Yamaha EF2000iS - Service Manual

Yamaha EF2000iS

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PRINTED ON RECYCLED PAPER

IMPRIMÉ SUR PAPIER RECYCLÉ

IMPRESO EN PAPEL RECICLADO

YAMAHA MOTOR POWERED PRODUCTS CO., LTD.

PRINTED IN JAPAN

2009. 06 × 1 !

(E, F, S)

SERVICE MANUAL

MANUEL D’ATELIER

MANUAL DE SERVICIO

EF2000iS

7DK-28197-40

331265

EF2000iS

7DK40-Cover 09.8.3 15:51 Page 1

Table of Contents

Default Chapter6
- Illustrated Symbols6
- Carburador7
- Index8
- Table of Contents10
- Sistema Eléctrico18
- Localización de20
General Information22
Chapter 122
Machine Identification22
- Serial Number22
- Starting Serial Number22
- Especificaciones23
Important Information24
- Notes on Service24
- Preparation for Removal and Disassembly Caution on Service24
- All Replacement Parts26
- Gaskets, Oil Seals, and O-Rings26
- Bearings and Oil Seals26
Special Tools and Testers28
Chapter 232
Periodic Inspections and Adjustments32
Introduction32
Maintenance Intervals Chart32
Periodic Maintenance/Lubrication Intervals32
Covers and Fuel Tank38
- Covers Removal38
- Covers and Fuel Tank (Except for Canada)40
- Covers and Fuel Tank Removal40
- (For Canada)42
- Covers and Fuel Tank Removal44
- Covers and Fuel Tank Installation46
- Engine Oil Leakage Checking48
- Oil Level Checking48
  - Oil Level Checking Steps48
  - Engine Oil Quantity50
- Oil Replacement50
  - Recommended Engine Oil50
  - Recommended Engine Oil Grade50
- Fuel Leakage52
- Fuel Tank Filter52
- Fuel Cock Strainer54
- Fuel Cock Strainer56
- Air Filter Element58
- Muffler60
- Valve Clearance Adjustment62
- Valve Clearance Adjustment64
- Compression Gauge68
- Compression Pressure68
- Standard Compression Pressure68
- Rated Engine Speed70
  - Testing Steps (above Maximum Level)70
  - Testing Steps (below Minimum Level)70
- Breather Hose72
Electrical74
- Spark Plug74
  - Spark Plug Gap74
  - Standard Spark Plug74
- Engine Switch76
- Economy Control Switch78
- Ac Pilot Light80
- Overload Warning Light80
- Overload Warning Light82
- Receptacle84
- DC Protector (Except for Canada)86
- DC Switch (no Fuse Breaker) (for Canada)88
- Ac Switch (no Fuse Breaker) (for Canada)88
Chapter 3. Engine90
- Control Panel (for Canada)92
- Control Panel Disassembly92
- (For Australia)94
- (For Europe)96
- (For Korea)98
Control Box90
- Control Box Disassembly90
Muffler100
- Assembling the Muffler102
Engine104
- Engine Removal104
Recoil Starter, Rotor and CDI Magneto106
- Recoil Starter Removal106
- Recoil Starter108
- Recoil Starter Disassembly108
- Recoil Starter Disassembly110
- Recoil Starter Inspection110
- Assembling the Recoil Starter112
- CDI Magneto and Rotor Installation116
- CDI Magneto and Rotor Removal116
Generator120
- Generator Removal120
- Generator Rotor and Stator Assembly Removal122
- Generator Rotor and Stator Assembly Installation126
Cylinder Head Cover and Cylinder Head128
- Cylinder Head Cover and Cylinder Head Removal128
- Cylinder Head Inspection132
- Push Rod Inspection132
- Assembling the Cylinder Head134
- Cylinder Head Cover134
Valve136
- Valve Removal136
- Valve and Valve Spring Inspection138
- Valve and Valve Spring Removal138
- Rocker Arm Inspection140
- Valve Face Contact Width142
- Valve Seat Inspection142
- Valve Lapping144
  - Valve Margin Thickness144
  - Valve Seat Width144
- Assembling the Valve and Valve Spring146
- Valve Spring Compressor146
Crankcase Cover and Camshaft148
- Crankcase Cover and Crankshaft Removal148
- Cam Lobes Length152
- Camshaft Inspection152
- Assembling the Camshaft154
- Crankcase Cover Inspection154
- Crankcase Cover Installation154
- Valve Lifter Inspection154
Piston, Connecting Rod, Crankshaft and Crankcase158
- Piston, Connecting Rod, Crankshaft and Crankcase Removal158
- Cylinder Inside Diameter162
- Cylinder Inspection162
- Piston and Piston Pin Inspection162
- Piston Ring Inspection166
- Connecting Rod Oil Clearance Inspection168
- Crankshaft Inspection168
- Piston and Piston Ring Installation170
- Assembling the Crankshaft172
Chapter 4. Carburetor174
- Carburetor Disassembly176
- Float Height Inspection180
- Throttle Control Motor182
- Choke Cable182
Carburetor and Air Filter174
- Carburetor Removal174
Chapter 5. Electrical184
- (For Canada)184
- (For Australia)186
- (For Europe and Korea)188
Electrical Components184
Circuit Diagram190
- (For Europe)200
- Control Unit200
- (Except for Europe)202
- Control Unit202
Switches206
- Checking Switch Continuity206
- Pocket Tester206
Ignition System208
- No Spark or Weak Spark208
- Troubleshooting Chart208
Generator System224
- Troubleshooting Chart224
  - Weak or no Ac Current224
  - Engine Does Not Start234
Chapter 6234
Troubleshooting234
- Engine Starts but Stalls236
- Engine Speed Does Not Increase237
- Engine Speed Is Uneven238
Throttle Control System239
Chapter 7. Specifications256
General Specifications256
Maintenance Specifications258
- Engine258
- Electrical261
- Generator262
Tightening Torque263
General Torque Specifications264
Definition of Units264
Lubrication Point and Type of Lubricants265
Wire Routing Diagram286
- Control Panel and Control Box (for Canada)286
- (For Australia)288
- (For Germany)290
- (For France)292
- (For Korea)294
- Engine and Generator296
- (Except for Europe)298

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