YAMAHA GENERATOR er guy SERVICE MANUALEF600 SERVICE MANUAL ©1986 by Yamaha Motor Corp., USA ‘st Edition - February 1983 2nd Printing - February 1986 ALL RIGHTS RESERVED BY YAMAHA MOTOR CORPORATION, U.S.A ‘CYPRESS, CALIFORNIA 90630 LIT-19616-00-04FOREWORD This service manual provides the procedure for the inspection and service of the Yamaha portable generator EF600. To help your understanding, many illustrations and diagrams are provided. We sincerely hope that this manual be used as @ handy guide to your service work including inspections, adjustments, disassembly and assembly. All information, illustrations and specifications contained in this manual are based on the product at the time of publication, and part of the information may not be appli- cable to your machine due to improvements which might have been newly introduced. NOTICE 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 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. This model has been designed and manufactured to perform within certain specifi- cations in regard to performance. Proper service with the correct tools is necessary to ensure that the generator will operate as designed. Yamaha Motor Company Ltd. is continually striving to further improve all models manufactured by Yamaha, Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where appli- cable, appear in future editions of this manual. Particularly important information is distinguished in this manual by the following notations: A WARNING indicates special procedures that must be followed to avoid injury to a generator operator or person inspecting or repairing the generator. CAUTION: ‘A CAUTION indicates special procedures that must be followed to avoid damage to the generator. NOTE: ANOTE provides key information to make procedures easier or clearer. | a : Apply engine oil to the area indicated. "Timm; : Apply grease to the area indicated. ea ie Sea toes os Oberation YAMAHA MOTOR CO., LTD POWER PRODUCT DIV.CONTENTS 1. SPECIFICATIONS WwW ENGINE... .4 GENERATOR . oa GENERAL... 24 EXTERNAL VIEWS 212 NEW MECHANISM . 213 2.MAINTENANCE. . 24 NOTE ON SERVICE 224 SPECIAL TOOLS AND TESTER 123 PERIODIC INSPECTION ....... +28 wo . ADJUSTMENT 4. DISASSEMBLY GENERATOR DISASSEMBLY . ENGINE DISASSEMBLY ... 5. INSPECTION . 54 ENGINE ELECTRICITY 6. ASSEMBLY 7, MISCELLANEOUS ma TIGHTENING TORQUE .7A SERVICE DATA ... -72 ASSEMBLY CHART 174 WIRING DIAGRAM . .7a7 TROUBLESHOOTING1, SPECIFICATIONS ENGINE F600 Type 4.stroke, side valve, forced air cooled Displacement | 70.6 cm? Bore x Stroke | 48x 39mm (1.89 x 1.54 in) Compression ratio 60:1 Rated output | 0.8 PS/3,000 r/min (S0H2) _1.0PS/3,600r/min (60Hz) Lubrication system Forced splash Governor system Centrifugal Ignition system CDI (Condensor Discharge Ignition) Ignition timing BTDC20° Spark plug BPMR6A (NGK) Starting system Recoil starter Stopping system By grounding Air cleaner Wet type Lubricant capacity 350 cm? (0.31 Imp at. 0.37 US at) Fuel Unleaded gasoline Fuel tank capacity |__2 liters (0.43 Imp gal, 0.53 US gal) Continuous rating operating 5OH2 60 Hz time I 5.0 hours 4.5 hours GENERATOR F600 Type Brush-less, auto exciting synchronous generator Phase Rated output AC: De: _ ~ Rated output current [_220v 240V | S0Hz | 60Hz S0HZ AC: [1.84 23A 7A De: TOA/12V — Number of AC outlet 1 Number of DC outlet {4 _ _ | Safety device against AC: | AC circuit breaker oe: DC circuit breaker GENERAL | F600 Length 446 mm (17.6 in} Width 200 mm (7. Height 315mm (12.4 in) Dry weight 20.8kg (45.85 Ib) Noise level | 50 Hz 60 Hz | 53 db A/T m (at rated output) | 56 db A/7 m (at rated output)EXTERNAL VIEWS Fuel tank cap —_| Handle a Exhaust pipe 9 | | Anand [item Voltage adjusting knob (Frequency adjusting knob) Oil drainNEW MECHANISM The new EF600 mirrors Yamaha's superlative concepts of compact design. One of the con- cepts is reflected in the control lever which enables you to choke, start and stop the engine with a single lever. In addition, this generator features ease of operation and easy carrying. carrying. 1. Control lever This single control lever permits you to choke, start and stop the engine. engine. The same lever control four functions. Engine switch [ Fuel cock Fuel tank breather Choke Push in the engine stop switch. 132. Fuel pump. The fuel pump is operated by the fluctuations of the pressure in the intake manifold and delivers gasoline to the carburetor. (& Veuve Fuel pipe (Fuel pump to carburetor) Fuel pump 3. Breather and fuel cock system ON position: The slot in the fuel cock OFF position: Both breather and fuel aligns with both breather ports are closed, and fuel ports and as a result, both ports are open. Breather hole From gasoline tank 144. Oil warning system When the oil level gets extremely low, the oil warning lamp will light to signal the lack of oil. With the oil werning lamp on, the engine can- not be started even by pulling the starter handle. Lack of engine oil will cause engine seizure, To warn the operator of lack of engine oil, the oil warning lamp will come on. When the engine oil level goes down below the specified level, the permanent magnet connected to the warning switch float makes the reed switch conduct and thus the current generated by the magneto flows through the warning device circuit. That is, no voltage is induced in the ignition coil. As a result, the spark plug does not fire, which stops the engine and at the same time, the current flow- ing to the warning device turns on the warn- ing lamp. 5. Spark plug Compared with the BP type plugs, it is smaller and has a built-in resistor to avoid interference with radio waves. Standard: EPMR-6A Oil level gauge | | | | | Distance srs tae Heat range Plug with builtin resistor ‘Small type plug (BANTAM) Project type 152. MAINTENANCE NOTES ON SERVICE 1. Fire prevention When servicing the generator, stop smoking and extinguish all maked lights. 2. Right tools Be sure to use the right special tool for the job in order to protect the part against damage, Always use the right tool and the right in- strument. (Avoid using open-end wrenches as much as possible, and use box and socket wrenches.) 3. Oil grease and bond Be sure to use genuine Yamaha oil, grease, and bond. 4, Expendable parts Always replace gaskets (packings), O-rings, cotter pins, and circlips with new parts when servicing generators. 5. Tightening torque Be sure to follow torque specifications. When tightening bolts, nuts and screws, start with a larger-diameter one and from an inner- positioned one to an outer-positioned in a criss-cross pattern. 246. Notes on disassembly and assembly Parts should be cleaned in solvent and blown off with compressed air after desassembly. @Contact surfaces of moving parts should be oiled when they are assembled. @Make sure that parts move smoothly after each section of the machine is assembled. @ Machine No. stamped position The machine No. is shown in six digits on the casing. It is necessary to mention the machine No. and model number when ordering repair parts or seeking information about the ma- chine. 22SPECIAL TOOLS & TESTERS For general No] __ Tool Name Part No. | Bolt 90890-01111 p ‘Attachment | 90890-01889 2_ | Magneto puller 90890-01990 3 [Pocket tester 9089003112 4_| Service gauge (thickness gauge) | 90890-03079 5_| Yamaha Bond No.4 ; 90890-05143 [6 | Valve lapper ‘90890-04107 7 |YAMAHAGENERA. | 120Varea_| 90890-03114 TOR TESTER 240V area 90890-03115 For USA. (No. | Tool Name Part No. | [Bolt YU-01269 1 | Rotor pull Pen | Rotor puller Tattachment | YU-01349 YU.01361 2 | Magneto puller Bolt VOSTEEE 3. | Pocket tester _ Yu.03112 5_| Yamaha bond No.4 | ACe-11007-30-00 23PERIODIC INSPECTION T mor First check | * a Voorn { tater | SM | cue cneckiten operation | AA | fatter | 54) Remarks eck | 20 | gee too | eu | Canal | ene conto! er uel oe, | 3 srram | shack ver operation Check rel starter option 3 reine | heck starting of erin and abnormal noise. 2 cnckemaeninee |g | 9 | 0 | © exhaust color oT Check tights of ans, bolts and nuts. _ Y Engine ol hangs : a5 Filey [Check tune, +O Check or fl ake o | o | o |o Chen fl cock Te [oe fo Clean fs tank ir, o fo | o | 0 i Tapia ol Check pipes for beste © | 0 |romeverra eee - ven Ebel | Check and cla pork lun oo [Plea system electrodes. | 0.6 ~0.7 mm Ganerator | Ghck OC recepiace ac AC receptacles for damage. ° Y o i) Cheek lamp, otetr DC protector and NFB. and 0 Y “When used in dusty area, the air cleaner element should be serviced more frequently. 241. Engine oil — Checking and replacement DChecking the oil level Place the engine on a level surface, remove the oil plug, and make sure the oil is filled up to the oil plug hole. @Oil refilling If necessary, place the engine on a level sur face, remove the oil plug, and add oil until the level reaches the edge of the oil fll hole. Engine Replacement intervals ‘After the first 20 Hours F600 |350cm*| and thereafter every 150 Hours Recommend oi Select the proper oil according to atmopheric ‘temperature. For instance, SAE # 30 when the ‘temperature is over 15°C (59°F). (U.S.A.) Yamalube 4 should be used over 0°C (32°F) ‘temperatures, API Service Classification SF or SE, if not available then SD may be used. 2. Air cleaner Check the air cleaner element for fouling or clogging. If it is fouled or clogged, hard star- ting or excessive fuel consumption will result. Thoroughly clean the element. 25 SAE #30 sor — Se os Yamalube 4 (USA) Sac #20 ? SAE #10 — wr@Remove the air cleaner cover, and remove the element. @Clean the element in gasoline. @after cleaning, soak the element ina 25 : 1 mixture of gasoline and oil and squeeze it lightly as illustrated. Apply a coat of grease to the outside edge of the element. Install the element with the electrical flocking side facing outward, Never twist the element as illustrated or it may break. 3. Fuel pump — checking and cleaning ‘© Checking @ Remove the fuel pump cup from the fuel pump. @Wash the fuel pump cup and filter with gasoline. @ After installing the removed parts, check for fuel leakage, @By pulling the starter handle, check to see if gasoline flows from the fuel pump to the carburetor. ans Inflammables. 264, Muffler Cleaning & Remove the muffler. @Tap on the muffler in the area shown in the illustration. To clean, don’t use a wire, or the noise damping material will come off so damping effect will be reduced. 5. Cleaning the combustion chamber © Checking Decarbonize the cylinder head and clean the cylinder head fins. 6. Spark plug ——NOTE: Standard plug: NGK BPMR-6A Plug gap: 0.6 ~ 0.7mm (0.024 ~ 0.028 in} The plug gap can be adjusted by bending the side electrode @Replace the spark plug if the center electrode is rounded at its edge. @Replace the gasket, if deformed or damaged. @Using a wire brush or plug cleaner, clean or decarbonize the spark plug, if necessary. 27 ' 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)‘© Decarbonize the threads and clean the insula- tor. © To tighten the spark plug, first screw in by hand and then turn it in 1/4 turn using a plug wrench, 7. Compression pressure @ Remove the spark plug and install a pressure gauge in the spark plug hole. @Pull the recoil starter briskly a few times and check the maximum reading of the pressure gauge. stO. Limite £85.3psi (Ib/in®) 71.1psi (bin?) Bkg/em? Bkglem? 8. Checking spark @ Remove the spark plug and install it onto the spark cap. Install another spark plug into the spark plug hole @Ground the side electrode to the cylinder, and pull the recoil starter so that spark takes place across the electrode gap. —— NOTE: When pulling the recoil starter, be sure to keep your hand off the high-tension wire, or you may get an electric shock. Pn Do not place the spark plug new an open spark plug hole fire way result. 283. ADJUSTMENT 1. Valve clearance adjustment D If the valve clealance is too small, grind the valve stem end with a grinder. Be careful so that the stem end is ground squarely. @If the valve clealance is too large, the valve stem end is excessively worn. So replace the valve with a new one. —NOTE: Standard valve clearance: 0.05 ~ 0.15 mm (0,002 ~ 0.006 in) 2. Governor adjustment Full-open 1) When installing the governor arm turn the governor fork all the way to the right to fully open the throttle, then tighten the nut. 2 Hook the tension spring as shown. 3. Voltage adjustment (Frequency adjustment) ES) Turning the Phillips-head screw counterclock- "| wise increase voltage, and turning clockwise é decreases voltage. a 344. DISASSEMBLY Cylinder head : Connecting rod dD Os ¥ cantante 4 powr ver aie ic cleaner Cmburetoran’y le => 18 =. Mutter oy 7 of CEI Camshaft ess |le Crankcase cover Mounting base How to read the above chart In the above chart, the parts are connected by arrow marks in the order of disassembly, You can see at a glance what parts will have to be disassembled to remove one of the parts which is to be checked. The piston and connecting rod, the starter and fan case, and the crankcase cover and governor arm can be removed as assemblies. atGENERATOR DISASSEMBLY 1. Drain the engine oil — Note; ——_____ ——___—— q— Bolts, nuts, and other parts which are to be removed, or portions which are to be disassembled. wn rao we Buu20% 110 mia m8 soveinwios pias & 421s ino] 10 [f = \ x Tx H E> i ue} on 6° 7 speideses 90) i G e u too ew 05 Piel soarod 90 ud WIRING DIAGRAM (oo Bunesxe sesuapuco) ooang oH 78 Tae suuaryoeia © Wve c+ ren: TAT& YAMAHA MOTOR CO. LTD.