Honda - Brio - Owners Manual - 2017 - 2017

dummyhead How to use this manual A few Words About Safety How to use this manual Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage this Honda product or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not recommended by Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight while servicing this product can result in faulty operation, damage to the product, or injury to others. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure that the hoist hook is securely attached to the product. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the way. Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Use only a nonflammable solvent, not gasoline, to clean parts. • Never store gasoline in an open container. • Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts. 0-1 dummyhead CONTENTS SPECIFICATIONS 1 SERVICE INFORMATION 2 MAINTENANCE 3 TROUBLESHOOTING 4 COVER 5 FUEL SYSTEM 6 GENERATOR/CHARGING SYSTEM 7 IGNITION SYSTEM 8 STARTING SYSTEM 9 OTHER ELECTRICAL 10 MUFFLER 11 GENERATOR/ENGINE REMOVAL/INSTALLATION 12 CYLINDER HEAD 13 CYLINDER BLOCK 14 HANDLE/WHEELS 15 TECHNICAL FEATURES 16 WIRING DIAGRAMS 17 INDEX PSV61Z37000E3.2017.06 dummyhead How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda EU7000is generator. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and tables. As you read this manual, you will find information that is preceded by a prevent damage to this Honda product, other property, or the environment. symbol. The purpose of this message is to help SAFETY MESSAGES Your safety and the safety of others are very important. To help you make informed decisions, we have provided safety messages and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing these products. You must use your own good judgment. You will find important safety information in a variety of forms, including: • Safety Labels – on the product. • Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. • Instructions – how to service these products correctly and safely. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS, AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda PRODUCTS. © Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: June 2017 0-3 Revised: June 2017 (61Z37000E2) dummyhead How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product. • Install new gaskets, O-rings, etc. when reassembling. • When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless a particular sequence is specified. • Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before assembly. • After assembly, check all parts for proper installation and operation. • Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the threads and ruin the hole. Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The use of incorrect tools and fasteners will damage the unit. SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommend engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use marine grease (water resistant urea based grease). Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. Use automatic transmission fluid. ( x )( ) page 1-1 Indicates the diameter, length, and quantity of metric bolts used. Indicates the reference page. 0-4 dummyhead How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated term AAT ACG API Assy. ATDC ATF ATT BAT BDC BTDC BARO CKP Comp. CMP CYL DLC EBT ECT ECM EMT EOP EVAP EX F GCU GFCI GND HO2S IAC IAT I.D. IG or IGN IN INJ L. MAP MIL O.D. OP PGM-FI P/N Qty R. SAE SCS STD SW TDC Bl Y Bu 0-5 Black Yellow Blue G R W Full term Ambient Air Temperature Alternator American Petroleum Institute Assembly After Top Dead Center Automatic Transmission Fluid Attachment Battery Bottom Dead Center Before Top Dead Center Barometric Pressure Crankshaft Position Complete Camshaft Position Cylinder Data Link Connector Engine Block Temperature Engine Coolant Temperature Engine Control Module Exhaust Manifold Temperature Engine Oil Pressure Evaporative Exhaust Front or Forward Generator Control Unit Ground Fault Circuit Interrupter Ground Heated Oxygen Sensor Idle Air Control Intake Air Temperature Inside Diameter Ignition Intake Injection Left Manifold Absolute Pressure Malfunction Indicator Lamp Outside Diameter Optional Part Programmed-Fuel Injection Part Number Quantity Right Society of Automotive Engineers Service Check Signal Standard Switch Top Dead Center Green Red White Br O Lb Brown Orange Light blue Lg P Gr Light green Pink Gray dummyhead How to use this manual HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins, and the shape of terminal (male or female). Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are shown for the dedicated connectors. The double frame connectors represent the male connectors and the single frame connectors represent the female connectors. Both the male and female connectors are shown by viewing them from the terminal side. FEMALE CONNECTOR VIEWING DIRECTION LOCK VIEWING DIRECTION TERMINAL ARRANGEMENT MALE CONNECTOR CONNECTOR No. The connector drawing shows the terminal arrangement of the connector with the lock of the connector UP. FEMALE CONNECTOR DRAWING (SINGLE FRAME) Female connector viewed from the terminal side. CONNECTOR No. LOCK MALE CONNECTOR DRAWING (DOUBLE FRAME) Male connector viewed from the terminal side. TERMINAL No. The system drawing shows the No.9 terminal of the connector. 0-6 dummyhead How to use this manual HOW TO READ A WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a male or female terminal. TERMINAL No. GCU 18 Bl/W Bl/Y Br/Y G G/O 10 G/O Bl/Y Bl W/Bu 11 Bl Bl/W 12 Br/Bu T3 STMAG(+12V) MAIN_SW+ MAIN_SWGND 3 T1 G G 20 C9 BAT_IN STMAG(+12V) 9 1 G STMAG 13 10 Bl/Y 7 Bl/W 9 Bl/W STMAG 8 Bl/W 3 29 Bl/Y GND PUSH SW1 Bl T2 15 STARTER SWITCH Bl/Y Bl 2 Bl/Y STARTER MOTOR G 1 G 14 GND3 W 5 W/Bu 1 Br/Bu MAIN SWITCH 13 BAT ACC Br/Bu Bl MAIN_SW2 G MAIN_SW1 2 MAINSW1 MAINSW2 ON G/O 4 15A G/O Br/W ACC Bl/Y BAT MAIN SWITCH 3 3A OFF 1 Br/Bu CONNECTOR/TERMINAL No. Indicates the ground. (Circled GND followed with No. in white background) Every connector and terminal has a number to help the users find the location and shape of the connector and the terminal arrangement by referring to the “Connector general layout drawing” and/or the “Connector drawing.” All the connector/terminal numbers shown in this Service Manual are either of those shown in this section. : Connector that joins a harness to a harness (Circled No. in black background) : Connector that connects to electrical equipment (Circled No. in white background) : Connector (Circled C followed with No. in white background) : Terminal (Circled T followed with No. in white background) : Ground (Circled GND followed with No. in white background) 0-7 dummytext 1. SPECIFICATIONS 1 SERIAL NUMBER LOCATION ·····················1-2 PERFORMANCE CURVES··························· 1-4 SPECIFICATIONS ·········································1-2 DIMENSIONAL DRAWINGS························· 1-5 1-1 dummyhead SPECIFICATIONS SERIAL NUMBER LOCATION SPECIFICATIONS The engine serial number is located on the cylinder block on the starter grip side of this unit, and the frame serial number is located on the front frame on the starter grip side of this unit. Refer to them when ordering parts or making technical inquiries. ENGINE SERIAL NUMBER FRAME SERIAL NUMBER SPECIFICATIONS TYPE DESCRIPTION It may be necessary to refer to this chart for reference purposes when reading this manual. Model Type EVAP control system GFCI Breather heater system AT EU7000is AT1 NOTE: "AT, AT1" and "CT" are Destination Code: AT, AT1 = U.S.A. CT = Canada DIMENSIONS AND WEIGHTS Model Description code Overall length Overall width Overall height Dry weight Operating weight 1-2 AT, AT1 type CT type AT, AT1 type CT type EU7000is EEJD 1,198 mm (47.2 in) 700 mm (27.6 in) 721 mm (28.4 in) 118.6 kg (261.5 lbs) 118.1 kg (260.4 lbs) 133.6 kg (294.5 lbs) 133.1 kg (293.4 lbs) CT dummyhead SPECIFICATIONS ENGINE Engine model Description code Type Displacement Bore x stroke Compression ratio Cooling system Ignition system Ignition timing Spark plug Fuel system Air cleaner Governor Lubrication system Oil capacity Recommended oil Starting system Stopping system Recommended fuel GX390T2 GCAGD 4 stroke, overhead valve, single cylinder, inclined by 25° 389 cm3 (23.7 cu-in) 88 x 64 mm (3.5 x 2.5 in) 8.2: 1 Forced air Full Transistorized ignition 20° B.T.D.C. / 3,300 min-1 (rpm) (No load) BPR6ES (NGK) Electronically controlled fuel injection Dual type Electric system Forced spray system 1.1 Liter (1.16 US qt, 0.97 Imp qt) SAE 10W-30 API service classification SJ or higher Recoil and electric starter Ignition primary circuit open Unleaded gasoline with a pump octane rating 86 or higher and an ethanol content of no more than 10% GENERATOR Model Description code Generator type Generator structure Excitation Voltage regulation system Phase Rated output Rated frequency Rated voltage Rated current Power factor EU7000is EEJD Multi-electrode field rotation type Self-ventilation, drip-proof type Self-excitation PWM (Pulse width modulation) Single phase 5.5 kVA 60 Hz 120/240 V 45.8/22.9 A 1.0 Cosθ CHARACTERISTICS Model Type Voltage variation rate Voltage stability Frequency variation rate EU7000is AT, AT1 Momentary Average Average time Momentary Average Average time Frequency stability Insulation resistance AC circuit protector Insulation type Rated rpm Fuel tank capacity Fuel consumption Max. operating hours at rated load without refueling Guaranteed sound power level (LWA) CT 10% max. 6% max. 3 sec. max. Within ± 1% 1% max. 1% max. 3 sec. max. Within ± 0.3 Hz 10 MΩ min. 64.1/32.1 A E B 2,400 – 3600 min-1 (rpm) 3,300 – 3,600 min-1 (rpm) *1 19.2 Liters (5.07 US gal, 4.22 Imp gal) 2.95 Liters (0.779 US gal, 0.649 Imp gal)/Hr. Approx. 6.5 Hr. LWA 91 dB (A) *1: At Eco-ThrottleTM OFF 1-3 dummyhead SPECIFICATIONS PERFORMANCE CURVES The curve shows performance of the generator under average conditions. Performance may vary to some degree depending on ambient temperature and humidity. The output voltage will be higher than usual when the generator is still cold, immediately after the engine starts. AC EXTERNAL CHARACTERISTIC CURVE AC VOLTAGE (V) 240 V RATED 22.9 A AC LOAD CURRENT (A) 1-4 120 V RATED 45.8 A dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS Unit: mm (in) 1,198 (47.2) 721 (28.4) 848 (33.4) 700 (27.6) 1-5 dummyhead MEMO dummytext 2. SERVICE INFORMATION 2 MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-6 TORQUE VALUES ········································2-3 CABLE/HARNESS ROUTING ······················ 2-8 LUBRICATION & SEAL POINTS··················2-6 TUBE ROUTING ········································· 2-24 2-1 dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Part Engine Item Engine speed 3,300 – 3,600 min-1 (rpm) *1 Piston pin Piston rings Connecting rod Crankshaft Valves Camshaft Cylinder barrel Crankcase cover Spark plug CKP sensor Starter motor – 2 Cylinder compression Cylinder Cylinder head Piston Unit: mm (in) Service limit Standard Sleeve I.D. Warpage Skirt O.D. Piston-to-cylinder clearance Piston pin bore I.D. Pin O.D. Piston pin-to-piston pin bore clearance Ring side Top clearance Second Ring end gap Top Second Oil (side rail) Ring width Top Second Small end I.D. Big end I.D. Big end oil clearance Big end side clearance Crank pin O.D. Runout Valve IN clearance EX Valve IN stem O.D. EX Valve guide I.D. IN/EX Guide-to-stem IN clearance EX Valve seat width Valve spring free length Valve spring perpendicularity Camshaft O.D. Cam height IN EX Camshaft holder I.D. Camshaft holder I.D. Gap Air gap Brush Length Mica depth 0.46 – 0.64 MPa (4.7 – 6.5 kgf/cm , 67 – 92 psi) at 600 min-1 (rpm) 88.000 – 88.017 (3.4646 – 3.4652) – 87.975 – 87.985 (3.4636 – 3.4640) 0.015 – 0.042 (0.0006 – 0.0017) 20.002 – 20.008 (0.7875 – 0.7877) 19.994 – 20.000 (0.7872– 0.7874) 0.002 – 0.014 (0.0001 – 0.0006) 0.030 – 0.060 (0.0012 – 0.0024) 0.060 – 0.090 (0.0024 – 0.0035) 0.200 – 0.350 (0.0079 – 0.0138) 0.350 – 0.500 (0.0138 – 0.0197) 0.20 – 0.70 (0.008 – 0.028) 1.160 – 1.175 (0.0457 – 0.0463) 1.130 – 1.145 (0.0445 – 0.0451) 20.005 – 20.020 (0.7876 – 0.7882) 36.025 – 36.039 (1.4183 – 1.4189) 0.040 – 0.064 (0.0016 – 0.0025) 0.1 – 0.4 (0.004 – 0.016) 35.975 – 35.985 (1.4163 – 1.4167) – 0.15 ± 0.02 (0.006 ± 0.001) 0.20 ± 0.02 (0.008 ± 0.001) 6.575 – 6.590 (0.2589 – 0.2594) 6.535 – 6.550 (0.2573 – 0.2579) 6.600 – 6.615 (0.2598 – 0.2604) 0.010 – 0.040 (0.0004 – 0.0016) 0.050 – 0.080 (0.0020 – 0.0032) 1.0 – 1.2 (0.04 – 0.05) 39.0 (1.54) – 15.966 – 15.984 (0.6286 – 0.6293) 32.448 – 32.748 (1.2775 – 1.2893) 31.935 – 32.235 (1.2573 – 1.2691) 16.000 – 16.018 (0.6299 – 0.6306) 16.000 – 16.018 (0.6299 – 0.6306) 0.70 – 0.80 (0.028 – 0.031) 0.2 – 0.6 (0.01 – 0.02) 10 (0.4) – – 88.17 (3.471) 0.10 (0.004) 87.85 (3.459) 0.12 (0.005) 20.042 (0.7891) 19.950 (0.7854) 0.08 (0.003) 0.15 (0.006) 0.15 (0.006) 1.0 (0.04) 1.0 (0.04) 1.0 (0.04) 1.140 (0.0449) 1.110 (0.0437) 20.07 (0.790) 36.07 (1.420) 0.12 (0.005) 1.0 (0.04) 35.93 (1.415) 0.1 (0.004) – – 6.44 (0.254) 6.40 (0.252) 6.66 (0.262) 0.11 (0.004) 0.13 (0.005) 2.0 (0.08) 37.5 (1.48) 1.5° 15.92 (0.627) 32.198 (1.2676) 29.886 (1.1766) 16.05 (0.632) 16.05 (0.632) – – 6 (0.2) 0.2 (0.01) *1: At Eco-Throttle OFF ELECTRICAL PARTS Part Throttle control motor Generator (Master) Generator (Slave) 2-2 Connector Terminal number 1–3 2–4 1–2 2–3 1–3 1–2 2–3 1–3 Standard 65 – 75 Ω 0.44 – 0.62 Ω 0.44 – 0.62 Ω dummyhead SERVICE INFORMATION Part Fuel pump Fuel injector EBT sensor Breather heater *1 Ignition coil Spark plug cap CKP sensor Item Fuel pressure Fuel flow Fuel pump motor resistance Resistance Resistance Resistance Resistance (Primary side) Resistance (Secondary side) Resistance Resistance Standard 294 kPa (3.0 kgf/cm2, 43 psi) 55 cc (1.9 US oz, 1.9 Imp oz) minimum/10 seconds 0 – 20 Ω (at 20 °C/68 °F) 11 – 13 Ω (at 24 °C/75 °F) 1.6 – 2.9 kΩ (at 20 °C – 30 °C/68 °F – 86 °F) 0.8 – 1.2 kΩ (at 25 °C/77 °F) 1.8 – 2.2 Ω 5.6 – 6.9 Ω 7.5 – 12.5 kΩ 297 – 363 Ω (at 20 °C/68 °F) *1: CT type only TORQUE VALUES ENGINE TORQUE VALUES Torque values kgf·m lbf·ft 1.8 13 2.3 17 3.6 26 Thread Dia. and pitch (mm) M14 x 1.25 M12 x 1.5 M10 x 1.25 N·m 18 22.5 35 Rocker arm pivot lock nut Rocker arm pivot bolt M6 x 0.5 M8 x 1.25 10 24 1.0 2.4 7 18 Flywheel nut M16 x 1.5 113 11.5 83 Crankcase cover bolt Connecting rod special bolt M8 x 1.25 M8 x 1.25 24 14 2.4 1.4 18 10 Exhaust pipe nut EBT sensor Starter motor nut washer Fuel injector joint bolt O2 sensor Oil level switch joint nut M8 x 1.25 M8 x 1.25 M8 x 1.25 M5 x 0.8 M12 x 1.25 M10 x 1.25 24 9 8.8 5.1 24.5 10 2.4 0.92 0.90 0.52 2.5 1.0 18 6.6 6.5 3.8 18 7 Item Spark plug Drain plug bolt Cylinder head bolt Remarks Apply engine oil to the threads and seating surface. Apply engine oil to the threads and seating surface. Degrease the crankshaft and flywheel tapered surface. Apply engine oil to the threads and seating surface. Apply engine oil to the threads and seating surface. 2-3 dummyhead SERVICE INFORMATION FRAME TORQUE VALUES Item Bottom rubber mount nut Bottom rubber mount nut Fuel pump mount nut Fuel meter mount screw Silencer chamber nut Air cleaner connecting tube band screw Handle pipe mount bolt Handle holder mount bolt Front frame mount bolt Muffler mount bolt Muffler mount nut Tail pipe mount screw Head cover lower shroud mount bolt Plug cover mount bolt Front cover mount bolt Front cover mount nut Battery maintenance cover mount bolt Fan cover mount nut Control panel mount nut Parallel operation outlets terminal nut Receptacle terminal screw Receptacle mounting nut Circuit protector mounting nut Ground terminal screw (CT type) Ground terminal screw (AT, AT1 type) Voltage selector switch nut GCU mounting nut Ground terminal screw (CT Type only) Circuit protector mounting screw Circuit protector terminal screw High tension cord holder mount screw Generator rotor mount nut Stator mount bolt Ignition coil mount bolt CKP sensor mount bolt Throttle control motor screw Ground terminal mounting nut Ground cable mounting nut 2-4 Thread Dia. and pitch (mm) M10 x 1.25 M8 x 1.25 M6 x 1.0 M5 x 0.8 M6 x 1.0 M4 x 0.7 N·m 34 24 12 4 8.5 0.7 Torque values kgf·m 3.5 2.4 1.2 0.41 0.87 0.07 lbf·ft 25 18 9 3.0 6.3 0.5 M8 x 1.25 M8 x 1.25 M8 x 1.25 M8 x 1.25 M8 x 1.25 M5 x 0.8 M6 x 1.0 21.5 21.5 24 27 24 3.5 8.5 2.2 2.2 2.4 2.8 2.4 0.36 0.87 16 16 18 20 18 2.6 6.3 M6 x 1.0 M6 x 1.0 M6 x 1.0 M6 x 1.0 2.3 8.5 8.5 2.3 0.24 0.87 0.87 0.24 1.7 6.3 6.3 1.7 M6 x 1.0 M6 x 1.0 M4 x 0.7 8.5 8.5 1.1 0.87 0.87 0.11 6.3 6.3 0.8 M4 x 0.7 M4 x 0.7 M11 x 1.0 M5 x 0.8 1.3 1.3 1.8 2.3 0.13 0.13 0.18 0.24 1.0 1.0 1.3 1.7 M5 x 0.8 2.3 0.24 1.7 M4 x 0.7 M4 x 0.7 M6 x 1.0 1.3 1.3 2.3 0.13 0.13 0.24 1.0 1.0 1.7 M3 x 0.5 M4 x 0.7 M5 screw 0.6 1.1 3.4 0.06 0.11 0.35 0.4 0.8 2.5 M16 x 1.5 170 17.3 125 M6 x 1.0 M6 x 1.0 M5 x 0.8 – M6 x 1.0 11 10 6 2.1 3 1.1 1.0 0.6 0.21 0.31 8 7 4.4 1.5 2.2 M6 x 1.0 8.5 0.87 6.3 Remarks Degrease the crankshaft and rotor tapered surface. Apply engine oil to the threads and seating surface. CT Bolt dummyhead SERVICE INFORMATION STANDARD TORQUE VALUES ENGINE Item Screw Bolt and nut Flange bolt and nut SH (Small head) flange bolt CT (Cutting threads) flange bolt (Retightening) Thread dia. (mm) 4 mm 5 mm 6 mm 5 mm 6 mm 8 mm 10 mm 12 mm 5 mm 6 mm 8 mm 10 mm 6 mm 6 mm N·m 2.0 4.3 9 5.3 10 22 34 54 5.3 12 23 39 9 12 Torque values kgf·m lbf·ft 0.20 1.5 0.44 3.2 0.92 6.6 0.54 3.9 1.0 7 2.2 16 3.5 25 5.5 40 0.54 3.9 1.2 9 2.3 17 4.0 29 0.92 6.6 1.2 9 N·m 1.0 2.0 4.3 9 5.3 10 22 34 54 3.4 5.3 12 27 39 9 10 Torque values kgf·m lbf·ft 0.10 1.5 0.20 1.5 0.44 3.2 0.92 6.6 0.54 3.9 1.0 7 2.2 16 3.5 25 5.5 40 0.54 3.9 0.54 3.9 1.2 9 2.8 20 4.0 29 0.92 6.6 1.0 7 FRAME Item Screw Bolt and nut Flange bolt and nut SH (Small head) flange bolt CT (Cutting threads) flange bolt (Retightening) Thread dia. (mm) 3 mm 4 mm 5 mm 6 mm 5 mm 6 mm 8 mm 10 mm 12 mm 4 mm 5 mm 6 mm 8 mm 10 mm 6 mm 6 mm 2-5 dummyhead SERVICE INFORMATION LUBRICATION & SEAL POINTS Material Engine oil Multi-purpose grease Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1) Adhesive (LOCTITE® #495) Location Crankshaft pin and gear teeth Piston outer surface, ring groove, and piston pin hole Piston pin outer surface Piston ring entire surface Cylinder inner surface Connecting rod big and small end bearing Camshaft cam lobes and journal Balancer shaft gear teeth and bearing Valve lifter pivot, pivot end, and slipper surface Valve stem sliding surface and stem end Valve rocker arm tappet surface and pivot Rocker arm pivot threads and pivot Fuel injector O-ring whole surface Each O-ring whole surface Oil seal lips Recoil starter case cut out Recoil starter ratchet Recoil starter ratchet cover (ratchet sliding portion) Recoil starter ratchet cover (cover bolt sliding portion) Recoil starter ratchet cover (Friction spring sliding portion) Recoil starter ratchet cover (cam sliding portion) Left maintenance cover hinge pin whole surface Right cover hinge and hinge pin whole surface, hinge spring contact area Camshaft cam profile Front cover Remarks 3 g (0.1 oz) 0.03 g (0.001 oz) 0.5 – 1.0 g (0.02 – 0.04 oz) 0.05 g (0.002 oz) 0.05 g (0.002 oz) 0.05 g (0.002 oz) When installing a new camshaft See page 5-5 TOOLS SPECIAL TOOLS Remover weight 07936-371020A 2-6 Valve guide driver, 6.6 mm 07942-6570100 Attachment, 32 × 35 mm 07746-0010100 dummyhead SERVICE INFORMATION Attachment, 52 × 55 mm 07746-0010400 Attachment, 72 × 75 mm 07746-0010600 Driver, 40 mm I.D. 07746-0030100 Driver attachment, 35 mm I.D. 07746-0030400 Pilot, 15 mm 07746-0040300 Pilot, 35 mm 07746-0040800 Driver handle 07749-0010000 Bearing remover shaft, 15 mm 07936-KC10500 Valve guide reamer, 6.612 mm 07984-ZE20001 Crank pulley holder 47 07925-6570000 Fuel pressure gauge 07APJ-Z37A100 2-7 dummyhead SERVICE INFORMATION COMMERCIALLY AVAILABLE TOOLS Tool name Digital multimeter Battery tester Valve seat cutter, 30 x 45 degree Valve seat cutter, 60 degree Solid pilot bar, 6.6 mm T handle Valve lapper Flywheel puller Strap wrench Compression gauge Leak down tester Ring compressor Tool number FLU87V BM310 (YUASA) NWYCU128 NWYCU114 NWY100-6.60 NWYTW505 LIL21100 OTC7403 S-17 EEPV303A KLIAT1006M LIL18500 Application Electrical testing Battery testing Valve seat reconditioning Flywheel removal Compression testing Cylinder leak down Piston installation There are two convenient ways to order, online or by toll-free phone. • To order online, go to the IN: SERVICE > Tools > Tool and Equipment Program > Online Catalog, and then search by model number. • To order by phone, call 1-888-424-6857. Customer service representatives are available from 7:30 AM until 7:00 PM CT, Monday through Friday. CABLE/HARNESS ROUTING WIRE HARNESS BAND CABLE Terminal number CABLE Wire color G G G W (CT type only) CABLE CABLE (CT type only) WIRE HARNESS BAND CABLE CABLE (CT type only) (Secure the white tape area) Bl Y Bu G R W 2-8 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray dummyhead SERVICE INFORMATION 8P CONNECTOR WIRE BAND (CT Type only) 10P CONNECTOR 6P CONNECTOR Bl Y Bu G R W 2P CONNECTOR (CT Type only) Control wire harness side Engine wire harness side Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray FUSE BOX Terminal number 1 3 5 Wire color R W Bu Generator wire harness side Control wire harness side Black Yellow Blue Green Red White Control wire harness side Engine wire harness side Terminal number 1 2 3 4 5 6 7 8 Terminal number 1 2 3 4 5 6 7 8 9 10 Wire color G Bl Y/R Y/Bl W R Y Bu Bl/W Bl/Y Wire color Bu Y Y/Bu Y R W Bl Bl/G Receptacle terminal side Breather heater wire harness side Terminal number 1 2 Wire color Terminal number 1 2 Wire color W R R R 2-9 dummyhead SERVICE INFORMATION WIRE HARNESS BAND MAIN WIRE HARNESS WIRE (Secure the yellow tape area) CONTROL WIRE HARNESS GENERATOR WIRE HARNESS / WIRE (Secure the yellow tape area) Terminal number Bl Bl/Y Bl BATTERY POSITIVE (+) TERMINAL DLC WIRE HARNESS BAND BATTERY NEGATIVE (-) TERMINAL WIRE (Secure the white tape area) WIRE DLC WIRE / INVERTER 3P CONNECTOR WIRE WIRE (Secure the white tape area) BREATHER HEATER WIRE (CT Type only) WIRE HARNESS CLIP WIRE WIRE DLC WIRE / BREATHER HEATER WIRE (CT Type only) WIRE BATTERY NEGATIVE (-) TERMINAL 2-10 Wire color BATTERY POSITIVE (+) TERMINAL WIRE INVERTER 6P CONNECTOR dummyhead SERVICE INFORMATION INVERTER 4P CONNECTOR DLC BATTERY POSITIVE (+) TERMINAL REMOTE 8P CONNECTOR Main wire harness side Control wire harness side Control wire harness side Generator wire harness side BATTERY NEGATIVE (-) TERMINAL INVERTER 3P CONNECTOR Terminal number 1 2 3 4 Wire color Terminal number 1 3 Wire color Terminal number 1 2 3 4 5 6 Wire color Terminal number 1 2 3 Wire color INVERTER 3P CONNECTOR INVERTER 6P CONNECTOR Terminal number 1 2 3 Wire color Terminal number 1 2 5 6 8 Wire color Terminal number 1 5 Wire color Terminal number 1 2 3 4 Wire color Generator wire harness side Gr Bu R W Control wire harness side R/W R G/O G/Bu O/W Bu/Y Bu/R R R W Bu Connector side Control wire harness side INVERTER 3P CONNECTOR Bl Y Bu G R W Black Yellow Blue Green Red White R W Bu Br/Bu G/Bu W/Bu W/G G W W Bu/R G Br/W Bu/Y Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray 2-11 dummyhead SERVICE INFORMATION AT Type: MAIN WIRE HARNESS CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR ECO-THROTTLE SWITCH WIRE CONNECTOR CONTROL WIRE HARNESS ECO-THROTTLE SWITCH WIRE CONNECTOR STARTER SWITCH 2P CONNECTOR MAIN SWITCH 4P CONNECTOR SUB WIRES CIRCUIT PROTECTOR WIRE CONNECTOR WIRE HARNESS BAND (9) CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR Control wire harness side Terminal number 1 2 3 4 PARALLEL OPERATION OUTLETS TERMINAL PARALLEL OPERATION OUTLETS TERMINAL PARALLEL OPERATION OUTLETS TERMINAL Terminal number Wire color Br/Bu Br/Bu G/O G/O Control wire harness side Terminal number 1 2 Wire color R/W R Bu Bu Bu Bu R R Bu W R Wire color G Bl/Y Starter switch side Main switch side 2-12 Terminal number 1 2 3 4 Wire color G Bl Br/W Bl/Y Terminal number Wire color G Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray dummyhead SERVICE INFORMATION WIRE BAND AT Type: RECEPTACLE TERMINAL CIRCUIT PROTECTOR TERMINAL CIRCUIT PROTECTOR TERMINAL RECEPTACLE TERMINAL NOISE FILTER 10 mm (0.4 in) RECEPTACLE TERMINAL MAIN WIRE HARNESS (Secure the white tape area) CIRCUIT PROTECTOR TERMINAL CIRCUIT PROTECTOR TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL VOLTAGE SELECTOR SWITCH 6P CONNECTOR RECEPTACLE TERMINAL RECEPTACLE TERMINAL Main wire harness side Main wire harness side Terminal number 1 2 4 5 6 Terminal number 1 2 3 4 5 6 Wire color R R Bu Bu R Wire color Bu W Gr Gr Bu Bu VOLTAGE SELECTOR SWITCH 6P CONNECTOR WIRE BAND Terminal number Wire color W Bu R Bu Bu R R W Bu Bu W R WIRE (Secure the yellow tape area) VOLTAGE SELECTOR SWITCH WIRE INVERTER 4P CONNECTOR WIRE WIRE Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray 2-13 dummyhead SERVICE INFORMATION AT1 Type: MAIN WIRE HARNESS CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR ECO-THROTTLE SWITCH WIRE CONNECTOR CONTROL WIRE HARNESS ECO-THROTTLE SWITCH WIRE CONNECTOR STARTER SWITCH 2P CONNECTOR MAIN SWITCH 4P CONNECTOR SUB WIRES CIRCUIT PROTECTOR WIRE CONNECTOR WIRE HARNESS BAND (9) CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR Control wire harness side Terminal number 1 2 3 4 PARALLEL OPERATION OUTLETS TERMINAL PARALLEL OPERATION OUTLETS TERMINAL PARALLEL OPERATION OUTLETS TERMINAL Terminal number Wire color Br/Bu Br/Bu G/O G/O Control wire harness side Terminal number 1 2 Wire color R/W R Bu Bu Bu Bu R R Bu W R Wire color G Bl/Y Starter switch side Main switch side 2-14 Terminal number 1 2 3 4 Wire color G Bl Br/W Bl/Y Terminal number Wire color G Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray dummyhead SERVICE INFORMATION WIRE BAND AT1 Type: RECEPTACLE TERMINAL CIRCUIT PROTECTOR TERMINAL CIRCUIT PROTECTOR TERMINAL RECEPTACLE TERMINAL NOISE FILTER 10 mm (0.4 in) RECEPTACLE TERMINAL MAIN WIRE HARNESS (Secure the white tape area) CIRCUIT PROTECTOR TERMINAL CIRCUIT PROTECTOR TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL VOLTAGE SELECTOR SWITCH 6P CONNECTOR RECEPTACLE TERMINAL RECEPTACLE TERMINAL Main wire harness side Main wire harness side Terminal number 1 2 4 5 6 Terminal number 1 2 3 4 5 6 Wire color R R Bu Bu R Wire color Bu W Gr Gr Bu Bu VOLTAGE SELECTOR SWITCH 6P CONNECTOR WIRE BAND Terminal number Wire color W Bu R Bu Bu R R W Bu Bu W R W WIRE (Secure the yellow tape area) VOLTAGE SELECTOR SWITCH WIRE INVERTER 4P CONNECTOR WIRE WIRE Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray 2-15 dummyhead SERVICE INFORMATION CT Type: BREATHER HEATER WIRE CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR ECO-THROTTLE SWITCH WIRE CONNECTOR ECO-THROTTLE SWITCH WIRE CONNECTOR PARALLEL OPERATION OUTLETS TERMINAL CONTROL WIRE HARNESS STARTER SWITCH 2P CONNECTOR SUB WIRES MAIN SWITCH 4P CONNECTOR TUBE CIRCUIT PROTECTOR WIRE CONNECTOR WIRE HARNESS BAND (9) CIRCUIT PROTECTOR WIRE CONNECTOR CIRCUIT PROTECTOR WIRE CONNECTOR PARALLEL OPERATION OUTLETS TERMINAL PARALLEL OPERATION OUTLETS TERMINAL MAIN WIRE HARNESS Control wire harness side Main switch side 2-16 Terminal number 1 2 3 4 Wire color Terminal number 1 2 3 4 Wire color Br/Bu Br/Bu G/O G/O G Bl Br/W Bl/Y Control wire harness side Terminal number 1 2 Terminal number Wire color R/W R Bu Bu Bu Bu R R Bu W R Wire color G Bl/Y Starter switch side Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Terminal number Wire color G G G G dummyhead SERVICE INFORMATION WIRE BAND CT Type: CIRCUIT PROTECTOR TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL CIRCUIT PROTECTOR TERMINAL CIRCUIT PROTECTOR TERMINAL CIRCUIT PROTECTOR TERMINAL NOISE FILTER 10 mm (0.4 in) MAIN WIRE BREATHER HEATER WIRE HARNESS (Secure the white tape area) CIRCUIT PROTECTOR TERMINAL CIRCUIT PROTECTOR TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL Main wire harness side Main wire harness side RECEPTACLE TERMINAL RECEPTACLE TERMINAL RECEPTACLE TERMINAL Terminal number 1 2 4 5 6 Wire color Terminal number 1 2 3 4 5 6 Wire color R R Bu Bu R Bu W Gr Gr Bu Bu CIRCUIT PROTECTOR TERMINAL Terminal number VOLTAGE SELECTOR SWITCH 6P CONNECTOR CIRCUIT PROTECTOR TERMINAL VOLTAGE SELECTOR SWITCH 6P CONNECTOR Wire color W Bu R Bu Bu R R W Bu W Bu W R Bu Bu R R WIRE BAND WIRE (Secure the yellow tape area) VOLTAGE SELECTOR SWITCH WIRE INVERTER 4P CONNECTOR WIRE WIRE Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray 2-17 dummyhead SERVICE INFORMATION CONTROL WIRE HARNESS GCU 4P CONNECTOR GCU 34P CONNECTOR GCU 2P CONNECTOR WIRE HARNESS BAND (3) GCU 5P CONNECTOR CONTROL WIRE HARNESS Front frame side CONTROL WIRE HARNESS GCU 34P CONNECTOR/2P CONNECTOR HARNESS (Secure the yellow tape area) GCU 34P CONNECTOR/ 2P CONNECTOR HARNESS (Be sure to set it under the control wire harness) Control wire harness side Terminal number 1 3 4 5 6 7 8 9 Wire color R G Bu W/G G/Bu Bl/W Bl/W G/O Control wire harness side Control wire harness side 2-18 Terminal number 10 11 12 13 14 15 16 17 Wire color Terminal number 1 2 3 4 Wire color Terminal number 1 2 Wire color G/O W/Bu Br/Bu Br/Y W R Bu Y G Bu/R Bu/Y Br/W Bl/G Bl Terminal number 18 20 21 22 23 24 25 26 Wire color W G Y O/W G/O G/Bu Bu/R Bu/Y Control wire harness side Terminal number 27 28 29 30 31 32 33 Wire color Terminal number 1 3 5 Wire color Bl Y Bu G R W Black Yellow Blue Green Red White Y/Bl Y Bl/Y R Bl Y/R Y/Bu Bu W R Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray dummyhead SERVICE INFORMATION IGNITION COIL CONNECTOR IGNITION COIL CONNECTOR STARTER MAGNETIC SWITCH CONNECTOR STARTER MAGNETIC SWITCH TERMINAL ENGINE WIRE HARNESS HIGH TENSION CORD FUEL PUMP 5P CONNECTOR WIRE HARNESS BAND (2) FUEL INJECTOR 2P CONNECTOR THROTTLE CONTROL MOTOR 4P CONNECTOR Engine wire harness side Terminal number 1 2 3 4 Wire color Y W Bu R Engine wire harness side Terminal number 1 2 Wire color Terminal number Wire color Bl Bl Bl/G Bl/W Bu R Throttle control motor side Engine wire harness side Terminal number 1 2 Wire color Y W Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray 2-19 dummyhead SERVICE INFORMATION STOPS Install the ground terminals touching the stops as shown. Terminal number Y Bl G G Bl Y Bu G R W ENGINE WIRE HARNESS Wire color Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray OIL LEVEL SWITCH CONNECTOR WIRE HARNESS BAND (2) OIL LEVEL SWITCH WIRE (GROUND TERMINAL) 2-20 dummyhead SERVICE INFORMATION WIRE HARNESS CLIP EBT SENSOR O2 SENSOR WIRE EBT SENSOR WIRE CT Type only: BREATHER HEATER 2P CONNECTOR WIRE BAND Engine wire harness side Breather heater harness side Terminal number 1 2 Wire color R R Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray 2-21 dummyhead SERVICE INFORMATION EBT SENSOR WIRE O2 SENSOR WIRE WIRE CLIP (4 PLACES) (On the lower shroud) CKP SENSOR CONNECTOR CKP SENSOR WIRE ENGINE WIRE HARNESS EBT SENSOR WIRE GENERATOR WIRE HARNESS HARNESS CLAMP O2 SENSOR WIRE EBT SENSOR CONNECTOR WIRE HARNESS BAND EBT SENSOR CONNECTOR GROUND CABLE O2 SENSOR CONNECTOR Terminal number AT Type Terminal number O2 sensor wire harness side Terminal number 1 Engine wire harness side Bl Bl CT Type Terminal number Wire color G G 2-22 Y/Bu Bu Y/R Bl Y/Bl Bl Wire color Wire color Bl Wire color Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray dummyhead SERVICE INFORMATION CKP SENSOR CONNECTOR WIRE HARNESS CLIP Terminal number Wire color Bu CKP SENSOR WIRE GENERATOR WIRE HARNESS GENERATOR HARNESS GROMMET GENERATOR WIRE HARNESS RED MARK GENERATOR WIRE HARNESS Generator wire harness side Generator wire harness side STATOR Bl Y Bu G R W Terminal number 1 2 3 Wire color Terminal number 1 2 3 Wire color Black Yellow Blue Green Red White Bu W R Bu W R Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray 2-23 dummyhead SERVICE INFORMATION TUBE ROUTING PAINT MARK HIGH TENSION BREATHER TUBE FUEL FEED GROMMET CORD FUEL PUMP HOSE CLAMP PAINT MARK PAINT MARK FUEL FEED HOSE QUICK CONNECT FITTING HEAD COVER QUICK CONNECT FITTING FUEL FEED HOSE HOSE CLAMP HOSE CLAMP AIR CLEANER FUEL FEED GROMMET QUICK CONNECT FITTING WIRE HARNESS BAND ENGINE WIRE HARNESS FUEL FEED HOSE FUEL FEED GROMMET ENGINE WIRE ENGINE WIRE HARNESS HARNESS 2-24 FUEL FEED HOSE dummyhead SERVICE INFORMATION AT, AT1 Type only: PURGE TUBE CANISTER CHARGE TUBE TUBE CLIP (B7) PAINT MARK TUBE CLAMP PAINT MARK TUBE CLAMP TUBE CLIP TUBE CLIP (B7) TUBE CLIP CANISTER PAINT MARK PAINT MARK TUBE CLAMP AIR CLEANER COVER CANISTER AIR TUBE CANISTER DRAIN TUBE 2-25 dummyhead SERVICE INFORMATION AT, AT1 Type only: PURGE TUBE CANISTER CHARGE TUBE TUBE CLIP (B7) TUBE CLIP CANISTER TUBE CLIP TUBE CLIP (B7) CANISTER AIR TUBE TUBE CLAMP CANISTER DRAIN TUBE BREATHER TUBE A CT Type only: BREATHER HEATER INSULATOR PAINT MARK WIRE HARNESS BAND BREATHER HEATER 10 mm (0.4 in) BREATHER HEATER INSULATOR BREATHER TUBE B BREATHER TUBE A WIRE HARNESS BAND 2-26 SILENCER CHAMBER WIRE HARNESS BAND dummytext 3. MAINTENANCE 3 MAINTENANCE SCHEDULE························3-2 SPARK ARRESTER CLEANING················ 3-10 ENGINE OIL LEVEL CHECK/CHANGE ·······3-4 VALVE CLEARANCE CHECK/ ADJUSTMENT ············································ 3-10 AIR CLEANER CHECK/CLEANING/ REPLACEMENT············································3-6 COMBUSTION CHAMBER CLEANING ····· 3-12 GFCI OPERATION (AT1 TYPE ONLY)·········3-7 FUEL TANK CLEANING····························· 3-12 EVAP CANISTER/EVAP CHARGE TUBE/ EVAP PURGE TUBE INSPECTION (AT, AT1 TYPE ONLY)··································3-7 FUEL PUMP FILTER CHANGE ·················· 3-13 FUEL FEED HOSE CHECK ························ 3-14 SPARK PLUG CHECK/ADJUSTMENT/ REPLACEMENT············································3-9 3-1 dummyhead MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE AT, AT1 TYPE ITEM Perform at every indicated month or operating hour interval, whichever comes first. Engine oil Check level Change Air cleaner Check Clean Replace GFCI operation Check (AT1 type only) Canister Check Purge tube Check Charge tube Check Spark plug Check–adjust Replace Spark arrester Clean Valve Check–adjust clearance Combustion Clean chamber Fuel tank Clean Fuel pump filter Change Fuel feed hose Check Each use REGULAR SERVICE PERIOD (2) Every Every First 6 months 3 months month or 100 hrs. or 50 hrs. or 20 hrs. Every year or 300 hrs. Refer to page 3-4 3-5 (1) 3-6 * 3-7 Every 2 years Every 2 years Every 2 years 3-7 3-9 3-10 3-10 After every 1,000 hrs. 3-12 Every 2 years or 1,000 hrs Every 2 years or 1,000 hrs Every 2 years (Replace if necessary) 3-12 3-13 3-14 * Replace paper element type only. (1) Service more frequently when used in dusty areas. (2) For commercial use, log hours of operation to determine proper maintenance intervals. • This generator is equipped with a catalytic converter. If the engine is not properly maintained, the catalyst in the muffler may lose effectiveness. 3-2 dummyhead MAINTENANCE CT TYPE ITEM Perform at every indicated month or operating hour interval, whichever comes first. Engine oil Air cleaner Spark plug Spark arrester Valve clearance Combustion chamber Fuel tank Fuel pump filter Fuel feed hose Each use Check level (Operation other than in winter) Check level (Operation in winter) Change Check Clean Replace Check–adjust Replace Clean REGULAR SERVICE PERIOD (2) Every Every First 6 3 month Every months months or 20 10 hrs. or 100 or 50 hrs. hrs. hrs. Clean Change Check Refe r to page 3-4 (3) 3-4 3-5 (1) 3-6 * 3-9 3-10 Check–adjust Clean Every year or 300 hrs. 3-10 After every 1,000 hrs. 3-12 Every 2 years or 1,000 hrs Every 2 years or 1,000 hrs Every 2 years (Replace if necessary) 3-12 3-13 3-14 * Replace paper element type only. (1) Service more frequently when used in dusty areas. (2) For commercial use, log hours of operation to determine proper maintenance intervals. (3) If the machine is operated with a light load in a cold climate for a prolonged period, the engine oil may become mixed with gasoline causing engine seizure. When using in cold district, check the oil level every 10 hours of operation, and change the oil if it flows out from the oil filler neck. • This generator is equipped with a catalytic converter. If the engine is not properly maintained, the catalyst in the muffler may lose effectiveness. 3-3 dummyhead MAINTENANCE ENGINE OIL LEVEL CHECK/CHANGE CHECK Place the generator on a level surface. Open the right maintenance cover. [1] Remove the oil filler cap/dipstick [1], and check the oil level. If it is below the upper limit [2], fill with the recommended oil to the upper limit of the oil filler neck. If the oil level is low, fill to the top of the oil filler neck with the recommended oil. Do not overfill. Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range. Recommended oil: SAE 10W-30 API service classification SJ or higher Check that the oil filler gasket [3] is in good condition; replace it if necessary. [1] Tighten the oil filler cap/dipstick securely, and close the right maintenance cover. [2] [3] SAE VISCOSITY GRADES AMBIENT TEMPERATURE 3-4 dummyhead MAINTENANCE CHANGE Drain the used engine oil while the engine is warm. Warm oil drains quickly and completely. Place the generator on a level surface and stop the engine. Open the right maintenance cover. Push the drain hole rubber cover [1] out from the bottom plate. [1] Place a suitable container [1] under the oil drain bolt. [4] Remove the oil filler cap/dipstick [2], drain bolt [3], and sealing washer [4]. Drain the oil into the suitable container. Dispose of the used engine oil in a manner that is compatible with the environment. We suggest you take the used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash, pour it on the ground, or pour it down a drain. Used engine oil contains substances that have been identified as carcinogenic. If repeatedly left in contact with the skin for prolonged periods, it may cause skin cancer. Wash your hands thoroughly with soap and water as soon as possible after contact with used engine oil. Install the drain bolt and new sealing washer, and tighten the drain bolt to the specified torque. [3] [1] [5] [2] TORQUE: 22.5 N·m (2.3 kgf·m, 17 lbf·ft) With the generator on a level surface, fill with the recommended oil to the top of the oil filler neck. Engine oil capacity: 1.1 Liter (1.16 US qt, 0.97 Imp qt) Check that the oil filler gasket [5] is in good condition; replace it if necessary. Tighten the oil filler cap/dipstick securely. Clean the oil drain guide and install the oil drain hole rubber cover. Close the right maintenance cover. 3-5 dummyhead MAINTENANCE AIR CLEANER CHECK/CLEANING/ REPLACEMENT • A dirty air cleaner will restrict air flow to the throttle body, reducing engine performance. If the engine is operated in dusty areas, clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE. • Operating the engine without an air filter element or with a damaged air filter element will allow dirt to enter the engine, causing rapid engine wear. [1] Open the left maintenance cover. Open the air cleaner cover lever [1] and remove the air cleaner cover [2] and foam element [3]. [3] [2] Clean the foam element in warm soapy water [1], rinse, and allow to dry thoroughly, or clean with a high flash point solvent and allow to dry. Dip the element in clean engine oil [2] and squeeze out the excess oil. Wash • Excess oil will restrict air flow through the foam element and may cause the engine to smoke at startup. • Do not twist the foam element to remove the excess oil. Twisting the element can damage it. Squeeze firmly Dry Do not twist [2] [1] Do not twist Install the foam element in the air cleaner cover. Inspect the paper element [1]. If the paper element is dirty or damaged, replace it with a new one. Remove any dirt from the inside of the air cleaner cover [2] using a moist clean rag. Be careful to prevent dirt from entering the air duct that leads to the throttle body. Install the air cleaner cover [2] and latch the air cleaner cover levers [3] securely. [3] Close and latch the left maintenance cover. [1] 3-6 [2] dummyhead MAINTENANCE GFCI OPERATION (AT1 TYPE ONLY) 1. Unplug all tools and appliances from the generator. [3] 2. Start the engine. 3. Make sure that the circuit protector is ON. [1] 4. Press the TEST button [1]: • The RESET button [2] should extend. • If the GFCI does not function as described, replace the GFCI receptacle [3]. 5. Press the RESET button: • The RESET button should be flush with the base. • If the RESET button is not flush with the TEST button, replace the GFCI receptacle. [2] LED operation: • If there is no fault current, the LED is lit. • If there is a fault current or you press the GFCI TEST button, the LED goes out. • If the GFCI is faulty, the LED does not come on. Replace the GFCI receptacle. EVAP CANISTER/EVAP CHARGE TUBE/EVAP PURGE TUBE INSPECTION (AT, AT1 TYPE ONLY) • Perform this inspection while the engine is stopped. • Before inspection, check the EVAP canister charge tube and EVAP canister purge tube for deterioration or damage. EVAP CANISTER CHARGE TUBE INSPECTION Remove the fuel filler cap. Open the left maintenance cover. Disconnect the EVAP canister charge tube [1] from the EVAP canister. Connect a commercially available hand-operated vacuum pump [2] to the EVAP canister charge tube. Operate the vacuum pump and be sure that there is airflow between the fuel tank and the EVAP canister charge tube. [1] If there is no airflow, check the EVAP canister charge tube. Connect the EVAP canister charge tube to the EVAP canister. • Route the charge tube properly (page 2-24). [2] 3-7 dummyhead MAINTENANCE EVAP CANISTER PURGE TUBE INSPECTION Open the left maintenance cover. Disconnect the EVAP canister purge tube [1] from the EVAP canister. Connect a commercially available hand-operated vacuum pump [2] to the EVAP canister purge tube. Operate the vacuum pump and be sure that there is airflow between the air cleaner and the EVAP canister purge tube. [1] If there is no airflow, check the EVAP canister purge tube. Connect the EVAP canister purge tube to the EVAP canister. • Route the purge tube properly (page 2-24). [2] EVAP CANISTER ASSEMBLY INSPECTION Open the left maintenance cover. Remove the EVAP canister [1]. Check the EVAP canister for damage or deformations, and replace it if necessary. Check the EVAP canister drain pipe [2] and EVAP canister air tube [3] for restrictions, and clean them if necessary. • Do not use compressed air to clean the EVAP canister assembly, or it may be damaged. Install the EVAP canister. [1] • Route the EVAP canister drain pipe and EVAP canister air tube properly (page 2-24). [3] 3-8 [2] dummyhead MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT/ REPLACEMENT If the engine has been running, the engine will be very hot. Allow it to cool before proceeding. Open the left maintenance cover. [2] Loosen the plug cover bolt [1] and remove the plug cover [2]. [1] Remove the spark plug cap [1], and remove the spark plug using a spark plug wrench [2]. [2] [1] Visually inspect the spark plug. Discard the plug if the insulator is cracked, chipped, or heavily fouled. SPARK PLUG: BPR6ES (NGK) Check the sealing washer for damage. Replace the spark plug if the sealing washer [1] is damaged. [1] 0.70 – 0.80 mm (0.028 – 0.031 in) Measure the plug gap with a wire-type feeler gauge. If the measurement is out of specification, adjust by bending the side electrode. PLUG GAP: 0.70 – 0.80 mm (0.028 – 0.031 in) Install the spark plug finger tight to seat the washer, and then tighten with a plug wrench to the specified torque. TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft) • A loose spark plug can become very hot and can damage the engine. Overtightening can damage the threads in the cylinder head. Install the plug cap and plug cover. 3-9 dummyhead MAINTENANCE SPARK ARRESTER CLEANING The engine and muffler becomes very hot during operation and they remain hot for a while after operation. Be sure that the engine is cool before servicing the spark arrester. [3] Remove the two screws [1], tail pipe [2], and spark arrester [3] from the muffler. Clean the carbon deposits from the spark arrester screen with a wire brush. • Be careful to avoid damaging the screen. [2] Check the spark arrester screen for damage. Replace the spark arrester if it is damaged. [1] Clean the tail pipe screen to remove carbon deposits. Install the spark arrester and tail pipe, and then tighten the two screws to the specified torque. TORQUE: 3.5 N·m (0.36 kgf·m, 2.6 lbf·ft) VALVE CLEARANCE CHECK/ ADJUSTMENT • Valve clearance inspection and adjustment must be performed when the engine is cold. [2] Open the left and right maintenance covers. Remove the head cover shroud (page 5-7). Remove the head cover bolt [1] and cylinder head cover [2]. [1] Remove the bolt [1] and slide off the timing inspection hole cover [2]. [2] Turn the crankshaft by pulling the recoil starter gently and set the piston at top dead center of the compression stroke (both valves fully closed). [1] 3-10 dummyhead MAINTENANCE The TDC mark [1] on the rotor will align with the timing mark [2] on the fan cover when the piston is at top dead center of the compression stroke. [1] [2] Insert a feeler gauge [1] between the rocker arm [2] and valve [3] to measure valve clearance. [1] VALVE CLEARANCE: IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in) EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in) If adjustment is necessary, proceed as follows: Hold the rocker arm pivot [4] and loosen the rocker arm pivot lock nut [5]. Turn the rocker arm pivot to obtain the specified clearance. Tighten the rocker arm pivot lock nut while holding the rocker arm pivot. [2] TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) [5] [4] Recheck the valve clearance after tightening the rocker arm pivot lock nut. After adjustment, reinstall the removed parts in the reverse order of removal. [3] 3-11 dummyhead MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder head (page 13-3). Clean any carbon deposits from the combustion chamber [1]. After cleaning, reinstall the removed parts in the reverse order of removal. [1] FUEL TANK CLEANING SERVICE BULLETIN #55 => Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Disassemble the fuel tank (page 6-11). Drain the fuel into a suitable container. Clean the fuel tank with a non-flammable solvent, and allow it to dry thoroughly. Assemble the fuel tank. Install the fuel tank (page 6-10) and check the fuel tank for any sign of fuel leakage. 3-12 dummyhead MAINTENANCE FUEL PUMP FILTER CHANGE SERVICE BULLETIN #55 => Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. • Replace the fuel filter in accordance with the maintenance schedule (page 3-2). Remove the fuel pump (page 6-9). Release the hooks [1] of the fuel filter [2] from the stoppers [3] by slightly spreading the hooks, and then turn the filter clockwise. Pull the filter off of the fuel pump. Remove the O-ring [4]. Install a new O-ring and then install a new filter in the correct direction so that the triangle marks on the filter and fuel pump body will be aligned when it is attached. Turn the filter counterclockwise until the hooks are completely secured by the stoppers, being careful not to damage them. [1] [3] [4] [2] REMOVAL: 2. Turn the filter clockwise. Install the fuel pump (page 6-9). 1. Spread the hooks. INSTALLATION: Turn the filter counterclockwise. Align the marks of the fuel filter shown. MARK 3-13 dummyhead MAINTENANCE FUEL FEED HOSE CHECK Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. [2] Check the fuel feed hose [1] for deterioration, cracks, or signs of leakage. Disconnect the spark plug cap [2] and fuel injector 2P connector . Turn the main switch ON and push the starter switch to operate the fuel pump and check for fuel leakage. Replace the fuel feed hose if there is damage, fuel leakage, corrosion, etc. [1] 3-14 dummytext 4. TROUBLESHOOTING 4 ENGINE STANDARD TROUBLESHOOTING···································4-2 SELF-DIAGNOSTIC TROUBLESHOOTING ·································· 4-9 4-1 dummyhead TROUBLESHOOTING ENGINE STANDARD TROUBLESHOOTING TROUBLESHOOTING • • • • Use a known-good battery for troubleshooting. Check that the connectors are connected securely. Check for sufficient fresh fuel in the fuel tank. Read the circuit tester's operation instructions carefully, and observe the instructions during inspection. ENGINE DOES NOT CRANK AT THE RECOIL STARTER Remove the recoil starter (page 9-6) and check whether the engine cranks. Cannot be cranked SERVICE BULLETIN #55 => Disassemble the engine and replace the faulty part(s) (page 14-3). Cranks Inspect the recoil starter (page 9-14). Abnormal Replace the faulty part(s). ENGINE CRANKS BUT WON’T START Check whether the i-Monitor is on when the main switch is turned ON. OFF Perform the i-MONITOR DOES NOT DISPLAY BY MAIN SWITCH TURNED ON(page 4-19). Displayed See OIL in SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-21). ON Check whether the Oil Alert® indicator is ON and “OIL” is displayed on the i-Monitor. Not displayed Check whether an error code is displayed on the i-Monitor when the starter switch is pressed. Displayed Perform the SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-9). Not displayed Does not operate Check whether the starter motor operates when the starter switch is pressed. Operates Go to page 4-3 4-2 Perform the STARTING SYSTEM TROUBLESHOOTING (page 9-2). dummyhead TROUBLESHOOTING From page 4-2 Turn the main switch OFF. Check the spark plug (page 3-9). Wet If the spark plug is correct, clean and dry the electrodes and then restart the engine. Dry Turn the main switch ON. Perform the spark test with a new spark plug (page 8-8). No spark Perform the IGNITION SYSTEM TROUBLESHOOTING (page 8-2). Spark Turn the main switch OFF. Check for a restricted spark arrestor (page 3-10). Normal Check the cylinder compression (page 13-5). Restricted Compression is too high Normal Compression is too low Clean the spark arrestor. Check the valve clearance (page 3-10), and then perform the cylinder compression test. If the cylinder compression is too high, remove carbon deposits in the combustion chamber (page 3-12). Check the decompressor operation of the camshaft (page 14-11). Check the valve clearance (page 3-10), and then perform the cylinder compression test. If the cylinder compression is too low, perform a leak down test. If there is no air leakage in the engine, check the following. - Valve spring free length (page 13-7) - Valve seat width (page 13-6) - Valve face irregularly worn (page 13-7) - Decompressor operation (page 14-11) - Piston ring side clearance (page 14-8) - Piston ring width (page 14-7) - Piston ring end gap (page 14-8) - Piston skirt O.D. (page 14-6) - Cylinder sleeve I.D. (page 14-5) Go to page 4-4. 4-3 dummyhead TROUBLESHOOTING From page 4-3 Abnormal Check the fuel flow (page 6-20). • Check the fuel pump circuit (page 6-2). • Check whether the fuel feed hose is leaking. • Check whether the fuel feed hose is pinched or clogged. Normal • Check whether the fuel tank cap breather is pinched or clogged. • Check whether the fuel pump filter is clogged. • Replace the fuel pump. Check the fuel pressure (page 6-20). Abnormal • Check whether the fuel feed hose is pinched or clogged. Normal • Replace the fuel pump. Turn the main switch OFF. Disconnect the fuel injector 2P connector and spark plug cap. Check whether the throttle valve position changes from fully open to half open when the main switch is ON and the starter switch is pressed. THROTTLE VALVE • Check whether the fuel pump filter is clogged. Abnormal Check the throttle control motor (page 6-21). 45° Main switch ON Normal Abnormal Turn the main switch OFF. Check the fuel injector system (page 6-4). Normal Replace the GCU and recheck. 4-4 • Replace or repair the fuel injector circuit • Replace the fuel injector dummyhead TROUBLESHOOTING ENGINE STARTS BUT THEN STALLS Check whether an error code is displayed on the i-Monitor when the main switch is ON and the starter switch is pressed. SERVICE BULLETIN #55 => Displayed Perform the SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-9). Not displayed Indicator is on Check whether the overload indicator is on when stopping the engine. See E-12, E-13, E-15, E-22, E-23 and E-25 in SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-37). Indicator is off Turn the main switch OFF. Check the spark plug (page 3-9). Wet If the spark plug is correct, clean and dry the electrodes and then restart the engine. Dry Turn the main switch ON. Perform the spark test with a new spark plug (page 8-8). No spark Perform the IGNITION SYSTEM TROUBLESHOOTING (page 8-2). Spark Turn the main switch OFF. Check whether the cooling fan passage of the front cover is blocked. Is not blocked Check the cylinder compression (page 13-5). Is blocked Remove the object that causes blockage. Compression is too high Normal Compression is too low Go to page 4-6 Check the valve clearance (page 3-10), and then perform the cylinder compression test. If the cylinder compression is too high, remove carbon deposits in the combustion chamber (page 3-12). Check the decompressor operation of the camshaft (page 14-11). Check the valve clearance (page 3-10), and then perform the cylinder compression test. If the cylinder compression is too low, perform a leak down test. If there is no air leakage in the engine, check the following. - Valve spring free length (page 13-7) - Valve seat width (page 13-6) - Valve face irregularly worn (page 13-7) - Decompressor operation (page 14-11) - Piston ring side clearance (page 14-8) - Piston ring width (page 14-7) - Piston ring end gap (page 14-8) - Piston skirt O.D. (page 14-6) - Cylinder sleeve I.D. (page 14-5) 4-5 dummyhead TROUBLESHOOTING From page 4-5 Abnormal Check the fuel flow (page 6-20). • Check whether the fuel feed hose is leaking. • Check whether the fuel feed hose is pinched or clogged. Normal • Check whether the fuel tank cap breather is pinched or clogged. • Check whether the fuel pump filter is clogged. • Replace the fuel pump. Check the fuel pressure (page 6-20) Abnormal • Check whether the fuel feed hose is pinched or clogged. Normal • Replace the fuel pump. Turn the main switch OFF. Disconnect the fuel injector 2P connector and spark plug cap. Check whether the throttle valve position changes from fully open to half open when the main switch is ON and the starter switch is pressed. THROTTLE VALVE Main switch ON Normal Turn the main switch OFF. Replace the GCU and recheck. 4-6 • Check whether the fuel pump filter is clogged. 45° Abnormal Check the throttle control motor (page 6-21). dummyhead TROUBLESHOOTING ENGINE SPEED DOES NOT STABILIZE Stop the engine. Disconnect the AC appliance. Restart the engine and check to see if an error code is displayed in the error log mode (page 4-10). Displayed Perform the SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-9). Not displayed Check whether the engine condition is stable. Stabilize System is OK. Does not stabilize Turn the main switch OFF. Check whether the cooling fan passage of the front cover is blocked. Is blocked Remove the object that causes blockage. Is not blocked Check whether the fuel that contains more than 10% ethanol or deteriorated fuel is used. Fuel is abnormal Replace the fuel. Fuel is normal Check the spark plug gap (page 3-9). Abnormal Adjust the spark plug gap. Normal Check for air leaking between the throttle body and engine block. Is it normal? Abnormal Check around the air intake tract and throttle body; replace the insulator and/or gasket if necessary. Normal Check the fuel flow (page 6-20). Normal Abnormal • Check whether the fuel feed hose is leaking. • Check whether the fuel feed hose is pinched or clogged. • Check whether the fuel tank cap breather is pinched or clogged. • Check whether the fuel pump filter is clogged. • Replace the fuel pump. Go to page 4-8 4-7 dummyhead TROUBLESHOOTING From page 4-7 Check the fuel pressure (page 6-20). Abnormal • Check whether the fuel feed hose is pinched or clogged. Normal • Replace the fuel pump. Turn the main switch OFF. Disconnect the fuel injector 2P connector and spark plug cap. Check whether the throttle valve position changes from fully open to half open when the main switch is ON and the starter switch is pressed. THROTTLE VALVE • Check whether the fuel pump filter is clogged. Abnormal Check the throttle control motor (page 6-21). 45° Main switch ON Normal Turn the main switch OFF. Replace the fuel injector (page 6-15). Stabilize Faulty original fuel injector. Stabilize Faulty original O2 sensor. Stabilize Faulty connector connection. Turn the main switch ON. Start the engine and check whether the engine condition is stable. Does not stabilize Replace the O2 sensor (page 6-18). Start the engine and check whether the engine condition is stable. Does not stabilize Turn the main switch OFF. Check for loose or poor contact on the fuel injector 2P connector, throttle control motor 4P connector and GCU 34P connector. Repair or replace if necessary. Turn the main switch ON. Start the engine and check whether the engine condition is stable. Does not stabilize Turn the main switch OFF. Replace the GCU and recheck. 4-8 dummyhead TROUBLESHOOTING SELF-DIAGNOSTIC TROUBLESHOOTING SELF-DIAGNOSTIC FUNCTION The generator control unit (GCU) has a self-diagnosis function. When it detects a fault, it notifies the operator by flashing an error code and turning on or flashing the overload indicator. When an error code appears on the i-Monitor, troubleshoot using the error code index. I-MONITOR ERROR LOG => LAMP Output indicator Overload indicator COLOR Green Red Check/Oil alert indicator Red Content/Signal Turns on when there is AC voltage output from the receptacle Turns on when an external abnormality such as excessive current is detected Turns on when the oil level is low, or blinks when a GCU malfunction is detected 4-9 dummyhead TROUBLESHOOTING HOW TO DISPLAY THE ERROR LOG I-MONITOR ERROR LOG => ERROR LOG MODE: NORMAL DISPLAY MODE: DETAILED ERROR LOG MODE: 3 sec. h h V VA 3 sec. V rpm V V VA 3 sec. 3 sec. NORMAL DISPLAY MODE: h VA Engine run time (hour) When you turn the main switch to the ON position, the i-Monitor displays the engine run-time. Every time you press the display button, the display will show the generator output, the engine speed, and the battery voltage in this sequence. Generator output (VA) Engine speed (rpm) rpm V Battery voltage (V) ERROR LOG MODE: Error log 1 Error code Error log 2 Error code Error log 3 Error code Error log 4 Error code Error log 5 Error code End 4-10 When you press the display button longer than 3 seconds, while in the Engine run time (hour) mode, the i-Monitor goes into the error log mode, displaying error codes for previous incidents. Every time you press the display button, the display will show the five latest error codes in the order from the newest to the oldest. When END appears in this mode, press the display button longer than 3 seconds to change the display back to the normal display mode. dummyhead TROUBLESHOOTING DETAILED ERROR LOG MODE: Engine run time (hour) h Inverter output voltage (master) (V) V V Inverter output voltage (slave) (V) A A Inverter output amperage (master) (A) Inverter output amperage (slave) (A) When you press the display button longer than 3 seconds on an error code, the display goes into a detailed error log mode, and it shows the engine run-time, generator output, engine speed, inverter temperature, throttle angle, battery voltage engine temperature, outside air temperature, barometric pressure, O2 sensor voltage, and generator output in volt-amperes (VA) for the incident in this sequence. When END appears in this mode, press the display button longer than 3 seconds to change the display back to the error log mode. Engine speed (rpm) rpm Inverter unit power module temperature (master) (°C) Inverter unit power module temperature (slave) (°C) Throttle valve angle (%) V Battery voltage (V) Engine temperature (°C) Ambient Air Temperature (°C) Barometric Pressure (kPa) V VA O2 sensor voltage (V) Output (VA) End Revised: June 2017 (61Z37000E2) 4-11 dummyhead TROUBLESHOOTING SYSTEM LOCATION GCU AAT SENSOR (GCU internal) O2 SENSOR BARO SENSOR (GCU internal) CKP SENSOR EBT SENSOR GENERATOR INVERTER UNIT THROTTLE CONTROL MOTOR 4-12 dummyhead TROUBLESHOOTING SYSTEM DIAGRAM INVERTER UNIT R MAIN_U_M W W MAIN_V_M Bu Bu MAIN_W_M R U W V 5V_GCU R R DC5V TH(A) W RXD_M Bu/R Bu/R M_TXD TH(/A) R TXD_M Bu/Y Bu/Y M_RXD GND_GCU O/W O/W INV_COMN RXD_S G/Bu G/Bu S_TXD TXD_S G/O G/O S_RXD GENERATOR (MASTER) R MAIN_U_S W W MAIN_V_S Bu Bu MAIN_W_S R U W GCU GND V GENERATOR (SLAVE) R U W V Bu TH(B) Y TH(/B) Bu STMAG Bl/W STMAG Bl/W THROTTLE CONTROL MOTOR BATTERY STARTER MOTOR W FUSE (15A) G/O Bl/Y G Br/Bu MAIN_SW+ Br/Bu W/Bu MAIN_SW- Bl/Y MAIN SWITCH i-MONITOR BATTERY Bl Br/W G/O G/O STMAG(+12V) G/O STMAG(+12V) Br/Y BAT_IN Bl/Y PUSH SW1 FUSE (3A) STARTER SWITCH G BARO SENSOR AAT SENSOR Bl Y/R TH+ Bl Y/Bl TH- EBT SENSOR O2 SENSOR Bu Bl O2 SENSOR Y/Bu PC+ Y O/A CKP SENSOR OIL LEVEL SWITCH DLC Br/W BAT_IN Bu/Y RXD Bu/R TXD G GND GND GND 4-13 dummyhead TROUBLESHOOTING TERMINAL ARRANGEMENT GCU 34P CONNECTOR Bl Y Bu G R W Terminal number 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 4-14 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) R G Bu W/G G/Bu Bl/W Bl/W G/O G/O W/Bu Br/Bu Br/Y W R Bu Y W G Y O/W G/O G/Bu Bu/R Bu/Y Y/Bl Y Bl/Y R Bl Y/R Y/Bu FFP (+) GND FFP (-) PUSH_SW2 PL (REM) STMAG STMAG STMAG (+12 V) STMAG (+12 V) MAIN_SWMAIN_SW+ BAT_IN TH (A) TH (/A) TH (/B) TH (B) INJ (+) GND INJ (-) INV_COMN S_RXD S_TXD M_TXD M_RXD THO/A PUSH_SW1 DC5V O2 SENSOR TH+ PC+ Fuel pump Fuel pump power GCU ground Fuel pump output Remote control starter switch input Remote control indicator light output Stater motor output Stater motor output Starter magnetic switch power Starter magnetic switch power Main switch minus side Main switch plus side Battery 12V input voltage Throttle control motor phase (A) output Throttle control motor phase (/A) output Throttle control motor phase (/B) output Throttle control motor phase (B) output Fuel injector power GCU ground Fuel injector output Inverter unit ground Inverter communication (Slave receive) Inverter communication (Slave transmit) Inverter communication (Master transmit) Inverter communication (Master receive) EBT sensor ground Oil level switch input Starter switch input 5V supply to Inverter O2 sensor input EBT sensor input CKP sensor input Fuel pump Remote control box Remote control box Starter magnetic switch Starter magnetic switch Main switch Main switch Main switch Main switch Main switch Throttle control motor Throttle control motor Throttle control motor Throttle control motor Fuel injector Fuel injector Inverter unit Inverter unit Inverter unit Inverter unit Inverter unit EBT sensor Oil level switch Starter switch Inverter unit O2 sensor EBT sensor CKP sensor dummyhead TROUBLESHOOTING GCU 2P CONNECTOR Bl Y Bu G R W Terminal number 1 2 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) Bl/G Bl IGNIGN+ Ignition coil Ignition coil Ignition coil output Ignition coil power GCU 4P CONNECTOR FOR OPTIONAL Dr.H Bl Y Bu G R W Terminal number 1 2 3 4 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) G Bu/R Bu/Y Br/W GND TXD RXD BAT_IN DLC DLC DLC DLC Dr.H communication ground Dr.H communication transmit Dr.H communication receive Dr.H communication power GCU 5P CONNECTOR Bl Y Bu G R W Terminal number 1 3 5 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) Bu W R W V U Generator (Master) Generator (Master) Generator (Master) Generator (W-phase input) Generator (V-phase input) Generator (U-phase input) INVERTER UNIT 3P CONNECTOR Bl Y Bu G R W Terminal number 1 2 3 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) R W Bu MAIN_U_M MAIN_V_M MAIN_W_M Generator (Master) Generator (Master) Generator (Master) Generator Master (U-phase input) Generator Master (V-phase input) Generator Master (W-phase input) 4-15 dummyhead TROUBLESHOOTING INVERTER UNIT 3P CONNECTOR Bl Y Bu G R W Terminal number 1 2 3 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) R W Bu MAIN_U_S MAIN_V_S MAIN_W_S Generator (Slave) Generator (Slave) Generator (Slave) Generator Slave (U-phase input) Generator Slave (V-phase input) Generator Slave (W-phase input) INVERTER UNIT 6P CONNECTOR Bl Y Bu G R W Terminal number 1 2 3 4 5 6 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) G/O G/Bu O/W Bu/Y Bu/R R TXD_S RXD_S GND_GCU TXD_M RXD_M 5V_GCU GCU GCU GCU GCU GCU GCU Generator (Slave) signal transmit Generator (Slave) signal receive Communication ground Generator (Master) signal transmit Generator (Master) signal receive 5 V input voltage INVERTER UNIT 3P CONNECTOR Bl Y Bu G R W Terminal number 1 3 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) R/W R GND ECO_SW Eco-Throttle switch Eco-Throttle switch Eco-Throttle switch ground Eco-Throttle switch output signal INVERTER UNIT 4P CONNECTOR Bl Y Bu G R W Terminal number 1 2 3 4 4-16 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Wire color Terminal mark Connection Signal (function) Gr Bu R W AC2_S AC1_S AC1_M AC2_M Voltage selector switch Voltage selector switch Receptacle Receptacle Sine wave output (–) Sine wave output (+) Sine wave output (+) Sine wave output (–) dummyhead TROUBLESHOOTING ERROR CODE INDEX : Indicator OFF Error code Overload indicator Check/ Oil alert indicator Error name Battery under charged Insufficient oil Starting system failure Starter switch input failure Abnormal battery voltage EBT sensor failure Engine speed failure GCU internal failure (SW power output error) Generator pulse failure GCU internal failure (RAM error) Air/fuel ratio failure Detection condition Battery voltage is less than specification for 1.5 seconds or more; cannot crank the engine. Engine oil level is lower than specification, or there is a short circuit in oil level switch circuit. Engine speed pulse cannot be detected when the engine is cranked with starter motor. Starter switch remains ON for more than specified period. Battery voltage is high. Engine temperature is higher than specification, or an open or short circuit in sensor circuit is detected. Engine speed is higher than specification. Voltage at GCU internal power switch is higher or lower than specification. Difference between the speed at generator and CKP sensor is detected. GCU internal memory registry error is detected. Programmed air/ fuel ratio is not obtained. : Indicator blinks Error recognition number of times 1 : Indicator stay ON Fail-safe Ref. page When pushing the starter switch with main switch turned ON, the starter motor is stopped 4-20 1 Engine is stopped 4-21 1 When pushing the starter switch with main switch turned ON, the starter motor is stopped 4-22 1 Display only 4-25 1 Engine is stopped 4-26 1 Engine is stopped 4-27 2 Engine is stopped 4-28 2 Engine is stopped 4-29 2 Engine is stopped 4-31 1 Engine is stopped 4-32 3 Engine is stopped 4-33 4-17 dummyhead TROUBLESHOOTING Error code * * * * Overload indicator Check/ Oil alert indicator *: No error code displayed. Can be displayed in Error log mode (page 4-10). Error Detection recognition Ref. Error name Fail-safe condition number of page times Inverter unit and Communication 2 Engine is stopped 4-34 GCU error between the communication inverter and GCU is error detected. 1 Engine is stopped 4-36 Inverter unit internal Communication error between the communication master inverter and error slave inverter is detected. 1 After shutting down Excessive current Inverter unit 4-37 the AC output, the caused by overload excessive current engine is left protection activated is detected. running at 2,400 min-1 (rpm). 1 After shutting down Excessive voltage 4-37 Inverter unit the AC output, the caused by internal excessive voltage engine is left protection activated failure is detected. running at 2,400 min-1 (rpm). 1 After shutting down FET device/power 4-38 Inverter unit the AC output, the module overheated engine is left protection activated temperature in the running at inverter exceeds 2,400 min-1 (rpm). the specified value. 2 Engine is stopped 4-38 Inverter unit internal There is abnormality in the failure figure monitored by (A/D input error) the inverter unit. Inverter unit internal There is 2 Engine is stopped 4-39 failure abnormality in the (FET open) FET device in the inverter. 1 Engine is stopped 4-39 Inverter unit internal There is abnormality in the failure FET device in the (FET short) inverter. Inverter unit internal There is 1 Engine is stopped 4-39 abnormality in the failure (Diode line short) diode in the inverter. Inverter unit internal There is 1 Engine is stopped 4-39 failure abnormality in the (SCR short) SCR in the inverter. RAM/ROM failure Inverter internal memory registry error is detected. 1 Engine is stopped 4-39 Inverter unit short protection activated Excessive current caused by a short circuit is detected. 1 4-40 AAT sensor (GCU internal) failure AAT sensor in the GCU abnormality is detected. BARO sensor in the GCU abnormality is detected. An open or short circuit in O2 sensor circuit is detected. 1 After shutting down the AC output, the engine is left running at 2,400 min-1 (rpm). Display only 1 Display only 4-41 3 Engine is stopped 4-42 BARO sensor (GCU internal) failure O2 sensor failure 4-18 4-41 dummyhead TROUBLESHOOTING i-MONITOR DOES NOT DISPLAY WITH MAIN SWITCH TURNED ON When turning the main switch to ON, the i-Monitor is on if use a known-good battery is used. GCU 18 13 Br/Y 12 Br/Bu 3 GND GND 10 G G MAIN_SW- 3 Bl/Y i-MONITOR MAIN_SW+ 20 11 W/Bu Bl/Y BAT_IN T3 BATTERY Bl Y Bu G R W W 5 W/Bu 1 Br/Bu T2 14 Bl 3 G Bl 1 G Bl MAIN_SW2 G MAIN_SW1 2 Br/Bu GND3 1 Br/Bu 3A Br/W ACC Bl/Y BAT 3 G/O 4 G/O 15A Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray MAIN SWITCH 13 MAIN SWITCH MAINSW1 MAINSW2 BAT ACC ON OFF Turn the main switch OFF. Check the fuses. Blown Replace the fuse. Abnormal Replace the GCU. Abnormal Replace the main switch. Good Check the " i-MONITOR DOES NOT DISPLAY" of the GCU inspection (page 10-9). Normal Check the main switch (page 10-6). Normal Turn the main switch OFF. Check the wire harness between the main switch and GCU for an open or short circuit. Abnormal Replace or repair the wire harness. 14 1 2 5 6 MAIN SWITCH 1 5 8 Br/Bu W/Bu GCU Br/Bu 13 2 1 4 3 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 3A G/O Br/Y Normal Go to page 4-20 4-19 dummyhead TROUBLESHOOTING From page 4-19 Check the wire harness between the battery and main switch for an open or short circuit. Abnormal Replace or repair the wire harness. Abnormal Replace or repair the wire harness. Abnormal Replace or recharge the battery (page 7-16). MAIN SWITCH 3 13 Bl/Y 5 4 3 2 1 10 9 8 7 6 2 1 4 3 1 2 3 4 5 6 7 8 9 10 15A Bl/Y G/O T3 Normal Check the wire harness between the GCU and ground for an open circuit. 3 18 G 5 4 3 2 1 10 9 8 7 6 GCU 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 2 3 4 5 6 7 8 9 10 1 18 Bl G GND3 Normal Replace the GCU and recheck. (Battery under charged) Turn the main switch OFF. Check the battery condition, using a battery tester (page 7-16). Normal Perform the engine start procedure and check to see if an error code is displayed. If the same condition exists, replace the GCU and recheck. 4-20 dummyhead TROUBLESHOOTING (Insufficient oil) GCU 18 2 O/A Y 28 Y 4 Y Y C5 Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray OIL LEVEL SWITCH Turn the main switch OFF. Check the oil level (page 3-4). Abnormal Add the recommended oil to the proper level. Abnormal Replace the oil level switch. Normal Check the oil level switch (page 8-10). Normal Turn the main switch OFF. Check the wire harness between the battery and GCU for an open or short circuit. Abnormal Replace or repair the wire harness. GCU 18 2 Y C5 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 Y Normal Perform the engine start procedure and check to see if an error code is displayed. If the same condition exists, replace the GCU and recheck. 4-21 dummyhead TROUBLESHOOTING (Starting system failure) U W Bu 5 2 Y/Bu 3 33 Y/Bu 3 7 Bl/W Bl/W Bl/W Bl/Y G/O 8 9 STMAG(+12V) 13 G/O C9 Bl/Y T3 Br/W G/O Bl/Y ACC BAT 4 T1 15A 3 Bl/Y Bl Bl/W Bu C4 10 Y/Bu G/O C3 Brown Orange Light blue Light green Pink Gray STMAG STMAG(+12V) 10 Bl/Y PC+ STMAG 9 Bl/W MAIN SWITCH T2 Bl Br O Lb Lg P Gr W 18 Y/Bu Black Yellow Blue Green Red White V V STATOR (MASTER) Bl Y Bu G R W 3 W Bu 3 W Bu 2 W Bu 5 1 3 W 20 R R 1 U GCU 1 R R 1 6 MAIN SWITCH ACC CKP SENSOR STARTER MOTOR BAT ON GND3 OFF Turn the main switch OFF. Check the battery condition, using a battery tester (page 7-16). Abnormal Replace or recharge the battery (page 7-16). Abnormal Replace the GCU. Abnormal Replace or repair the wire harness. Normal Check the "PUSH THE STARTER SWITCH BUT STARTER MOTOR DOES NOT TURN" of the GCU inspection (page 10-9). Normal Check the wire harness between the starter motor and GCU for an open or short circuit. 18 3 5 4 3 2 1 10 9 8 7 6 1 2 3 4 5 6 7 8 9 10 GCU 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 Bl/W Bl/W C9 STATER MAGNETIC SWITCH Normal Check the CKP sensor (page 8-9). Normal Go to page 4-23 4-22 Abnormal Replace the CKP sensor (page 8-7). dummyhead TROUBLESHOOTING From page 4-22 Check the wire harness between the CKP sensor and GCU for an open or short circuit. Abnormal Replace or repair the wire harness. Abnormal Replace or repair the wire harness. GCU 18 2 Y/Bu C3 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 Y/Bu Normal Bl Bl Check the motor cable between the battery and starter motor for an open circuit. T1 T3 STARTER MOTOR BATTERY TERMINAL Normal Check the starter motor (page 9-16). Abnormal Replace or repair the starter motor. Abnormal Adjust the CKP sensor air gap. Normal Check the CKP sensor air gap (page 8-8). Normal Go to page 4-24 4-23 dummyhead TROUBLESHOOTING From page 4-23 Check the flywheel ring gear (page 9-10). Abnormal Replace the flywheel. Abnormal Replace the stator. Abnormal Replace or repair the wire harness. Abnormal Replace or repair the wire harness. Normal Check the stator coil resistance (page 7-17). Normal Turn the main switch OFF. Check the wire harness between the generator and GCU for an open or short circuit. Bu R 1 6 3 20 3 2 1 1 5 1 3 5 5 W W R Bu 3 1 Normal Check the wire harness between the main switch and GCU for an open circuit. MAIN SWITCH GCU 18 13 2 1 4 3 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 G/O Normal Perform the engine start procedure and check to see if an error code is displayed. If the same error code occurs, replace the GCU and recheck. 4-24 dummyhead TROUBLESHOOTING (Starter switch input failure) GCU 18 29 Bl/Y PUSH SW1 15 Bl/Y STARTER SWITCH 2 Bl/Y 1 G 1 G G 3 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Bl Bl Y Bu G R W GND3 Turn the main switch OFF. Check the starter switch (page 10-9). Abnormal Replace the starter switch. Abnormal Replace the GCU. Normal Check the "STARTER MOTOR TURNS AT THE MAIN SWITCH TURNED ON" of the GCU inspection (page 10-9). Normal Check the wire harness between the starter switch and GCU for a short circuit. STARTER SWITCH Abnormal Replace or repair the wire harness. GCU 18 15 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 2 1 1 18 Bl/Y Normal Perform the engine start procedure and check to see if an error code is displayed. If the same error code occurs, replace the GCU and recheck. 4-25 dummyhead TROUBLESHOOTING (Abnormal battery voltage) Turn the main switch OFF. Check the battery voltage. Normal battery voltage should be 12.3 V to 13.2 V. Abnormal Replace the battery. Normal Turn the main switch ON. With the engine running at normal operating temperature, measure the battery voltage. The battery voltage should not exceed 14.5 V while the engine is running. Normal Perform the engine start procedure and check to see if an error code is displayed. If the same error code occurs, replace the GCU and recheck. 4-26 Abnormal Replace the GCU and recheck. dummyhead TROUBLESHOOTING (EBT sensor failure) GCU 3 18 Y/R Y/R Y/Bl Y/Bl Y/R Br O Lb Lg P Gr C7 Brown Orange Light blue Light green Pink Gray 27 TH- C8 Bl Black Yellow Blue Green Red White Bl Bl Y Bu G R W TH+ Y/Bl 4 Y/Bl 32 3 Y/R EBT SENSOR Turn the main switch OFF. Check the front cover for blockages in the cooling air passage. Is blocked Remove the blockage. Abnormal Replace the EBT sensor. Abnormal Replace or repair the wire harness. Is not blocked Check the EBT sensor (page 6-22). Normal Turn the main switch OFF. Check the wire harness between the EBT sensor and GCU for an open or short circuit. Y/R Y/R Y/Bl 18 3 C7 C8 5 4 3 2 1 10 9 8 7 6 1 2 3 4 5 6 7 8 9 10 GCU 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 Y/Bl Normal Perform the engine start procedure and check to see if an error code is displayed. If the same error code occurs, replace the GCU and recheck. 4-27 dummyhead TROUBLESHOOTING (Engine speed failure) GCU 2 18 W R R Y Y Bu Bu 14 W 2 Y 17 5 R 15 6 W Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray 16 TH(/B) Y Bu R AA TH(B) 8 3 Bu 1 R 4 W 2 Y W 1 Bu TH(A) TH(/A) BB THROTTLE CONTROL MOTOR Turn the main switch OFF. Measure the resistance at the throttle control motor (page 6-21). Abnormal Replace the throttle control motor. Abnormal Replace the GCU. Normal Check the "THROTTLE CONTROL MOTOR DOES NOT MOVE" of the GCU inspection (page 10-9). Normal Turn the main switch OFF. Check the wire harness between the throttle control motor and GCU for an open or short circuit. Abnormal THROTTLE CONTROL MOTOR 2 8 GCU W Bu Y Y 2 1 4 3 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 Bu W R R 1 18 Normal Perform the engine start procedure twice and check to see if an error code is displayed. If the same error code occurs, replace the GCU and recheck. 4-28 Replace or repair the wire harness. dummyhead TROUBLESHOOTING (GCU internal failure: SW power output error) GCU 1 Bu Bu W W Bu Bu 3 5 1 U W 5 W R U 3 W 20 R V 1 R 1 R 2 3 6 W V STATOR (MASTER) Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Turn the main switch OFF. Check the stator coil resistance (master) (page 7-17). Abnormal Replace the stator. Abnormal Replace the inverter unit. Normal Check the inverter unit ((page 7-18). Normal Turn the main switch OFF. Check the wire harness between the generator and GCU for an open or short circuit. Bu Abnormal Replace or repair the wire harness. R 1 6 3 20 3 2 1 1 5 1 3 5 5 W W R Bu 3 1 Normal Go to page 4-30 4-29 dummyhead TROUBLESHOOTING From page 4-29 Check the control panel main wire harness for an open or short circuit. Abnormal Replace or repair the wire harness. Normal Not displayed Replace the inverter unit. Perform the engine start procedure twice and check to see if an error code is displayed. Same error code displayed Replace the GCU and recheck. 4-30 Faulty original inverter unit. dummyhead TROUBLESHOOTING (Generator pulse failure) GCU 1 Bu Bu W W Bu Bu 3 5 2 1 U W 5 W R U 3 W 20 R 1 R 3 R V 1 6 W V 18 2 3 Y/Bu Y/Bu PC+ Y/Bu 33 Y/Bu STATOR (MASTER) Black Yellow Blue Green Red White Br O Lb Lg P Gr Bu C3 Bl Y Bu G R W Brown Orange Light blue Light green Pink Gray C4 CKP SENSOR Turn the main switch OFF. Check the stator coil resistance (page 7-17). Abnormal Replace the stator. Abnormal Replace the GCU. Abnormal Replace the inverter unit. Normal Check the "E-06 IS DISPLAYED BY ENGINE STARTS" of the GCU inspection (page 10-9). Normal Check the inverter unit (page 7-18). Normal Check the wire harness between the generator and GCU for an open or short circuit. Bu Abnormal Replace or repair the wire harness. R 1 6 3 20 3 2 1 1 5 1 3 5 5 W W R Bu 3 1 Normal Go to page 4-32 4-31 dummyhead TROUBLESHOOTING From page 4-31 Check the CKP sensor (page 8-9). Abnormal Replace the CKP sensor (page 8-7). Abnormal Replace or repair the wire harness. Abnormal Replace or repair the wire harness. Not displayed Faulty original inverter unit. Normal Turn the main switch OFF. Check the wire harness between the CKP sensor and GCU for an open or short circuit. GCU 18 2 Y/Bu C3 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 Y/Bu Normal Check the control panel main wire harness for an open or short circuit. Normal Replace the inverter unit. Perform the engine start procedure twice and check to see if an error code is displayed. Same error code displayed Replace the GCU and recheck. (GCU internal failure: RAM error) 1. Perform the engine start procedure. 2. Check to see if an error code is displayed. If the same error code occurs, replace the GCU and recheck. 4-32 dummyhead TROUBLESHOOTING (Air/fuel ratio failure) No good Turn the main switch OFF. Check the fuel quality. Replace the fuel. Good Check the air cleaner element (page 3-6). Dirty Replace the air cleaner element. Abnormal • Check whether the fuel feed hose is leaking. Clean Check the fuel flow (page 6-20). • Check whether the fuel feed hose is pinched or clogged. • Check whether the fuel tank cap breather is pinched or clogged. Normal • Check whether the fuel pump filter is clogged. • Replace the fuel pump. Abnormal Check the fuel pump pressure (page 6-20). • Check whether the fuel pump filter is clogged. • Check whether the fuel feed hose is pinched or clogged. • Replace the fuel pump. Normal Turn the main switch OFF. Disconnect the fuel injector 2P connector and spark plug cap. Check whether the throttle valve position changes from fully open to half open when the main switch is ON and the starter switch is pressed. THROTTLE VALVE Abnormal Check the throttle control motor (page 6-21). 45° Main switch ON Normal Turn the main switch OFF. Check the O2 sensor (E-53: page 4-42). Abnormal • Replace or repair the O2 sensor circuit. • Replace the O2 sensor Normal Go to page 4-34 4-33 dummyhead TROUBLESHOOTING From page 4-33 Not displayed Replace the fuel injector. Faulty original fuel injector. Perform the engine start procedure three times and check to see if an error code is displayed. Same error code displayed Replace the GCU and recheck. (Inverter unit and GCU communication error) MAIN_U_M 1 R W Bu MAIN_V_M 2 W Bu R Bu/R Bu/Y Bu/Y O/W O/W G/Bu G/Bu G/O G/O 5 RXD_M STATOR (MASTER) TXD_M W W Bu Bu GND_GCU RXD_S M_TXD M_RXD INV_COMN S_TXD TXD_S V 23 MAIN_W_S 1 W 24 2 MAIN_V_S 3 1 U MAIN_U_S DC5V 1 R 2 3 R 4 5 7 30 R Bu/R 6 5V_GCU GCU 18 25 3 3 26 MAIN_W_M V 3 W 22 2 3 R 1 U INVERTER UNIT 4 6 2 , S_RXD STATOR (SLAVE) Turn the main switch OFF. Check the stator (page 7-17). Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Abnormal Replace the stator. Abnormal Replace the inverter unit. Normal Normal Check the inverter unit inspection (page 7-18). Normal Normal Go to page 4-35 4-34 dummyhead TROUBLESHOOTING From page 4-34 Abnormal Check the wire harness between the inverter unit and GCU for an open or short circuit. INVERTER UNIT 3 Replace or repair the wire harness. GCU 18 R Bu/R Bu/Y 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 6 5 4 3 2 1 1 18 G/O G/Bu O/W Normal Not displayed Replace the inverter unit. Faulty original inverter unit. Perform the engine start procedure twice and check to see if an error code is displayed. Same error code displayed Replace the GCU and recheck. 4-35 dummyhead TROUBLESHOOTING (Inverter unit internal communication error) 1 W Bu Bu MAIN_V_M 2 W Bu/R Bu/Y Bu/Y O/W O/W G/Bu G/Bu G/O G/O 5 TXD_M Bu Bu RXD_S M_TXD M_RXD INV_COMN S_TXD TXD_S V 23 MAIN_W_S 1 W 24 2 MAIN_V_S 3 1 U MAIN_U_S GND_GCU DC5V 1 R W 2 3 R W 4 5 7 30 Bu/R 6 R RXD_M STATOR (MASTER) GCU 18 R 25 3 3 5V_GCU 26 MAIN_W_M V 3 W 22 2 3 R MAIN_U_M R 1 U INVERTER UNIT 4 6 2 , S_RXD STATOR (SLAVE) Turn the main switch OFF. Check the stator (page 7-17). Normal Normal Perform the engine start procedure and check to see if an error code is displayed. If the same error code occurs, replace the inverter unit and recheck. 4-36 Abnormal Bl Y Bu G R W Black Yellow Blue Green Red White Replace the stator. Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray dummyhead TROUBLESHOOTING , , , (Inverter unit excessive current protection activated/ Inverter unit excessive voltage protection activated) AT Type: INVERTER UNIT 30A T13 T6 T12 R R R 3 R 4 22 2 Gr W W C17 4 2 Gr T5 CIRCUIT PROTECTOR W Bu 1 AC1_M AC2_M AC1_S AC2_S PARALLEL OPERATION OUTLETS CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 1 20 T4 C16 1 Bu Bu Bu R R Bu W 5 6 NOISE FILTER Bu Gr 3 T19 21 20 C14 C13 30 C12 T14 Bu Bu Bu R T9 T8 T7 W 3 Bu T14 T16 T17 6 1 R Bu T15 2 R R W 5 Bu 4 Bu C15 Bu NOISE FILTER Bu Bu T11 AT1 Type: INVERTER UNIT PARALLEL OPERATION OUTLETS CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 1 T13 R 30A T6 T12 R R R 3 T5 CIRCUIT PROTECTOR 4 W 22 Gr Gr 2 Bu 4 C17 20 W C16 Bu Bu R R W T17 W Bu T4 GFCI Bu R 5 6 Bu T24 GFCI 1 Bu NOISE FILTER T19 T18 W 2 1 AC1_M AC2_M AC1_S AC2_S T10 3 Gr 21 Bu C15 20 C14 C13 30 C12 4 Bu Bu Bu T9 T8 R T7 3 W 6 1 R T14 T15 2 R R W Bu 5 Bu Bu Bu NOISE FILTER Bu Bu T11 CT Type: CIRCUIT PROTECTOR INVERTER UNIT 1 T23 R T6 T22 R R 3 R PARALLEL OPERATION OUTLETS VOLTAGE SELECTOR SWITCH T19 T18 GND12 1 Bu 6 Bu R Bu CIRCUIT PROTECTOR G 2 4 C16 R W 5 Bu 20 T13 Gr 30A T4 GND11 Bu T12 3 Bu C17 Bu G 2 NOISE FILTER T20 W GND13 W Gr T21 G 4 22 Gr T5 CIRCUIT PROTECTOR W W Bu 1 AC1_M AC2_M AC1_S AC2_S 29A T10 21 Bu 4 C15 20 C14 C13 30 C12 Bu Bu 2 W T17 Bu Bu T9 T8 T15 T16 T7 W 3 1 R 6 R R T14 5 Bu R R W Bu W W W Bu W T11 Bu T10 0.5A GND14 2 G 4 R R 1 W GND10 R R R 12 Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray R 1 R 2 BREATHER HEATER Not displayed Turn the main switch OFF. System is OK (error is cleared). Disconnect the AC appliance and stop the engine. Restart the engine and check to see if an error code is displayed in the error log mode (page 4-10). Same error code displayed Abnormal Check the stator (page 7-17). Replace the stator. Normal Go to page 4-38 4-37 dummyhead TROUBLESHOOTING From page 4-37 Check the inverter unit inspection (page 7-18). Abnormal Replace the inverter unit. Abnormal Replace or repair the wire harness. Normal Check the control panel main wire harness for an open or short circuit. Normal Restart the engine and check to see if an error code is displayed in the error log mode (page 4-10). If the same error code occurs, replace the inverter unit and recheck. , (Inverter unit overheated protection activated) 1. Stop the engine and disconnect the AC appliance. 2. Check the front cover cooling air passage for blockages. Remove any blockages. 3. Wait for several minutes. With the engine running at normal operating temperature, check to see if an error code is displayed in the error log mode (page 4-10). If the same error code occurs, replace the inverter unit and recheck. , (Inverter unit internal failure: A/D input error) 1. Perform the engine start procedure twice. 2. Check to see if an error code is displayed. If the same error code occurs, replace the inverter unit and recheck. 4-38 dummyhead TROUBLESHOOTING , , , , , , , (Inverter unit internal failure: FET open/FET short/Diode line short/SCR short) Check the stator (page 7-17). , Abnormal Replace the stator. Abnormal Replace the inverter unit. Abnormal Replace or repair the wire harness. Normal Check the inverter unit inspection (page 7-18). Normal Check the control panel main wire harness for an open or short circuit. Normal Perform the engine start procedure and check to see if an error code is displayed. (Perform the engine start procedure twice when the or .) If the same error code occurs, replace the inverter unit and recheck. , (Inverter unit internal failure: RAM/ROM failure) 1. Perform the engine start procedure. 2. Check to see if an error code is displayed. If the same error code occurs, replace the inverter unit. 4-39 dummyhead TROUBLESHOOTING , (Inverter unit short protection activated) AT Type: INVERTER UNIT 30A T13 T6 T12 R R R 3 R 4 22 2 Gr W W C17 4 2 Gr T5 CIRCUIT PROTECTOR W Bu 1 AC1_M AC2_M AC1_S AC2_S PARALLEL OPERATION OUTLETS CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 1 20 T4 C16 1 Bu Bu Bu R R Bu W 5 6 NOISE FILTER Bu Gr 3 T19 21 Bu 20 C14 C13 30 C12 T14 Bu Bu Bu R T9 T8 T7 W 3 Bu T14 T16 T17 6 1 R Bu T15 2 R R W 5 4 Bu C15 Bu NOISE FILTER Bu Bu T11 AT1 Type: INVERTER UNIT PARALLEL OPERATION OUTLETS CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 1 T13 R 30A T6 T12 R R R 3 T5 CIRCUIT PROTECTOR 4 W 22 Gr Gr 2 Bu 4 C17 20 W C16 Bu Bu R R W T17 W Bu T4 GFCI Bu R 5 6 Bu T24 GFCI 1 Bu NOISE FILTER T19 T18 W 2 1 AC1_M AC2_M AC1_S AC2_S T10 3 Gr 21 Bu C15 20 C14 C13 30 C12 Bu Bu Bu T9 T8 R T7 3 W 6 1 R T14 T15 2 R R W Bu 5 4 Bu Bu Bu NOISE FILTER Bu Bu T11 CT Type: CIRCUIT PROTECTOR INVERTER UNIT 1 T23 R T6 T22 R R 3 R PARALLEL OPERATION OUTLETS VOLTAGE SELECTOR SWITCH T19 T18 GND12 1 Bu 6 Bu Bu R CIRCUIT PROTECTOR G 2 4 C16 R W 5 Bu 20 T13 Gr 30A T4 GND11 Bu T12 3 Bu C17 Bu G 2 NOISE FILTER T20 W GND13 W Gr T21 G 4 22 Gr T5 CIRCUIT PROTECTOR W W Bu 1 AC1_M AC2_M AC1_S AC2_S 29A T10 21 Bu 4 C15 20 C14 C13 30 C12 Bu Bu 2 W T17 Bu Bu T9 T8 T15 T16 T7 W 3 1 R 6 R R T14 5 Bu R R W Bu W W W Bu W T11 Bu T10 0.5A GND14 2 G 4 R R R W R GND10 12 2 1 R Brown Orange Light blue Light green Pink Gray R Br O Lb Lg P Gr R Black Yellow Blue Green Red White 1 Bl Y Bu G R W BREATHER HEATER Stop the engine and disconnect the AC appliance. Restart the engine and check to see if an error code is displayed in the error log mode (page 4-10). Not displayed System is OK (error is cleared). Same error code displayed Turn the main switch OFF. Check the stator (page 7-17). Normal Go to (page 4-41) 4-40 Abnormal Replace the stator. dummyhead TROUBLESHOOTING From page 4-40 Turn the main switch OFF. Check the inverter unit inspection (page 7-18). Abnormal Replace the inverter unit. Abnormal Replace or repair the wire harness. Normal Check the control panel main wire harness for an open or short circuit. Normal Restart the engine and check to see if an error code is displayed in the error log mode (page 4-10). If the same error code occurs, replace the inverter unit and recheck. (AAT sensor failure) With the engine running at normal operating temperature, check to see if an error code is displayed. If the same error code occurs, replace the GCU and recheck. (BARO sensor failure) With the engine running at normal operating temperature, check to see if an error code is displayed. If the same error code occurs, replace the GCU and recheck. 4-41 dummyhead TROUBLESHOOTING (O2 sensor failure) GCU 3 18 Bl Bl O2 SENSOR Bl 31 2 Bl 1 9 Bl Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray O2 SENSOR Turn the main switch OFF. Check the wire harness between the O2 sensor and GCU for an open or short circuit. 1 18 3 Bl 5 4 3 2 1 10 9 8 7 6 1 2 3 4 5 6 7 8 9 10 9 Abnormal Replace or repair the wire harness. GCU 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 Bl Normal Not displayed Replace the O2 sensor. Start the engine and keep it running for more than 90 seconds. Do it three times and check to see if an error code is displayed. Same error code displayed Turn the main switch OFF. Replace the GCU and recheck. 4-42 Faulty original O2 sensor. dummytext 5. COVER 5 MAINTENANCE COVER REMOVAL/ INSTALLATION·············································5-2 FRONT COVER REMOVAL/ INSTALLATION ············································ 5-5 RIGHT SIDE SHROUD REMOVAL/ INSTALLATION·············································5-3 REAR COVER/OUTER MUFFLER PROTECTOR REMOVAL/ INSTALLATION ············································ 5-6 UNDER COVER REMOVAL/ INSTALLATION·············································5-4 HEAD COVER SHROUD REMOVAL/ INSTALLATION ············································ 5-7 5-1 dummyhead COVER MAINTENANCE COVER REMOVAL/INSTALLATION COVER LEFT MAINTENANCE COVER LOCK PIN LATCH PIN LATCH SPRING RETAINER HINGE PLATE BOLT (5 X 8 mm) RIGHT COVER HINGE LATCH SPRING RIGHT MAINTENANCE COVER HINGE SPRING RETAINER LATCH PIN (contact area) LOCK PIN 5-2 WASHER (2) dummyhead COVER RIGHT SIDE SHROUD REMOVAL/INSTALLATION Do not touch the insulator with bare hands. The glass wool of the material sticks in the skin and is dangerous. Open the right maintenance cover. SPECIAL BOLT (6 mm) (3) SHROUD COVER COLLAR (2) RIGHT SIDE SHROUD INSULATOR INSTALLATION: Install the insulator on the right side shroud by aligning the cutout with the convex on the shroud. CUTOUT RIGHT SIDE SHROUD BOLT (6 X 22 mm) (2) CONVEX RIGHT SIDE SHROUD INSULATOR 5-3 dummyhead COVER UNDER COVER REMOVAL/INSTALLATION Remove the wheel shaft (page 15-2). CANISTER AIR TUBE (AT, AT1 Type only) UNDER COVER SEAL DRAIN HOLE RUBBER COVER UNDER COVER TUBE HOLE RUBBER COVER (CT Type only) 5-4 BOLT (6 X 16 mm) (2) CANISTER DRAIN TUBE (AT, AT1 Type only) dummyhead COVER FRONT COVER REMOVAL/INSTALLATION Remove the handle (page 15-3). FRONT COVER SEAL A SPECIAL BOLT (6 X 26 mm) (2) 8.5 N·m (0.87 kgf·m, 6.3 lbf·ft) SPRING NUT BATTERY MAINTENANCE COVER FRONT COVER COLLAR (2) CAP NUT (6 mm) (2) 8.5 N·m (0.87 kgf·m, 6.3 lbf·ft) FRONT COVER INSTALLATION: Align the groove of the front cover with the rib of the front frame. FRONT COVER SEAL C • Apply adhesive (LOCTITE® #495) to the cover installation area. FRONT COVER • Before applying the adhesive, degrease the adhesive area. GROOVE FRONT FRAME • After applying the adhesive, press the seal for 10 to 30 seconds. FRONT COVER SEAL C SEAL A RIB Make sure that the adhesive does not overflow to this area. ADHESIVE AREA 5-5 dummyhead COVER REAR COVER/OUTER MUFFLER PROTECTOR REMOVAL/ INSTALLATION • The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Allow it to cool before proceeding. • Do not touch the insulator with bare hands. The glass wool of the material sticks in the skin and is dangerous. OUTER MUFFLER PROTECTOR INSULATOR OUTER MUFFLER PROTECTOR SEAL REAR COVER SEAL CAP NUT (6 mm) (2) BOLT (6 X 30 mm) (4) REAR COVER COLLAR (6) REAR PIPE SERVICE BULLETIN #50 => 5-6 REAR COVER dummyhead COVER HEAD COVER SHROUD REMOVAL/INSTALLATION Open the left maintenance cover. HEAD COVER SPARK PLUG CAP WASHER (6 mm) (2) BREATHER TUBE BOLT (6 X 12 mm) (2) PLUG COVER PLUG COVER BOLT 2.3 N·m (0.24 kgf·m, 1.7 lbf·ft) SPECIAL BOLT (6 mm) HEAD COVER SHROUD LOWER COVER SHROUD 5-7 dummyhead MEMO dummytext 6. FUEL SYSTEM 6 FUEL PUMP SYSTEM TROUBLESHOOTING···································6-2 THROTTLE BODY REMOVAL/ INSTALLATION ·········································· 6-16 FUEL INJECTOR SYSTEM TROUBLESHOOTING···································6-4 THROTTLE BODY DISASSEMBLY/ ASSEMBLY ················································· 6-17 FUEL PRESSURE RELIEVING·····················6-6 O2 SENSOR REMOVAL/ INSTALLATION ·········································· 6-18 FUEL PUMP UNIT REMOVAL/INSTALLATION··························6-9 FUEL TANK REMOVAL/ INSTALLATION···········································6-10 FUEL TANK DISASSEMBLY/ ASSEMBLY ·················································6-11 FUEL TANK CAP REMOVAL/ INSTALLATION (AT, AT1 TYPE ONLY) ····6-12 AIR CLEANER REMOVAL/ INSTALLATION···········································6-13 EVAP CANISTER REMOVAL/ INSTALLATION (AT, AT1 TYPE ONLY) ····6-14 FUEL INJECTOR REMOVAL/ INSTALLATION···········································6-15 EBT SENSOR REMOVAL/ INSTALLATION ·········································· 6-19 BREATHER HEATER REMOVAL/ INSTALLATION (CT TYPE ONLY) ············· 6-19 FUEL LINE INSPECTION ··························· 6-20 FUEL PUMP INSPECTION ························· 6-21 THROTTLE CONTROL MOTOR INSPECTION··············································· 6-21 FUEL INJECTOR INSPECTION ················· 6-21 EBT SENSOR INSPECTION ······················ 6-22 BREATHER HEATER INSPECTION (CT TYPE ONLY) ········································ 6-22 6-1 dummyhead FUEL SYSTEM FUEL PUMP SYSTEM TROUBLESHOOTING FUEL SYSTEM FUEL PUMP DOES NOT OPERATE SERVICE BULLETIN #55 => GCU 3 18 R R Bu Bu FFP(+) Bl Y Bu G R W FFP(-) 4 8 Bu 1 6 R 12 Br/Bu 11 MAIN_SWGND G G G 1 20 G MAIN_SW+ 3 W/Bu GND Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray Bl R Bu 3 11 2 1 14 GND3 W 5 W/Bu 1 Br/Bu 13 FUEL PUMP Bl MAIN_SW2 G MAIN_SW1 2 Br/Bu 1 Br/Bu MAIN SWITCH MAIN SWITCH MAINSW1 MAINSW2 ON OFF Check whether the i-Monitor is on when the main switch is turned ON. OFF Perform the i-MONITOR DOES NOT DISPLAY BY MAIN SWITCH TURNED ON (page 4-19). ON Check whether an error code is displayed on the i-Monitor when the main switch is ON and the starter switch is pressed. Not displayed Go to page 6-3 6-2 Displayed Perform the SELF-DIAGNOSTIC TROUBLESHOOTING Relieve the fuel pressure and disconnect the fuel pump side quick-connect fitting (page 6-6). BOLT (6 x 25 mm) (4) FUEL TANK SEAL INSTALLATION: WASHER (6 mm) (4) Set the fuel tank seal with the lip of the seal facing upward. FUEL TANK SEAL LIP FUEL TANK CONTROL PANEL SIDE TANK CUSHION RUBBER (4) ASSEMBLY: Install the rubber with the thicker side down as shown. DOWN TANK CUSHION COLLAR (4) TUBE CLIP (B7) (AT, AT1 TYPE ONLY) EVAP CHARGE TUBE (AT, AT1 TYPE ONLY) 6-10 dummyhead FUEL SYSTEM FUEL TANK DISASSEMBLY/ASSEMBLY Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the following: – fuel tank (page 6-10) – fuel pump (page 6-9) FUEL FILLER CAP AT, AT1 Type: FUEL FILLER CAP CT Type: FLAT SCREW (5 x 10 mm) (2) 4 N·m (0.41 kgf·m, 3.0 lbf·ft) FUEL GAUGE FUEL TANK STRAINER Before installation, clean the screen and check for damage. Replace necessary. FUEL TANK Fuel Tank Capacity: 19.2 Liters (5.07 US gal, 4.22 Imp gal) 6-11 dummyhead FUEL SYSTEM FUEL TANK CAP REMOVAL/INSTALLATION (AT, AT1 TYPE ONLY) REMOVAL Open the fuel tank cap. Unhook one tip of the anchor [1] using pliers [2], and then unhook the other tip in the same manner. [2] [1] Never try to force the anchor when removing it. Draw the loop [1] of the anchor [2] from the hole [3] of the fuel filler neck using pliers. [2] [1] [3] Pull one tip of the anchor [1] out of the fuel filler neck using pliers [2], and then pull the other tip out in the same manner. [2] [1] Be careful to avoid damaging the breather pipe in the fuel filler neck. Remove the anchor from the filler neck. INSTALLATION Attach the loop part [1] of the anchor [2] in the hole [3] of the fuel filler neck. [2] [3] Hook the tips of the anchor in the reverse order of removal. [1] 6-12 dummyhead FUEL SYSTEM AIR CLEANER REMOVAL/INSTALLATION Open the left maintenance cover. Remove the breather heater (CT Type only: page 6-19). • When installing, route the tubes properly (page 2-24). SILENCER CHAMBER SEAL BREATHER TUBE (AT, AT1 Type only) NUT (6 mm) (2) 8.5 N·m (0.87 kgf·m, 6.3 lbf·ft) COVER CLIP (4) SILENCER CHAMBER SILENCER COVER AIR CLEANER CONNECTING TUBE EVAP PURGE TUBE (AT, AT1 Type only) CONNECTING TUBE BAND (2) 0.7 N·m (0.07 kgf·m, 0.5 lbf·ft) FLAME TRAP AIR CLEANER BRACKET INTAKE AIR GUIDE TUBE BOLT (6 x 22 mm) (3) NUT (6 mm) BOLT (6 x 14 mm) (3) PAPER ELEMENT AIR CLEANER CASE INSTALLATION: Insert the intake port of the air cleaner case into the separator seal rubber B on the front frame as shown. SEPARATOR SEAL RUBBER B INTAKE PORT AIR CLEANER GRID FOAM ELEMENT AIR CLEANER COVER INTAKE AIR GUIDE TUBE FRONT FRAME 6-13 dummyhead FUEL SYSTEM EVAP CANISTER REMOVAL/INSTALLATION (AT, AT1 TYPE ONLY) Open the left maintenance cover. CHARGE TUBE TUBE CLIP (B7) CANISTER STAY PURGE TUBE TUBE CLIP TUBE CLIP (B7) CANISTER MOUNT RUBBER (2) TUBE CLIP (B7) CANISTER AIR CLEANER COVER CANISTER DRAIN TUBE TUBE CLIP 6-14 CANISTER AIR TUBE dummyhead FUEL SYSTEM FUEL INJECTOR REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Be careful not to allow dirt and debris between the injector and O-ring. Open the left maintenance cover. Disconnect the throttle body side quick connect fitting (page 6-6). • When installing, route the fuel feed hose properly (page 2-24). • Replace the O-ring and seal ring with new ones as a set. SEAL RING O-RING FLANGE BOLT (5 x 20 mm) (2) INJECTOR JOINT THROTTLE BODY 5.1 N·m (0.52 kgf·m, 3.8 lbf·ft) FUEL INJECTOR INSTALLATION: TAB FUEL FEED HOSE TAB Attach the tab of the fuel injector with the tab of the injector joint. 6-15 dummyhead FUEL SYSTEM THROTTLE BODY REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the silencer chamber (page 6-13). Relieve the fuel pressure and disconnect the throttle body side quick-connect fitting (page 6-6). • When installing, route the fuel feed hose properly (page 2-24). THROTTLE INSULATOR INSULATOR PACKING HARNESS CLIP THROTTLE BODY PACKING THROTTLE BODY SPACER COUPLER HOLDER THROTTLE BODY FUEL FEED HOSE AIR CLEANER PACKING 6-16 dummyhead FUEL SYSTEM THROTTLE BODY DISASSEMBLY/ASSEMBLY • The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual. • Do not damage the throttle body. It may cause incorrect throttle valve operation. • Be careful not to drop dirt and debris into the throttle body. SCREW WASHER (2) SCREW (2) 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) THROTTLE CONTROL MOTOR MIDDLE GEAR THROTTLE BODY MOTOR PACKING 6-17 dummyhead FUEL SYSTEM O2 SENSOR REMOVAL/INSTALLATION • Replace the O2 sensor if grease, oil, water, or other materials get in the air hole or inside the sensor. Do not reuse the contaminated sensor. • Do not get any cleaning agents inside the O2 sensor. • The O2 sensor may be damaged if dropped. Replace it with a new one, if dropped. Remove the muffler and air guide insulator (page 11-2). Remove the O2 sensor wire clamp [1]. [2] Hold the center of the O2 sensor cap [2] as shown. Disconnect the cap from the sensor while slightly turning it less than 1/2 of a turn. • Do not use pliers or other tools when disconnecting the O2 sensor cap. • Do not pull the O2 sensor wire. [1] Remove the O2 sensor. • Do not use an impact wrench when removing or installing the O2 sensor, or it may be damaged. Install the O2 sensor onto the exhaust pipe. Tighten the O2 sensor to the specified torque. TORQUE: 24.5 N·m (2.5 kgf·m, 18 lbf·ft) Connect the O2 sensor cap [1] to the O2 sensor by pushing it straight down as shown. [1] Install the O2 sensor wire clamp [2]. • Be careful not to tilt the O2 sensor cap when connecting the cap to the O2 sensor. • Make sure that the gap between the O2 sensor and sensor cap is less than 2.0 mm (0.08 in). 2.0 mm (0.08 in) [2] [1] [2] The O2 sensor cap facing the harness band side. 6-18 dummyhead FUEL SYSTEM EBT SENSOR REMOVAL/ INSTALLATION Remove the head cover lower shroud (page 13-2). Disconnect the EBT sensor wire connectors [1]. Remove the EBT sensor [2]. Install the EBT sensor and new sealing washer [3], and tighten the EBT sensor to the specified torque. [1] TORQUE: 9 N·m (0.92 kgf·m, 6.6 lbf·ft) [3] [2] BREATHER HEATER REMOVAL/ INSTALLATION (CT TYPE ONLY) Open the left maintenance cover. Disconnect the breather heater 2P connector [1] . [3] Remove the wire bands [1]. Disconnect the breather tubes [2] and remove the breather heater insulator [3]. Remove the breather heater [4]. [4] [1] Installation is in the reverse order of removal. [2] [3] Eliminate space between mating surface. TAPING PORTION 6-19 dummyhead FUEL SYSTEM FUEL LINE INSPECTION SPECIAL TOOL #8 => FUEL PRESSURE TEST Open the left maintenance cover. [3] Remove the fuel feed hose [1] from the hose clip [2]. Relieve the fuel pressure and disconnect the injector side quick-connect fitting (page 6-6). Attach the fuel pressure gauge. TOOLS: Fuel pressure gauge [3] 074APJ-Z37A100 Connect the fuel pump 5P connector and negative (-) battery terminal. Start the engine using the electric starter and read the fuel pressure. [2] STANDARD: 294 kPa (3.0 kgf/cm2, 43 psi) If the fuel pressure is higher than specified, replace the fuel pump assembly. See NOTE below. If the fuel pressure is lower than specified, inspect the following: – Leaking fuel line – Pinched or clogged fuel feed hose or fuel tank cap breather – Clogged fuel filter (page 3-13) – Fuel pump unit (page 6-21) A fuel pressure reading that is greater or less than the standard fuel pressure may not be an indication of a faulty fuel pump. Inspect all other fuel system components for problems before replacing the fuel pump. Contact Techline for assistance. After inspection, relieve the fuel pressure (page 6-6). Remove the fuel pressure gauge from the injector. Reconnect the quick connect fitting onto the injector (page 6-8). FUEL FLOW INSPECTION Open the left maintenance cover. Relieve the fuel pressure and disconnect the injector side quick-connect fitting (page 6-6). Place the end of the fuel feed hose into an approved gasoline container. • Wipe up any spilled gasoline. Temporarily connect the fuel pump 5P connector and battery cables. Turn the main switch ON and push the START button. Measure the amount of fuel flow. • The fuel pump operates for 5 seconds. Repeat 2 times to meet the total measuring time. • After measuring the fuel flow, pour the fuel back into the fuel tank. Amount of fuel flow: 55 cc (1.9 US oz, 1.9 Imp oz) minimum/ 10 seconds If fuel flow is less than specified, inspect the following: – Fuel pump unit (page 6-21) – Clogged fuel filter (page 3-13) – Pinched or clogged fuel feed hose. Connect the quick connect fitting (page 6-8). 6-20 [1] dummyhead FUEL SYSTEM FUEL PUMP INSPECTION Remove the fuel pump cover (page 6-6). Disconnect the fuel pump 5P connector . Measure the resistance between the terminals of the 5P connector. Standard resistance: 0 – 20 Ω (at 20 °C/68 °F) THROTTLE CONTROL MOTOR INSPECTION Remove the throttle body (page 6-16). Measure the resistance between the terminals of the 4P connector . Connector Terminal Ω 1–3 65 – 75 2–4 65 – 75 FUEL INJECTOR INSPECTION Open the left maintenance cover. Disconnect the fuel injector 2P connector . Measure the resistance between the terminals of the 2P connector. Standard resistance: 11 – 13 Ω (at 24 °C/75 °F) 6-21 dummyhead FUEL SYSTEM EBT SENSOR INSPECTION Remove the air cleaner case and air cleaner bracket (page 6-13). Disconnect the EBT sensor wire connectors ( ). and Measure the resistance between the terminals. Standard resistance: 1.6 – 2.9 kΩ (at 20 °C – 30 °C/68 °F – 86 °F) BREATHER HEATER INSPECTION (CT TYPE ONLY) Open the left maintenance cover. [1] Remove the wire band [1]. Disconnect the breather heater 2P connector . Measure the resistance between the terminals of the 2P connector. Standard resistance: 0.8 – 1.2 kΩ (at 25 °C/77 °F) 6-22 dummytext 7. GENERATOR/CHARGING SYSTEM GENERATOR TROUBLESHOOTING···········7-2 CHARGING SYSTEM TROUBLESHOOTING···································7-8 BATTERY REMOVAL/INSTALLATION········7-9 INVERTER UNIT REMOVAL/ INSTALLATION···········································7-10 FRONT FRAME REMOVAL/ INSTALLATION···········································7-11 FAN COVER REMOVAL/INSTALLATION··7-12 COOLING FAN REMOVAL/ INSTALLATION ·········································· 7-13 GENERATOR REMOVAL/ INSTALLATION ·········································· 7-14 BATTERY CHARGING ······························· 7-16 BATTERY INSPECTION ····························· 7-16 STATOR INSPECTION ······························· 7-17 INVERTER UNIT INSPECTION ·················· 7-18 7-1 7 dummyhead GENERATOR/CHARGING SYSTEM GENERATOR TROUBLESHOOTING GENERATOR/CHARGING SYSTEM High voltage and electrical current present. Touching the non-insulated portions of the meter leads or generator wiring can cause shock or electrocution. Wear insulated gloves and avoid handling non-insulated wiring. MECHANICAL TROUBLESHOOTING When presented with an EU7000is inverter generator exhibiting error codes or unusual running problems, follow the steps below BEFORE troubleshooting by the error code(s) found on page 4-9. Remember, mechanical problems can lead to error codes and replacement of expensive electronic components that may not be faulty. Some of these steps, hints, and directions may seem irrelevant or an inefficient use of time. It has been shown that following these steps leads to easier and earlier identification of the actual problem or faulty component. Follow these steps and, when necessary, contact Techline or your District Service Manager if additional assistance is necessary. REMINDER: All major component replacement requires prior warranty authorization from Techline or your District Service Manager. Major components include the inverter, GCU, stator, rotor, and major engine components. It may not be necessary to perform all of the following troubleshooting steps: • Always complete sections 1 and 2. • If the generator starts and immediately stalls or runs less than 10 seconds, refer to sections 3 to 5. • If the generator runs for more than 10 seconds, refer to sections 6 and 7. 1. QUESTION THE CUSTOMER When an EU7000is generator is brought in for repair, be sure to fill out the i-Monitor Detail Error Log (found in the back of this manual). This document is required before your DSM or Techline representative can authorize warrantable inverter generator repairs. Important information to get from the customer: EU7000iS i-MONITOR DETAIL ERROR LOG FAX this page to Techline at (678) 339-2519 or email to petl@ahm. Dealer name:____________________________________________________ Dealer number:________ Contact:________________________________________________________ Telephone number: ( Generator Model: Frame serial number (including prefix): Date of purchase: __________________ ___________________________________________ ____________________ 1. Describe the failure: ______________________________________________________________ ___________________________________________________________________________________ 2. Describe how the generator was being used at the time of the failure. • Description of generator usage at the time of the failure 3. 4. • Receptacles used • Loads (manufacturer, model, volts, and amps of each load) • Extension cord length and gauge Extension cord gauge ________ and length _______________ (if applicable). i-Monitor error log (see READING THE ERROR CODES and error detail code definitions on pa Error Code #1 ____________ Error Number in Units Detail # display Error Code #2 ____________ Error Number in Units Detail # display Error Code #3 ____________ Error Number in Units Detail # display 1 Hour 1 Hour 1 Hour 2 Volts 2 Volts 2 Volts 2. CHECK THE CONDITION OF THE GENERATOR With the customer present, document the condition of the fuel, oil (level, color, odor) and air filter. 7-2 OIL AIR FILTER Revised: June 2017 (61Z37000E2) dummyhead GENERATOR/CHARGING SYSTEM Note the position of the Eco Throttle® switch and the voltage selector switch at the time the unit is brought in. Is the wheel kit installed? The unit requires open space under and around the generator for cooling purposes. ECO THROTTLE SWITCH Is there evidence of the unit being run in an enclosure or restricted area? Exhaust soot on painted surfaces is a good indicator. VOLTAGE SELECTOR SWITCH WHEEL KIT 3. NOTE ANY UNUSUAL RECOIL RESISTANCE Use the recoil starter to determine the presence of an electronic brake load on the generator. If such a load is present, the unit will be difficult to pull over by hand. Disconnecting the GCU (Generator Control Unit) from the stator normally relieves this load. Disconnecting the 3-pin connector (red, white, blue wires) on the left side of the control panel also relieves the load. A faulty GCU could cause the problem, and may not force error codes from the i-Monitor. 3-PIN CONNECTOR 4. CHECK THE VOLTAGE SELECTOR SWITCH If the engine starts and the green output indicator light illuminates for several seconds, followed by the green light going out and the red overload indicator light illuminating while the engine defaults to a low idle speed, there may be a problem with the voltage selector switch. There may also be a buzzing noise coming from the switch when it is in either position. 4-PIN CONNECTOR INVERTER Turn the unit off and disconnect the 4-pin connector from the inverter as shown. Restart the unit. If the green output indicator stays illuminated and the Eco Throttle switch functions properly, the voltage selector switch may be faulty. Test the voltage selector switch according to the shop manual procedure. Revised: June 2017 (61Z37000E2) 7-3 dummyhead GENERATOR/CHARGING SYSTEM 5. INSPECTION Perform a visual inspection of the GCU and inverter. Component inspection is listed in the order in which they need to be removed to access the next component. Inverter: Visually inspect the back of the inverter for any discolored or damaged wiring, capacitors, or connectors, and note any bubbling, corrosion, or other unusual conditions. If any of these issues are present, the inverter is likely faulty. While the inverter may be faulty, it may not be the cause for the overall generator failure. Some other circumstance, or other component failure, may have caused the inverter to fail. Contact Techline or your District Service Manager for further instruction. INVERTER GCU: To visually inspect the GCU, remove the front cover and the control panel. Visually inspect the circuit board on the backside of the GCU for any discolored spots, deterioration, contamination, or deformed capacitors. GCU Stator: The output and resistance tests performed in the Generator Troubleshooting Guide or the appropriate shop manual should be enough to determine if the stator is good or not. The stator resistance readings should be consistent. If there is more than 0.2 Ω of difference between readings, the stator has failed. ROTOR WINDOW The stator can also be visually inspected by removing the spark plug, inverter, recoil starter, and cooling fan, and then looking through the rotor windows at the stator windings. Rotate the rotor by hand and slowly look for any signs of overheated or discolored stator windings. If the wheel kit had been removed and the unit was mounted on a service truck, look for broken, damaged, or loose rotor magnets due to excessive vibration. 7-4 Revised: June 2017 (61Z37000E2) dummyhead GENERATOR/CHARGING SYSTEM 6. CHECK THE SPARK ARRESTER SCREEN Clean or replace as necessary. A badly clogged screen could also be an indicator that the muffler passages are clogged or reduced due to carbon buildup. Excess carbon buildup may indicate high engine hours, operation with a restricted air cleaner, or operating the generator in an enclosure. SPARK ARRESTER SCREEN If the spark arrester was heavily clogged, run the generator outdoors on the load bank for 30 minutes at 50 ~ 60% load to dynamically decarbon the combustion chamber. Let the generator cool down, and then reinstall the spark arrester. 7. FUEL PRESSURE TEST If the generator displays an E-0A code, surges under load, or surges and stalls, the fuel system needs to be inspected. Test the fuel pressure: • Remove the fuel feed hose from the hose clip. • Relieve the fuel pressure by disconnecting the injector side quick-connect fitting. • Attach the fuel pressure gauge. FUEL PRESSURE GAUGE HOSE CLIP TOOL: Fuel pressure gauge P/N 074APJ-Z37A100 • Start the engine using the electrical starter and read the fuel pressure. STANDARD: 43 psi (294 kPa, 3.0 kgf/cm2) If the fuel pressure is lower than specified, inspect the fuel filter. If the fuel filter is clean, contact Techline. FUEL FEED HOSE Refer to page 4-33 for additional information. 8. START AND LOAD TEST THE GENERATOR Note any changes in the way the engine runs. • If the problem is now resolved, be sure to note the hours and any stored error codes on the repair order. • If a problem remains after the above steps have been taken, refer to page 7-6 to troubleshoot the generator. Perform the visual inspection (step 5 on page 7-4) when removing the control panel and inverter. • If the generator starts and runs but does not carry the rated load during the load bank test, check the following: – Throttle control motor not functioning properly – Engine compression Repair as necessary and repeat load bank test. Revised: June 2017 (61Z37000E2) 7-5 dummyhead GENERATOR/CHARGING SYSTEM NO AC OUTPUT AT Type: INVERTER UNIT 30A T13 T6 T12 R R R R 3 AC1_M AC2_M AC1_S AC2_S PARALLEL OPERATION OUTLETS CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 1 4 22 2 Gr W W C17 2 4 1 Gr T5 CIRCUIT PROTECTOR W Bu 20 T4 C16 1 Bu Bu Bu R R Bu W 5 6 NOISE FILTER Bu Gr 3 T19 21 20 C14 C13 30 C12 T14 Bu Bu Bu R 3 Bu T14 T9 T8 T16 T7 W T17 6 1 R Bu T15 2 R R W 5 Bu 4 Bu C15 Bu NOISE FILTER Bu Bu T11 T10 AT1 Type: INVERTER UNIT T13 R 30A T6 T12 R R R 3 T5 CIRCUIT PROTECTOR 4 W 22 Gr Gr 2 Bu 4 C17 20 W C16 Bu Bu R R W T17 W Bu T4 GFCI Bu R 5 6 Bu T24 GFCI 1 Bu NOISE FILTER T19 T18 W 2 1 AC1_M AC2_M AC1_S AC2_S PARALLEL OPERATION OUTLETS CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 1 3 Gr 21 Bu C15 20 C14 C13 30 C12 Bu Bu Bu T9 T8 R T7 3 W 6 1 R T14 T15 2 R R W Bu 5 4 Bu Bu Bu NOISE FILTER Bu Bu T11 T10 CT Type: CIRCUIT PROTECTOR INVERTER UNIT 1 T23 R 29A T6 T22 R R 3 R Bu 6 Bu Bu CIRCUIT PROTECTOR G 2 4 C16 T19 T18 GND12 1 20 R R W 5 Bu C17 Bu T13 30A T4 GND11 Bu T12 3 Gr G 2 Bu NOISE FILTER T20 W GND13 W Gr T21 G 4 22 Gr T5 CIRCUIT PROTECTOR W W Bu 1 AC1_M AC2_M AC1_S AC2_S PARALLEL OPERATION OUTLETS VOLTAGE SELECTOR SWITCH 21 Bu 4 C15 20 C14 C13 30 C12 Bu Bu W 2 R T17 R Bu T9 T8 T15 T16 T7 W 3 1 R 6 R R W T14 5 Bu Bu Bu W W W Bu W T11 Bu T10 0.5A GND14 G 4 R R R W GND10 R R 12 2 1 R Brown Orange Light blue Light green Pink Gray R Br O Lb Lg P Gr 1 Black Yellow Blue Green Red White 2 Bl Y Bu G R W BREATHER HEATER Check for error codes on the i-Monitor while the engine running. Displayed Perform the SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-9). Not displayed Check to see if the overload indicator is ON with the engine running. OFF Go to page 7-7 7-6 ON Perform the INVERTER UNIT EXCESSIVE CURRENT PROTECTION ACTIVATED/ INVERTER UNIT EXCESSIVE VOLTAGE PROTECTION ACTIVATED (page 4-37). dummyhead GENERATOR/CHARGING SYSTEM From page 7-6 Abnormal Check the stator (page 7-17). Replace the stator. Normal Check the inverter unit (page 7-18). Abnormal Replace the inverter unit. Normal •Check the following control panel parts: Abnormal Replace or repair the faulty part(s). • Receptacles • Circuit protectors • Voltage selector switch • Main wire harness in the control panel for open circuit Normal Replace the inverter and recheck. LOW AC OUTPUT Check whether an error code is displayed on the i-Monitor with the engine running. Displayed Perform the SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-9). Not displayed Check the engine speed with the circuit protector in the ON position, and the Eco-Throttle switch in the OFF position, Check the voltage selector switch in the "120/240" position. Abnormal Perform the ENGINE SPEED DOES NOT STABILIZE (page 4-7). Check the engine speed. STANDARD: 3,300 – 3,600 min-1 (rpm) Normal Check the stator inspection (page 7-17). Abnormal Replace the generator. Normal Normal Replace the inverter. Faulty original inverter unit. Restart the engine and warm up the engine to operating temperature. Recheck the AC voltage at the AC output. Abnormal Replace the GCU and recheck. 7-7 dummyhead GENERATOR/CHARGING SYSTEM CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1 W 5 W W Bu Bu 5 2 V W R 3 W Bu U 3 R 1 3 W Bu 1 U GCU 20 R R 1 6 V 18 12 Br/Bu 3 W/Bu MAIN_SW- 3 Bl/Y GND GND G 10 Bl/Y MAIN_SW+ 20 11 STATOR (MASTER) BAT_IN 13 Br/Y G T3 BATTERY W/Bu 5 W 1 Br/Bu T2 14 Bl 3 G 1 G Bl MAIN_SW2 G MAIN_SW1 2 Br/Bu GND3 1 Br/Bu 3A Br/W ACC Bl/Y BAT 3 G/O G/O 15A 4 Bl/Y MAIN SWITCH 13 Bl Y Bu G R W Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray MAIN SWITCH MAINSW1 MAINSW2 BAT ACC ON OFF Check whether the i-Monitor is on when the main switch is turned ON. OFF Perform the i-MONITOR DOES NOT DISPLAY BY MAIN SWITCH TURNED ON (page 4-19). ON Check the battery condition, using a battery tester (page 7-16). Abnormal Replace or recharge the battery. Normal With the engine running at normal operating temperature, measure the battery voltage. The battery voltage should not exceed 14.5 V while the engine is running. 7-8 Abnormal Replace the GCU and recheck. dummyhead GENERATOR/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Hydrogen gas from batteries is highly flammable and explosive. You can be burned or seriously injured when charging the battery. • Keep heat, sparks, and flame away. • The battery is a Valve Regulated Lead Acid (VRLA) maintenance-free battery. Do not open or tamper with the battery. • The YTZ-14S battery specially designed for use in this generator. Other batters must not be used. • When removing the battery, turn the main switch to the off position. • When removing the battery, disconnect the negative (–) cable first, then disconnect the positive (+) cable • When installing the battery, connect the positive (+) cable first, then the negative (–) cable. BATTERY (YTZ-14S) REMOVAL/ INSTALLATION: Remove or install the battery by tipping it as shown. Install the battery with the terminals facing to the front. BATTERY BAND NEGATIVE (–) TERMINAL COVER BOLT 2.3 N·m (0.24 kgf·m, 1.7 lbf·ft) TERMINAL NUT (2) POSITIVE (+) TERMINAL BOLT (2) BATTERY MAINTENANCE COVER TERMINAL 7-9 dummyhead GENERATOR/CHARGING SYSTEM INVERTER UNIT REMOVAL/INSTALLATION Remove the front cover (page 5-5). BOLT (5 X 12 mm) WIRE HARNESS CLIP BRACKET REMOVAL: BOLT WASHER (6 X 25 mm) (2) Remove as shown. INVERTER UNIT COLLAR (2) INVERTER UNIT RUBBER (2) 7-10 GROOVES dummyhead GENERATOR/CHARGING SYSTEM FRONT FRAME REMOVAL/INSTALLATION Remove the following: – – – – Front cover (page 5-5) Inverter unit (page 7-10) Control panel (page 10-2) Recoil starter (page 9-6) SEPARATOR SEAL RUBBER A INSTALLATION: Install the separator seal rubber to the front frame securely as shown. WIRE HARNESS BAND (2) ENGINE WIRE HARNESS FRONT FRAME FRONT FRAME INVERTER UNIT CUSHION RUBBER (3) FAN COVER SEPARATOR SEAL RUBBER A HARNESS CLIP B GENERATOR WIRE HARNESS BATTERY BOX RUBBER (4) SEPARATOR SEAL RUBBER B INSTALLATION: BOLT (8 X 12 mm) (5) 24 N·m (2.4 kgf·m, 18 lbf·ft) Install the separator seal rubber to the front frame securely as shown. FRONT FRAME INTAKE AIR GUIDE TUBE SEPARATOR SEAL RUBBER B 7-11 dummyhead GENERATOR/CHARGING SYSTEM FAN COVER REMOVAL/INSTALLATION • The fan cover can be removed with the engine in the frame. Remove the following: – Front frame (page 7-11) – Fuel tank (page 6-10) – Recoil starter (page 9-6) Remove the nuts (10 mm) and raise the fan cover until the stud bolt of the bottom rubber is clear from the fan cover by placing wooden blocks under the engine. GROUND TERMINAL INSTALLATION: Install the terminals on the fan cover so they touch the stops as shown. STOPS BOLT (6 X 12 mm) (2) BOLT (6 X 23 mm) STUD BOLT (6 X 20 mm) (3) NUT (6 mm) (2) 8.5 N·m (0.87 kgf·m, 6.3 lbf·ft) FAN COVER BRACKET BOLT (6 X 23 mm) (2) FAN COVER INSTALLATION: Install the generator harness grommet in the cutout of the fan cover as shown. BOLT (6 X 12 mm) (2) SPRING NUT (6 mm) (5) CUTOUT TIMING INSPECTION HOLE COVER BOLT (6 X 12 mm) GENERATOR HARNESS GROMMET 7-12 BOLT (6 X 30 mm) (2) FLANGE NUT (10 mm) (2) 34 N·m (3.5 kgf·m, 25 lbf·ft) dummyhead GENERATOR/CHARGING SYSTEM COOLING FAN REMOVAL/INSTALLATION Remove the following: – Fan cover (page 7-12) – CKP sensor (page 8-7) BOLT (10 X 25 mm) REMOVAL/INSTALLATION: Remove the CKP SENSOR, and hold the rotor with a commercially available strap wrench and loosen or tighten the flange bolt. Take care not to damage the fan. STRAP WRENCH (Commercially available) RECOIL PULLEY ADAPTER COOLING FAN INSTALLATION: Install the cooling fan by aligning the four lugs with the holes of the rotor. WASHER (10 mm) STARTER PULLEY LUG HOLE BOLT (6 X 35 mm) (4) Tighten the bolts in a crisscross pattern in two or three steps. 7-13 dummyhead GENERATOR/CHARGING SYSTEM GENERATOR REMOVAL/INSTALLATION EXPLODED VIEW WOODRUFF KEY GENERATOR WIRE HARNESS STATOR COLLAR B (2) (DOUBLE NOTCHED) STATOR COLLAR A (2) (SINGLE NOTCHED) STATOR FLANGE SOCKET BOLT (6 X 78 mm) (4) 11 N·m (1.1 kgf·m, 8 lbf·ft) SPECIAL NUT (16 mm) REMOVAL/INSTALLATION: Hold the rotor with a commercially available strap wrench, and then loosen or tighten the special nut. STRAP WRENCH (Commercially available) TORQUE: 170 N·m (17.3 kgf·m, 125 lbf·ft) 7-14 ROTOR REMOVAL: Remove the rotor using a commercially available flywheel puller. Do not remove the rotor by tapping it with a hammer. FLYWHEEL PULLER (Commercially available) dummyhead GENERATOR/CHARGING SYSTEM GENERATOR INSTALLATION Install the stator collars on the stator as shown. GENERATOR • Do not interchange the double-notched collars with WIRE HARNESS the single notched collars. • When the generator wire harness is removed, RED TAPE connect the generator wire harness as shown. STATOR COLLAR B (2) THREE TERMINAL STATOR Clean off any oil or grease from the crankshaft taper and tapered hole in the rotor. Install the woodruff key on the crankshaft. STATOR COLLAR A (2) [1] Install the stator while placing the generator wire harness as shown and tighten the four flange socket bolts (6 x 78 mm). Check for any foreign material attached to the inside of the rotor before installation. Install the rotor [1] by aligning the key groove with the woodruff key on the crankshaft. Note that the magnetic force of the rotor is very strong. Take care not to pinch your fingers during installation. Apply engine oil to the threads of the special nut [2]. Holding the rotor with a commercially available strap wrench [3], tighten the special nut to the specified torque. [2] [3] TORQUE: 170 N·m (17.3 kgf·m, 125 lbf·ft) 7-15 dummyhead GENERATOR/CHARGING SYSTEM BATTERY CHARGING Remove the battery (page 7-9). Connect the positive (+) terminal of the charger to the positive terminal of the battery, and connect the negative (–) terminal of the charger to the negative terminal of the battery. Charging time: 1.1 A: 5 - 10 hours (Slow-charging) 5.5 A: approx. 1.0 hours (Quick-charging) • Only use the battery charger in a sufficiently ventilated room with no flammable material in the area. • Keep fire and sparks away from a charging battery. • Turn power ON/OFF at the charger, not at the battery terminals. • Discontinue charging if the battery feels hot to touch (electrolyte temperature exceeds 45 °C/ 113 °F). • Use the battery charger designed for maintenancefree batteries. • Quick-charging should only be done in an emergency; slow-charging is preferred. • Wait for approximately 30 minutes after charging before measuring the battery voltage. BATTERY INSPECTION Remove the battery (page 7-9). RECOMMENDED BATTERY TESTER: BM-310 (YUASA) or equivalent. Battery voltage: 13.0 - 13.2 V (Fully charged) If the battery voltage is less than 12.3 V, charge the battery. 7-16 dummyhead GENERATOR/CHARGING SYSTEM STATOR INSPECTION Turn the main switch OFF. Remove the inverter unit (page 7-10). Pull the recoil starter and measure the voltage between the terminals of the generator 3P connectors ( and ) with the generator mounted. Generator Connector Terminal number Specific voltage 1-2 Master 2-3 AC 15 V or more 1-3 1-2 Slave 2-3 AC 15 V or more 1-3 If the output voltage is less than the standard voltage, Measure the resistance between the terminals of the and ) according to the table below. generator 3P connectors ( Generator Connector Terminal number Standard resistance 1-2 Master 2-3 0.44 - 0.62 Ω 1-3 1-2 Slave 2-3 0.44 - 0.62 Ω 1-3 If the resistance is out of the specification, check the stator coil resistance according to the table below. Stator Terminal number N2 W2 Standard resistance V2 N1-U1 Master N1-V1 U2 0.22 - 0.31 Ω N1-W1 N2-U2 Slave N2-V2 0.22 - 0.31 Ω N2-W2 If all resistances are OK, replace or repair the generator wire harness. If the resistance is out of specification, replace the stator. U1 N1 W1 V1 7-17 dummyhead GENERATOR/CHARGING SYSTEM INVERTER UNIT INSPECTION Remove the inverter unit (page 7-10). Check for continuity between the terminals. • Use a recommended analog multi-tester. SP-15D (SANWA) or equivalent SP-18D (SANWA) or equivalent TH-5H (KOWA) or equivalent Tester probe (-) Connector Connector Terminal No. 1 2 Tester probe (+) 3 1 2 3 1 No Continuity No Continuity No Continuity No Continuity No Continuity No Continuity 2 No Continuity No Continuity No Continuity No Continuity No Continuity No Continuity 3 No Continuity No Continuity No Continuity No Continuity No Continuity No Continuity 4 No Continuity No Continuity No Continuity No Continuity No Continuity No Continuity 3 No Continuity No Continuity No Continuity No Continuity No Continuity No Continuity 4 No Continuity No Continuity No Continuity No Continuity No Continuity No Continuity Tester probe (+) Tester probe (-) 7-18 Connector Connector Terminal No. 1 2 3 1 2 3 1 No Continuity No Continuity No Continuity No Continuity No Continuity No Continuity 2 No Continuity No Continuity No Continuity No Continuity No Continuity No Continuity dummytext 8. IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING···································8-2 IGNITION COIL REMOVAL/ INSTALLATION·············································8-6 CKP SENSOR REMOVAL/ INSTALLATION·············································8-7 CKP SENSOR AIR GAP ADJUSTMENT······8-8 SPARK TEST ················································ 8-8 CKP SENSOR INSPECTION ························ 8-9 IGNITION COIL INSPECTION ······················ 8-9 SPARK PLUG CAP INSPECTION·············· 8-10 OIL LEVEL SWITCH INSPECTION ············ 8-10 8-1 8 dummyhead IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING IGNITION SYSTEM NO SPARK AT THE SPARK PLUG 5 W Bu 3 W Bu U V W 2 3 W Bu R R 5 W Bu 3 1 20 R 1 U W GCU 1 R 1 6 V STATOR (MASTER) 2 19 Bl Bl Bl/G Bl/G Y/Bu Y/Bu Y Y IGN+ 1 8 Bl/G 2 7 Bl 33 28 4 Y 12 Br/Bu 11 MAIN_SW+ GND 20 G 1 Y G O/A MAIN_SW- G G PC+ 3 W/Bu Y/Bu IGN- 18 3 Y/Bu GND 3 C2 Y C5 C4 Bl G C1 Bu Bl Bl/G C3 14 IGNITION COIL GND3 W 5 W/Bu 1 Br/Bu CKP SENSOR OIL LEVEL SWITCH 13 Bl Br/Bu 2 SPARK PLUG G MAIN_SW2 MAIN_SW1 1 Br/Bu MAIN SWITCH MAIN SWITCH MAINSW1 MAINSW2 ON OFF Bl Y Bu G R W 8-2 Black Yellow Blue Green Red White Br O Lb Lg P Gr Brown Orange Light blue Light green Pink Gray dummyhead IGNITION SYSTEM OFF Check whether the i-Monitor is on when the main switch is turned ON. Perform the i-MONITOR DOES NOT DISPLAY BY MAIN SWITCH TURNED ON (page 4-19). ON Check whether the Oil Alert indicator is ON and “OIL” is displayed on the iMonitor with the main switch is turned ON and the starter switch is pressed. Displayed See OIL in SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-9). Displayed Perform the SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-9). Abnormal Replace the oil level switch (page 14-3). Abnormal Replace the GCU. Not displayed Check whether an error code is displayed on the i-Monitor with the main switch is turned ON and the starter switch is pressed. Not displayed Check the oil level switch (page 8-10). Normal Check the "NO SPARK AT SPARK PLUG" of the GCU inspection (page 10-9). Normal Check the wire harness between the oil level switch and GCU for an open or short circuit. Abnormal Replace or repair the wire harness. GCU 18 2 Y C5 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 Y Normal Go to page 8-4 8-3 dummyhead IGNITION SYSTEM From page 8-3 Abnormal Check the CKP sensor (page 8-8). Replace the CKP sensor (page 8-7). Normal Check the wire harness between the CKP sensor and GCU for an open or short circuit. Abnormal Replace or repair the wire harness. GCU 18 2 Y/Bu C3 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 Y/Bu Normal Check the ignition coil (page 8-9). Abnormal Replace the ignition coil (page 8-6). Abnormal Replace or repair the wire harness. Normal Check the wire harness between the ignition coil and GCU for an open circuit. GCU Bl 19 2 Bl/G Bl 4 3 2 1 8 7 6 5 2 1 1 2 3 4 5 6 7 8 Bl/G C2 C1 IGNITION COIL Normal Go to page 8-5 8-4 dummyhead IGNITION SYSTEM From page 8-4 Check the stator coil resistance (master) (page 7-17). Abnormal Replace the stator. Abnormal Replace or repair the wire harness. Normal Check the wire harness between the generator and GCU for an open or short circuit. Bu R 1 6 3 20 3 2 1 1 5 1 3 5 5 W W R Bu 3 1 Normal Check the CKP sensor air gap (page 8-8). Abnormal Adjust the CKP sensor (page 8-8). . Normal Replace the GCU and recheck. 8-5 dummyhead IGNITION SYSTEM IGNITION COIL REMOVAL/ INSTALLATION Remove the following: – – – – – Fuel tank (page 6-10) Rear cover and outer muffler protector (page 5-6) Muffler (page 11-2) Air guide insulator (page 11-2) Upper shroud (page 9-7) BOLT (6 X 12 mm) (5) CYLINDER HEAD SHROUD UPPER SHROUD BRACKET SPARK PLUG CAP COLLAR (6.6 mm) (2) TAPPING SCREW (5 X 10 mm) (2) 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) HIGH TENSION CORD HOLDER 8-6 BOLT (6 X 45 mm) (2) IGNITION COIL 10 N·m (1.0 kgf·m, 7 lbf·ft) dummyhead IGNITION SYSTEM CKP SENSOR REMOVAL/ INSTALLATION Remove the fan cover (page 7-12). SENSOR BRACKET CKP SENSOR HARNESS CLIP BOLT (6 X 25 mm) (2) SOCKET BOLT (5 X 14 mm) (2) 6 N·m (0.6 kgf·m, 4.4 lbf·ft) 8-7 dummyhead IGNITION SYSTEM CKP SENSOR AIR GAP ADJUSTMENT Install the CKP sensor/sensor bracket [1] and loosely install the sensor bracket mounting bolts [2]. [2] • Take care not to pinch the generator wire harness with the sensor bracket. Insert an appropriate thickness gauge between the CKP sensor and projection part of the rotor. CKP SENSOR AIR GAP: 0.2 – 0.6 mm (0.01 – 0.02 in) [1] Push the CKP sensor firmly against the rotor and tighten the pulser coil bracket mounting bolt. TORQUE: 6 N·m (0.6 kgf·m, 4.4 lbf·ft) Remove the thickness gauge. 0.2 – 0.6 mm (0.01 – 0.02 in) SPARK TEST Check for the following before performing the spark test. [1] • Faulty spark plug • Loose spark plug cap • Water in the spark plug cap (causing the ignition coil secondary voltage to leak) • Loose ignition coil connector Open the left maintenance cover. Disconnect the spark plug cap [1] from the spark plug [2]. Disconnect the fuel injector 2P connector . Connect a known-good spark plug [3] to the spark plug cap and ground the side electrode against the cylinder head cover [4]. Turn the main switch to the ON position, crank the engine by pulling the recoil starter forcefully, and check for a spark across the electrodes. [2] [4] [1] [3] 8-8 dummyhead IGNITION SYSTEM CKP SENSOR INSPECTION Remove the air cleaner bracket (page 6-13). Disconnect the CKP sensor wire connector . Measure the resistance between the terminal and ground. Specified resistance: 297 - 363 Ω (at 20 °C/68 °F) IGNITION COIL INSPECTION PRIMARY SIDE Remove the upper shroud (page 9-7). Disconnect the ignition coil primary wire connectors ( and ). Measure the resistance of the primary coil by attaching the ohmmeter leads to the ignition coil wire terminals. • Use a recommended analog multi-tester. SP-15D (SANWA) or equivalent SP-18D (SANWA) or equivalent TH-5H (KOWA) or equivalent RESISTANCE: 1.8 – 2.2 Ω If the measured resistance is out of specification, replace the ignition coil. SECONDARY SIDE Remove the upper shroud (page 9-7). Disconnect the ignition coil primary wire connectors ( and ). Measure the resistance of the secondary coil by attaching one ohmmeter lead to the ignition coil wire terminal (Black) and the other to the spark plug cap end. • Use a recommended analog multi-tester. SP-15D (SANWA) or equivalent SP-18D (SANWA) or equivalent TH-5H (KOWA) or equivalent RESISTANCE: 5.6 – 6.9 kΩ If the measured resistance is out of specification, replace the ignition coil. 8-9 dummyhead IGNITION SYSTEM SPARK PLUG CAP INSPECTION Remove the spark plug cap from the high tension cord. Measure the resistance of the spark plug cap by attaching one ohmmeter lead to the terminal in the spark plug cap and the other to the terminal connected to the high tension cord terminal. RESISTANCE: 7.5 – 12.5 kΩ If the measured resistance is out of specification, replace the spark plug cap. OIL LEVEL SWITCH INSPECTION SYSTEM INSPECTION Remove the right side shroud (page 5-3). Disconnect the oil level switch wire connector . Check continuity between the oil level switch wire connector switch side (Yellow) terminal and engine ground [1]. There should be no continuity when the engine is full of oil. If the correct continuity is not obtained, inspect the oil level switch. [1] SWITCH INSPECTION Remove the oil level switch (page 14-3). [1] Check continuity between the oil level switch [1] wire connector (Yellow) terminal and switch body with an ohmmeter. Check the float by dipping the switch into a container of oil. The ohmmeter reading should go from continuity to no continuity as the switch is lowered into the oil. LOW OIL LEVEL (CONTINUITY) 8-10 NORMAL OIL LEVEL (NO CONTINUITY) dummytext 9. STARTING SYSTEM STARTING SYSTEM TROUBLESHOOTING···································9-2 RECOIL STARTER REMOVAL/ INSTALLATION·············································9-6 UPPER SHROUD REMOVAL/ INSTALLATION·············································9-7 FLYWHEEL REMOVAL ······························ 9-10 FLYWHEEL INSTALLATION······················ 9-10 9 RECOIL STARTER DISASSEMBLY/ ASSEMBLY ················································· 9-11 RECOIL STARTER INSPECTION ·············· 9-14 STARTER MOTOR REMOVAL/ INSTALLATION·············································9-8 STARTER MOTOR DISASSEMBLY/ ASSEMBLY ················································· 9-15 INNER MUFFLER PROTECTOR REMOVAL/INSTALLATION··························9-9 STARTER MOTOR INSPECTION ·············· 9-16 BRUSH REPLACEMENT···························· 9-18 9-1 dummyhead STARTING SYSTEM STARTING SYSTEM TROUBLESHOOTING STARTING SYSTEM STARTER MOTOR DOES NOT TURN GCU 18 Bl/W Bl/Y Br/Y G G/O 9 10 G/O Bl Bl/Y W/Bu 11 Bl Bl/W 12 Br/Bu T3 T1 STMAG(+12V) MAIN_SW+ MAIN_SWGND G 3 C9 BAT_IN STMAG(+12V) 1 G STMAG 13 9 Bl/W 10 Bl/Y 7 3 Bl/W STMAG 8 Bl/W 20 G 29 Bl/Y GND PUSH SW1 Bl T2 15 STARTER SWITCH Bl/Y Bl 2 Bl/Y STARTER MOTOR G 1 G 14 GND3 W 5 W/Bu 1 Br/Bu MAIN SWITCH MAINSW1 MAINSW2 13 BAT ACC Br/Bu Bl MAIN_SW2 G MAIN_SW1 2 Brown Orange Light blue Light green Pink Gray ON OFF Br/Bu 3A 15A Check the battery condition using a battery tester (page 7-16). 1 Br O Lb Lg P Gr G/O Br/W ACC Bl/Y BAT MAIN SWITCH 3 Black Yellow Blue Green Red White G/O 4 Bl Y Bu G R W Abnormal Replace or recharge the battery. OFF Perform the i-MONITOR DOES NOT DISPLAY BY MAIN SWITCH TURNED ON (page 4-19). Normal Check whether the i-Monitor is on when the main switch is turned ON. ON Go to page 9-3 9-2 dummyhead STARTING SYSTEM From page 9-2 Displayed Check whether an error code is displayed on the i-Monitor when the main switch is ON and the starter switch is pressed. Perform the SELF-DIAGNOSTIC TROUBLESHOOTING (page 4-9). Not displayed You should hear the starter magnetic switch “CLICK” when the starter switch is pushed. Not “CLICK” heard “CLICK” heard Bl Bl Check the wire harness between the battery and starter motor for an open circuit. T1 T3 STARTER MOTOR BATTERY TERMINAL Abnormal Normal Replace or repair the wire harness. Check the starter magnetic switch (page 9-16). Normal Abnormal Replace the starter magnetic switch (page 9-15). Go to page 9-4 Check the starter motor . 9-3 dummyhead STARTING SYSTEM From page 9-3 Check the "PUSH THE STARTER SWITCH BUT STARTER MOTOR DOES NOT TURN" of the GCU inspection (page 10-9). Abnormal Replace the GCU. Abnormal Replace or repair the wire harness. Abnormal Replace the starter switch (page 10-3). Abnormal Replace or repair the wire harness. Normal Check the wire harness between the starter motor and GCU for an open or short circuit. 18 3 5 4 3 2 1 10 9 8 7 6 1 2 3 4 5 6 7 8 9 10 GCU 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 Bl/W Bl/W C9 STATER MAGNETIC SWITCH Normal Check the starter switch (page 10-9). Normal Check the wire harness between the starter switch and GCU for an open circuit. Check the wire harness between the starter switch and ground for an open circuit. 18 GCU 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 3 15 STARTER SWITCH G Bl/Y 5 4 3 2 1 10 9 8 7 6 1 2 3 4 5 6 7 8 9 10 2 1 Bl G GND3 Normal Go to page 9-5 9-4 1 18 dummyhead STARTING SYSTEM From page 9-4 Normal Check the wire harness between the main switch and GCU for an open circuit. MAIN SWITCH Abnormal Replace or repair the wire harness. Abnormal Replace the starter magnetic switch (page 9-15). GCU 18 13 2 1 4 3 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 33 32 31 30 29 28 27 26 25 24 23 22 21 20 1 18 G/O Normal Check the starter magnetic switch page 9-16. Normal Replace the GCU and recheck. 9-5 dummyhead STARTING SYSTEM RECOIL STARTER REMOVAL/INSTALLATION Remove the inverter unit (page 7-10). COLLAR (3) RECOIL STARTER NUT (6 mm) (3) STARTER GRIP INSTALLATION: Knot the end of the rope as shown. RECOIL STARTER ROPE REMOVAL/INSTALLATION: Make a knot between the recoil starter case and front frame before removing or installing the starter grip. 9-6 dummyhead STARTING SYSTEM UPPER SHROUD REMOVAL/INSTALLATION Do not touch the insulator with bare hands. The glass wool of the material sticks in the skin and is dangerous. Remove the following: – Fuel tank (page 6-10) – Head cover shroud (page 13-2) UPPER SHROUD UPPER SHROUD INSULATOR INSTALLATION: Insert the flange of the upper shroud into the groove of the right side shroud. ASSEMBLY: Install the insulator on the upper shroud with the binder clip bent as shown. FLANGE GROOVE UPPER SHROUD INSULATOR UPPER SHROUD BOLT (6 x 12 mm) (5) RIGHT SIDE SHROUD BINDER CLIP 9-7 dummyhead STARTING SYSTEM STARTER MOTOR REMOVAL/ INSTALLATION Remove the following: – – – – – Fuel tank (page 6-10) Rear cover and outer muffler protector (page 5-6) Muffler (page 11-2) Inner muffler protector (page 9-9) Upper shroud (page 9-7) NUT WASHER (8 mm) 8.8 N·m (0.90 kgf·m, 6.5 lbf·ft) STARTER MOTOR BOLT (10 x 35 mm) (2) 9-8 dummyhead STARTING SYSTEM INNER MUFFLER PROTECTOR REMOVAL/INSTALLATION Remove the following: – Rear cover and outer muffler protector (page 5-6) – Muffler (page 11-2) INNER MUFFLER PROTECTOR INSTALLATION: Install the inner muffler protector by aligning the stopper rubber with the cutout on the frame side channel. CUT OUT STOPPER RUBBER BOLT (6 x 12 mm) (5) SPECIAL BOLT (6 mm) (3) STOPPER RUBBER (2) NUT (6 mm) (2) (AT, AT1 type only) STUD BOLT (8 mm) (2) BOLT (8 x 16 mm) (2) 9-9 dummyhead STARTING SYSTEM FLYWHEEL REMOVAL Holding the flywheel with the crank pulley holder, loosen the special nut. TOOL: CRANK PULLEY HOLDER 47 [1] [1] 07925-6570000 Remove the flywheel using the commercially available flywheel puller [1]. [1] FLYWHEEL INSTALLATION Clean off any grease or oil from the taper in the crankshaft or the tapered hole in the flywheel. [1] Install the woodruff [1] key on the crankshaft and then install the flywheel [2]. Apply engine oil to the threads of the special nut [3]. [2] Install the special nut and washer [4]. [3] Holding the flywheel with the crank pulley holder, tighten the 16 mm special nut. TORQUE: 113 N·m (11.5 kgf·m, 83 lbf·ft) TOOL: CRANK PULLEY HOLDER 47 [1] 9-10 07925-6570000 [4] [1] dummyhead STARTING SYSTEM RECOIL STARTER DISASSEMBLY/ASSEMBLY • Wear gloves and eye protection. • During disassembly, take care not to allow the return spring to come out from the spring cover. EXPLODED VIEW RECOIL STARTER ROPE ASSEMBLY: Check the rope for fraying or wear before installation. Apply 3 g (0.1 oz) Apply 0.03 g (0.001 oz) RATCHET (2) FRICTION SPRING Apply 0.05 g (0.002 oz) RETURN SPRING RATCHET SPRING (2) STARTER CASE COVER BOLT STARTER REEL RATCHET COVER Apply 0.5 – 1.0 g (0.02 – 0.04 oz) 9-11 dummyhead STARTING SYSTEM RECOIL STARTER ASSEMBLY Insert the starter rope [1] into the recoil starter reel [2] and tie the rope as shown. Wind the rope counterclockwise onto the reel. [2] [1] Wind the spring [1] and install it to the recoil starter reel [2] by aligning the outer end to the groove of the reel. [1] [2] Apply 3 g (0.1 oz) of grease to the case claw and boss of the starter case [1]. Align the spring inner hook [2] to the case claw [3] on the case by turning the starter reel [4] counterclockwise. [2] [1] [4] [3] Apply 0.03 g (0.001 oz) of grease to the two ratchets [1]. [1] Install the ratchet spring [2] and ratchet as shown. [2] 9-12 dummyhead STARTING SYSTEM Apply 0.5 – 1.0 g (0.02 – 0.04 oz) of grease to the ratchet sliding portion of the ratchet cover [1]. [1] Apply 0.05 g (0.002 oz) of grease to the following of the ratchet cover: – Cover bolt sliding portion – Friction spring sliding portion – Cam sliding portion [3] [2] Install the friction spring [2] and ratchet cover. Apply locking agent to the thread of the cover bolt [3]. Tighten the cover bolt. Turn the reel three full turns counterclockwise to preload the return spring. [1] Pass the rope through the starter case hole [1] and starter grip [2] and knot the end of the rope as shown. [2] Check the operation of the ratchet by pulling the starter rope out several times. 9-13 dummyhead STARTING SYSTEM RECOIL STARTER INSPECTION RECOIL STARTER OPERATION Remove the recoil starter (page 9-6). Pull the recoil starter rope several times to inspect that the ratchets [1] operate properly (the ratchet ends come out from the ratchet cover [2]. [2] [1] STARTER PULLEY Remove the recoil starter (page 9-6). Inspect all of the square holes [1] of the starter pulley [2] for deformation. [1] [2] 9-14 dummyhead STARTING SYSTEM STARTER MOTOR DISASSEMBLY/ ASSEMBLY LOCK RING YOKE DISASSEMBLY: ASSEMBLY: Hold the armature upright, place an offset wrench over the pinion stopper, and drive the collar down exposing the lock ring. Remove the lock ring; then remove the collar and drive assembly. Make sure that there is no obstruction on the magnet. BRUSH TERMINAL NUT OVERRUNNING CLUTCH ARMATURE PINION GEAR LOCK RING PINION STOPPER PINION STOPPER THRUST COLLAR ASSEMBLY: Check for smooth movement by rotating the overrunning clutch. Check the gear teeth for wear or damage; replace if necessary. Also, check the flywheel ring gear teeth if the pinion gear teeth are damaged. REAR BRACKET FRONT BRACKET NUT (6 mm) (2) THROUGH BOLT (5 x 98 mm) (2) PINION DRIVE LEVER STARTER MAGNETIC SWITCH BRUSH HOLDER INSULATOR BRUSH SPRING (4) BRUSH HOLDER BRUSH (4) FRONT BRACKET/REAR BRACKET INSTALLATION Install the armature in the yoke. Align the cutout [1] of the rear bracket with the brush terminal grommet [2] and install the rear bracket. [3] [7] [2] Install the pinion drive lever to the overrunning clutch [3]. Set the starter magnetic switch [4] by aligning the magnetic switch pin [5] with the pinion drive lever [6]. Install the front bracket [7] and two through bolts and tighten the flange nuts. [6] [5] [4] [1] 9-15 dummyhead STARTING SYSTEM STARTER MOTOR INSPECTION STARTER MAGNETIC SWITCH Connect a 12V battery to the magnetic switch terminal and switch body as shown. There should be continuity between the battery and starter motor terminals. There should be no continuity when the battery is disconnected. Be sure the battery is in good condition before performing this test. BRUSH LENGTH Measure the brush length. If the brush length is less than the service limit, replace the brush. STANDARD: 10 mm (0.4 in) SERVICE LIMIT: 6 mm (0.2 in) ARMATURE MICA DEPTH Visually inspect the commutator surface for dust, rust, or other damage. If necessary, wipe it with a clean lintfree cloth. If rusted or damaged, dress with a fine emery cloth. When the mica is clogged, or its depth is smaller than the service limit value, recut the grooves using a hacksaw blade or a small file. SERVICE LIMIT: 0.2 mm (0.01 in) ARMATURE CONTINUITY CHECK COMMUTATOR SEGMENTS Check for continuity between segments. If an open circuit (no continuity) exists between any two segments, replace the armature. 9-16 dummyhead STARTING SYSTEM ARMATURE CONTINUITY CHECK COMMUTATOR TO CORE Check for continuity between the commutator segments and the armature coil core. Replace the armature if continuity exists. ARMATURE CONTINUITY CHECK COMMUTATOR TO SHAFT Check for continuity between the commutator and the armature shaft. Replace the armature if continuity exists between any of the commutator segments and the armature shaft. BRUSH CONTINUITY CHECK Check for continuity between the brushes. There should be continuity between both the positive brushes. There should be continuity between both the negative brushes. There should be no continuity from either positive brush to either negative brush. If necessary, replace the yoke assembly. 9-17 dummyhead STARTING SYSTEM OVERRUNNING CLUTCH Hold the armature [1] as shown and check that the overrunning clutch [2] turns counterclockwise and slides smoothly. If necessary, apply oil or replace the overrunning clutch (page 9-15). [2] [1] Hold the overrunning clutch as shown and check that the pinion gear [3] turns clockwise freely and does not turn counterclockwise. If necessary, apply oil or replace the overrunning clutch (page 9-15). TURN Check the pinion gear for wear or damage and replace the over running clutch if necessary (page 9-15). If the pinion gear is worn or damaged, the flywheel ring gear must be inspected. [3] NOT TURN [2] BRUSH REPLACEMENT Cut off the brush lead [1] at the point shown and remove the brush [2]. [3] Cut here [2] Remove the remaining brush lead and deposited solder from the terminal [3]. [1] Hold a new brush [1] in the same direction as the removed brush and put a new plate [2] over the new brush and terminal [3], and press it using a pair of pliers as shown. [3] [2] Press here Press here [1] Solder the plate on the terminal [1]. • Before soldering, heat the pressed part of the plate enough to make sure solder [2] reaches the end of the pressed part [3]. • Prevent solder from flowing down the brush lead. • Do not allow solder to run down onto the field winding of the yoke. Solder here [3] [2] 9-18 [1] dummytext 10. OTHER ELECTRICAL CONTROL PANEL REMOVAL/ INSTALLATION···········································10-2 VOLTAGE SELECTOR SWITCH INSPECTION··············································· 10-7 CONTROL PANEL DISASSEMBLY/ ASSEMBLY ·················································10-3 CIRCUIT PROTECTOR INSPECTION········ 10-8 MAIN SWITCH INSPECTION······················10-6 ECO-THROTTLE SWITCH INSPECTION ···············································10-7 STARTER SWITCH INSPECTION·············· 10-9 10 GCU INSPECTION ······································ 10-9 10-1 dummyhead OTHER ELECTRICAL CONTROL PANEL REMOVAL/ INSTALLATION OTHER ELECTRICAL Remove the following: – Battery (page 7-9) – Front cover (page 5-5) – Inverter unit (page 7-10) CONTROL PANEL SCREW (5 x 8 mm) RIGHT HANDLE BRACKET INSTALLATION: Loosely install the nuts, then pull the bracket up and tighten the nuts securely. FRONT COVER SEAL (4) NUT (8 mm) (4) (CT Type only) BOLT CAP NUT (6 mm) (3) 8.5 N·m (0.87 kgf·m, 6.3 lbf·ft) 10-2 LEFT HANDLE BRACKET INSTALLATION: Loosely install the nuts, then pull the bracket up and tighten the nuts securely. dummyhead OTHER ELECTRICAL CONTROL PANEL DISASSEMBLY/ASSEMBLY AT TYPE • When installing, route the harness connections properly (page 2-8). SCREW (5 x 8 mm) 2.3 N·m (0.24 kgf·m, 1.7 lbf·ft) SPRING WASHER (3) SCREW (4 x 6 mm) (4) WASHER (6) MAIN WIRE HARNESS 1.1 N·m (0.11 kgf·m, 0.8 lbf·ft) SUB WIRES NUT (3) 1.1 N·m (0.11 kgf·m, 0.8 lbf·ft) CIRCUIT PROTECTOR (30 A) CIRCUIT PROTECTOR (20 A) (2) NOISE FILTER (3) CIRCUIT PROTECTOR (30 A) WIRE HARNESS BAND (9) RECEPTACLE (30 A-125 V) WIRE BAND RECEPTACLE (20 A-125 V) NOISE FILTER SUPPORTER (3) SCREW (8) RECEPTACLE (30 A-125/250 V) 1.3 N·m (0.13 kgf·m, 1.0 lbf·ft) SCREW (5 x 12 mm) (2) SCREW (3 x 5 mm) (4) 0.6 N·m (0.06 kgf·m, 0.4 lbf·ft) NUT (4 mm) (9) 1.3 N·m (0.13 kgf·m, 1.0 lbf·ft) NUT (3) GCU 1.8 N·m (0.18 kgf·m, 1.3 lbf·ft) VOLTAGE SELECTOR SWITCH ECO-THROTTLE CONTROL HARNESS GROMMET SWITCH MAIN SWITCH CONTROL WIRE HARNESS PARALLEL OPERATION OUTLET (3) STARTER SWITCH 10-3 dummyhead OTHER ELECTRICAL AT1 TYPE • When installing, route the harness connections properly (page 2-8). SCREW (5 x 8 mm) 2.3 N·m (0.24 kgf·m, 1.7 lbf·ft) SPRING WASHER (3) SCREW (4 x 6 mm) (4) WASHER (6) MAIN WIRE HARNESS 1.1 N·m (0.11 kgf·m, 0.8 lbf·ft) SUB WIRES NUT (3) 1.1 N·m (0.11 kgf·m, 0.8 lbf·ft) CIRCUIT PROTECTOR (30 A) CIRCUIT PROTECTOR (20 A) (2) NOISE FILTER (3) CIRCUIT PROTECTOR (30 A) WIRE HARNESS BAND (9) RECEPTACLE (30 A-125 V) WIRE BAND RECEPTACLE GFCI (20 A-125 V) (2) NOISE FILTER SUPPORTER (3) SCREW (9) RECEPTACLE (30 A-125/250 V) 1.3 N·m (0.13 kgf·m, 1.0 lbf·ft) SCREW (5 x 12 mm) (2) SCREW (3 x 5 mm) (4) 0.6 N·m (0.06 kgf·m, 0.4 lbf·ft) NUT (4 mm) (11) 1.3 N·m (0.13 kgf·m, 1.0 lbf·ft) NUT (3) GCU 1.8 N·m (0.18 kgf·m, 1.3 lbf·ft) VOLTAGE SELECTOR SWITCH ECO-THROTTLE CONTROL HARNESS GROMMET SWITCH MAIN SWITCH CONTROL WIRE HARNESS PARALLEL OPERATION OUTLET (3) STARTER SWITCH 10-4 dummyhead OTHER ELECTRICAL CT TYPE • When installing, route the harness connections properly (page 2-8). SPRING WASHER (3) WASHER (6) NUT (4 mm) (3) 1.1 N·m (0.11 kgf·m, 0.8 lbf·ft) WIRE HARNESS BAND (9) SCREW (5 x 8 mm) 2.3 N·m (0.24 kgf·m, 1.7 lbf·ft) MAIN WIRE HARNESS SUB WIRES CIRCUIT PROTECTOR (29 A) CIRCUIT PROTECTOR (30 A) CIRCUIT PROTECTOR (20 A) (2) NOISE FILTER (2) CIRCUIT PROTECTOR (30 A) RECEPTACLE (30 A-125 V) WIRE BAND RECEPTACLE (20 A-125 V) SCREW (4 x 6 mm) (8) RECEPTACLE (30 A-125/250 V) 1.1 N·m (0.11 kgf·m, 0.8 lbf·ft) NOISE FILTER SUPPORTER (2) SCREW (6 x 8 mm) 2.3 N·m (0.24 kgf·m, 1.7 lbf·ft) SCREW (12) 1.3 N·m (0.13 kgf·m, 1.0 lbf·ft) SCREW (3 x 5 mm) (8) 0.6 N·m (0.06 kgf·m, 0.4 lbf·ft) NUT (4 mm) (9) 1.3 N·m (0.13 kgf·m, 1.0 lbf·ft) NUT (3) 1.8 N·m (0.18 kgf·m, 1.3 lbf·ft) GCU VOLTAGE SELECTOR SWITCH ECO-THROTTLE SWITCH SCREW (5 x 12 mm) (2) CONTROL HARNESS GROMMET MAIN SWITCH CONTROL WIRE HARNESS STARTER SWITCH PARALLEL OPERATION OUTLET (3) 10-5 dummyhead OTHER ELECTRICAL GCU 34P CONNECTOR CONNECTION You should hear the connector "CLICK" when the GCU connector 34P connector [1] is connected. After connecting the GCU 34P connector, make sure the connector is completely seated as shown. [1] OK NG • After connecting the GCU 34P connector, secure the wire band [2]. • When securing the wire band, be sure to set the GCU 34P connector harness [3] under the control wire harness [4]. • Secure the wire band at the outer end [5] of the yellow tape of the GCU 34P connector harness to prevent stress to the harness. [2] Front frame side [4] [4] [2] [3] [2] MAIN SWITCH INSPECTION Check for continuity between the switch terminals. There should be continuity between the terminals with the switch in the ON position and no continuity with the switch in the OFF position. Position ON OFF 10-6 Terminal 1 2 3 4 [5] dummyhead OTHER ELECTRICAL ECO-THROTTLE SWITCH INSPECTION Check for continuity between the switch terminals. There should be no continuity between the terminals with the switch in the ON position and continuity with the switch in the OFF position. VOLTAGE SELECTOR SWITCH INSPECTION Check for continuity between the terminals according to the table below. 3 5 2 1 6 4 9 7 12 Terminal Position 11 1 2 3 4 5 6 7 8 9 10 11 12 8 10 120 V only 120 V/240 V Terminal Position 120 V only 120 V/240 V 10-7 dummyhead OTHER ELECTRICAL CIRCUIT PROTECTOR INSPECTION CIRCUIT PROTECTOR 30 A/20 A Check for continuity between the terminals. There should be continuity between the terminals with the switch in the ON position. CIRCUIT PROTECTOR 30 A Check for continuity between the terminals according to the table below. 3 1 Position Terminal 1 2 3 4 OFF ON No Continuity Continuity No Continuity Continuity 2 4 CIRCUIT PROTECTOR 29 A (CT TYPE ONLY) Check for continuity between the terminals according to the table below. 3 1 Position Terminal 1 2 3 4 10-8 OFF ON No Continuity Continuity No Continuity Continuity 2 4 dummyhead OTHER ELECTRICAL STARTER SWITCH INSPECTION Check for continuity between the terminals. There should be continuity between the terminals with the switch in the Push position. Position Terminal 1 2 Push Free GCU INSPECTION Remove the GCU (page 10-3). Check for continuity between the terminals. Symptom i-monitor does not display No spark at spark plug Push the starter switch but starter motor does not turn Throttle control motor does not move Starter motor turns at the main switch turned ON E-06 is displayed by engine starts Inspection terminals Between the connector No.1, No.3 and No.5 Between the connector No.3 and connector No.1 Between the connector No.1, No.3 and No.5 Between the connector No.3 and No.29 Between the connector and No.17 Between the connector Between the connector Standard No continuity No continuity No continuity 720 – 880 Ω No.14, No.15, No.16 No continuity No.7 and No.9 No.1, No.3 and No.5 No continuity No continuity 10-9 dummyhead MEMO dummytext 11. MUFFLER MUFFLER REMOVAL/INSTALLATION······11-2 11 11-1 dummyhead MUFFLER MUFFLER REMOVAL/INSTALLATION MUFFLER The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Allow it to cool before proceeding. Remove the rear cover/outer muffler protector (page 5-6). AIR GUIDE INSULATOR EXHAUST PIPE GASKET NUT (6 mm) (6) AIR GUIDE INNER MUFFLER SEPARATOR EXHAUST PIPE INSTALLATION: Remove any carbon deposits. MUFFLER COLLAR (2) NUT (8 mm) (2) 24 N·m (2.4 kgf·m, 18 lbf·ft) NUT (8 mm) (2) 24 N·m (2.4 kgf·m, 18 lbf·ft) MUFFLER GASKET BOLT (8 x 40 mm) (2) MUFFLER SCREW (5 x 16 mm) (2) 3.5 N·m (0.36 kgf·m, 2.6 lbf·ft) SPARK ARRESTER EXHAUST TAIL PIPE INSTALLATION: Remove any carbon deposits. 11-2 27 N·m (2.7 kgf·m, 20 lbf·ft) dummytext 12. GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE REMOVAL/ INSTALLATION···········································12-2 FRAME BOTTOM RUBBERS REMOVAL/ INSTALLATION ·········································· 12-5 UNDER SHROUD REMOVAL/ INSTALLATION···········································12-4 12 12-1 dummyhead GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE REMOVAL/INSTALLATION GENERATOR/ENGINE REMOVAL/INSTALLATION REMOVAL Remove the following: – – – – – – – – – – AT, AT1 TYPE ONLY: Left and right maintenance cover (page 5-2) Fuel tank (page 6-11) Front cover (page 5-5) Inverter unit (page 7-10) Control panel (page 10-2) Recoil starter (page 9-6) Rear cover and outer muffler protector (page 5-6) Muffler (page 11-2) Inner muffler protector (page 9-9) Air cleaner bracket (page 6-13) [1] AT, AT1 Type only: Disconnect the EVAP canister purge tube [1] from the EVAP canister assembly [2]. [2] Open the wire harness band [1] and disconnect the CKP sensor wire connector [2] and EBT sensor wire connectors [3] and O2 sensor 1P connector [4]. [1] [4] [3] [2] Remove the ground terminal harness band [1]. 12-2 and open the wire [1] dummyhead GENERATOR/ENGINE REMOVAL/INSTALLATION Remove the four nuts [1] and the ground cable terminal [2]. Remove the generator/engine assembly. [2] [1] INSTALLATION GENERATOR/ENGINE ASSEMBLY REAR ENGINE MOUNT BRACKET BOLT (8 x 30 mm) (2) NUT (10 mm) (4) 34 N·m (3.5 kgf·m, 25 lbf·ft) Installation is the reverse order of removal. • Remember to reattach the ground cable when bolting the generator to the frame. TORQUE: Ground terminal mounting nut: 3 N·m (0.31 kgf·m, 2.2 lbf·ft) 12-3 dummyhead GENERATOR/ENGINE REMOVAL/INSTALLATION UNDER SHROUD REMOVAL/INSTALLATION Remove the generator/engine assembly from the frame (page 12-2). BOLT (6 x 30 mm) (2) OIL DRAIN GUIDE UNDER SHROUD BOLT (6 x 12 mm) (2) 12-4 dummyhead GENERATOR/ENGINE REMOVAL/INSTALLATION FRAME BOTTOM RUBBERS REMOVAL/INSTALLATION Remove the generator/engine assembly (page 12-2). Remove the stand and wheels shaft (page 15-2). NUT (6 mm) 8.5 N·m (0.87 kgf·m, 6.3 lbf·ft) NUT (10 mm) FRONT LEFT ENGINE BRACKET FRAME BOTTOM RUBBER A (2) ASSEMBLY: Before installation, check for cracks or deformation, and then install by aligning the tab with the hole in the frame. LOCK WASHER (6 mm) TAB ENGINE GROUND CABLE HOLE STOPPER RUBBER (3) BOTTOM RUBBER C BOTTOM RUBBER B NUT (8 mm) (4) 24 N·m (2.4 kgf·m, 18 lbf·ft) WIRE HARNESS BAND (2) 12-5 dummyhead MEMO dummytext 13. CYLINDER HEAD HEAD COVER LOWER SHROUD REMOVAL/INSTALLATION························13-2 CYLINDER HEAD/VALVES INSPECTION··············································· 13-5 CYLINDER HEAD REMOVAL/ INSTALLATION···········································13-3 VALVE GUIDE REPLACEMENT ················ 13-8 CYLINDER HEAD DISASSEMBLY/ ASSEMBLY ·················································13-4 VALVE GUIDE REAMING ·························· 13-9 VALVE SEAT RECONDITIONING············ 13-10 13 13-1 dummyhead CYLINDER HEAD HEAD COVER LOWER SHROUD REMOVAL/INSTALLATION CYLINDER HEAD Remove the following: – Head cover shroud (page 5-7) – Air cleaner bracket (page 6-13) EBT SENSOR ENGINE SHROUD BOLT (6 x 25 mm) LOWER SHROUD BRACKET LOWER SHROUD SPECIAL BOLT (6 mm) (3) EBT SENSOR WIRE BOLT (6 x 12 mm) (2) EBT SENSOR WIRE CONNECTORS 8.5 N·m (0.87 kgf·m, 6.3 lbf·ft) O2 SENSOR WIRE O2 SENSOR 1P CONNECTOR 13-2 dummyhead CYLINDER HEAD CYLINDER HEAD REMOVAL/INSTALLATION Remove the following: – – – – – – – Fuel tank (page 6-10) Air guide insulator/exhaust pipe (page 11-2) Cylinder head shroud/upper shroud bracket (page 5-7) Air cleaner bracket (page 6-13) Throttle body (page 6-16) Head cover lower shroud (page 13-2) EBT sensor (page 6-22) CYLINDER HEAD COVER GASKET ASSEMBLY: Install the gasket as shown noting the installation direction. BOLT (10 x 80 mm) (4) (Bolt threads) CYLINDER HEAD COVER TORQUE: HEAD COVER BOLT 35 N·m (3.6 kgf·m, 26 lbf·ft) REMOVAL/INSTALLATION: CYLINDER HEAD COVER GASKET Loosen and tighten the bolts in a crisscross pattern in 2-3 steps. CYLINDER HEAD GASKET HEAD COVER WASHER DOWEL PIN (2) HEAD COVER GROMMET CYLINDER HEAD COVER CYLINDER HEAD REMOVAL/INSTALLATION: Before installation, remove any carbon deposits from the combustion chamber and inspect the valve seats. Measure the cylinder compression after assembly. 13-3 dummyhead CYLINDER HEAD CYLINDER HEAD DISASSEMBLY/ ASSEMBLY Remove the cylinder head (page 13-3). INTAKE/EXHAUST VALVE SPRING RETAINER DISASSEMBLY: Push down and slide the valve spring retainer to the side so that the valve stem slips through the hole at the side of the valve spring retainer. EXHAUST VALVE ASSEMBLY: Do not interchange with the intake valve. Do not remove the valve spring retainer while the cylinder head is installed to the cylinder barrel, or the valve will drop into the cylinder. CYLINDER HEAD SPARK PLUG 18 N·m (1.8 kgf·m, 31 lbf·ft) VALVE SPRING SEAT The exhaust valve is smaller than the intake valve. VALVE GUIDE CLIP EXHAUST VALVE GUIDE INTAKE VALVE ASSEMBLY: Do not interchange with the exhaust valve. The intake valve is larger than the exhaust valve. INTAKE VALVE GUIDE VALVE STEM SEAL PUSH ROD GUIDE PLATE ROCKER ARM PIVOT LOCK NUT (2) 10 N·m (1.0 kgf·m, 7 lbf·ft) ROCKER ARM PIVOT (2) VALVE SPRING (2) PUSH ROD (2) ASSEMBLY: ROCKER ARM PIVOT BOLT (2) 24 N·m (2.4 kgf·m, 18 lbf·ft) (Apply to the threads and pivot) VALVE ROCKER ARM (2) ASSEMBLY: Before installing the push rods, check the ends of the push rods for wear. Roll each push rod across a flat surface and check for straightness. Be sure the ends of the push rods are firmly seated in the valve lifters. (Apply to the tappet surface and pivot) Before installing the rocker arm, check for wear on the surfaces of the rocker arm that contact the pivot bolt, push rod, and valve stem. 13-4 dummyhead CYLINDER HEAD CYLINDER HEAD/VALVES INSPECTION CYLINDER COMPRESSION CHECK Start the engine and warm up to normal operating temperature. Turn the main switch to the OFF position. Disconnect the spark plug cap [1] from the spark plug. Remove the spark plug using a spark plug wrench. [1] Pull the recoil starter several times to expel unburned gas. Attach a commercially available compression gauge set EEPV303A [2] to the spark plug hole. Disconnect the fuel injector 2P connector . Turn the main switch ON and push the starter switch. Measure the cylinder compression. CYLINDER COMPRESSION: 0.46 – 0.64 MPa (4.7 – 6.5 kgf/cm2, 67 – 92 psi) at 600 min-1 (rpm) [2] CYLINDER HEAD WARPAGE Remove the carbon deposits from the combustion chamber. Check the spark plug hole and valve areas for cracks. [2] [1] Check the cylinder head warpage using a straightedge [1] and feeler gauge [2]. SERVICE LIMIT: 0.10 mm (0.004 in) If the measurement is more than the service limit, replace the cylinder head. 13-5 dummyhead CYLINDER HEAD VALVE SEAT WIDTH Remove the carbon deposits from the combustion chamber. VALVE LAPPER LIL21100 (Commercially available) Inspect each valve face for irregularities. If necessary, replace the valve. Apply a light coat of Prussian Blue or erasable felttipped marker ink to each valve seat. Insert the valve, and snap it closed against its seat several times. Be sure the valve does not rotate on the seat. The transferred marking compound will show any area of the valve face that is not concentric. Measure the valve seat width of the cylinder head. STANDARD: SERVICE LIMIT: CONTACT TOO HIGH 1.0 – 1.2 mm (0.04 – 0.05 in) 2.0 mm (0.08 in) If the measurement is more than the service limit, recondition the valve seat (page 13-10). Check whether the valve seat contact area of the valve is too high. VALVE SEAT WIDTH If the valve seat is too high or too low, recondition the valve seat (page 13-10). VALVE GUIDE I.D. Ream the valve guide [1] to remove any carbon deposits before measuring. TOOL: Valve guide reamer 6.612 mm [2] 07984-ZE20001 • Turn the special tool (valve guide reamer) clockwise, never counterclockwise. • Continue to rotate the special tool while removing it from the valve guide. HANDLE NWYTW505 (Commercially available) [2] COMBUSTION CHAMBER SIDE [1] VALVE SPRING SIDE Measure and record each valve guide I.D. STANDARD: SERVICE LIMIT: 6.600 – 6.615 mm (0.2598 – 0.2604 in) 6.66 mm (0.262 in) If the measured valve guide I.D. is more than the service limit, replace the valve guide (page 13-8). 13-6 dummyhead CYLINDER HEAD VALVE FACE Inspect each valve for face irregularities. If necessary, replace the valve (page 13-4). VALVE FACE VALVE STEM O.D. Inspect each valve for bending or abnormal stem wear. If necessary, replace the valve (page 13-4). Measure and record each valve stem O.D. STANDARD: SERVICE LIMIT: IN: 6.575 – 6.590 mm (0.2589 – 0.2594 in) EX: 6.535 – 6.550 mm (0.2573 – 0.2579 in) IN: 6.44 mm (0.254 in) EX: 6.40 mm (0.252 in) If the measurement is less than the service limit, replace the valve (page 13-4). GUIDE-TO-STEM CLEARANCE Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance. STANDARD: SERVICE LIMIT: IN: 0.010 – 0.040 mm (0.0004 – 0.0016 in) EX: 0.050 – 0.080 mm (0.0020 – 0.0032 in) IN: 0.11 mm (0.004 in) EX: 0.13 mm (0.005 in) If the calculated clearance is more than the service limit, replace the following: – Valves (page 13-4) – Valve guide (page 13-8) VALVE SPRING FREE LENGTH Measure the valve spring free length. STANDARD: SERVICE LIMIT: 39.0 mm (1.54 in) 37.5 mm (1.48 in) If the measured length is less than the service limit, replace the valve spring (page 13-4). 13-7 dummyhead CYLINDER HEAD VALVE SPRING PERPENDICULARITY Measure the valve spring perpendicularity. SERVICE LIMIT: 1.5° max. If the measured perpendicularity is more than the service limit, replace the valve spring (page 13-4). PUSH ROD RUNOUT Check both ends of the push rod for wear. Check the push rod for straightness. If necessary, replace the push rod (page 13-4). VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Use a hot plate or oven to heat the cylinder head evenly to 150 °C (300 °F). To avoid burns, use heavy gloves when handling the heated cylinder head. • Do not use a torch to heat the cylinder head; warpage of the cylinder head may result. • Do not get the cylinder head hotter than 150 °C (300 °F); excessive heat may loosen the valve seat. Remove the heated cylinder head from the hot plate and support it with wooden blocks. 13-8 dummyhead CYLINDER HEAD Drive the valve guides [1] out of the cylinder head from the combustion chamber side. [2] TOOL: Valve guide driver, 6.6 mm [2] 07942-6570100 COMBUSTION CHAMBER SIDE [1] When driving the valve guides out, be careful not to damage the cylinder head. Remove the new valve guides from the refrigerator one at a time as needed. [3] Drive the exhaust valve guide [1] until the valve guide clip [2] is fully seated as shown from the valve spring side of the cylinder head. TOOL: Valve guide driver, 6.6 mm [3] 07942-6570100 Drive the intake valve guide [4] to the specified height (measured from the end of the valve guide to the cylinder head as shown) from the valve spring side of the cylinder head. TOOL: Valve guide driver, 6.6 mm [2] VALVE SPRING SIDE [4] [1] 07942-6570100 INTAKE VALVE GUIDE INSTALLATION HEIGHT: 5.0 mm (0.20 in) 5.0 mm (0.20 in) After installing the valve guide, check the guide for damage. Replace the valve guide if damaged. Let the cylinder head cool to room temperature. Ream the valve guide. VALVE GUIDE REAMING For best results, be sure the cylinder head is at room temperature before reaming valve guides. Coat the reamer and valve guide with cutting oil. TOOL: Valve guide reamer 6.612 mm [1] 07984-ZE20001 Rotate the reamer clockwise through the valve guide the full length of the reamer. • Turn the special tool (valve guide reamer) clockwise, never counterclockwise. • Continue to rotate the special tool while removing it from the valve guide. HANDLE NWYTW505 (Commercially available) [1] COMBUSTION CHAMBER SIDE VALVE SPRING SIDE Thoroughly clean the cylinder head to remove any cutting residue. 13-9 dummyhead CYLINDER HEAD Check the valve guide bore; it should be straight, round, and centered in the valve guide. Insert the valve and check operation. If the valve does not operate smoothly, the guide may have been bent during installation. Replace the valve guide if it is bent or damaged. Check the valve guide-to-stem clearance (page 13-7). VALVE SEAT RECONDITIONING Thoroughly clean the combustion chamber and valve seats to remove carbon deposits. Apply a light coat of Prussian Blue or erasable felttipped marker ink to the valve seat. Insert the valve, and snap it closed against its seat several times. Be sure the valve does not rotate on the seat. The transferred marking compound will show any area of the seat that is not concentric. VALVE LAPPER LIL21100 (Commercially available) Measure the valve seat width of the cylinder head. STANDARD: SERVICE LIMIT: 1.0 – 1.2 mm (0.04 – 0.05 in) 2.0 mm (0.08 in) If the measurement is more than the service limit, recondition the valve seat. Check whether the valve seat contact area of the valve is too high. If the valve seat is too high or too low, recondition the valve seat. Valve seat cutters/grinders [1] or equivalent valve seat refacing equipment is recommended to correct a worn valve seat. [1] • Turn the cutter clockwise, never counterclockwise. • Continue to turn the cutter as you lift it from the valve seat. 13-10 dummyhead CYLINDER HEAD The 32° cutter removes material from the top edge (contact too high). TOOLS: Solid pilot bar, 6.6 mm Cutter, 30 x 45 degree CONTACT TO STANDARD NWY100-6.60 NWYCU128 The 60° cutter removes material from the bottom edge (contact too low). TOOLS: Solid pilot bar, 6.6 mm Cutter, 60 degree VALVE FACE NWY100-6.60 NWYCU114 Be sure that the width of the finished valve seat is within specification. STANDARD: SERVICE LIMIT: 1.0 – 1.2 mm (0.04 – 0.05 in) 2.0 mm (0.08 in) CONTACT TOO HIGH CONTACT TOO LOW VALVE FACE VALVE FACE Make a light pass with the 45° cutter to remove any possible burrs at the edge of the seat. TOOLS: Solid pilot bar, 6.6 mm Cutter, 30 x 45 degree NWY100-6.60 NWYCU128 After resurfacing the seats, inspect for even valve seating. Apply Prussian Blue compound or erasable felt-tipped marker ink to the valve seat. Insert the valve, and snap it closed against its seat several times. Be sure the valve does not rotate on the seat. The seating surface, as shown by the transferred marking compound, should have good contact all the way around. Thoroughly clean the cylinder head to remove any cutting residual. VALVE FACE VALVE FACE 32° 60° Lap the valves into their seats, using a commercially available valve lapper and lapping compound. After lapping, wash all residual compound off the cylinder head and valve. VALVE LAPPER LIL21100 (Commercially available) • Do not push the valve against the seat with force during lapping. Apply a light pass with the valve lapper. • Avoid lapping the valve in the same position as it causes uneven wear. Lap the valve by turning the lapper slowly. • Take care not to allow the lapping compound to enter the gap between the stem and guide. Adjust the valve clearance after assembly (page 3-10). 13-11 dummyhead MEMO dummytext 14. CYLINDER BLOCK CRANKCASE COVER REMOVAL/ INSTALLATION···········································14-2 CRANKSHAFT/CAMSHAFT/BALANCER WEIGHT/PISTON REMOVAL/ INSTALLATION···········································14-3 PISTON DISASSEMBLY/ASSEMBLY ······· 14-4 CYLINDER BLOCK INSPECTION·············· 14-5 BEARING/OIL SEAL REPLACEMENT ···· 14-12 14 14-1 dummyhead CYLINDER BLOCK CRANKCASE COVER REMOVAL/ INSTALLATION CYLINDER BLOCK Remove the following: – – – – Engine/generator (page 12-2) Generator (page 7-14) Flywheel (page 9-10) Cylinder head (page 13-3) DOWEL PIN (2) CRANKSHAFT BEARING (6207) CRANKCASE GASKET CRANKCASE COVER CRANKCASE COVER BOLT (8 x 40 mm) (4) 24 N·m (2.4 kgf·m, 18 lbf·ft) BALL BEARING (6202) O-RING OIL FILLER CAP/ DIPSTICK OIL SEAL (35 x 52 x 8 mm) CRANKCASE COVER BOLT (8 x 60 mm) (3) 24 N·m (2.4 kgf·m, 18 lbf·ft) 14-2 dummyhead CYLINDER BLOCK CRANKSHAFT/CAMSHAFT/BALANCER WEIGHT/PISTON REMOVAL/ INSTALLATION PISTON INSTALLATION: Install the piston to the cylinder barrel with the mark on the piston head toward the push rod hole of the cylinder head. MARK (Viewed from cylinder head side) HOLE VALVE LIFTER (2) REMOVAL: When removing the valve lifters, mark them so the intake and exhaust sides can be distinguished. INSTALLATION: Attach the valve lifters to the cylinder barrel immediately before installing the camshaft. SEALING WASHER (12 mm) CAMSHAFT INSTALLATION: Align the punch marks of the camshaft and the crankshaft (marked on the timing gear). OIL LEVEL SWITCH JOINT NUT (10 mm) 10 N·m (1.0 kgf·m, 7 lbf·ft) DRAIN PLUG BOLT 22.5 N·m (2.3 kgf·m, 17 lbf·ft) MARKS CAMSHAFT CRANKSHAFT OIL LEVEL SWITCH O-RING (14 mm) BOLT (6 x 12 mm) (2) BALANCER WEIGHT INSTALLATION: Align the punch marks of the balancer weight and the crankshaft (marked on the balancer drive gear). BALANCER WEIGHT CONNECTING ROD SPECIAL BOLT (2) 14 N·m (1.4 kgf·m, 10 lbf·ft) (Apply to the threads and seating surface) CRANKSHAFT INSTALLATION: Before installing the crankshaft, check the oil seal of the cylinder barrel for damage or hardening. Be careful not to damage the oil seal when installing the crankshaft. CONNECTING ROD LOWER END INSTALLATION: Set the connecting rod lower end with the oil dipper toward the camshaft. MARKS CRANKSHAFT 14-3 dummyhead CYLINDER BLOCK PISTON DISASSEMBLY/ASSEMBLY Remove the piston (page 14-3). MAKER MARK PISTON RING SET TOP RING ASSEMBLY: To install the oil ring, install the spacer first, and then install the side rails. Be sure that the top ring and second ring are not interchanged. 120° 120° Install the top ring and second ring on the piston with the maker mark side facing up. Check that the piston rings rotate smoothly after installing them. SECOND RING SIDE RAIL OIL RING (COMBINATION RING) 10 mm (0.4 in) SPACER Space the piston ring end gaps 120 degrees apart, and do not align the ring end gaps with the piston pin bore. PISTON 120° SIDE RAIL 10 mm (0.4 in) TOP RING SECOND RING MARK OIL RING PISTON PISTON PIN CONNECTING ROD UPPER END ASSEMBLY: PISTON PIN CLIP (2) Set the connecting rod upper end with the long end toward the mark on the piston head. ASSEMBLY: Install by setting one end of the piston pin clip in the groove of the piston pin bore, holding the other end with long needle nose pliers, and rotating the clip in. Install the piston pin clip as shown. Do not align the end gap of the piston pin clip with the cutout of the piston pin bore. END GAP CUTOUT 14-4 PISTON PIN CLIP LONG END dummyhead CYLINDER BLOCK CYLINDER BLOCK INSPECTION CAM SHAFT HOLDER I.D. CRANKCASE COVER SIDE Measure the camshaft holder I.D. of the crankcase cover. STANDARD: 16.000 – 16.018 mm (0.6299 – 0.6306 in) SERVICE LIMIT: 16.05 mm (0.632 in) If the measurement is more than the service limit, replace the crankcase cover (page 14-2). Inspect the camshaft O.D. (page 14-10) with this inspection. CYLINDER BARREL SIDE Measure the camshaft holder I.D. of the cylinder barrel. STANDARD: SERVICE LIMIT: 16.000 – 16.018 mm (0.6299 – 0.6306 in) 16.05 mm (0.632 in) If the measurement is more than the service limit, replace the cylinder barrel (page 14-3). Inspect the camshaft O.D. (page 14-10) with this inspection. CYLINDER SLEEVE I.D. Measure and record the cylinder I.D. at three levels in both the “X” axis (perpendicular to crankshaft) and the “Y” axis (parallel to crankshaft). Take the maximum reading to determine cylinder wear and taper. STANDARD: SERVICE LIMIT: 88.000 – 88.017 mm (3.4646 – 3.4652 in) 88.17 mm (3.471 in) If the measurement is more than the service limit, replace the cylinder barrel (page 14-3). Inspect the piston skirt O.D. (page 14-6) with this inspection. X Y TOP MIDDLE BOTTOM 14-5 dummyhead CYLINDER BLOCK PISTON SKIRT O.D. Measure and record the piston O.D. at a point 10 mm (0.4 in) from the bottom of the skirt and 90 degrees to the piston pin bore. STANDARD: SERVICE LIMIT: 87.975 – 87.985 mm (3.4636 – 3.4640 in) 87.85 mm (3.459 in) 90° If the measurement is less than the service limit, replace the piston (page 14-4). Inspect the cylinder sleeve I.D. (page 14-5) with this inspection. 10 mm (0.4 in) PISTON-TO-CYLINDER CLEARANCE Subtract the piston skirt O.D. from the cylinder sleeve I.D. to obtain the piston-to-cylinder clearance. STANDARD: SERVICE LIMIT: 0.015 – 0.042 mm (0.0006 – 0.0017 in) 0.12 mm (0.005 in) If the calculated clearance is more than the service limit, replace the piston (page 14-4) and recheck the clearance. If the clearance is still more than the service limit with the new piston, replace the cylinder barrel (page 14-3). PISTON PIN BORE I.D. Measure and record the piston pin bore I.D. of the piston. STANDARD: SERVICE LIMIT: 20.002 – 20.008 mm (0.7875 – 0.7877 in) 20.042 mm (0.7891 in) If the measurement is less than the service limit, replace the piston (page 14-4). Inspect the piston pin O.D. (page 14-7) with this inspection. 14-6 dummyhead CYLINDER BLOCK PISTON PIN O.D. Measure and record the piston pin O.D. at three points (both ends and middle). Take the minimum reading to determine piston pin O.D. STANDARD: SERVICE LIMIT: 19.994 – 20.000 mm (0.7872 – 0.7874 in) 19.950 mm (0.7854 in) If the measurement is less than the service limit, replace the piston pin. Inspect the piston pin bore I.D. (page 14-6). Inspect the connecting rod small end I.D. (page 14-8) with this inspection. PISTON PIN-TO-PISTON PIN BORE CLEARANCE Subtract the piston pin O.D. from the piston pin bore I.D. to obtain the piston pin-to-piston pin bore clearance. STANDARD: SERVICE LIMIT: 0.002 – 0.014 mm (0.0001 – 0.0006 in) 0.08 mm (0.003 in) If the calculated clearance is more than the service limit, replace the piston pin (page 14-4) and recheck the clearance. If the clearance is still more than the service limit with the new piston pin, replace the piston (page 14-4). PISTON RING WIDTH Measure each piston ring width. STANDARD: Top: Second: SERVICE LIMIT: Top: Second: 1.160 – 1.175 mm (0.0457 – 0.0463 in) 1.130 – 1.145 mm (0.0445 – 0.0451 in) 1.140 mm (0.0449 in) 1.110 mm (0.0437 in) If any measurement is less than the service limit, replace the piston rings (top, second, oil) as a set (page 14-4). 14-7 dummyhead CYLINDER BLOCK PISTON RING SIDE CLEARANCE Measure the clearance between each piston ring and ring groove of the piston using a feeler gauge. STANDARD: Top: Second: SERVICE LIMIT: Top: Second: 0.030 – 0.060 mm (0.0012 – 0.0024 in) 0.060 – 0.090 mm (0.0024 – 0.0035 in) 0.15 mm (0.006 in) 0.15 mm (0.006 in) If any measurement is more than the service limit, inspect the piston ring width. If the piston ring width is normal, replace the piston (page 14-4) and reinspect the clearance. If necessary, replace the piston rings (top, second, oil) as a set (page 14-4) and reinspect the clearance. If any measurement is still more than the service limit with the new piston rings, replace the piston (page 144). PISTON RING END GAP Before inspection, check whether the cylinder sleeve I.D. (page 14-5) is within the specification. Measure each piston ring [1] end gap using a feeler gauge. STANDARD: Top: Second: Oil (side rail) SERVICE LIMIT: Top/Second: Oil (side rail) 0.200 – 0.350 mm (0.0079 – 0.0138 in) 0.350 – 0.500 mm (0.0138 – 0.0197 in) 0.20 – 0.70 mm (0.008 – 0.028 in) 1.0 mm (0.04 in) 1.0 mm (0.04 in) If any measurement is more than the service limit, replace the piston rings (top, second, oil) as a set (page 14-4). CONNECTING ROD SMALL END I.D. Measure the connecting rod small end I.D. STANDARD: SERVICE LIMIT: 20.005 – 20.020 mm (0.7876 – 0.7882 in) 20.07 mm (0.790 in) If the measurement is more than the service limit, replace the connecting rod (page 14-4). Inspect the piston pin O.D. (page 14-7) with this inspection. 14-8 [1] dummyhead CYLINDER BLOCK CONNECTING ROD BIG END I.D. Set the connecting rod lower end to the connecting rod upper end. Apply engine oil to the connecting rod bolt threads and seating surface. Tighten the connecting rod bolts to the specified torque. TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) Measure the connecting rod big end I.D. STANDARD: SERVICE LIMIT: 36.025 – 36.039 mm (1.4183 – 1.4189 in) 36.07 mm (1.420 in) If the measurement is more than the service limit, replace the connecting rod (page 14-4). CONNECTING ROD BIG END SIDE CLEARANCE Measure the clearance between the connecting rod big end and crankshaft using a feeler gauge. STANDARD: SERVICE LIMIT: 0.1 – 0.4 mm (0.004 – 0.016 in) 1.0 mm (0.04 in) If the measurement is more than the service limit, replace the connecting rod (page 14-4) and recheck the clearance. If the clearance is still more than the service limit with the new connecting rod, replace the crankshaft (page 14-3). CONNECTING ROD BIG END OIL CLEARANCE Clean all oil from the crank pin and connecting rod big end surface. [1] Place a piece of Plastigauge® [1] on the crank pin, install the connecting rod upper end and the connecting rod lower end. Apply engine oil to the connecting rod bolt threads and seating surface. Tighten the connecting rod bolts to the specified torque. TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) Do not rotate the crankshaft while the Plastigauge is in place. Remove the connecting rod and measure Plastigauge [1] using the Plastigauge scale [2]. STANDARD: SERVICE LIMIT: the 0.040 – 0.064 mm (0.0016 – 0.0025 in) 0.12 mm (0.005 in) [1] [2] If the clearance is more than the service limit, inspect the following: • Connecting rod big end I.D. (page 14-9) • Crank pin O.D. (page 14-10) If the part that is not within the service limit is replaced, reinspect the clearance. 14-9 dummyhead CYLINDER BLOCK CRANK PIN O.D. Measure the crank pin O.D. of the crankshaft. STANDARD: SERVICE LIMIT: 35.975 – 35.985 mm (1.4163 – 1.4167 in) 35.93 mm (1.415 in) If the measurement is less than the service limit, replace the crankshaft (page 14-3). CRANKSHAFT RUNOUT Set the crankshaft on V-blocks and measure the runout using a dial indicator. SERVICE LIMIT: 0.1 mm (0.004 in) If the measured runout is more than the service limit, replace the crankshaft (page 14-3). 20 mm (0.8 in) CAMSHAFT O.D. Measure the camshaft O.D. of the camshaft. STANDARD: SERVICE LIMIT: 15.966 – 15.984 mm (0.6286 – 0.6293 in) 15.92 mm (0.627 in) If the measurement is less than the service limit, replace the camshaft (page 14-3). 14-10 17 mm (0.7 in) 45 mm (1.8 in) dummyhead CYLINDER BLOCK CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft. STANDARD: SERVICE LIMIT: IN: 32.448 – 32.748 mm (1.2775 – 1.2893 in) EX: 31.935 – 32.235 mm (1.2573 – 1.2691 in) IN: 32.198 mm (1.2676 in) EX: 29.886 mm (1.1766 in) If the measurement is less than the service limit, replace the camshaft (page 14-3). DECOMPRESSOR WEIGHT Check for a worn and weakened spring. Check that the decompressor weight moves smoothly. If the decompressor weight does not move correctly, replace the camshaft (page 14-3). RADIAL BALL BEARING Clean the bearing with solvent and dry it thoroughly. Turn the inner race (outer race: cylinder barrel side crankshaft bearing only) of the radial ball bearing with your finger and check for play. If it is noisy or has excessive play, replace the radial ball bearing (page 14-12). 14-11 dummyhead CYLINDER BLOCK BEARING/OIL SEAL REPLACEMENT CRANKCASE COVER LOCATION BALANCER WEIGHT BEARING (6202) CRANKSHAFT OIL SEAL (35 x 52 x 8 mm) CRANKSHAFT BEARING (6207) BALANCER WEIGHT BEARING Pull out the bearing [1] using the special tools. [1] TOOLS: Bearing remover shaft, 15 mm [2] 07936-KC10500 Remover weight [3] 07936-371020A [3] Apply oil to the circumference of a new bearing (4). Drive the bearing until it is fully seated on the end using the special tools. TOOLS: Attachment, 32 × 35 mm [5] Pilot, 15 mm [6] Driver handle [7] 07746-0010100 07746-0040300 07749-0010000 [2] [7] [5] [6] [4] (circumference) 14-12 dummyhead CYLINDER BLOCK CRANKSHAFT BEARING Drive out the bearing [1]. Apply oil to the circumference of a new bearing [2]. Drive the bearing until it is fully seated on the end using the special tools. TOOLS: Attachment, 72 × 75 mm [3] Pilot, 35 mm [4] Driver handle [5] [1] 07746-0010600 07746-0040800 07749-0010000 [5] [3] [2] [4] (circumference) CRANKSHAFT OIL SEAL Remove the oil seal from the crankcase cover. Apply grease to the lip of a new oil seal [1]. Drive the oil seal in the position as shown using the special tools. TOOLS: Attachment, 52 × 55 mm [2] Driver handle [3] [3] [2] 07746-0010400 07749-0010000 [1] 2 mm (0.08 in) OIL SEAL RIP 14-13 dummyhead CYLINDER BLOCK CYLINDER BARREL LOCATION BALANCER WEIGHT BEARING (6202) CRANKSHAFT OIL SEAL (35 x 52 x 8 mm) BALANCER WEIGHT BEARING Pull the bearing [1] out using the special tools. TOOLS: Bearing remover shaft, 15 mm [2] 07936-KC10500 Remover weight [3] 07936-371020A [3] Apply oil to the circumference of a new bearing [4]. Drive the bearing in until it is fully seated in the cylinder barrel using the special tools. TOOLS: Attachment, 32 × 35 mm [5] Pilot, 15 mm [6] Driver handle [7] 07746-0010100 07746-0040300 07749-0010000 [2] [1] [7] [5] [4] (circumference) [6] 14-14 dummyhead CYLINDER BLOCK CRANKSHAFT OIL SEAL Remove the oil seal from the cylinder barrel. [3] Apply grease to the lip of a new oil seal [1]. Drive the oil seal in the position shown using the special tools. TOOLS: Attachment, 52 × 55 mm [2] Driver handle [3] [2] 07746-0010400 07749-0010000 [1] 2 mm (0.08 in) OIL SEAL LIP CRANKSHAFT CRANKSHAFT BEARING Install the 16 mm flywheel nut [1] to protect the crankshaft threads. [2] [1] Pull off the bearing [2] using a commercially available bearing puller [3]. Apply oil to the inner surface of the new bearing [4] inner race [5]. Drive the bearing in until it is fully seated on the end using the special tools and a hydraulic press. TOOLS: Driver attachment, 35 mm I.D. [6] Driver, 40 mm I.D. [7] [3] 07746-0030400 07746-0030100 [7] [6] [5] [4] 14-15 dummyhead MEMO dummytext 15. HANDLE/WHEELS WHEEL/STAND REMOVAL/ INSTALLATION···········································15-2 HANDLE REMOVAL/INSTALLATION········ 15-3 HANDLE DISASSEMBLY/ASSEMBLY ······ 15-4 15 15-1 dummyhead HANDLE/WHEELS WHEEL/STAND REMOVAL/INSTALLATION HANDLE/WHEELS WHEEL (2) REAR LONGER BOLT (8 X 20 mm) (4) STAND (2) WHEEL SHAFT BOLT (8 X 20 mm) (4) 15-2 SHORTER SPLIT PIN (4.0 X 28 mm) (2) WASHER (2) dummyhead HANDLE/WHEELS HANDLE REMOVAL/INSTALLATION CONCAVE WASHER (12 mm) (2) WASHER (12 mm) (2) HANDLE HOLDER BOLT (2) 21.5 N·m (2.2 kgf·m, 16 lbf·ft) HANDLE 15-3 dummyhead HANDLE/WHEELS HANDLE DISASSEMBLY/ASSEMBLY HANDLE LEVER SPRING INSTALLATION: Hook the handle lever spring as shown. HANDLE HOLDER HANDLE LEVER SOCKET BOLT (8 X 45 mm) (2) 21.5 N·m (2.2 kgf·m, 16 lbf·ft) SOCKET BOLT (8 X 22 mm) (2) 21.5 N·m (2.2 kgf·m, 16 lbf·ft) HANDLE LEVER SPRING HANDLE LEVER (2) HANDLE PIPE LEFT HANDLE HOLDER RIGHT HANDLE HOLDER HANDLE LEVER RUBBER (2) STOPPER RUBBER (2) HANDLE COLLAR (2) HANDLE GRIP RUBBER (2) 15-4 dummytext 16. TECHNICAL FEATURES PGM-FI (PROGRAMMED-FUEL INJECTION) SYSTEM ·································16-2 IGNITION SYSTEM ···································16-22 OTHER GCU OPERATION ······················· 16-23 INVERTER UNIT ······································· 16-25 16 16-1 dummyhead TECHNICAL FEATURES PGM-FI (PROGRAMMED-FUEL INJECTION) SYSTEM TECHNICAL FEATURES SYSTEM COMPONENTS This model utilizes a PGM-FI (Programmed-Fuel Injection) system, instead of a conventional carburetor system. This system consists of the following: Fuel injector, throttle body, GCU, inverter unit, fuel pump, CKP sensor, generator, BARO sensor (GCU internal), AAT sensor (GCU internal), EBT sensor, and O2 sensor. FUEL PUMP It delivers fuel from the fuel tank to the fuel injector by applying constant pressure. GCU GCU regulates the amount of fuel discharged from the injector by controlling the fuel pump system. It controls PGM-FI system according to collected signals from each sensor. It also controls electrical systems such as the throttle valve control system, ignition system, and starter system. AAT SENSOR (GCU internal) This sensor measures the ambient air temperature. O2 SENSOR This sensor measures the density of oxygen in exhaust gas. BARO SENSOR (GCU internal) This sensor measures the barometric pressure. CKP SENSOR This sensor detects the crankshaft angle in order to determine the fuel discharge timing and ignition timing. THROTTLE CONTROL MOTOR It opens/closes the throttle valve by the stepping motor. GCU presumes the degree of throttle opening based on the output pulse signal to the motor. EBT SENSOR This sensor measures the engine block temperature. GENERATOR It detects the pulse signal in order to compute the rotation speed. FUEL INJECTOR Electromagnetic valve to discharge fuel. INVERTER UNIT THROTTLE BODY It controls the volume of intake air by opening/ closing the throttle valve. PGM-FI BARO SENSOR EBT SENSOR 16-2 Programmed-Fuel Injection Barometric Pressure Sensor Engine Block Temperature Sensor It detects the generator output and electrical load at the receptacle and sends signals to the GCU. AAT SENSOR CKP SENSOR GCU Ambient Air Temperature Sensor Crankshaft Position Sensor Generator Control unit dummyhead TECHNICAL FEATURES COMPARISON BETWEEN ELECTRICALLY CONTROLLED CARBURETOR AND PGM-FI SYSTEM BASIC OPERATION The electrically controlled carburetor and PGM-FI system change the volume of incoming air-fuel mixture by opening/closing the throttle valve in order to regulate the engine speed. The carburetor changes the amount of mixture by sucking fuel into the carburetor bore in accordance with the volume of incoming air; the PGM-FI system by controlling the volume of fuel discharged from the injector. NO LOAD TO LOW LOAD When there is no load to low load at the receptacle, the engine runs at the pre-set target rotation (2,400 rpm). ELECTRICALLY CONTROLLED CARBURETOR (AT NO LOAD TO LOW LOAD): • The mixture is supplied from the side port as the GCU opens the throttle valve partially. CARBURETOR (AT NO LOAD TO LOW LOAD): CHOKE VALVE AIR THROTTLE VALVE FUEL SIDE PORT PGM-FI (AT NO LOAD TO LOW LOAD): • The GCU opens the throttle valve partially. The discharge volume from the fuel injector is determined by GCU according to the throttle position and engine speed with corrections based upon the signals from inverter, EBT sensor, AAT sensor, BARO sensor, and O2 sensor. PGM-FI THROTTLE BODY (AT NO LOAD TO LOW LOAD): GENERATOR THROTTLE CONTROL MOTOR EBT SENSOR AAT SENSOR BARO SENSOR O2 SENSOR GCU • Engine revs • Throttle valve angle Basic discharge volume • Engine Block Temperature Correction • Ambient Air Temperature • Barometric Pressure FUEL PUMP FUEL • O2 density FUEL INJECTION SIGNAL AIR INJECTOR THROTTLE VALVE 16-3 dummyhead TECHNICAL FEATURES LOW LOAD TO HIGH LOAD When the load at the receptacle increases, the engine speed starts decreasing as the resistance caused by the load increases. ELECTRICALLY CONTROLLED CARBURETOR (AT LOW LOAD TO HIGH LOAD): • When the engine speed starts decreasing under high load, GCU increases the volume of incoming air by opening the throttle valve. The amount of fuel sucked from the main nozzle increases in accordance with the increasing volume of incoming air. The engine speed increases as the target rotation is set to high speed in order to meet the demand of the load. CARBURETOR (AT LOW LOAD TO HIGH LOAD): MAIN NOZZLE AIR THROTTLE VALVE CHOKE VALVE FUEL PGM-FI (AT LOW LOAD TO HIGH LOAD): • When the engine speed starts decreasing under high load, the GCU increases the volume of incoming air by opening the throttle valve. The GCU controls the discharge volume from the fuel injector according to the throttle position. The engine speed increases as the target rotation is set to high speed in order to meet the demand of the load. PGM-FI THROTTLE BODY (AT LOW LOAD TO HIGH LOAD): GCU • Engine revs • Throttle valve angle Basic discharge volume • Engine Block Temperature Correction • Ambient Air Temperature • Barometric Pressure • O2 density FUEL INJECTION SIGNAL FUEL PUMP FUEL AIR INJECTOR THROTTLE VALVE 16-4 dummyhead TECHNICAL FEATURES HIGH LOAD TO LOW LOAD When the load at the receptacle decreases, the engine speed starts increasing as the resistance caused by the load becomes less. ELECTRICALLY CONTROLLED CARBURETOR (AT HIGH LOAD TO LOW LOAD): • When the engine speed starts increasing under low load, GCU limits the volume of incoming air by closing the throttle valve from the current position as required. The amount of fuel sucked from the main nozzle decreases in accordance with the decreasing volume of incoming air. The engine speed decreases as the target rotation is set to low speed enough to satisfy the demand of the load. CARBURETOR (AT HIGH LOAD TO LOW LOAD): MAIN NOZZLE AIR THROTTLE VALVE CHOKE VALVE FUEL PGM-FI (AT HIGH LOAD TO LOW LOAD): • When the GCU detects the increasing engine speed based upon the signal from the generator, it limits the volume of incoming air by closing the throttle valve from the current position as needed. The discharge volume from the fuel injector is controlled according to the throttle position. The engine speed decreases as the target rotation is set to low speed enough to satisfy the demand of the load. PGM-FI THROTTLE BODY (AT HIGH LOAD TO LOW LOAD): GCU • Engine revs • Throttle valve angle Basic discharge volume • Engine Block Temperature Correction • Ambient Air Temperature • Barometric Pressure • O2 density FUEL INJECTION SIGNAL FUEL PUMP FUEL AIR INJECTOR THROTTLE VALVE 16-5 dummyhead TECHNICAL FEATURES FUEL ENRICHMENT FOR COLD ENGINE ENGINE RUNNING CONDITION WHEN IT IS STILL COLD: Fuel does not vaporize well in a cold engine and air-fuel ratio becomes very lean, causing unstable engine speed. COLD ENGINE WITH CARBURETOR: When the GCU detects a cold engine, it enriches the mixture in order to stabilize the engine speed by closing the choke valve to increase the vacuum pressure to discharge more fuel from the main nozzle. CARBURETOR: CHOKE VALVE AIR FUEL COLD ENGINE WITH PGM-FI: When the GCU detects a cold engine, it enriches the mixture by increasing the fuel discharge duration. PGM-FI THROTTLE BODY: GCU • Engine revs • Throttle valve angle Basic discharge volume • Engine Block Temperature Correction • Ambient Air Temperature • Barometric Pressure • O2 density FUEL INJECTION SIGNAL FUEL PUMP FUEL AIR INJECTOR THROTTLE VALVE 16-6 dummyhead TECHNICAL FEATURES FUEL SUPPLY CUT ON ENGINE STOPPING ENGINE CONDITION WHEN STOPPING: When you turn the main switch to the OFF position, the GCU stops the engine by shutting down the ignition system and opening the throttle valve as the engine speed decreases. ENGINE STOPPING WITH CARBURETOR: When you turn the main switch to the OFF position, the unburned air-fuel mixture is released into atmosphere as the GCU cuts off the ignition. As the engine speed goes down to certain point, the throttle valve opens fully and the engine stops. CARBURETOR: AIR THROTTLE VALVE FUEL ENGINE STOPPING WITH PGM-FI: When you turn the main switch to the OFF position, the GCU cuts off the ignition system and fuel supply to prevent the unburned air-fuel mixture from being released into the atmosphere. As the engine speed goes down to certain point, the throttle valve opens fully and the engine stops. PGM-FI THROTTLE BODY: FUEL PUMP FUEL GCU FUEL INJECTION STOP SIGNAL AIR INJECTOR THROTTLE VALVE 16-7 dummyhead TECHNICAL FEATURES PGM-FI ELECTRICAL CONTROL SYSTEM SYSTEM OVERVIEW GCU controls engine's running condition by operating the components such as fuel injector and fuel pump, depending on output signals from each sensor. DETECTOR SECTION CONTROL SECTION OPERATE SECTION GCU R Bu/R FUEL PUMP CONTROL Bu/Y INVERTER UNIT R Bu FUEL PUMP O/W G/Bu G/O 5V INJECTION VOLUME (DURATION) CONTROL/ INJECTION TIMING CONTROL 5V BARO SENSOR 5V THROTTLE VALVE OPENING ANGLE CONTROL 5V Y/R Bl Y/Bl Y FUEL INJECTOR CORRECTION SIGNAL AAT SENSOR Bl W W R Y THROTTLE CONTROL MOTOR Bu EBT SENSOR Bl O2 SENSOR Bu Y/Bu CRANKSHAFT ANGLE CKP SENSOR R W GENERATOR (MASTER) U W Bu ENGINE SPEED SIGNAL V THROTTLE CONTROL MOTOR W STEPPING MOTOR ANGLE SIGNAL R Y Bu Bl MAIN SWITCH G Br/Bu Bl Br/Bu W/Bu MAIN SWITCH SIGNAL IGNITION TIMING CONTROL Bl/G IGNITION COIL/ SPARK PLUG Y OIL LEVEL SWITCH BATTERY Bl/W Bl/Y STARTER SWITCH G STARTER MAGNETIC SWITCH CONTROL BATTERY STARTER MOTOR MAIN SWITCH Br/W G/O i-MONITOR CONTROL 16-8 i-MONITOR dummyhead TECHNICAL FEATURES FUEL INJECTION CONTROL BASIC FUEL DISCHARGE VOLUME The PGM-FI system uses a set of pre-programmed fuel injection quantity values and chooses the most appropriate value according to engine speed and throttle position. The chosen value is referred to as the basic fuel discharge volume, which is modified according to correction signals from various sensors to determine the final injection volume. The amount of fuel that flows through the injector is controlled by the length of time the valve stays open, as the injector has only two positions, fully open or fully closed. GCU Generator Throttle control motor Selects basic fuel discharge volume Final fuel discharge volume Fuel Injector Correction EBT sensor O2 sensor BARO sensor AAT sensor FUEL DISCHARGE TIMING The GCU presumes the TDC by one pulse signal per one revolution of the crankshaft from the CKP sensor, and then injects an equal amount of fuel at the exhaust stroke and the compression stroke. STROKE EXHAUST STROKE INTAKE STROKE COMPRESSION STROKE EXPANSION STROKE EXHAUST STROKE INTAKE STROKE COMPRESSION STROKE CKP SENSOR PULSE DISCHARGE TIMING IGNITION TIMING 16-9 dummyhead TECHNICAL FEATURES FUEL INJECTOR SUMMARY: • A fuel injector is a solenoid valve that consists of a needle valve/plunger, solenoid coil, solenoid spring, and filter. • Constantly pressurized fuel (294 kPa (3 kgf/cm2, 43 psi) is supplied to the fuel injector. • The fuel injector is either fully closed or fully open with a fixed stroke. The amount of fuel injected is dependent on how long the fuel injector is kept open. • The GCU applies voltage to the fuel injector to open it while the generator is generating the voltage. PLUNGER (NEEDLE VALVE) SOLENOID SPRING FILTER SOLENOID COIL OPERATION: 1. The fuel pressurized by the fuel pump is blocked at the fuel injector nozzle that consists of a plunger/needle valve and valve seat. 2. When the GCU applies current to the solenoid coil in the fuel injector, the coil becomes an electromagnet that pulls the plunger/ needle valve while compressing the solenoid spring. 3. The nozzle opens as the plunger/needle valve lifts up. The fuel blocked at the fuel injector nozzle passes the filter and then sprays into the intake port. FILTER FUEL PUMP SOLENOID SPRING SOLENOID COIL PLUNGER/ NEEDLE VALVE FUEL INJECTOR NOZZLE VALVE SEAT 4. When the GCU stops current to the solenoid coil in the fuel injector, the coil is no longer electromagnetic and the nozzle will be shut by the returning force of the solenoid spring, which blocks the fuel. FUEL PUMP SOLENOID SPRING SOLENOID COIL PLUNGER/ NEEDLE VALVE FUEL INJECTOR NOZZLE 16-10 VALVE SEAT dummyhead TECHNICAL FEATURES FUEL PUMP SUMMARY: • The fuel pump is located inside the fuel tank. • The fuel pump draws in the fuel via the fuel filter and delivers it to the fuel injector. The pressure regulator maintains a constant fuel pressure of 294 kPa (3 kgf/cm2, 43 psi). FUEL PUMP CONSTRUCTION: The fuel pump assembly consists of a pump section, residual pressure check valve, suction port, and discharge port. The pump section consists of a motor-driven impeller and pump chamber composed of a pump casing and pump cover. FUEL PUMP OPERATION: • When the motor turns, fin grooves located on impeller circumference produce a pressure difference due to hydro-friction force. Fuel is drawn into the pump, and then delivered out of the pump. • The drawn fuel via the filter circulates inside the motor and passes the residual pressure check valve, then is delivered through the discharge port. • When engine is turned OFF and fuel pump is not operating, the check valve maintains residual fuel pressure to ease engine restarting. • The fuel pressure regulator maintains fuel pressure by the regulator valve that opens when fuel pressure in the discharge circuit (between the pump and fuel injector) becomes higher than a certain value. TO FUEL INJECTOR DISCHARGE PORT PRESSURE REGULATOR VALVE PUMP COVER RESIDUAL PRESSURE CHECK VALVE ARMATURE COIL CASING IMPELLER FILTER SUCTION PORT 16-11 dummyhead TECHNICAL FEATURES ROLE OF EACH SENSOR Each sensor provides information to the GCU by interpreting physical information such as temperature and pressure into electronic signals (voltage). THROTTLE CONTROL MOTOR O2 SENSOR BARO SENSOR OUTPUT VOLTAGE OUTPUT PULSE V ELECTROMOTIVE FORCE (VOLTAGE) Barometric air pressure TIME V kPa AAT SENSOR OUTPUT VOLTAGE V TIME Ambient air temperature °C GCU EBT SENSOR OUTPUT VOLTAGE V Engine block temperature CKP SENSOR INPUT VOLTAGE °C GENERATOR INPUT VOLTAGE TIME 16-12 TIME INVERTER UNIT dummyhead TECHNICAL FEATURES SENSORS There are two kinds of sensor output: One translates changes of the electrical resistance into changes of voltage, the other produces its own voltage or current. OUTPUT VOLTAGE SENT TO GCU As shown on the diagram below, two resistors divide the source voltage when connected to the source in series. 5V 2.5 V 2.5 V A= 1 kΩ B= 1 kΩ When resistor A and B have the same resistance value, source voltage would be divided equally. When one of them has a larger resistance value than the other, it would receive a larger share of the load. The EBT sensor and AAT sensor utilize this principle. The GCU receives changes of physical information (changes of temperature, pressure etc.) as variable voltage by reading it at both ends of resistor B (Resistor A: fixed resistor/Resistor B: variable resistor that reacts to physical changes). For example, when the source voltage is 5 V, the resistance value of resistor A is 1.0 kΩ, and the resistance value of resistor B is 19.0 kΩ, the voltage measured at point C would be 4.75 V, as shown below. If the value of resistor B is 0.06 kΩ, the voltage measured at point C would be 0.28 V. e.g. EBT (engine block temperature) SENSOR When engine block temperature is – 25 °C: When engine block temperature is 150 °C: GCU EBT SENSOR GCU 5V 5V A= 1.0 kΩ EBT SENSOR CPU CPU C= 4.75 V B= 19.0 kΩ A= 1.0 KΩ C= 0.28V B= 0.06 kΩ 16-13 dummyhead TECHNICAL FEATURES CKP SENSOR • The CKP sensor detects crankshaft angle. • The CKP sensor consists of the reluctor on the flywheel and the pickup in the CKP sensor with a built-in permanent magnet and coil. • When reluctors on the flywheel cross the CKP sensor as the crankshaft rotates, changes of magnetic flux in the pickup coil occur. The CKP sensor detects the changes by converting them into pulse voltages and inputs the pulse into GCU (one pulse per one crankshaft rotation). • Depending on the signal, the GCU controls the following: – timing of fuel discharge – ignition timing RELUCTOR CKP SENSOR GCU FLYWHEEL CKP SENSOR PICKUP RELUCTOR CKP SENSOR OUTPUT VOLTAGE 16-14 SENSOR OUTPUT VOLTAGE (WITH BUILT-IN PERMANENT MAGNET AND COIL) dummyhead TECHNICAL FEATURES GENERATOR • The stator detects the engine speed. • The stator outputs ten pulse signals to the GCU per one revolution of the crankshaft. • Depending on these signals, the GCU controls the following: – degree of throttle opening – amount of fuel discharge (duration) STATOR GCU MASTER WAVEFORM SHIPPING CIRCUIT CPU STATOR (MASTER) CKP SENSOR PULSE STATOR PULSE 16-15 dummyhead TECHNICAL FEATURES THROTTLE CONTROL MOTOR • The throttle control motor consists of a stepping motor that controls the throttle valve angle. • The stepping motor operates in steps according to the number of pulse signal output from the GCU. The GCU can presume the throttle valve position according to the number of output pulses. • The signals from the throttle control motor are used to control the basic fuel discharge volume and basic ignition timing. THROTTLE CONTROL MOTOR GCU CPU THROTTLE CONTROL MOTOR EXAMPLE OF STEPPING MOTOR ANGLE PRESUMPTION: moves ONE STEP THROTTLE VALVE GCU ONE INPUT PULSE THROTTLE VALVE GCU FIFTEEN INPUT PULSES 16-16 THROTTLE CONTROL MOTOR (STEPPING MOTOR) moves FIFTEEN STEPS THROTTLE CONTROL MOTOR (STEPPING MOTOR) dummyhead TECHNICAL FEATURES BARO SENSOR • The BARO sensor measures the barometric pressure in order to detect the air density. • The BARO sensor consists of a pressure sensing device (silicone diaphragm) that varies the resistance values when pressure is applied, and an amplifier that amplifies the voltage. • The output voltage from the BARO sensor becomes lower at high altitude where the barometric pressure is low (the air is thin) and becomes higher at low altitude where the pressure is high (the air is dense). • Depending on sensor output voltage, the GCU corrects the discharge duration corresponding to the barometric pressure. GCU GCU 5V BARO SENSOR 5V OUTPUT VOLTAGE BARO SENSOR OUTPUT VOLTAGE (V) HIGH BAROMETRIC PRESSURE LOW LOW HIGH (kPa) 16-17 dummyhead TECHNICAL FEATURES EBT SENSOR • The EBT sensor detects engine block temperature. • The EBT sensor consists of a thermistor that varies its resistance value according to changes in temperature. • Output voltage from the EBT sensor is high when the engine block temperature is low. The voltage becomes lower as temperature increases. • Depending on sensor output voltage, the GCU corrects the discharge duration corresponding to the engine block temperature. GCU 5V EBT SENSOR OUTPUT VOLTAGE EBT SENSOR OUTPUT VOLTAGE (V) HIGH ENGINE BLOCK TEMPERATURE LOW (°C) LOW 16-18 HIGH dummyhead TECHNICAL FEATURES AAT SENSOR • The AAT sensor detects the ambient air temperature. • The AAT sensor consists of a thermistor that varies its resistance value according to changes in temperature. • Output voltage from the AAT sensor is high when intake air temperature is low. The voltage becomes lower as temperature increases. • Depending on sensor output voltage, the GCU corrects the discharge duration corresponding to the ambient air temperature. GCU GCU 5V AAT SENSOR OUTPUT VOLTAGE AAT SENSOR OUTPUT VOLTAGE (V) HIGH AMBIENT AIR TEMPERATURE LOW LOW HIGH (°C) 16-19 dummyhead TECHNICAL FEATURES O2 SENSOR • The O2 sensor detects the amount of oxygen in exhaust gas. • The O2 sensor consists of a cylindrical-shaped, white-gold-coated zirconia device. The inside of the device is exposed to the atmosphere, whereas its outside is exposed to exhaust gas. The zirconia device: produces electromotive force by difference in the oxygen concentration between the atmosphere and the exhaust gas when the temperature is higher than a certain value. • The O2 sensor detects changes in oxygen concentration in the exhaust gas by measuring the electromotive force. The GCU inputs the values as voltages. • The output voltage of the O2 sensor is approximately 0 V when the difference of oxygen concentration between the atmosphere and the exhaust gas is very small (when air/fuel ratio is lean), whereas the output voltage is approximately 1 V when the difference is very big (when air/fuel ratio is rich). • Depending on the sensor output voltage, the GCU corrects discharge duration corresponding with the oxygen concentration in the exhaust gas. GCU O2 SENSOR INPUT VOLTAGE O2 SENSOR ATMOSPHERE WHITE-GOLD-COATED POLE (ATMOSPHERE SIDE) ZIRCONIA DEVICE WHITE-GOLD-COATED POLE (EXHAUST GAS SIDE) O2 SIGNAL VOLTAGE CHARACTERISTICS: ELECTROMOTIVE FORCE CHARACTERISTICS: ELECTROMOTIVE FORCE (VOLTAGE) ELECTROMOTIVE FORCE (VOLTAGE) STOICHIOMETRIC MIXTURE HIGH HIGH LOW TIME 16-20 LOW RICH AIR/FUEL RATIO LEAN dummyhead TECHNICAL FEATURES TARGET ROTATION CONTROL The GCU controls the volume of incoming air by opening/closing the throttle valve in order to obtain the target rotation that the inverter unit requires. GCU Engine speed Generator Electric governor control Inverter unit Target throttle valve angle Throttle control motor Target rotation 16-21 dummyhead TECHNICAL FEATURES IGNITION SYSTEM IGNITION TIMING CONTROL BASIC IGNITION TIMING The ignition system uses a set of pre-programmed ignition timing values and chooses the most appropriate value according to the engine speed and throttle position. The GCU detects the engine speed by receiving ten pulse signals per one revolution of the crankshaft from the generator, and the throttle valve position according to the number of input pulses sent to the throttle control motor (stepping motor). The GCU chooses the most appropriate ignition timing in order to gain the optimal balance of fuel economy and durability of the unit in any engine speed and output voltage. GCU CKP sensor Throttle control motor Selects basic ignition timing Determines final ignition timing Ignition coil Generator Spark plug The GCU presumes the standard angle of ignition timing (TDC) based on one pulse signal per one revolution of the crankshaft from the CKP sensor, and then makes the spark plug ignite at the exhaust stroke and compression stroke. STROKE EXHAUST STROKE INTAKE STROKE COMPRESSION STROKE EXPANSION STROKE EXHAUST STROKE INTAKE STROKE COMPRESSION STROKE CKP SENSOR PULSE IGNITION TIMING INJECTION TIMING The power for the ignition coil is supplied from the generator output in order to make battery-less operation possible. 16-22 dummyhead TECHNICAL FEATURES OTHER GCU OPERATION COMPONENT DIAGRAM RECEPTACLE AC OUTPUT GENERATOR CONTROL UNIT SPARK PLUG VOLTAGE SELECTOR SWITCH OIL LEVEL SWITCH OIL ALERT CIRCUIT POWER TRANSISTOR IGNITION COIL EBT SENSOR THROTTLE CONTROL MOTOR ECO THROTTLE SWITCH STARTER RELAY STARTER MOTOR ON/OFF switch DUAL VOLTAGE INVERTER UNIT OUTPUT INDICATOR 32 bit CPU LED display INVERTER (MASTER) OVERLOAD INDICATOR INVERTER (SLAVE) CHECK/OIL ALERT INDICATOR COMMUNICATION LCD DRIVER i-MONITOR ROTOR DUAL STATOR WINDING DISPLAY BUTTON CKP SENSOR 3-PHASE AC WAVEFORM SHAPING CIRCUIT EEPROM AC/DC CONVERTER UNIT POWER SUPPLY POWER SUPPLY/ CHARGING BATTERY SYSTEM START/STOP SIGNAL MAIN SWITCH STARTER SIGNAL STARTER SWITCH PRINCIPLE OF OPERATION NORMAL START Starting with the starter motor: • When you turn the main switch to the ON position and press the starter switch, the CPU and the throttle valve are initialized by the battery. After they are initialized, the signal enters the CPU, operating the starter relay and the starter motor. When the generator coils generate voltage by engine rotation, the ignition system starts functioning and the engine starts. Starting with the recoil starter: • When the main switch is turned to the ON position and the recoil starter is operated, the generator coils generate voltage to activate the CPU and the throttle valve. The ignition system begins operating at this time so the engine can be started. 16-23 dummyhead TECHNICAL FEATURES NORMAL STOP When you turn the main switch to the OFF position, the stop signal is transmitted to the GCU and to the inverter unit. The inverter unit stops generator output. The GCU shuts off the fuel supply and ignition in order to stop the engine. ENGINE SPEED LIMITER The ignition is cut off when the engine speed exceeds 4,400 rpm, and ignition is resumed when engine speed goes below 4,400 rpm, which protects the generator system from engine over-speeding. However, if the engine speed exceeds 3,900 rpm for more than 3 seconds, the i-Monitor will display an error code and the engine will be shut down. OIL ALERT When the engine oil runs low, activating the oil level switch, the ignition is cut off. At the time the engine is stopped, the Oil Alert indicator (red) comes ON and the i-Monitor displays “OIL”. STARTER MOTOR When you press the starter switch, the CPU receives the signal, operating the starter relay and the starter motor. The starter relay is controlled so that it cannot be activated when the engine is running. COMMUNICATION WITH INVERTER The control unit and inverters are constantly communicating during operation, transmitting signals for inverter problem detection and generator output status. When the communication line is disconnected or the inverter breaks down, a fail-safe procedure will be performed. BATTERY CHARGE When the generator is operating, the battery is charged by the inverter with a controlled output of 0.6 A. The charging is stopped when the battery voltage reaches 14.5 V. The charging is also stopped when the battery voltage becomes less than 3 V, assuming the battery terminals are disconnected. 16-24 dummyhead TECHNICAL FEATURES INVERTER UNIT COMPONENT DIAGRAM INVERTER UNIT DUAL GENERATOR MASTER SERIES/PARALLEL SWITCH SCR+ DIODE FET BRIDGE VOLTAGE SELECTOR SWITCH FILTER RECEPTACLE ECO THROTTLE SWITCH ROTATION DETECTION MASTER OUTPUT EEP ROM 32 bit CPU TARGET ROTATION SETUP STATUS TARGET ROTATION SETUP THROTTLE CONTROL MOTOR SLAVE OUTPUT ENGINE GENERATOR CONTROL UNIT GREEN RED SERIAL COMMUNICATION MASTER STATUS STARTER MOTOR SLAVE OUTPUT SCR+ DIODE EEP ROM 32 bit CPU FET BRIDGE FILTER SLAVE STATUS i-MONITOR RED 32 bit CPU EEP ROM SLAVE PRINCIPLE OF OPERATION DUAL VOLTAGE INVERTER Two 3-phase alternators are built in the generator. The inverter unit consists of two inverters, a master and a slave, and it maintains synchronization by having them communicate with each other. You can obtain power at two levels of voltage by connecting the two inverters in series or in parallel. When the inverters are connected in series, you can obtain 120 volt output from either inverter. The output in this case is one half of the rated power. INVERTER V2: 120V V1: 240V INVERTER V3: 120V INVERTER INVERTER V4: 120V Changing output voltage with the voltage selector switch AC OVERLOAD PROTECTION Each of these two inverters is equipped with an over-current protection function. The output indicator (green) is turned on during the normal operation, and if an overload is detected, the overload indicator (red) will be turned on by the output current detector circuit. If the overload lasts 10 seconds or more, the AC output from the generator is shut down in order to protect the generator. When the inverters are connected in series with only one inverter generating output, the over-current protection function operates at about one half of the rated power to shut down AC output. 16-25 dummyhead TECHNICAL FEATURES ECO THROTTLE The Eco Throttle sets the engine speed based upon the engine load factor and temperature. When the inverters are connected in series generating output only from one inverter, the engine speed is controlled based upon the inverter with the high load factor. The 3-phase AC output supplies power for the engine speed control. INVER TER GCU MASTER ENGINE SPEED DETECTION THROTTLE ANGLE COMPUTATION TARGET ROTATION ECO THROTTLE SWIT CH MASTER LOAD FACTOR Choosing higher one SLAVE SLAVE LOAD FACTOR CONTROL MOTOR (THROTTLE SIDE) ENGINE STALL PREVENTION The engine load is detected by the GCU based on the throttle angle and engine speed. When the engine load exceeds engine capacity, the inverter limits the output voltage. This function prevents the reduction of engine speed in order to realize the efficient use of engine power, improving the maximum output and providing enough output to keep up with a heavy load such as an electric motor. COMMUNICATION WITH GCU The communication between the inverter unit and GCU is done via a serial communication line that sends data signals one bit at a time. INVERTER UNIT GCU 5V_GCU DC5V INV_COMN GND_GCU RXD_M M_TXD TXD_M M_RXD RXD_S TXD_S S_TXD S_RXD EXAMPLE OF SERIAL COMMUNICATION: INVERTER UNIT GCU RXD TXD SIGNAL 16-26 dummytext 17. WIRING DIAGRAMS WIRING DIAGRAM (AT TYPE) ···················17-3 WIRING DIAGRAM (CT TYPE)··················· 17-5 WIRING DIAGRAM (AT1 TYPE) ·················17-4 17 17-1 dummyhead WIRING DIAGRAM (AT TYPE) WIRING DIAGRAMS INVERTER UNIT BLOCK CONTROL PANEL BLOCK 4 Bu 22 Gr Gr T6 T12 R R T5 CIRCUIT PROTECTOR W W C17 2 3 30A R W 4 1 2 2 T13 R 3 Bu 1 U AC1_M AC2_M AC1_S AC2_S 4 Bu 1 MAIN_U_M MAIN_V_M MAIN_W_M 2 R W 3 R W PARALLEL OPERATION OUTLETS CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 6 1 GENERATOR BLOCK T4 C16 20 1 Bu Bu NOISE FILTER Bu Bu R R Gr G 21 Bu C15 Bu 4 G Bu Bu 3 Bu T9 T8 T16 T7 W 6 T17 C13 2 T14 T15 2 R 1 R 7 R W C14 20 Bu R GND2 C12 30 Bu Bu 3 R T18 5 INVERTER UNIT STATOR (MASTER) Bu W T19 3 GND1 5 V 6 W R/W NOISE FILTER 1 3 V 3 Bu T10 6 5 Bu/R 4 Bu/Y O/W 3 1 2 W MAIN_U_S MAIN_V_S MAIN_W_S Bu T11 G/Bu 2 5 R STATOR (SLAVE) Bu R G/O 1 5V_GCU RXD_M TXD_M GND_GCU RXD_S TXD_S G GND9 GROUND C11 FRAME BLOCK R ECO-THROTTLE SWITCH R/W C10 1 Bu NOISE FILTER 5 Bu 5 Bu U 3 R W 1 R W 3 W V 1 20 R W 19 2 Bl 1 Bl/G IGN+ IGN- 18 Bu/Y O/W G/Bu G/O Bl 7 Bl Bl/G 8 Bl/G 21 18 27 32 31 28 33 16 17 15 14 W W 6 W R R 5 R Y Y Bu Bu Y/Bu Y/Bu 2 Y 1 Bu 3 Y/Bu Y Y 4 Y Bl 2 Y/R Y/Bl W Y 1 R 4 Bu Bl/W Y/R Bl/W 7 Bl 3 Y/R 8 2 Bl 13 Br/Y Y/Bl 4 Y/Bl G/O 9 W Y G/O R Br/Bu Bu W/Bu Bl/W G/Bu Bl/Y W/G G G 7 Y 11 12 10 5 W 6 R 10 Bl/Y 29 20 3 1 G 5 9 Bl/W 6 8 Bu G 3 Bl/Y DC5V M_TXD M_RXD INV_COMN S_TXD S_RXD N.C. N.C. N.C. TH(A) TH(/A) TH(B) TH(/B) PC+ O/A O2 SENSOR TH+ THINJ(+) INJ(-) FFP(+) FFP(-) STMAG STMAG BAT_IN STMAG(+12V) STMAG(+12V) MAIN_SW+ MAIN_SWPL(REM) PUSH_SW2 GND GND PUSH SW1 GCU OUTPUT OVERLOAD CHECK/OIL ALERT LCD 23 24 22 26 25 30 R Bu/R STARTER SWITCH FREE PUSH 17 4 Br/W 3 Bu/Y 2 Bu/R 1 Bl/Y Bl G BAT_IN RXD TXD GND MAIN SWITCH MAINSW1 MAINSW2 16 BAT ACC ON 2 G Bu/R DLC 1 T3 OFF 4 Bu/Y 3 G Bl Br/W 15 Bl/Y 2 Bl/Y Bl GROUND TERMINAL 14 8 G 6 2 G/Bu 8 2 1 5 G Bl Br/Bu 11 2 1 C9 GND3 GND4 GND6 FUSE BOX Bl 2 Br/Y SPARK PLUG G 1 3A 15A G/O G/O G/O G/O Br/W Bl/Y 4 THROTTLE CONTROL MOTOR EBT SENSOR CKP SENSOR OIL O2 SENSOR LEVEL SWITCH FUEL INJECTOR Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray 13 Br/Bu 3 BB Bl/Y IGNITION COIL Bl T1 Br/Bu AA REMOTE 1 Bl Bl Bl/W R Bu Y W 10 C4 3 W W/Bu C8 Bl Bl C7 Bu 1 Y 4 W 2 Y Bu Y R Bu W C2 R Bl Bl/G C1 9 OFF G W/G C5 ON G GND7 1 C3 ECO-THROTTLE SWITCH STARTER SWITCH G Y/Bl Y/R Bl Y Y/Bu BATTERY G 1 G GND5 T2 Bl W R 3 2 ECO SW HZ GND 1 W Bu U MAIN_SW2 MAIN_SW1 ACC BAT MAIN SWITCH FUEL PUMP STARTER MOTOR GROUND GROUND GROUND G GND8 ENGINE BLOCK 17-3 dummyhead WIRING DIAGRAM (AT1 TYPE) INVERTER UNIT BLOCK CONTROL PANEL BLOCK 4 Bu 22 Gr Gr C17 T6 T12 R R Bu Bu 20 C16 R T24 R W W T17 W Bu T4 GFCI GFCI Bu R 5 Bu NOISE FILTER Gr 3 GND1 6 V T19 T18 1 Bu W 30A T5 CIRCUIT PROTECTOR W 2 3 R W 4 1 2 2 T13 R 3 Bu 1 U AC1_M AC2_M AC1_S AC2_S 4 Bu 1 MAIN_U_M MAIN_V_M MAIN_W_M 2 R W 3 R W PARALLEL OPERATION OUTLETS CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 6 1 GENERATOR BLOCK G 21 Bu C15 Bu 4 G T14 Bu T9 T8 2 T15 3 W 6 T7 2 C13 3 R 1 R 3 2 ECO SW HZ GND Bu 3 Bu 6 T11 Bu T10 5 4 Bu/Y O/W 3 MAIN_U_S MAIN_V_S MAIN_W_S Bu R Bu/R G/Bu 2 1 2 W Bu G/O 1 5 R STATOR (SLAVE) C12 NOISE FILTER 3 V 5V_GCU RXD_M TXD_M GND_GCU RXD_S TXD_S 30 R/W 1 W Bu W Bu Bu R 1 R R W C14 Bu R GND2 7 U 20 5 INVERTER UNIT STATOR (MASTER) G GND9 GROUND C11 FRAME BLOCK R ECO-THROTTLE SWITCH R/W C10 1 Bu NOISE FILTER 5 Bu 5 Bu U 3 R W 1 R W 3 W V 1 20 R W 19 2 Bl 1 Bl/G IGN+ IGN- 18 Bu/Y O/W G/Bu G/O Bl 7 Bl Bl/G 8 Bl/G 21 18 27 32 31 28 33 16 17 15 14 W W 6 W R R 5 R Y Y Bu Bu Y/Bu Y/Bu 2 Y 1 Bu 3 Y/Bu Y Y 4 Y Bl 2 Y/R Y/Bl W Y 1 R 4 Bu Bl/W Y/R Bl/W 7 Bl 3 Y/R 8 2 Bl 13 Br/Y Y/Bl 4 Y/Bl G/O 9 W Y G/O R Br/Bu Bu W/Bu Bl/W G/Bu Bl/Y W/G G G 7 Y 11 12 10 5 W 6 R 10 Bl/Y 29 20 3 1 G 5 9 Bl/W 6 8 Bu G 3 Bl/Y DC5V M_TXD M_RXD INV_COMN S_TXD S_RXD N.C. N.C. N.C. TH(A) TH(/A) TH(B) TH(/B) PC+ O/A O2 SENSOR TH+ THINJ(+) INJ(-) FFP(+) FFP(-) STMAG STMAG BAT_IN STMAG(+12V) STMAG(+12V) MAIN_SW+ MAIN_SWPL(REM) PUSH_SW2 GND GND PUSH SW1 GCU OUTPUT OVERLOAD CHECK/OIL ALERT LCD 23 24 22 26 25 30 R Bu/R STARTER SWITCH FREE PUSH 17 4 Br/W 3 Bu/Y 2 Bu/R 1 Bl/Y Bl G BAT_IN RXD TXD GND MAIN SWITCH MAINSW1 MAINSW2 16 ON 2 G Bu/R DLC 1 T3 OFF 4 Bu/Y 3 G Bl Br/W 15 Bl/Y 2 Bl/Y Bl GROUND TERMINAL 14 8 G 6 2 G/Bu 8 2 1 5 G Bl Br/Bu 11 2 1 C9 T1 GND3 GND4 GND6 FUSE BOX 13 Br/Bu Bl 2 Br/Y IGNITION COIL SPARK PLUG ENGINE BLOCK 17-4 3A 15A G/O G/O G/O G/O G Br/W Bl/Y 4 Bl/Y 1 BB Br/Bu 3 AA THROTTLE CONTROL MOTOR EBT SENSOR CKP SENSOR OIL O2 SENSOR LEVEL SWITCH FUEL INJECTOR REMOTE 1 Bl Bl Bl/W R Bu Y W 10 C4 3 W W/Bu C8 Bl Bl Bl C7 Bu 1 Y 4 W 2 Y Bu Y R Bu W C2 R Bl Bl/G C1 9 FUEL PUMP STARTER MOTOR OFF G W/G C5 ON G GND7 1 C3 ECO-THROTTLE SWITCH STARTER SWITCH G Y/Bl Y/R Bl Y Y/Bu BATTERY G 1 G GND5 T2 GROUND GROUND GROUND G GND8 MAIN_SW2 MAIN_SW1 ACC BAT MAIN SWITCH Bl Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray BAT ACC dummyhead WIRING DIAGRAM (CT TYPE) INVERTER UNIT BLOCK CONTROL PANEL BLOCK CIRCUIT PROTECTOR 4 1 T23 R 29A VOLTAGE SELECTOR SWITCH T6 T22 R R T5 3 R CIRCUIT PROTECTOR 22 Gr Gr 4 T20 Bu Bu Bu C17 20 C16 T19 Bu NOISE FILTER Bu Bu R R GND12 W T13 Gr 30A T4 GND11 Bu T12 3 GND1 5 V 6 W CIRCUIT PROTECTOR T18 1 T21 W GND13 W G Bu G W W 4 2 3 AC1_M AC2_M AC1_S AC2_S 2 1 W Bu 2 W Bu 1 U MAIN_U_M MAIN_V_M MAIN_W_M 1 R 3 R G 6 PARALLEL OPERATION OUTLETS 2 GENERATOR BLOCK G 21 Bu C15 Bu 4 G W R T17 6 3 C13 30 Bu T9 T8 T15 T16 T7 C12 W 1 R 2 R T14 Bu 2 GND2 7 R W C14 Bu R Bu Bu 3 R 20 5 INVERTER UNIT STATOR (MASTER) 1 R 3 2 ECO SW HZ GND W W W R/W 1 W Bu U Bu 3 MAIN_U_S MAIN_V_S MAIN_W_S 6 T10 5 GND14 4 Bu/Y O/W 3 1 2 W Bu T11 0.5A Bu/R G/Bu 2 R STATOR (SLAVE) R Bu G/O 1 5V_GCU RXD_M TXD_M GND_GCU RXD_S TXD_S 5 W V G G GND10 C11 FRAME BLOCK R ECO-THROTTLE SWITCH R/W C10 1 W Bu Bu 5 Bu NOISE FILTER 5 W 3 W U 3 R 1 R V 1 20 R W 19 2 Bl 1 Bl/G IGN+ IGN- 18 Bu/R Bu/Y O/W G/Bu G/O Bl 7 Bl Bl/G 8 Bl/G 21 18 27 32 31 28 33 16 17 15 14 W W 6 W R R 5 R Y Y 2 Y Bu Bu Y/Bu Y/Bu 1 Bu 3 Y/Bu Y Y 4 Y Bl 2 Y/R Y/Bl W Y 1 R 4 Bu Bl/W Bl/W Br/Y 7 Bl Y/R Y/Bl 4 13 3 8 2 Bl Y/R Y/Bl G/O 9 W Y G/O R Br/Bu Bu W/Bu Bl/W G/Bu Bl/Y W/G G G 7 Y 11 12 10 5 W 6 R 10 Bl/Y 29 20 3 1 G 5 9 Bl/W 6 8 Bu G 3 Bl/Y DC5V M_TXD M_RXD INV_COMN S_TXD S_RXD N.C. N.C. N.C. TH(A) TH(/A) TH(B) TH(/B) PC+ O/A O2 SENSOR TH+ THINJ(+) INJ(-) FFP(+) FFP(-) STMAG STMAG BAT_IN STMAG(+12V) STMAG(+12V) MAIN_SW+ MAIN_SWPL(REM) PUSH_SW2 GND GND PUSH SW1 GCU OUTPUT OVERLOAD CHECK/OIL ALERT LCD 23 24 22 26 25 30 R STARTER SWITCH FREE PUSH 17 4 Br/W 3 Bu/Y 2 Bu/R 1 Bl/Y Bl G BAT_IN RXD TXD GND MAIN SWITCH MAINSW1 MAINSW2 16 BAT ACC ON 2 G Bu/R DLC 1 T3 OFF Br/W 3 4 G G 4 Bu/Y R 15 R 2 Bl/Y W 1 G 1 G 14 12 8 G W/G 6 1 2 G/Bu 8 2 1 5 R Br/Bu 11 2 1 C9 GND3 GND4 GND6 FUSE BOX SPARK PLUG THROTTLE CONTROL MOTOR EBT SENSOR CKP SENSOR OIL O2 SENSOR LEVEL SWITCH FUEL INJECTOR Black Br Brown Y Yellow O Orange Bu Blue Lb Light blue G Green Lg Light green R Red P Pink W White Gr Gray 13 Bl 2 G Br/Bu 1 3A 15A G/O G/O G/O G/O Br/W 3 Br/Y Bl/Y 4 BB Bl/Y IGNITION COIL Bl T1 Br/Bu AA REMOTE 1 R G G Bl Bl Bl/W R Bu Y W 10 C4 3 W W/Bu C8 Bl Bl C7 Bu 1 Y 4 W 2 Y Bu Y R Bu W C2 R Bl Bl/G C1 9 OFF G R R Bl GROUND TERMINAL 2 C5 ON G GND7 1 C3 ECO-THROTTLE SWITCH STARTER SWITCH G Y/Bl Y/R Bl Y Y/Bu BATTERY Bl/Y 2 R GND5 T2 Bl W 3 BREATER HEATER FUEL PUMP STARTER MOTOR GROUND GROUND GROUND G MAIN_SW2 MAIN_SW1 ACC BAT MAIN SWITCH GND8 ENGINE BLOCK 17-5 dummyhead MEMO INDEX dummytext INDEX AIR CLEANER CHECK/CLEANING/REPLACEMENT ···3-6 AIR CLEANER REMOVAL/INSTALLATION ·················6-13 BATTERY CHARGING ·················································7-16 BATTERY INSPECTION···············································7-16 BATTERY REMOVAL/INSTALLATION ··························7-9 BEARING/OIL SEAL REPLACEMENT ·······················14-12 BREATHER HEATER INSPECTION (CT TYPE ONLY) ·····················································6-22 BREATHER HEATER REMOVAL/INSTALLATION (CT TYPE ONLY) ·····················································6-19 BRUSH REPLACEMENT··············································9-18 CABLE/HARNESS ROUTING ········································2-8 CHARGING SYSTEM TROUBLESHOOTING················7-8 CIRCUIT PROTECTOR INSPECTION ·························10-8 CKP SENSOR AIR GAP ADJUSTMENT························8-8 CKP SENSOR INSPECTION··········································8-9 CKP SENSOR REMOVAL/INSTALLATION ···················8-7 COMBUSTION CHAMBER CLEANING ·······················3-12 CONTROL PANEL DISASSEMBLY/ASSEMBLY ·········10-3 CONTROL PANEL REMOVAL/INSTALLATION···········10-2 COOLING FAN REMOVAL/INSTALLATION ················7-13 CRANKCASE COVER REMOVAL/INSTALLATION·····14-2 CRANKSHAFT/CAMSHAFT/BALANCER WEIGHT/ PISTON REMOVAL/INSTALLATION ·······················14-3 CYLINDER BLOCK INSPECTION································14-5 CYLINDER HEAD DISASSEMBLY/ASSEMBLY ··········13-4 CYLINDER HEAD REMOVAL/INSTALLATION············13-3 CYLINDER HEAD/VALVES INSPECTION ···················13-5 DIMENSIONAL DRAWINGS···········································1-5 EBT SENSOR INSPECTION ········································6-22 EBT SENSOR REMOVAL/INSTALLATION··················6-19 ECO-THROTTLE SWITCH INSPECTION ····················10-7 ENGINE OIL LEVEL CHECK/CHANGE ·························3-4 ENGINE STANDARD TROUBLESHOOTING ················4-2 EVAP CANISTER REMOVAL/INSTALLATION (AT, AT1 TYPE ONLY) ·············································6-14 EVAP CANISTER/EVAP CHARGE TUBE/EVAP PURGE TUBE INSPECTION (AT, AT1 TYPE ONLY)3-7 FAN COVER REMOVAL/INSTALLATION ····················7-12 FLYWHEEL INSTALLATION ········································9-10 FLYWHEEL REMOVAL ················································9-10 FRAME BOTTOM RUBBERS REMOVAL/ INSTALLATION ························································12-5 FRONT COVER REMOVAL/INSTALLATION·················5-5 FRONT FRAME REMOVAL/INSTALLATION ···············7-11 FUEL FEED HOSE CHECK··········································3-14 FUEL INJECTOR INSPECTION ···································6-21 FUEL INJECTOR REMOVAL/INSTALLATION·············6-15 FUEL INJECTOR SYSTEM TROUBLESHOOTING ·······6-4 FUEL LINE INSPECTION ·············································6-20 FUEL PRESSURE RELIEVING ······································6-6 FUEL PUMP FILTER CHANGE····································3-13 FUEL PUMP INSPECTION···········································6-21 FUEL PUMP SYSTEM TROUBLESHOOTING···············6-2 FUEL PUMP UNIT REMOVAL/INSTALLATION ·············6-9 FUEL TANK CAP REMOVAL/INSTALLATION (AT, AT1 TYPE ONLY) ·············································6-12 FUEL TANK CLEANING ···············································3-12 FUEL TANK DISASSEMBLY/ASSEMBLY····················6-11 FUEL TANK REMOVAL/INSTALLATION ·····················6-10 GCU INSPECTION ·······················································10-9 GENERATOR REMOVAL/INSTALLATION ··················7-14 GENERATOR TROUBLESHOOTING ····························7-2 GENERATOR/ENGINE REMOVAL/INSTALLATION ···12-2 GFCI OPERATION (AT1 TYPE ONLY) ··························3-8 A B C D E F G HANDLE DISASSEMBLY/ASSEMBLY ························ 15-4 HANDLE REMOVAL/INSTALLATION ·························· 15-3 HEAD COVER LOWER SHROUD REMOVAL/ INSTALLATION························································ 13-2 HEAD COVER SHROUD REMOVAL/INSTALLATION ·· 5-7 IGNITION COIL INSPECTION ······································· 8-9 IGNITION COIL REMOVAL/INSTALLATION ················· 8-6 IGNITION SYSTEM ···················································· 16-22 IGNITION SYSTEM TROUBLESHOOTING··················· 8-2 INNER MUFFLER PROTECTOR REMOVAL/ INSTALLATION·························································· 9-9 INVERTER UNIT ························································ 16-25 INVERTER UNIT INSPECTION ··································· 7-18 INVERTER UNIT REMOVAL/INSTALLATION ············· 7-10 LUBRICATION & SEAL POINTS···································· 2-6 MAIN SWITCH INSPECTION······································· 10-6 MAINTENANCE COVER REMOVAL/INSTALLATION··· 5-2 MAINTENANCE SCHEDULE ········································· 3-2 MAINTENANCE STANDARDS ······································ 2-2 MUFFLER REMOVAL/INSTALLATION························ 11-2 O2 SENSOR REMOVAL/INSTALLATION···················· 6-18 OIL LEVEL SWITCH INSPECTION······························ 8-10 OTHER GCU OPERATION ········································ 16-23 PERFORMANCE CURVES············································ 1-4 PGM-FI (PROGRAMMED-FUEL INJECTION) SYSTEM ·································································· 16-2 PISTON DISASSEMBLY/ASSEMBLY·························· 14-4 REAR COVER/OUTER MUFFLER PROTECTOR REMOVAL/INSTALLATION ······································· 5-6 RECOIL STARTER DISASSEMBLY/ASSEMBLY········ 9-11 RECOIL STARTER INSPECTION································ 9-14 RECOIL STARTER REMOVAL/INSTALLATION ··········· 9-6 RIGHT SIDE SHROUD REMOVAL/INSTALLATION ····· 5-3 SELF-DIAGNOSTIC TROUBLESHOOTING ·················· 4-9 SERIAL NUMBER LOCATION ······································· 1-2 SPARK ARRESTER CLEANING·································· 3-10 SPARK PLUG CAP INSPECTION ······························· 8-10 SPARK PLUG CHECK/ADJUSTMENT/ REPLACEMENT ························································ 3-9 SPARK TEST ································································· 8-8 SPECIFICATIONS·························································· 1-2 STARTER MOTOR DISASSEMBLY/ASSEMBLY········ 9-15 STARTER MOTOR INSPECTION································ 9-16 STARTER MOTOR REMOVAL/INSTALLATION ··········· 9-8 STARTER SWITCH INSPECTION······························· 10-9 STARTING SYSTEM TROUBLESHOOTING················· 9-2 STATOR INSPECTION ················································ 7-17 THROTTLE BODY DISASSEMBLY/ASSEMBLY········· 6-17 THROTTLE BODY REMOVAL/INSTALLATION ·········· 6-16 THROTTLE CONTROL MOTOR INSPECTION··········· 6-21 TOOLS ··········································································· 2-6 TORQUE VALUES ························································· 2-3 TUBE ROUTING··························································· 2-24 UNDER COVER REMOVAL/INSTALLATION ················ 5-4 UNDER SHROUD REMOVAL/INSTALLATION ··········· 12-4 UPPER SHROUD REMOVAL/INSTALLATION·············· 9-7 VALVE CLEARANCE CHECK/ADJUSTMENT ············ 3-10 VALVE GUIDE REAMING ············································ 13-9 VALVE GUIDE REPLACEMENT·································· 13-8 VALVE SEAT RECONDITIONING ····························· 13-10 VOLTAGE SELECTOR SWITCH INSPECTION ·········· 10-7 WHEEL/STAND REMOVAL/INSTALLATION··············· 15-2 WIRING DIAGRAM (AT TYPE) ···································· 17-3 WIRING DIAGRAM (AT1 TYPE) ·································· 17-4 WIRING DIAGRAM (CT TYPE) ···································· 17-5 H I L M O P R S 18 T U V W 18-1 dummytext MEMO