri-
od.
YAMAHA MOTOR CORPORATION, U.S.A.
MAKES NO OTHER WARRANTY OF ANY KIND,
EXPRESSED OR IMPLIED. ALL IMPLIED WAR-
RANTIES OF MERCHANTABILITY AND FIT-
NESS FOR A PARTICULAR PURPOSE WHICH
EXCEED THE OBLIGATIONS AND TIME LIMITS
STATED IN THIS WARRANTY ARE HEREBY
DISCLAIMED BY YAMAHA MOTOR CORPORA-
TION, U.S.A., AND EXCLUDED FROM THIS
WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS
ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION MAY
NOT APPLY TO YOU. ALSO EXCLUDED FROM
THIS WARRANTY ARE ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES INCLUDING
LOSS OF USE. SOME STATES DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF
INCIDENTAL OR CONSEQUENTIAL DAM-
AGES, SO THE ABOVE EXCLUSION MAY NOT
APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC
LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH VARY FROM STATE
TO STATE.
YAMAHA MOTOR CORPORATION, U.S.A.
Post Office Box 6555
Cypress, California 90630
CE00051*
YAMAHA MOTOR CORPORATION, U.S.A.
WATER PUMP LIMITED WARRANTY
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Q. What costs are my responsibility during
the warranty period?
A. The customer’s responsibility includes all
costs of normal maintenance services,
non-warranty repairs, accident damages,
as well as oil and spark plugs.
Q. What are some examples of “abnormal”
strain, neglect, or abuse?
A. These terms are general and overlap each
other in areas. Specific examples include:
Running the machine out of oil; lack of
proper maintenance; operating the
machine with a broken or damaged part
which causes another part to fail; and so
on. If you have any specific questions on
operation or maintenance, please contact
your dealer for advice.
Q. Does the warranty cover incidental costs
such as transportation due to a failure?
A. No. The warranty is limited to repair of
the machine itself.
Q. May I perform any or all of the
recommended maintenance shown in the
Owner’s Manual instead of having the
dealer do them?
A. Yes, if you are a qualified mechanic and
follow the procedures specified in the
Owner’s and Service Manual. We do
recommend, however, that items
requiring special tools or equipment be
done by a Yamaha water pump dealer.
Q. Will the warranty be void or cancelled if
I do not operate or maintain my new
Yamaha exactly as specified in the
Owner’s Manual?
A. No. The warranty on a new Yamaha
cannot be “voided” or “cancelled.”
However, if a particular failure is caused
by operation or maintenance other than
as shown in the Owner’s Manual, that
failure may not be covered under
warranty.
Q. What responsibility does my dealer have
under this warranty?
A. Each Yamaha water pump dealer is
expected to:
1. Check the operation of the water
pump before sale.
2. Explain the operation, maintenance,
and warranty requirements to your
satisfaction at the time of sale, and
upon your request at any later date.
In addition, each Yamaha water pump
dealer is held responsible for his setup,
service and warranty repair work.
Q. Is the warranty transferable to second
owners?
A. Yes. The remainder of the existing
warranty can be transfered upon request.
The unit has to be inspected and re-
registered by an authorized Yamaha
water pump dealer for the policy to
remain effective.
CUSTOMER SERVICE
If your machine requires warranty service,
you must take it to any authorized Yamaha
water pump dealer within the continental
United States. Be sure to bring your warran-
ty registration identification or other valid
proof of the original date of purchase. If a
question or problem arises regarding war-
ranty, first contact the owner of the dealer-
ship. Since all warranty matters are han-
dled at the dealer level, this person is in
the best position to help you. If you are
still not satisfied and require additional
assistance, please write:
YAMAHA MOTOR CORPORATION U.S.A.
CUSTOMER RELATIONS DEPARTMENT
P.O. Box 6555
Cypress, California 90630
When contacting Yamaha Motor Corpora-
tion U.S.A. don’t forget to include any
important information such as names,
addresses, model, engine serial number,
dates and receipts.
CHANGE OF ADDRESS
The federal government requires each
manufacturer to maintain a complete, up-to-
date list of all first purchasers against the
possibility of a safety-related defect and
recall. This list is compiled from the purchase
registrations sent to Yamaha Motor
Corporation, U.S.A. by the selling dealer at
the time of your purchase. If you should
move after you have purchased your new
water pump, please advise us of your new
address by sending a postcard listing your
Yamaha model name, engine number,
dealer number (or dealer’s name) as it is
shown on your warranty identification,
your name and new mailing address. Mail
to:
YAMAHA MOTOR CORPORATION, U.S.A.
WARRANTY DEPARTMENT
P.O. Box 6555
Cypress, California 90630
This will ensure that Yamaha Motor
Corporation, U.S.A. has an up-to-date
registration record in accordance with
federal law.
WARRANTY QUESTIONS AND ANSWERS
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AE00062
LOCATION OF IMPORTANT LABELS
Please read the following labels carefully before oper-
ating this machine.
NOTE:
Maintain or replace safety and instruction labels, as
necessary.
792-016
1
2
1
2
0246810
ENGINE AIR INDEX (California only)
LEAST CLEAN
MOST CLEAN
NOTE : THE LOWER THE AIR INDEX, THE LESS THE POLLUTION
FOR THE FOLLOWING USE:
THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT
MODERATE INTERMEDIATE EXTENDED
CHECK OWNERS MANUAL FOR FURTHER DETAILS
THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY!
IMPORTANT ENGINE INFORMATION
ENGINE FAMILY : zzzzzzzzzzzz
E M
REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
YAMAHA MOTOR POWERED PRODUCTS CO.,LTD.
DISPLACEMENT :
VALVE LASH ( )
rpm
NO OTHER ADJUSTMENTS NEEDED.
ENGINE OIL :
IDLE SPEED :
FUEL : THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE.
IGNITION TIMING & IDLE MIXTURE
zzz
IN :
TYPE
z.zz~z.zz
EX :
z.zz~z.zz
zzzz
~ zzzz
AT NO LOAD
SE
SAE 10W
- 30
THIS ENGINE MEETS zzzz - zzzz CALIFORNIA EMISSION REGULATIONS FOR SMALL OFF-ROAD ENGINES.
THIS ENGINE CONFORMS TO PHASE 2 U.S.EPA REGULATIONS FOR SMALL NONROAD ENGINES.
EMISSIONS COMPLIANCE PERIOD:CATEGORY A (EPA)
zzz
-
zzzzz
-
zz
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–4 –
AE00071
SAFETY INFORMATION
AE00072
EXHAUST FUMES ARE POISONOUS
9Never operate the engine in a closed area or it
may cause unconsciousness and death within a
short time. Operate the engine in a well ventilated
area.
AE00075
FUEL IS HIGHLY FLAMMABLE AND POISONOUS
9Always turn off the engine when refuelling.
9Never refuel while smoking or in the vicinity of an
open flame.
9Take care not to spill any fuel on the engine or
muffler when refuelling.
9If you swallow any fuel, inhale fuel vapor, or allow
any to get in your eye(s), see your doctor immedi-
ately. If any fuel spills on your skin or clothing,
immediately wash with soap and water and
change your clothes.
9When operating or transporting the machine, be
sure it is kept upright. If it tilts, fuel may leak from
the carburetor or fuel tank.
AE00861
ENGINE AND MUFFLER MAY BE HOT
9Place the machine in a place where pedestrians
or children are not likely to touch the machine.
9Do not place any flammable materials near the
exhaust outlet during operation.
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–5 –
745-019a
a
9Keep the machine at least 1 m (3 ft) from buildings
or other equipment, or the engine may overheat.
a1 m (3ft)
9Do not operate the engine with a dust cover.
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AE00101
CONTROL FUNCTION
AE00102
DESCRIPTION
1Fuel tank
2Fuel tank cap
3Fuel cock
4Air filter cover
5Spark plug
6Muffler
7Choke lever
8Engine switch
9Oil filler cap
0Oil drain plug
qRecoil starter
wOil warning light
eThrottle lever
rPriming plug
tWater drain plug
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–7 –
CE00162
WATER HOSE INSTALLATION
1. Install the hose joints on the pump.
cC
When installing the joint to the pump, be sure the
gasket is in place.
2. Connect the hoses on the joints with clamp.
3. Connect the strainer on the inlet hose end.
cC
9Be sure the hoses are installed securely or air
leak will occur and water will not be drawn up.
9Be sure the strainer is installed or pump dam-
age will occur.
cC
Install the strainer
A) 50 mm (2 in) suction port diameter for YP20G
or
B) 80 mm (3 in) suction port diameter for YP30G
both with filtering perforations 8 mm (0.31 in) or
less in diameter.
AE00111
OIL WARNING SYSTEM
When the oil level falls below the lower level, the
engine stops automatically. Unless you refill with oil,
the engine will not start again.
NOTE:
If the engine stalls or does not start, turn the engine
switch to “ON”position and then pull the recoil starter.
If the oil warning light flickers for a few seconds, the
engine oil is insufficient. Add oil and restart.
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–8 –
AE00124
ENGINE SWITCH
The engine switch controls the ignition system.
1“ON”
Ignition circuit is switched on.
The engine can be started.
2“OFF”
Ignition circuit is switched off.
The engine will not run.
CE00171
THROTTLE LEVER
The throttle lever controls the engine speed. Move the
throttle lever in direction 1to decrease engine speed.
Move the throttle lever in direction 2to increase
engine speed.
aThrottle lever
cC
Always check throttle operation before starting the
engine.
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–9 –
707-041
707-037
CE00201
PRE-OPERATION CHECK
NOTE:
Pre-operation checks should be made each time the
water pump is used.
w
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.
AE00212
FUEL
Make sure there is sufficient fuel in the tank.
Your Yamaha engine has been designed to use regu-
lar unleaded gasoline with a pump octane number ((R
+ M)/2) of 86 or higher, or research octane number of
91 or higher.
w
9Fuel is highly flammable and poisonous.
Check “SAFETY INFORMATION”(See page 4)
carefully before refueling.
9Do not fill above the top of the fuel filter or it
may overflow when the fuel heats up later and
expands.
9Wipe up any spilled fuel immediately.
9After refueling, make sure the tank cap is tight-
ened securely.
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
Total:
4.5 L (0.99 Imp gal, 1.19 US gal)
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–10 –
CE00222
ENGINE OIL
Make sure the engine oil is between upper and lower
levels.
Add oil as necessary.
700-103
q
w
700-065
0°C 25°C
80°F32°F
A YAMALUBE 4(10W-30)
D SAE 10W C SAE #20 B SAE #30
Insert the oil level gauge in the filler hole without
screwing it in.
1Upper level
2Lower level
CE00252
WATER PRIMING
Make sure the water is at pump casing upper level.
Add water as necessary.
1Upper level
cC
Be sure the pump is filled up with water before
starting the engine or mechanical seal damage will
occur.
NOTE:
Recommended engine oil classification:
API Service “SE”or “SF”.
cC
The water pump has been shipped without engine
oil. Fill with oil or it will not start.
Recommended oil:
AYAMALUBE 4 (10W-30) or SAE 10W-30
type SE motor oil
BSAE #30
CSAE #20
DSAE 10W
Engine oil quantity:
0.6 L (0.53 lmp qt, 0.63 US qt)
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–11 –
NOTE:
9Be sure the pump is placed on a firm place and as
near to available water source as possible.
9The higher the suction head is the more time will
be required for priming with less discharge.
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–12 –
705-037
q
700-006a
q
CE00303
OPERATION
NOTE:
The water pump has been shipped without engine oil.
Fill with oil or it will not start.
1Upper level
2. Turn the engine switch to the “ON”position.
1“ON”
3. Turn the choke lever to the “1”position.
1Choke lever
NOTE:
The choke is not required to start a warm engine.
Turn the choke lever to the operating position.
4. Move the throttle lever slightly to right.
CE00312
STARTING THE ENGINE
cC
Be sure the pump is filled up with water before
starting the engine.
1. Turn the fuel cock lever to the “ON”position.
1“ON”
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–13 –
704-010
5. Pull slowly on the recoil starter until it is engaged,
then pull it briskly.
6. After the engine starts, warm up the engine until
the engine does not stop when the choke lever is
returned to the operating position.
705-038
q
7. Turn the choke lever back to the operating posi-
tion.
1Operating position
8. Set the throttle lever in desired position.
1Decrease engine speed
2Increase engine speed
CE00382
STOPPING THE ENGINE
1. Move the throttle lever fully to left.
2. Turn the engine switch to the “OFF”position.
1“OFF”
3. Turn the fuel cock lever to the “OFF”position.
1“OFF”
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CE00383
DRAIN OF WATER AFTER USE
Water inside casing freezes at below 0°C (32°F) in
winter and thereby pump may possibly be broken.
After use, drain water from drain port at bottom to
store.
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–15 –
**
Check condition
1. Spark Plug adjust gap and clean. 0
Replace if necessary.
Check oil level 0
2. Engine Oil Replace 00
3. ** Clean. 0
Air Filter Replace if necessary.
Clean fuel cock and
4. Fuel Filter fuel tank filter. 0
Replace if necessary.
5.* ** Check and adjust 0
Valve Clearance when engine is cold.
Check fuel hose for
6. Fuel Line crack or damage. 0
*Replace if necessary.
** Check breather hose
7.* Crankcase for cracks or damage. 0
breather system Replace if necessary.
8.* ** Check and adjust 0
Idle speed engine idle speed.
Check for leakage.
**
Retighten or 0
9. Exhaust System *
replace gasket if necessary.
Check muffler screen and
spark arrester. Clean/ 0
replace if necessary.
10. Choke lever Check choke operation. 0
11.* Cooling System Check fan damage. 0
12. Starting System Check recoil starter 0
operation.
13.* ** More frequently if 0
Decarbonization necessary.
Check for leakage.
14. Water Pump Retighten or replace 0
O-ring and/or gasket.
Check all fittings and
15* Fittings/Fasteners fasteners. 0
Correct if necessary.
No. Item Remarks
Pre-Opera-
tion check
(daily)
Initial Every
1 month or
20 Hr
3 month or
50 Hr
6 month or
100 Hr
12 month or
300 Hr
AE00401
PERIODIC MAINTENANCE
CE00403
MAINTENANCE CHART
Regular maintenance is most important for best performance and safe operation.
w
Stop the engine before starting maintenance work.
* : It is recommended that these items be serviced by a Yamaha dealer.
** : Related to emission control system.
cC
Use only Yamaha specified genuine parts for replacement. Ask an authorized
Yamaha dealer for further attention.
**
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