DiagnosticsYamaha Ef4500ise (001 218)

YAMAHA GENERATOR
THEORY & DIAGNOSTICS

GUIDE
Downloaded from www.Manualslib.com manuals search engine

2009
Yamaha Generator Theory and Diagnostics Guide
©2008 by Yamaha Motor Corporation, U.S.A.
December 2008
All rights reserved. Any reprinting

or unauthorized use
without written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
Specifications, features and options are subject to
change without notice.
08-1169

TABLE OF CONTENTS
GENERATOR INFORMATION AND THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1

Importance of Warranty Registrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Gasoline, Ethanol, Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Yamaha Inverter and Conventional Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
AC Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
12 Volt DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Voltage and Frequency Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Yamaha Generator Inverter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Model Name Clarification YG/EF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Model Introduction Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Extension Cord Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
High Altitude Jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Special Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
GENERATOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2
CONVENTIONAL GENERATOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Determining if a Problem is Generator or Engine Related . . . . . . . . . . . . . . . . . . . . . 2-1
THEORY FOR NON-AVR TYPE GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
THEORY FOR AVR TYPE GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
AVR TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
NON-AVR TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
TROUBLESHOOTING YAMAHA INVERTER GENERATORS . . . . . . . . . . . . . . . . . . . . 2-18
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Electric Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Choke Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
CURRENT MODEL SPECIFICATIONS AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . Section 3
CONSUMER SERIES GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inverter EF1000iS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inverter EF2400iS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Inverter EF2800i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Conventional EF2600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Inverter EF3000iSE / B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Conventional EF4000DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Inverter EF4500iSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Inverter EF6300iSDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Conventional EF12000DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
INDUSTRIAL SERIES GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Inverter YG2800i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Conventional YG4000D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
Conventional YG6600DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

Generator Information and Theory
GENERATOR INFORMATION AND THEORY Inverter generators differ from conventional genera-
tors in many ways. Inverter generators (Yamaha
Introduction models with Smart Throttle) do not rely on rpm to
control frequency (Hz). A highly specialized control
The purpose of this manual is to provide training
unit manages functions such as AC power modifica-
and information for Yamaha dealers who may not be
tion, rpm, circuit breaker protection, overload warn-
familiar with Yamaha Generators. It will help build a
ing, and electrical output. Inverters do not need to
better understanding of how Yamaha Generators
run at 3,600 rpm as most use a 3-phase multi-pole
work, basic troubleshooting techniques, and tips for
stator. The inverter can produce more electricity with
dealership personnel.
fewer revolutions versus a single-phase conven-
tional generator. Typically, multi-pole coils work in
The Importance of Warranty Registration
conjunction with numerous permanent magnets to
It is important to warranty register every applicable produce higher output at a lower rpm. Less revolu-
Yamaha product sold by your dealership. It is essen- tions means higher fuel economy at lower outputs
tial for customer satisfaction and insures your cus- and quieter operation.
tomer can receive warranty service from an
Inverter generators also provide very stable and
authorized Yamaha dealer should the need arise.
clean power. The AC power produced by the multi-
Furthermore, warranty repairs performed on a
pole coil is rectified into DC power – the control unit
unit not warranty registered, will not be consid-
then inverts the DC power back into AC power. This
ered for reimbursement. Warranty registrations
final inversion creates clean, high-quality electricity.
also assist Yamaha with contact information in the
In most cases, the electricity produced by a Yamaha
event of a recall or safety related issue.
Inverter Generator is cleaner than most commercial/
Gasoline, Ethanol, Propane residential power.
All models of Yamaha generators run on regular

gasoline. Up to 10% ethanol is acceptable for run-
ning conditions. However, ethanol tends to attract
moisture which will lead to poor performance, so it
should not be used when storing a generator for
more than a few days.
Currently, there are no propane conversion kits
available that Yamaha Motor Corporation, U.S.A.
supports. Further, Yamaha recommends against the
use of any aftermarket generator propane conver-
sion kits. *
Yamaha Inverter and Conventional Generators
The AC power created by conventional generators is
known as “raw” power. The electricity produced by HIGH QUALITY
the stator (coils) and rotor (magnets) is delivered to AC
the outlet without modification of the AC sine wave.

In addition, conventional generators must run at
3,600 rpm in order to maintain the required 60 Hz
cycle. The power generated by a conventional gen- *PWM: Pulse Width Modulation is very clean and
erator depends on a constant engine speed. Any stable output with a waveform distortion ratio of
fluctuation of rpm will create peaks (spikes) and val- 2.5% or less. This low distortion ratio means the
leys in the AC sine wave. Conventional generators output is cleaner than most commercial / residential
rely on large, heavy stators and rotors, which means power, making it safe to run sensitive computer
a heavier generator. Conventional generators are equipment, televisions, and microchip-controlled
typically less fuel efficient at low output levels power tools.
because they must run at 3,600 rpm at all times.
1-1

Yamaha Generator Theory & Diagnostics Guide
Yamaha inverter generators use a microcomputer-controlled sine wave inverter. Most inverter generators are
in a soundproof case, and designed in response to the diverse needs of the market today.
The Yamaha inverter generator supplies high quality electricity equivalent to household power supply.
NOTE: The EF3000iSE is used in this introduction section for explanation purposes.
Air intake Fuel tank cap Fuel gauge
Recoil starter Control panel Service hatch Exhaust MF Battery Service hatch
Main switch Economy control switch DC output AC receptacles

⎧
⎪
⎨
⎪
⎩
USA specification
Fuel pet cock

Fuel petcock Choke knob Oil warning lamp
Output indicator
Over load indicator
1-2

EF3000iSE new model guide 3/14/03 4:20 PM Page 3
Power Generation ■ Throttle motor (stepping motor)

The throttle motor receives pulses from the con-
Stage 1 The rectifier circuit converts three- phase
trol unit and opens or closes the throttle valve
AC into DC and it maintains stable DC
approximately 0.7° per pulse.
voltage using a constant voltage circuit.
Stage 2 The constant voltage DC current is
stored in a condenser.
Stepping
STEPPING motor
MOTOR
Stage 3 The PWM, Pulse Width Modulator,
inverter circuit generates a stable sine
wave AC current.
Stage 4 The filter circuit further smoothens the
sine wave of the AC current and reduces
electrical noise.
Protective functions:
■ Overload (over current) protection device
The control unit has similar function to conven-
tional NFB (no fuse breaker). When the output
current exceeds a specified amperage, AC out- Functions of the Electronic Governor
put is interrupted. The inverter control unit is preprogrammed with the
ideal engine speed settings in relation to electrical
■ Overheat protection current output. It uses these settings as a cross-ref-
When the internal temperature of the control erence with the detected current output to control
unit becomes abnormally high, AC output is the throttle motor (and consequently the throttle
interrupted. EF3000iSE new model guide 3/14/03
valve)4:20 PM Page
to adjust 4 speed to an optimum level.
engine
Therefore, the engine speed will always be at the
■ Over-voltage protection device appropriate level according to the load on the sys-
AC output is interrupted when excessive current tem.
flows into the generator from an outside power
With an inverter generator, even if the engine
source causing voltage to rise in the control
speed changes it has no effect on the output
unit.
frequency.
Other Functions of the Control Unit: The electronic governor system is maintenance-free
Throttle Control – Control unit commands the throttle as it cannot be adjusted externally.
motor to adjust engine speed automatically in accor-
dance with the amount of the electrical consump-
tion.
THROTTLE
CONTROL
Electronic Governor
An electronic governor takes the place of a conven- ENGINE rpm
DETECTOR
tional mechanical governor, and opens and closes
the carburetor throttle valve electrically.
Components and functions:
■ Inverter control unit
The control unit constantly monitors AC output
and adjusts the throttle motor to produce the
necessary engine speed.
1-3

Engine Control unit
Alternator Recoil starter
Yamaha Generator Theory

Muffler & Diagnostics Guide Battery
AC OUTPUTS Reference information:

There are two levels of output available from Yamaha Ferrite magnets are magnetically stable and have a
generators: strong coercive force and so do not become demag-
netized. While they have excellent corrosion resis-
1. Peak Output (short period of time). tance, they are also brittle due to the way they are
2. Rated Output (continuous duty). produced. Great care must be taken when assem-
bling them as jarring or shocks of force can
In normal operation of course, these levels would adversely affect their efficiency and/or cause
merge. The built-in Thermal or Nonfuse Breakers breakage.
(NFB) are designed to protect against harmful over-
loads, while allowing for these different levels. The
length of time the breaker allows the generator to
produce a particular level without interrupting the
current flow varies. This flexibility permits the gen-
erator to be used for a wide variety of applications:
1. The stated peak output is the amount of cur-
rent that can be utilized for short time periods
before the NFB disconnects the output. This
output levelEF3000iSE
allows fornew model
jobs guideduration,
of short 3/14/03 4:20 PM Page 2
requiring maximum output (tool startup).
2. The rated output is the amount of current the
generator can supply for continuous operation. EF3000iSE/EF3000iSEB
EF3000iSE/EF3000iSEB
12 Volt DC Output
The DC output is intended only to charge a 12-volt Control Unit
battery. If any 12-volt devices should be connected The control unit is a sealed unit.
to a 12V battery and never to the 12V plug on the
generator. It is possible that a device could be dam- Functions:
aged if it is connected directly to a generator. AC power generation
Electronic governor (throttle control)
The DC output is controlled only by the capability, Economy control program
condition, and state of charge of the battery. Self-protective function
Over current
Voltage and Frequency Standards Over voltage
High temperature
In the U.S., standard commercial electricity is deliv-
ered at 110~120 V AC, and 220~240 V AC. The
electrical frequency standard is 60 cycles per sec-
ond (60 Hz).
Multi-pole Alternator Features

Used in Inverter Generators
The combination of ferrite magnets in the rotor and
multi-pole stator provides a compact and high per-
formance alternator.
High-frequency multi-pole alternator features:
16-pole rotor CONTROL UNIT
Control unit
24-pole stator coil
3-phase AC power generation
1-4

Section
Yamaha Generator Inverter System

The control unit and multi-pole alternator cooperate to generate AC output. The inverter, controlled by a 16-bit
microcomputer, is a Pulse WidthControl
Modulation
unit (PWM) sine wave inverter.
1. The generator’s output frequency remains unchanged even when the engine speed varies.
2. The output voltage is stable.
3. The output waveform is a sine wave with a distortion ratio of less than 2.5%, equivalent to household
electricity.
PRINCIPLES OF POWER GENERATION WITH AN INVERTER PORTABLE GENERATOR
*Synchronous Generator — Theory & Troubleshooting
s Generator — Theory & Troubleshooting

*An alternator that uses highly efficient ferrite magnets generates three-phase AC.
• 120V Model: AC 135 to 225V, 300 to 550 Hz
• 230V Model: AC 260 to 488V, 300 to 550Hz Condenser Winding Sine Wave
THEORY FOR DAMPER WINDINGS
For generators with a condensor control

(non AVR), the electricity output is not
a very high quality sine-wave, but does
meet most requirements for "rough use"
power demand.
When the generator begins to get a load
applied, the sine wave is altered by the
load voltage running through the stator and
inducing its own magnetic field, which alters
the path of theCondenser
rotor coil’sWinding
magnetic
CONVENTIONAL Sine Wave
flux.
SINE WAVE Inverter
INVERTER Sine
SINE Wave
WAVE
The altered flux line distorts the output sine.
ontrol
1-5
not
does
"Downloaded from www.Manualslib.com manuals search engine
Resistance 250Ω Terminal: F3-1, 3-5, 3-2, 3-4
500Ω Terminal: 1-5, 2-4
Yamaha Generator Theory & Diagnostics Guide Throttle valve position:
During assembly: Close
During engine starting: Open
Throttle Motor 2. When changes in voltage cannot be accepted.
Caution during resistance measurement: 3. When charging batteries.
Do not allow the lead wire of the tester to touch the
next terminal when measuring the resistance
between terminals.
Caution during assembly:

To prevent damage to the throttle valve when reas-
sembling the carburetor, re-install the carburetor
with the throttle valve fully opened.
If the engine is difficult to start after the carbure-

tor is installed, fully open the throttle valve by
hand and then start the engine.
Economy Control Characteristics
Economy Control Characteristics
of an EF3000iSE/B
Economy switch ON: 2800 rpm (with no load)

Economy switch OFF: 3550 rpm
The engine will run at 2800 rpm with economy
switch turned on, if the electrical consumption is
below 1/4 of its rated output.
When a light and electric motor are connected to the
generator at the same time, turning one of the
Resistance 250Ω Terminal: F3-1, 3-5, 3-2, 3-4 devices on and off causes a change in voltage and
500Ω Terminal: 1-5, 2-4 could have an adverse effect on the other device.
Throttle valve position:
During assembly: Close In these kinds of cases, first turn the economy
During engine starting: Open switch off before use.
Throttle valve operation:
■ The throttle valve is fully opened when the
Economy Control Operation and Features engine is not running.
Because output frequency of an inverter generator ■ When the engine is started with no load, the
is unrelated to the engine speed, it is possible to use throttle valve will be set in an almost completely
a wide range of engine speed. closed position as soon as the engine is started.
(When the economy switch is “ON,” it will be in
It also becomes possible to use low engine speed to
a position to maintain 2800 rpm.)
meet a low electrical consumption.
■ The engine speed will be adjusted according to
The control unit commands the throttle motor built
the requirements of the load on the system.
into the carburetor to control the throttle valve, which
gives it the ability to continuously control the engine ■ The throttle stops at the fully opened position
speed, which in turn makes the economy control when the engine is turned off in order to prepare
system possible. for the next attempt to start the engine.
However, the economy
Economy control
Control switch should be
Characteristics In temperatures of 0° or below, the engine will auto-
turned off in case of the following occasions: matically run at 3550 rpm for three minutes for
warming up purposes, even when the economy
1. When operating an electric motor, such as
control switch is turned ON.
water pump, which requires a large starting cur-
rent.
1-6

e 3/14/03 4:20 PM Page 5
Continuous Running Time The frequency variation of Yamaha inverter gen-

erators is less than 0.1%.
EF3000iSE is able to run for 20.5 hours with 1/4
load with fuel tank full, when economy control switch
is on.
With rated load: 8.0 hours Voltage Variation
With 1/4 load: 20.5 Hours
The output voltage with no load is approximately
Refer to Section 3 for model specific run times and 10% higher than rated voltage for a case of conven-
rated load information. tional synchronous type generators to achieve the
rated voltage when full rated load is connected. Thus
the voltage variation occurs due to the change in
engine speed and the influence of the internal resis-
tance.
However, adapting an inverter system, the voltage
variation can be minimized, because the output volt-
age cannot be influenced directly from engine
speed.
Frequency Variation
Conventional synchronous generators have an
engine speed with no load set at approximately 6%
higher than rated engine speed (3600rpm for 60 Hz)
to maintain rated frequency when full rated load is
applied. This is the reason why no-load frequency is
slightly higher than rated frequency.
However, adapting an inverter system, which gener- The voltage variation of Yamaha inverter genera-
ates genuine sine wave electricity, the frequency tors is smaller than 3%.
variation of an inverter generator is not influenced by
The waveform distortion rate of Yamaha inverter
the engine speed. Therefore, an inverter generator
generators is smaller than 2.5%.
provides constant AC output frequency even if the
load changes which is equivalent quality to the com-
mercial power supplies.
1-7

Instantaneous Frequency Fluctuation & Electronic Breaker

Instantaneous Voltage Drop
As opposed to the non-fuse breaker (NFB) used in
■ Momentary frequency fluctuation: synchronous type generators, Yamaha inverter gen-
The frequency and voltage fluctuates momen- erators use an electronic breaker circuit housed in
tarily when the load is altered if the engine can- the control unit. When output from the control unit
not keep up with the load changes in the case exceeds a specific limit, output is automatically inter-
of conventional synchronous generators. rupted to protect the generator from damage.
The control unit is designed to continuously monitor
In contrast the momentary frequency fluctuation
the output current for overloads, and if the current
of Yamaha inverter generators is as stable as
overload continues longer than a specified time,
the commercial power source with this new
output is interrupted.
inverter system.
Characteristics of Electronic Breaker

When using induction motors or similar devices
The frequency fluctuation rate of Yamaha inverter (such as underwater pumps) which require a large
generators is less than 0.1%. starting current with the generator, the current will
not be interrupted even if the starting current
■ Momentary voltage drop:
exceeds several times the generator’s rated output.
However, the momentary voltage drop occurs,
Only when the large over current continues longer
when large electric load is turned on. This is
than a specified time, the control unit will interrupt
caused by the fact that the electric energy
the circuit, and in this way it resembles a mechani-
stored in the condenser runs short momentarily
cal NFB.
until the engine speed picks up to sufficient
engine speed to compensate the energy short- The engine must be stopped and power interrupted
age in the condenser. The ratio of such momen- to the control unit in order for the system to reset
tary voltage drop and the rated voltage is after the electronic breaker has activated.
defined as momentary voltage drop rate. The
NOTE: If a device’s power switch is ON when it is
momentary voltage drop rate of Yamaha inverter
connected the generator and the generator is sub-
generators is usually less than 20%. Naturally,
sequently started, the device may unexpectedly
the smaller the load capacity is applied, the
activate or start up as a result, creating a potentially
smaller the momentary voltage drop becomes.
dangerous situation.
In case of incandescent lamps, large amounts
of current flow the moment it is switched on. The
rush current may be as large as 10 times the
rated current of the lamp. Therefore, when a
large wattage incandescent lamp(s) are switched
on, the momentary voltage drop is greater.
1-8

Control Panel Output Indicator

Refer to Section 3 for model specific control panel When the generator is running normally and gener-
diagrams. ating power, this indicator is lit green.
When using a device which requires a large starting
Indicators
current, the overload warning light (red) and output
Overload Warning Lamp indicator (green) will temporarily light simultane-
ously. This operation is normal.
During power generation, if a problem occurs with a
connected device, there is an overload, or the After the connected device has started up, the over-
inverter control unit overheats, the electronic breaker load warning light (red) will turn off, while the output
will be activated and interrupt power output to pro- indicator (green) will continue to be lit.
tect the generator and/or connected devices.
■ When the electronic breaker operates:
Oil Warning Lamp
The engine continues to run, but the control unit
stops output As with all Yamaha generators, the engine will shut
The output indicator (green) turns off off automatically when the oil level decreases to a
specified level.
The overload indicator (red) turns on
When this happens and the recoil starter is pulled,
the engine will not start and the oil warning light will
■ When the overload warning light turns on: turn on.
Stop the engine.
Verify the required load of the connected device,
and reduce to the rated load of the generator if
necessary. Verify whether or not there is a prob-
lem with a connected device. (A possible cause
of excessive current drain.)
Check for foreign matter in the cooling air inlet
and areas around the control unit which could
block incoming air.
■ To return the generator to normal output

operation:
Temporarily stopping the engine and re-starting
automatically resets the system to its original
state. (The system cannot be reset unless power
to the control unit is interrupted by stopping the
engine.)
1-9

Ventilation
Be aware of the surroundings where generators are being used. Three (3) feet of clear space is necessary for
safe operation. Adequate ventilation is also necessary, as the generator’s engine needs fresh air for the intake,
Generator
and the exhaust must be safely Rotor
Muffler
vented. Refer to the Owner’s Manual for complete information.
Ass’y cooling
air inlet
Cooling fan
Lubrication System
The engine Flow
unitsof of
cooling air over generator and muffler
all Yamaha conventional and inverter generators use a splash type oiling system.
Cooling System
Control unit
The centrifugal fan equipped on the rotor performs forced air cooling of the system over the path listed below.
Each part of the system is therefore continuously kept at a stable operating temperature with only a single
fan.
Cooling systems will vary from one model to another. The EF3000iSE is shown here as an example. Refer to
the Owner’s or Service Manual for model Cooling
specific information.
air inlets
• Cooling air path
• Control unit cover
• Control unit Intake box
• Alternator Cooling fan Fan case
• Engine (cylinder)
Flow of cooling air over generator and muffler
EF3000iSE
EF3000iSE new model
new model guide
guide 3/14/03 4:20
3/14/03 4:20 PM
PM Page 10
Page 10
• Muffler
Controller
Cooling air inlets
Generator
Generator
Cooling air inlets
RotorAss’y
Rotor cooling
Ass’y cooling
Muffler
Muffler
airinlet
air inlet
Battery Coolingfan
Cooling fan
Muffler Generator cooling air inlet

Generator fan
Recoil starter Flow of
Flow of cooling
cooling air
air over
over generator
generator and
and muffler
muffler
Overall flow of cooling air
– 10 – Controlunit
Control unit
Generator Storage
To prepare a Yamaha generator for storage follow these basic
procedures:
• The carburetor float bowl should be emptied using the
float bowl drain screw located on the float bowl.
• The fuel tank should be full and contain the proper amount Cooling
Cooling
airinlets
air inlets
of a fuel stabilizer.
• The unit should be covered and stored in a cool dry
place. Intakebox
Intake box
• Refer to the Owner’s or Service Manual for complete stor- Coolingfan
Cooling fan Fancase
Fan case
age information.
Flow of
Flow of cooling
cooling air
air over
over generator
generator and
and muffler
muffler
1-10
Controller
Controller

1 Main c
q 2 Sub c
3 DC co
Y Y Y R
4 DC re
DC 12V Output Y Y Y Y Y Y W B
5 Contro
u AC pil
L Br Br
G
L
G
R
O G
R Y L Br
u 6
R Br Br
DC output is provided on Yamaha inverter generators exclusively for battery charging. R
B
R R
R
y 7 AC re
Groun
G R R
Y
R t 8
Rated output: DC 12V ~ 12A (12V ~ 8.3A for Canada) r L
O
R
B
R
B o G/Y 9 Econo
w B R R B
Overlo
L O O L Y
Gy Y Y B/W Y
L O O L Br O O O
B/W
O !0 i
0
e
DC re
B/W
O
O O G/Y q
DC pr
W
BW !1 w
Engin
B
!2 e
Oil wa
B G/Y
B/W B/W B/W B/W

r
G
Y
G
Y
O O O O O
G/Y R/W G/Y B Br
B/W
B t Speed
Oil lev
R
guide 3/14/03 4:20 PM Page 11 @0 R
L
R
L
R
R/W
R O B/W R
Br y
O O
!9
T.C.I.
Y Y
W W
L B/W
!4 OFF
ON
u
R
!7
@2 @4 B/W
L
!3 START
i Spark
B
!8 W
R L Y
O
G/Y
!5 o T.C.I.
Stepp
R
G
L @1 R
R R/W
p
DC-DC
R
B
G/Y L
a
Rectif
R
1 Main coil s
B
R R
G/Y R/W
Batter
R
q 2 Sub coil M @5 !6 d
3 DC coil
@3 f Starte
4 DC rectifier g Starte
Y Y Y R
Y Y Y Y Y Y W B
5 Control unit
u 6 AC pilot light
L Br Br
G
L
G
R
O G
R Y L
u Br
R Br Br
R
B
y 7 AC receptacle
R R
R
8 Ground (Earth) terminal

G R R
Y
t R
L
r 9 Economy control switch
R R
O
o B R R B
B B G/Y
0 Overload indicator light

L O O L Y
Gy Y Y B/W Y
B/W
L O O L
!0 i
Br O O O
O
q DC receptacle
B/W
O
O O G/Y
w DC protector (breaker)
W
BW !1
e Engine switch
B
!2
r Oil warning light
B G/Y
B/W B/W B/W B/W
G
Y
G
Y
O O O
t Speed limiter assenbly
O O
G/Y R/W G/Y B Br
B/W
B
y Oil level gauge

R
@0 R
L
R
L
R
R/W
R O B/W R
Br
O O
!9
u T.C.I. unit
Y Y
W W
!4 L B/W
OFF
ON
!7
@2 @4
!3 i Spark plug L
START
DC 12V circuit is entirely separated from!5AC circuit.

R o T.C.I. magneto
L
B/W
Y
O
!8 W G/Y
Stepping motor
Economy control switch must be turned off while charging apabattery,
R
@1 R R/W
as the engine speed 3550 rpm is required
DC-DC converter
R
B
to generate rated DC-output.

R
B
G/Y
s Rectifier
R R
L
G/Y R/W
d Battery
R
!6
The total electric
M
@5 consumption of both the AC and the DC output should not Rectifier
exceed the total rated output of
@3 f Starter relay
the generator, which is 2800 Va, when both output are used together.
g Starter motor
Rectifier (for DC output)
(~) (–)
(+) (~)
Polarity of rectifier 7VU-87105-00

Rectifier
1-11

(~) (–)
Battery Charging First-aid procedures: If your skin or clothes

come in contact with the electrolyte, wash them
■ Conditions of use of the DC power supply
with a large amount of water immediately. If it
■ Charging a 12V battery enters your eyes, wash with a large amount of
Do not use for other than charging a 12V water and consult the doctor immediately.
battery.
WARNING
The time taken to charge a battery depends on how
• When handling a battery, keep good ventila-
the battery is discharged. Charging is complete
tion and keep electric sparks, like from
when the specific gravity of the battery is 1.26~1.28.
short-circuit, away. Also, keep fire away.
Check the specific gravity in every hour or so.
Explosion might happen because a flamma-
A 40AH battery of a compact car which is half dis- ble gas occurs from the battery.
charged will be almost fully charged in about 3
• The battery electrolyte is diluted sulfuric
hours. Be sure to check the level of the electrolyte.
acid. If it comes in contact with your eyes or
Do not take energy from the battery nor run the skin, the affected part will be burnt. If it
starter when the battery is being charged. This could should happen, wash the part with a large
cause a large current to flow through the generator amount of water for at least 15 minutes and
coil, burning it. consult the doctor immediately.
■ Precautions for charging the battery
WARNING
The battery will produce a flammable gas. The
wrong handling might result in explosion or
serious injuries. Be sure to observe the follow-
ing when charging a battery.
1. Keep fire and electric sparks away. Explosion
might happen.
2. Secure a good ventilation where the battery
is charged. Otherwise, explosion might hap-
pen.
3. Be very careful to handle the electrolyte
(diluted sulfuric acid). It will burn anything,
so keep it away from your eyes, skin and
clothes.
4. Before charging a battery, remove all cords
connected to the battery, doing it first from
the negative side. When reconnecting, do
the positive side first. If you do it incorrectly,
a short-circuit could result.
1-12

EF2800i AC-CDI
The Yamaha EF2800i Inverter generator is the only
generator in the Yamaha line-up to use an AC-CDI.
A CDI unit which uses AC power to charge the con-
denser is referred to as an AC-CDI.
Taking the low voltage power generated by the
charge coil (which is wound around a single stator
core in the multi-polar alternator), a voltage booster
circuit boosts the voltage in the CDI in order to
charge the condenser. In a typical CDI system, volt-
age of approximately 200~400 volts is generated by
the charge coil.
The advantages are the charge coil can be made
both lighter and smaller. Also a heavier wire can be
used for the charge coil to increase its reliability.
An overrun limiter is incorporated into the EF2800i’s
AC-CDI unit.
The ignition spark is regulated to prevent engine
speed overrun when the engine speed exceeds
4500 rpm.
A new oil warning system was designed to match
the new CDI system, while maintaining the same
function of the conventional oil warning system.
1-13

The EF1000iS
Exclusive to the EF1000iS, the double-coil system is
a unique design that adds to the main coil a second
coil specifically for running at lower rpm. Increasing
the number of coils in this second low-speed coil
enables it to generate optimum electricity when the
engine is running at lower rpm. When the engine
rpm increases, however, these extra coils become
unwanted resistance that reduced generating effi-
ciency. Thus, a system has been adopted that auto-
matically selects the right coil in relation to the
engine rpm; the low speed coil becomes the main
generating coil at low rpm and the main coil from
middle to high rpm. This is a Yamaha-exclusive tech-
nology that might be called a dual-stage system to
accommodate low and middle range rpm. The result
is a generating system that can provide optimum
electricity supply that is stable even at low rpm and
thus run with less noise and better fuel economy.
EF1000iS
1-14

Power Boost Technology

EF3000iSEB is equipped with a DC-DC converter, which supplies supplemental electric current to the inverter
control unit to boost up the generator output by an additional 500 watts for maximum 10 seconds. This feature
Control Unit
is exclusive on the EF3000iSEB.
Control Unit
DC-DC Converter (Power Boost Technology)

The DC-DC converter is an electrical device to step
up DC voltage. The EF3000iSEB DC-DC converter
steps up the battery voltage from 12 volts to 190
volts.
DC-DC converter is automatically activated to
increase generator output when the AC output cur-
rent exceeds 20 amps and the voltage at the con-
denser inside the control unit drops down to below
190 volts.
The power source is a 12-V battery installed in the
generator to operate the starter motor. DC-DC con- DC-DC converter
verter works for maximum 10 seconds, only when a
DC-DC converter
large amount of starting current is needed and
increases maximum output of generator from 3000
VA to 3200 VA temporarily.
Specifications of DC-DC converter
1. DC input 12V Battery
2. DC output DC190V
3. Rated DC current 2.53 A
1-15
– 14 – – 14 –
Yamaha Generator
3/14/03 4:20 PM Theory
EF3000iSE new model guide Page 15 & Diagnostics Guide
Overload Indicator Lamp:
The DC-DC converter is turned on automatically,
when the generator output exceeds over 180% of its
rated load to boost generator output to assist the
starting current of the load, such as an air condi-
tioner.
When the DC-DC converter is turned on automati-
cally, the generator is obviously overloaded, thus the
overload indicator lamp blinks quickly with 0.5-sec-
ond interval for 10 seconds. And the lamp blinks
slowly with 1-second interval for 3 minutes and 50
seconds. During this period, the DC-DC converter is
prevented from rebooting to prevent the battery from
over-discharged.
Designation of LED Indicators:

DC-DC converter unit is equipped with two indicator lamps (LED) on the unit. When the DC-DC converter is
activated automatically, indicator lamps are lit or blink to designate the state of the system. The designations
of indicator lamps are listed in the table below.
⎫
⎪
⎪
⎪
⎪
⎬
⎪
⎪
⎪
⎪
⎭
Green LED Red LED Designation

ON OFF Standby mode
Blink OFF Output (for 10 seconds maximum)
OFF Blink For 10 seconds after shutdown
OFF ON Alarm mode
⎫
⎪
⎪
⎪
⎪
⎬
⎪
⎪
⎪
⎪
⎭
Green LED Red LED Designation

ON OFF Standby mode
Blink OFF Output (for 10 seconds maximum)
OFF Blink For 10 seconds after shutdown
OFF ON Alarm mode
NOTE: The red LED turns ON and interrupts DC-DC converter output automatically to protect the component,
when any of the abnormal operating conditions is detected, and returns to normal operation automatically as
soon as the abnormality is recovered.
Abnormal conditions are:
1. Too high temperature in the component
2. Too low battery voltage, below 9.5V
3. Too high battery voltage, over 18V
1-16

TCI Ignition System

TCI ignition system is equipped with a speed limiter
function.
Speed limiter: 4500 rpm
Oil Warning System

The oil-warning unit is built in the speed limiter unit.
The oil-warning switch is installed in the crankcase.
When the engine oil level drops below the specified
level, the ignition system is grounded and the engine
will be automatically stopped. This function prevents
the engine from serious damage.
The oil-warning lamp turns on by attempting to start
the engine so as to warn the operator that the
engine oil should be replaced or refilled.
The ignition coil and TCI unit is a single built-in unit,

while the speed limiter unit is a separate component
installed in the control box.
1-17

Auto-decompression System Muffler Cleaning

All Yamaha EF3000iSE
generators new
are equipped with an
model guide auto- 4:201. PMTurn
3/14/03 the 23
Page engine switch to the “STOP” position to
decompression system to facilitate engine starting stop the engine.
operation.
2. Loosen the bolt ① and remove the muffler cap
While the engine is stationary or running at very low and muffler screen.
guide 3/14/03speed,
4:20 PMa pinPage
provided
18 in the camshaft is projected
above the basic circle of exhaust cam lobe.
The pin, consequently, pushes the valve lifter caus-
ing the exhaust valve to stay open, thus compres-
sion pressure is released.
When the engine speed becomes faster, the decom-
pression weight, which holds the pin in the position,
is thrown out and the pin moves back, thus the
engine can be started as the exhaust valve func-
tions normally. 1
1
3. Remove the carbon deposits on the muffler cap
②, the muffler screen ③ and the spark arrester
2
④ using a wire brush.
3
42
3
4
4. Install the muffler screen ③, the muffler cap ②

and the spark arrester ④.
1-18

Battery Initial Charging Procedure
1. Cases in which Charging of a New Battery is Required (Initial Charging)
Although the Sealed Motorcycle MF Battery can be used after it is filled with electrolyte, it may not be able
to start a motor in cases like those indicated in the table below. In such cases, perform initial charging
before using the battery. Furthermore, initial charging is not required if the terminal voltage (*1) ten minutes
after filling with electrolyte is not less than 12.5V.
2. Initial Charging Procedure

Although the procedure for initial charging of the Sealed Motorcycle MF Battery is based on the charging
procedure indicated on the top of the battery, it is recommended to determine the duration of initial charg-
ing based on the terminal voltage.
YT4L-BS
NOTE:
a. Terminal Voltage
Use a digital voltmeter (or voltmeter of class 1 accuracy or better) to mea-
sure battery terminal voltage. Continue to measure terminal voltage in the
same manner.
b. Standard Current Charging Time
Set the standard current to the current value indicated as the standard
charging current on the top of the battery.
If the terminal voltage is less than 11.5V, internal resistance may be high
due to long-term storage, charge the battery by following the procedure.
It is necessary to adjust the voltmeter so that the standard current flows
after five minutes. Charging a battery that has become excessively discharged to less than a battery ter-
minal voltage of 11.5V charging may not be possible at the normal charging voltage (16~17V) due to high
internal resistance. In such cases, initially increase the charging voltage (maximum 25V), and then charge
for about 5 minutes. (The battery must be replaced if there is no change in the voltmeter reading (A) after
5 minutes.) Since excessively high current will flow once the current begins to flow, always make sure to
adjust the voltage of the charger so as not to exceed the standard current. This initial charging procedure
can be performed automatically by using the Yuasa MF Battery Charger (such as model PS1512).
3. Assessing Battery Performance After Initial Charging
Assessment of battery performance following charging of the Sealed Motorcycle MF Battery should be
made by measuring battery terminal voltage after allowing the battery to stand for about 30 minutes fol-
lowing completion of charging.
NOTE: Use of the Yuasa Model BM-310 Battery

Tester lets you make a more accurate assess-
ment of battery performance.
1-19

No Fuse Breaker (NFB)

WARNING
Sometimes called a Non Fuse Breaker, this device
acts like a fuse to interrupt power in the event of a Electrocution, severe personal injury or death
sudden spike or surge in current. Unlike a fuse, how- can occur: Do not connect any generator to any
ever, the NFB can be reset. building’s electrical system unless an isolation
switch has been installed by a licensed electri-
Electronic Breaker
cian. Refer to the Generator Owner's Manual.
An electronic circuit breaker automatically cuts off
the current when the output voltage exceeds the
maximum capacity.
Property damage can occur: Do not connect any
Smart-Throttle generator to any building's electrical system
Because output frequency of an Inverter Generator unless an isolation switch has been installed by
is unrelated to engine rpm it becomes possible to a licensed electrician. Refer to the Generator
utilize a wide range of engine rpm. This feature Owner's Manual.
helps quiet running by choosing the minimum
engine rpm necessary for the actual electrical load.
A double coil system such as on the EF1000iS Take It Step-By-Step
makes possible a higher output even at a low rpm
Follow these steps when determining your energy
setting. Smart Throttle ONLY applies to inverter
needs:
models that have an electronic throttle servo motor
to control engine speed. 1. Identify the wattage requirements for the tools
and appliances that you want to power. The
Economy Control (also called Economy Idle)
power requirements for the tool or appliance are
Conventional generators, and in some cases inverter
found on its identification plate or in the Owner's
generators use economy control / idle. This function
Manual. If the power requirement is given in
causes the unit to idle down when a load is not pres-
amps, multiply the amps times volts to derive
ent.
the required watts.
Ground Fault Interruption (GFI) Amps x Volts = Watts
Shuts down the power when a fault to ground is
2. Add up the required watts of all the tools and
detected. A device that interrupts the power flowing
appliances you expect to operate simultane-
through a GFI receptacle when a proper ground/
ously.
earth ground is not present or a short were to take
place - to prevent electrocution 3. The total watts derived in step 2 equals the size
Yamaha generator you need. These three sim-
Right Sizing and Power Management: ple steps will “size” a generator. However, you
Determining Your Consumer Series Customer’s must keep in mind that devices with electric
Energy Needs motors require at least 2-3 times their running
wattage for start-up power. This multiplier varies
When selling a generator, it is important to select
with the age, type, and condition of the electric
one that is capable of meeting the energy require-
motor. A good “rule of thumb” to use for this is
ments of the customer. Match the rated output of
Horse Power multiplied by 932 usually equals a
the generator to the maximum anticipated power
motor’s starting wattage (HP x 932 = SW).
demand.
The chart on the next page lets you immediately
This section will assist in estimating the power
add up all of the appliances you will most likely uti-
requirements, so the purchase will satisfy the needs.
lize:
Make a list of the appliances and devices or tools
that you expect to operate, as well as the approxi-
mate power requirements for each device.
After making the list, estimate the highest demand
on the generator under the “worstcase” conditions.
With this figure, determine the appropriate model
Yamaha generator for your particular needs.
1-20

CONSUMER GENERATOR WORKSHEET
Additional Additional
Running Starting Running Starting
Wattage Wattage Wattage Wattage
Requirements* Requirements Totals Requirements* Requirements Totals
HEATING/COOLING: APPLIANCES
Furnace Fan, gas Lights- Wattage Actual:
or fuel oil furnace VCR 50 0
1/8 horsepower 300 500 Heating Pad 65 0
1/6 horsepower 500 750 Radio 100 0
1/4 horsepower 600 1000 Television - Black & 100 0
2/5 horsepower 700 1400 White
3/5 horsepower 875 2350 Television - Color 300 0
Central Dehumidifier 400 0
Air Conditioner Electric Blanket 400 0
10,000 BTU 1500 2200 Garage Door Opener - 550 1100
20,000 BTU 2500 3300 1/4HP
24,000 BTU 3800 4950 Garage Door Opener - 725 1400
1/3HP
32,000 BTU 5000 6500
Well Pump - 1/3 hp 750 1400
40,000 BTU 6000 6700
Well Pump - 1/2 hp 1000 2100
HEATING/COOLING: SUB-TOTAL:
Sump Pump - 1/3 hp 800 1300
KITCHEN
Sump Pump - 1/2 hp 1050 2150
Refrigerator, Average 600 2200
Vacuum Cleaner - 800 0
Dish Washer - 700 1400
Standard
Cool Dry
Vacuum Cleaner - 1100 0
Dish Washer - 1450 1400
Deluxe
Hot Dry
APPLIANCES SUB-TOTAL:
Clothes Dryer - Gas 700 1800
Clothes Dryer - 5750 1800
*Running wattage values are for estimation only.
Electric
Microwave Oven, 1500 1650
1000W
Washing Machine 750 2300
Coffee Maker 1000 0
Toaster 2-slice 1100 0
Toaster 4-slice 1650 0
Electric Skillet 1500 0
Electric Range 1500 0
6-in. element
Electric Range 2100 0
8-in. element
Freezer 2500 2200
KITCHEN SUB-TOTAL:
BATHROOM
Hair Dryer 1500 watt 1500 0
Iron 1200 0
BATHROOM SUBTOTAL:
1-21

CONSUMER APPLICATION TABLE
EF3000ISEB
EF12000DE
EF3000ISE
EF4000DE
EF5200DE
EF6600DE
EF2400IS
EF1000IS
EF2800I
EF2600
APPLICATION / WATTS*
VCR 50 • • • • • • • • • •
75 Watt Light Bulb (Single) 75 • • • • • • • • • •
Radio 100 • • • • • • • • • •
Television (B&W) 100 • • • • • • • • • •
Window Fan 250 • • • • • • • • • •
Blender 300 • • • • • • • • • •
3/4" Drill 350 • • • • • • • • • •
Television (Color) 350 • • • • • • • • • •
RV W/NO Appliances • • • • • • • • • •
On 400~600
RV Refrigerator 600 • • • • • • • • • •
650 Watt Microwave Oven 1000 • • • • • • • • • •
Washing Machine 750 • • • • • • • • • •
Jigsaw 800 • • • • • • • • • •
Coffee Maker 850 • • • • • • • • • •
Electric Weed Trimmer 1000 • • • • • • • • • •
Router 1000 • • • • • • • • • •
Belt Sander 1000 • • • • • • • • • •
2-Slice Toaster 1100 • • • • • • • • • •
Vacuum Cleaner 1100 • • • • • • • • • •
Disc Sander 1200 • • • • • • • • • •
Chain Saw 1200 • • • • • • • • • •
13,500 btu • • • • • • • • • •
RV Air Conditioner 1200
Space Heater 1300 • • • • • • • • • •
RV Water Heater 1500 • • • • • • • • • •
1000 Watt Microwave 1500 • • • • • • • • • •
1500 Watt Blow Dryer 1600 • • • • • • • • • •
Electric Range • • • • • • • • • •
(One Element) 1500
4-Slice Toaster 1650 • • • • • • • • • •
7 1/4" Circular Saw 2000 • • • • • • • • • •
Disc Grinder 2000 • • • • • • • • • •
Air Compressor 2000 • • • • • • • • • •
Air Conditioner • • • • • •
(10,000 BTU) 2500**
Refrigerator / Freezer 250 • • • • • •
Water Heater 3000 • • • • • •
Well Pump 4500 • • •
**Capable of running most 13,500 btu air conditioners.
1-22

Determining Your Industrial Series Customer’s This chart provides information on the wattage needs
Energy Needs of common commercial devices and tools:
INDUSTRIAL APPLICATION TABLE industrial generator worksheet
Inverter Premium Additional

Series Series Running Starting
Wattage Wattage
Requirements* Requirements Totals
YG6600DE
YG4000D
YG5200D
YG6600D
COMMERCIAL
YG2800i
PRODUCTS:
APPLICATION* Watts 1/4" Drill 300 300
3/4" Drill 350 • • • • •
Jigsaw 300 300
3-1/4" Planer 500 • • • • •
Electric Weed Trimmer 500 500
Reciprocating Saw 500 • • • • •
Router 1000 1000
Airless Sprayer 1/3 HP 600 • • • • •
Belt Sander 1000 1000
1/2" Drill 700 • • • • •
Disc Sander 1200 1200
Electric Weed Trimmer 1000 • • • • •
Chain Saw 1200 1200
Rotary Hammer 1000 • • • • •
Worm Drive Saw 1560 3100
Router 1000 • • • • •
Belt Sander 1000 • • • • •
12" Concrete Cutter 1800 3600
6-1/2" Planer 1200 • • • • • 7 1/4" Circular Saw 1500
Disc Sander 1200 • • • • • Disc Grinder 2000 4000

Electric Chain Saw 1200 • • • • • Air Compressor, 2000 4000
Average
Space Heater 1300 • • • • •
COMMERCIAL SUB-TOTAL:
Demolition Hammer 1500 • • • • •
PRODUCTS:
10" Miter Saw 1500 • • • • •
GRAND TOTAL
16" Beam Saw 1500 • • • • •
14" Cut-off Saw 1500 • • • • •
9" Disc Grinder 1800 • • • • •
12" Concrete Cutter 1800 • • • • •
7-1/4" Circular Saw 2000 • • • • •
Air Compressor 2000 • • • • •
Submersible Pump 1 HP 2000 • • • • •
Concrete Vibrator 2000 • • • • •
Air Conditioner 13,500 BTU 1200 • • • • •
Air Conditioner 10,000 BTU 2500 • • • •
Air Conditioner 15,000 BTU • • • •
1-23

CONSUMER DECIBEL LEVEL INDUSTRIAL DECIBEL LEVEL

COMPARISONS COMPARISONS
GENERAL ESTIMATES OF WORK-RELATED NOISES GENERAL ESTIMATES OF WORK-RELATED NOISES
120 120 Ambulance Siren 120 120 Ambulance Siren

119 Pneumatic Drill
114 114 Hammer Drill

114 114 Hammer Drill
108 Continuous Miner
105 105 Airless Paint Sprayer
105 105 Airless Paint Sprayer
98 Hand Drill
96 96 Tractor
96 96 Tractor
90 90 Lawn Mower
EF12000DE 80 dBA
90 90 Lawn Mower
EF5200D, 73.5 dBA 80 80

Ringing Telephone
EF6600DE 80 80 Ringing Telephone
EF4000DE,
EF2600A
69 dBA 70 70
Vacuum Cleaner YG5200D, 73.5 dBA 70 Vacuum Cleaner
YG6600D, 70
YG6600DE
EF2600
EF2800i
67 dBA
60~67 dBA
60 60
Normal Speech
EF2400iS 53~58 dBA

YG000D 69 dBA 60 60 Normal Speech
YG2800i 60~69 dBA

EF3000iSE, 51~57 dBA 50 50
Business Office
EF3000iSEB 50 50 Business Office
EF1000iS 47~57 dBA 35 35 Soft Whisper

35 35 Soft Whisper
25 25 Bedroom at Night
25 25 Bedroom at Night
1-24

Model Name Clarification YG/EF

Yamaha generators have various model names that
represent the characteristics of the respective mod-
els as follows:
Consumer Generators
E F 6600 DE
AC Max. output B: Boost Technology

(kVA) at 60Hz D: Dual 120/240V AC output
E: Electric Starter
F: Four stroke I: Inverter Technology
DA: Air cooled diesel engine S: Soundproof Type
DL: Liquid cooled diesel engine
G: Generators*
E: Engine generator
Y: Yamaha*
*NOTE: The letters YG are always used together to designate Yamaha Industrial Series Generators.
Model Introduction Year

Unlike Motorsports products, Yamaha does not use
or recognize model years for generators. Instead,
Yamaha uses the term Model Introduction Year
(MIY) to help identify one model from another. The
MIY is used to identify the year that a certain unit
was either first introduced to the US Market, or
received a significant technological update. The MIY
does not necessarily coincide with the actual year of
manufacture. In certain cases it may be necessary
to explain this to a customer who is buying a new
generator from your dealership. This explanation will
create a higher level of customer satisfaction by
preventing a customer from believing that they are
buying a used/or non-current generator.
1-25

Extension Cord Guidelines Resistor and Non-Resistor Spark Plugs
Resistor type spark plugs are used in all Yamaha
A proper extension cord must always be used. If a generators. Do not use non-resistor type spark
cord is not heavy enough for the load it must carry, plugs. Refer the Owner’s Manual or Service Manual
it could burn or there could be a severe reduction in for complete information.
power available at the end of the cord.
Neutral Ground and Floating Ground (Open
The following chart shows the minimum extension Ground – False Ground+)
cord wire size for the amount of the expected load. Neutral Ground (also called “neutral bond”) means
Note that the wire size increases with the length of earth ground and neutral are bonded together
the cord as the anticipated load increases. Light- (wired together). This creates less chance of electro-
gauge cords can be easily damaged. Practical con- cution by providing two paths for electricity to travel
siderations suggest that small-size cords (20 gauge in the event of a short.
or smaller) be avoided.
Floating Ground means that earth ground and neu-
tral are NOT bonded together. All Yamaha Inverters
use a “floating ground” grounding method.
EXTENSION CORD GAUGE
Devices that require a Neutral Ground (bonded neu-
*LOAD MINIMUM GAUGE (AWG)
tral) will not work correctly when plugged into a float-
(AMPERES) 0 ~ 50 Feet 50 ~ 100 Feet 100 ~ 150 Feet
ing ground generator - this is because the device
2 22 20 18 can not locate an earth ground presence.
3 22 18 16 Ground Fault Circuit Interrupter (GFCI)
4 20 16 16 A GFCI protected outlet interrupts power delivery
5 18 16 14 when a fault or short to ground is detected to pre-
6 18 16 14 vent electrocution. It is a device that interrupts the
power flowing through a GFCI receptacle when a
8 16 14 12
proper ground is not present or if/when a short
10 16 12 12 occurs. All Yamaha Industrial series generators (YG
12 16 12 10 models) are equipped with GFCI protected outlets.
14 14 12 10
16 14 10 10
18 14 10 8
20 12 10 8
22 12 10 8
25 12 10 8
30 10 8 6
35 10 8 6
40 8 6 4
50 6 4 2
60 4 2 2
1-26

High Altitude Jetting
Rejetting Yamaha generators for high-altitude applications should be done by an authorized Yamaha dealer or other qualified technician. Several factors
affect jetting decisions, including: altitude, average temperature, and barometric pressure. The following chart describes general high altitude jetting set-
tings. In North America, aftermarket jetting parts are available from Sudco Mikuni, phone (323) 728-5407, www.sudco.com.
2000 3000 3600 4000
Meters / Meters / Meters / Meters /
Carb Sudco Mikuni Sudco Mikuni Sea Level 6561 Ft 9842 Ft 11,881 Ft. 13,123 Ft.
Tier Carburetor Carburetor Main Jet Main Jet Main Jet Main Jet Main Jet
Model 3 Model Number Type Number Number Number Number Number
EF1000 7FL-14101-00 USA/CAN N102/221 57.5 57.5 56.3 56.3 55.0
EF1000A / EF1000B 7TA 7XD 7TA-14101-10 USA/CAN N102/221 56.3 56.3 55.0 55.0 53.8
EF1000iS 7VV 7VV-14101-03 USA N100/606 57.5 53.8 51.3 50.0

EF1000iS 7CG 7CG-14101-00 USA N100/606 58.8 55.0 52.5 50.0
EF1600 7NH 7CJ 7NH-14101-10 USA/CAN N100/606 75.0 73.8 72.5 72.5 71.3
EF2400iS 7CF 7CF-E4101-01 USA N100/606 86.3 82.5 80.0 77.5
EF2400iSJ • 7CF 7CF-E4101-11 USA N100/606 91.3 85.0 83.3 82.5
EF2600/EF2600A 7NJ 7CA 7NJ-14101-10 USA/CAN N100/606 91.3 90.0 87.5 87.5 86.3
EF2300/EF2600/ 7CA 7DF 7CN-E4101-10 OTH/JPN/USA N100/606 91.3 90.0 87.5 86.3
EF2600FW
EF2600J • 7CA 7CN-E4101-A0 USA N100/606 86.3 80.0 78.8 77.5
1-27
EF2800i/YG2800i 7VU 7VU-14101-11 USA N100/606 88.8 85.0 81.3 80.0 78.8
EF2800iJ • 7VU 7VU-14101-20 USA N100/606 91.3 85.0 83.8 82.5
EF3000iSE 7WL 7CH 7CP-E4101-00 USA N100/606 101.3 96.3 93.8 82.5 90.0
EF3000iSEJ • 7CH 7CP-E4101-10 USA N100/606 86.3 80.0 78.8 77.5
EF4500iSE • 7XF 7CU-E4101-31 USA N100/606 115.0 106.3 101.3 82.5 97.5
EF4000 7VW 7VW-14101-20 USA/CAN N100/606 86.3 82.5 81.3 80.0 78.8
EF4000 7VW 7VW-14101-30 USA/CAN N100/606 86.3 82.5 81.3 80.0 78.8
EF4500/EF5200 7WV 7RG-14101-20 USA N102/221 98.8 98.8 98.8 98.8 98.8
EF4600A 7WX 7UV-14101-00 USA/CAN N102/221 100.0 97.5 96.3 96.3 95.0
EF6000/EF6600 7WW 7RH-14101-21 USA N100/606 98.8 98.8 97.5 97.5 96.3
EF6000/EF6600 7RU-14101-31 USA N100/606 98.8 98.8 97.5 97.5 96.3
EF6600 7CC 7CB 7CT-E4101-20 USA N100/606 98.8 98.8 97.5 96.3
EF6600DE 7CC 7CB 7CU-E4101-00 USA N100/606 98.8 98.8 97.5 96.3
EF4000DE/ • 7CC 7CB 7CU-E4101-40 USA N100/606 115.0 107.5 101.3 98.8
EF5200DE/
EF6600DE
YG4000D/YG5200D • 7CC 7CB 7CT-E4101-70 USA N100/606 115.0 107.5 101.3 98.8
EF6600A 7WY 7UW-14101-00 USA/CAN N102/221 105.0 100.0 98.8 97.5 96.3
Special Diagnostic Tools Most generator test sets also feature a frequen-
cy meter to enable you to make that adjust-
Utilizing the correct diagnostic tool for the job is
ment.
critical to our main goal, Customer Satisfaction.
Having the correct tools will ensure that the problem Another excellent use for the generator test set,
is fixed right the first time. There are 5 important which very often becomes a major problem in
diagnostic tools the Service Department should customer satisfaction, is for the proper selection
have to properly diagnose and repair most Inverter of a generator for a given application.
and Conventional generators.
If there is any question as to the amount of cur-
1. Load Bank Tester / rent that a certain appliance or a combination of
Generator Test Set tools will require, all the guess work can be
The load bank main use is to duplicate prob- eliminated by plugging the generator test set
lems, and verify the generator works properly into an external power source with high amper-
after a repair. It can apply an adjustable load age capabilities and then plugging the appli-
between 1-50amps. Many generators are capa- ance or tools into the generator test set.
ble of producing large amounts of power, so it is
The generator test set’s amp meter will not only
necessary to use a tool to create a large, mea-
tell you the required amount of current for nor-
surable load to simulate any output issues. Heat
mal operation, but will also tell you what the
guns, drills, fans, and grinders are not good
start up current requirements are.
diagnostic tools as there is no way to measure
and maintain a large load. As a dealer techni- Start up current requirements are an often over-
cian it is difficult to determine exactly how much looked step in proper generator selection and
load you are applying when not using a load should always be taken into consideration.
bank tester. The load bank can also be used as
You will need to take the start up amperage plus
a sales tool to determine if a generator has
a cushion, to determine the generator size. The
enough capacity to meet the customer’s needs.
cushion will allow for the possibility of future
Generator Test (Load Bank) Uses requirement increases.
Typically, the only way to test the generator if
The customer will be much happier with your
you don’t have a load bank, is to plug some type
dealership if you were able to foresee his future
of tool into it and turn it on. If it operates the tool,
needs. Especially when his needs do change
you assume that it’s making electricity and must
and he would have had to purchase another
be fixed.
generator, if you had not made him aware of that
This is not necessarily true. possibility.
Just because one appliance works, it does not 2. Hertz (Hz) Meter
guarantee that the unit will work for the cus- The hertz meter is used to properly set the fre-
tomer. If the customer gets the unit home or to a quency. U.S. applications will be 60 Hz adjusted
construction site and immediately finds out that by increasing or decreasing engine rpm.
it still does not work for his application, your
3. Pulse Tachometer
Customer Satisfaction level with this customer
A tachometer is used to set the rpm on all gaso-
will be in serious jeopardy.
line powered models.
This can be easily avoided by the use of a gen-
erator test set. The generator test set will make
it possible to select the amount of current used
by a particular customer under real world condi-
tions.
You can even select the amount of current for a
given generators rated output and let it run for
awhile at that power load. If it passes that test
you are practically guaranteed that it will work
for your customer.
1-28

4. AmWatt™ Meter
AmWatt™ Hand-held Appliance Load Tester by
Reliance controls. This one-of-a-kind meter
gives instant accurate readout of amps or watts
used by common cord-connected household
appliances and lights. It is a useful consumer
tool for rightsizing a generator or determing the
load a device draws (under 15 amps or 1800
2. Rotor assembly puller
watts).
You can remove the rotor assembly using the
flywheel magnet puller and M6 bolts (3).
90890-01351 FLYWHEEL MAGNET PULLER
90890-01355 BOLT, FLYWHEEL MAGNET PULLER
5. Multi-Meter & Analog Meter

Resistance tests should be done with a digital
meter. An analog ohm meter will not read a 10
or 20 percent variance from 1 ohm or less. Be
certain to “zero” an analog meter before use.
Also, use clips to connect the leads to the wires
being tested. holding both test wires to the leads
3. Engine tachometer
with your hands will distort the test results. An
Use of the PET-1000 or PET-2000DX engine
analog meter is required to test condensers on
tachometer made by Oihama Kogyo Co., Ltd. is
conventional generators.
recommended.
Note that the reading may not be right if the
ADDITIONAL SPECIAL TOOLS position of the engine tachometer is wrong.
Keep it away from the engine.
1. Rotor assembly holder
A tool available in markets will serve. 90793-80009
ENGINE TACHOMETER
HOZAN C-349 (drum remover) overall length: (PET-1000)
360mm
90793-80032
ENGINE TACHOMETER
(PET-2000DX)
1-29

Generator Diagnostics
CONVENTIONAL GENERATOR DIAGNOSTICS
Introduction
All conventional Yamaha generators, with the excep-
tion to the EDL6500S, are brushless self-exciting
type generators. There are two methods of brush-
less self-exciting generators.
The first method is by using residual magnetism
within the rotor as a source of excitation. These are
models below 4,000 watts and are referred to as
non-AVR type models.
The second method is through the use of a perma-
nent magnet within the Exciter Field Coil. These are
models that are rated at 4,000 watts or higher and
are usually referred to as AVR or Automatic Voltage
Regulator models, which we will cover in detail
later.
The EDL6500S uses the same basic theory to gen-
erate electricity, with the exception to it’s method of
self-excitation. This is done by supplying DC current
from the AVR circuit board to the rotor, through
brushes that ride on a set of slip rings on the rotor.
2-1

Theory for Non-AVR Type Generators

The diagnostic procedures for all non-AVR models
are the same. It will be necessary, however, to refer
to each models service manual for the exact speci-
fication of voltage and resistance readings.
These models depend on residual magnetism within
the rotor to begin the cycle of electricity.
As the rotor turns, the residual magnetism creates a
small amount of AC voltage within the sub-coil. That
voltage is then sent back and forth between the
condenser and the sub-coil.
That AC voltage is then rectified into DC voltage by

a diode known as the rotor rectifier.
The DC voltage then turns the rotor into a large

magnet.
This process is repeated until the engine is

at full speed and the generator reaches it’s
rated output.
The non-AVR type generator relies on a
steady engine speed to maintain a constant
voltage.
2-2

Troubleshooting Procedures
for Non-AVR Type Generators
Occasionally, the rotor may lose it’s residual magne-
tism and make it impossible for the generator to
begin the cycle of electricity. This can be caused by
prolonged periods of non-use or from the shock of
being dropped. If the problem description was
something like, “The unit has been unused for quite
sometime and it worked fine the last time it was
used, but now has no output” or “The unit was work-
ing fine until it was dropped while being loaded onto
the truck, and now it has no output. This could be
the cause.
This repair is actually quite simple. First verify the
problem by starting the engine, then turn the AC
protector to the “ON” position.
With your meter set to a high enough AC scale to
accept 200 volts, insert the meter leads into the
receptacle, polarity is not important.
If there is little or no output, remove the generator
end cap and locate the sub-coils 2 pin connector
with the two green wires.
NOTE: The sub-coil wires on most conventional
models are green but check the manual of the
model you are working on for exact colors and con-
nectors.
With the generator running, apply a 12 volt DC
REMAGNETIZING ROTOR
power source to the two green wires, again, polarity
is not important, for about 5 seconds.
Recheck for output at the receptacle. If power is now G
restored, turn the generator off for a minute or two. G
Restart the generator and again check for voltage
output.
If voltage is restored, you should still make any
minor adjustments such as frequency, which is
directly related to engine RPM and is adjusted with
the governor, as well as check the operation of the
generator by using a generator test set.
If the voltage was not restored or the unit came in for
another problem such as low voltage, further trou-
bleshooting will be required.
Because voltage output is directly related to engine
speed, a low voltage problem may be caused by
incorrect engine RPM. So, check that first.
Using a tachometer, set the engine RPM to the RPM
specified in the Service Manual. In most cases it will
be 3,750 RPM, without a load. Then recheck the
voltage at the receptacle. If the voltage is correct,
the problem is fixed.
2-3

If not, continue to the next step.

With the meter set for 200 volts AC and the genera-
tor end cap removed, check for voltage between the
brown and the red wire.
If the voltage is 120, then the problem is in the con-
trol box, such as the AC protector or the receptacle
itself, or with the wiring between the generator and
the control box.
Check all wiring and test the AC protector and the
receptacle for continuity. SUB-COIL RESISTANCE TEST
If the voltage is below specification, then the prob-

lem is within the generator unit itself.
Start by disconnecting the sub and main coil leads
and set your meter to the specified range to check
their resistance. Measure the sub coils resistance
between the two Green wires.
Next measure the main coils resistance between the MAIN COIL RESISTANCE TEST
Brown and Red wires.
Even if the stator passes both of these tests, there
are still two important tests to perform before we can
eliminate the stator as the problem.
Those two tests are a “Short to Ground” and
“Shorted Together” test.
To better understand these tests, we need to know
the construction of the two types of coils.
The first type is a single lead coil. This is where an SINGLE LEAD COIL RESISTANCE TEST
insulated wire is wrapped around an iron core, with
one end of the wire attached to the core.
A resistance test on this type of coil is taken between
the unattached end of the wire and the core. A short
to ground test does not apply here.
2-4

The other type is a dual lead coil which is used in DUAL LEAD COIL RESISTANCE TEST
generator applications. It has an insulated wire
wrapped around an iron core with neither end
attached to the core. Because the wire is insulated
there is no physical contact between the wire and
the core. A normal resistance test is performed by
attaching the meter leads to each end of the coil
leads.
DUAL LEAD COIL SHORT TO GROUND TEST
In this case a short to ground test does apply. The

short to ground test is performed by connecting one
lead of the meter to either coil lead and the other
meter lead to the core. With the meter on the highest
ohm scale possible, it should read an open circuit.
Any resistance reading at all, indicates a bad coil.
In the generator’s stator assembly, there are actually

DOUBLE COIL SHORTED TOGETHER TEST
two individual coils wrapped separately around the
same core. This is where the shorted together test
comes in.
When one meter lead is attached to any wire from
one of the coils and the other meter lead is attached
to any wire from the other coil, an open circuit should
exist.
Any resistance reading indicates the two coils are
shorted together.
Test the main and sub-coils for a short to ground. MAIN COIL SHORT TO GROUND TEST
With the meter on the highest resistance setting and
one meter lead on either the Red or the Brown wire
from the main coil and the other lead on the core,
there should be an open circuit.
2-5

Then from either Green wire from the sub-coil to the SUB-COIL SHORT TO GROUND TEST
core. Any resistance reading from either test, indi-
cates that the stator is shorted to ground and must
be replaced.
Next test for them being shorted together. With the SUB-COIL TO MAIN COIL
meter on the highest resistance setting and one lead SHORTED TOGETHER TEST
on either the Brown or the Red wire from the main
coil and the other lead on either of the Green wires
from the sub-coil, check for an open circuit. Any
resistance reading indicates that the two coils are
shorted together and the stator must be replaced.
If the stator passes all of the above tests, it can be
eliminated from being the cause of the problem.
For the next test it will be necessary to remove the
front of the control panel and disconnect the con-
denser. To avoid electrical shock, do not touch the
terminals of the condenser. Short the terminals
together with an insulated screwdriver to discharge
it.
Using your analog meter on the RX1k ohm scale,
connect the meter leads to the condenser. The CONDENSER TEST
meter should swing to one side and then quickly
return. If it does not, switch the meter leads on the
terminals.
If the meter still does not move or swings to one side
but does not return, then the condenser must be
replaced.
The rotor assembly will need to be removed in order
to perform the final two test. Refer to the Service
Manual for the model you are working on, for the
correct procedure.
2-6

Use extreme care when handling the stator and

rotor. DO NOT set them on their windings.
Damage will occur.
CHECKING ROTOR RECTIFIER

Once the rotor has been removed, unsolder the IN ONE DIRECTION
diode or diodes, depending on the model, using
caution not to damage it by overheating.
Set your meter to the diode checker scale or the
highest ohm scale if your meter does not have a
diode checker. Test across the diode and note the
reading.
Switch the meter leads and test again, noting the CHECKING ROTOR RECTIFIER
reading. You should have continuity, or a resistance IN OPPOSITE DIRECTION
reading, in one direction, but not in the other direc-
tion.
The diode is bad if you have continuity in both direc-
tions, or an open circuit in both directions.
The last step is testing the Main Field Coil or better
known as the rotor windings.
The resistance test must be done with the diode(s) ROTOR RESISTANCE TEST
still unsoldered. Connect the meter to both ends of
the rotor windings, using care not to touch both
leads with your hands, as this will cause the meter
to read your body’s resistance.
2-7

Then test for a short to ground. Connect one meter ROTOR SHORT TO GROUND TEST
lead to one end of the rotor winding and the other
end to the core of the rotor. There should be an open
circuit on a good rotor.
One of these tests should reveal the faulty compo-
nent.
Theory for AVR Type Generators

As mentioned earlier, the generation of electricity
begins with a small permanent magnet inside the
Exciter Field Coil, as opposed to residual magnetism
in the rotor, on non-AVR types.
When the engine begins to turn, a small amount of
AC voltage is generated by the Exciter Armature
Coil, one of the three sections that make up the
rotor, spinning inside of the Exciter Field Coil’s per-
manent magnet.
This AC voltage is then fully rectified into DC voltage

by four diodes mounted on the rotor. These diodes
are referred to as Rotor Rectifiers and are the sec-
ond of the three rotor sections.
2-8

That DC current then flows through the Main Field

Coil, the last section of the rotor, and turns it into a
north and a south pole magnet.
The magnet spinning inside the sub-coil will then
produce about 4-6 volts AC in the sub-coil.
That AC current is fully rectified by diodes within the

AVR circuit board. This increased DC current then
flows back through the Exciter Field Coil, Exciter
Armature Coil, Main Field Coil and Sub-Coil, which
causes their voltage to rise and in turn causes the
voltage in the Main Coil to rise to the rated output.
There are only three extra components in this type
of generator. They are the AVR circuit board, Exciter
Field Coil and the Exciter Armature Coil.
The AVR circuit board makes it possible to hold a
more constant voltage even if there is some fluctua-
tion in the engine RPM.
This is achieved by two voltage detecting taps on
the main stator coil that are connected to the AVR
board.
When the voltage in the main stator coil reaches the
rated output, but is about to exceed it because of
increasing engine RPM, the AVR board detects that
voltage increase and reduces the amount of output
voltage from itself to the exciter field coil.
The voltage reduction to the exciter field coil in turn
reduces it’s output voltage through the rotor and
thus reduces the voltage from the main coil. This
process is continuously repeated to maintain a con-
stant voltage.
2-9

Troubleshooting Procedures
for AVR Type Generators
The troubleshooting procedure starts out exactly the
same way as with the non-AVR type.
First check the engine speed, especially if the prob- MAIN COIL RESISTANCE TEST
lem is slightly low voltage. Adjust if out of specifica-
tion. Br R
Turn on the AC protector and check the voltage out-

put at the receptacle. Continue on to the next step if
it is out of specification.
Check the voltage at the generator unit. Remember,
if the voltage is OK there, but not at the receptacle,
then it is a wiring or control box problem. And if it is
not OK there, then the problem is in the generator
unit.
As with the non-AVR type, perform the normal resis-
tance test, short to ground test and the shorted
together test on all of the coils.
SUB-COIL RESISTANCE TEST
Be sure to reference the proper Service Manual for
the model you are working on for specifications and
wiring color codes.
Disconnect all of the coils at the connectors.
Start with the resistance test on the Main Coil, the
sub-coil resistance test,
EXCITER FIELD COIL RESISTANCE TEST

and the Exciter Field Coil resistance test, which is
the two pin connector with the black and white
wires.
2-10

Now do the short to ground test on all three of these SUB-COIL SHORT TO GROUND TEST
coils. Remember, we want to see an open circuit on
a good component.
EXCITER FIELD COIL

SHORT TO GROUND TEST
MAIN COIL SHORT TO GROUND TEST

Br R
2-11

And last, check for the Sub and Main Coils for being
MAIN AND SUB-COIL
shorted together.
SHORT TOGETHER TEST
CONDENSER TEST
If the problem was not found in any of these areas,
proceed to the condenser test using the analog
meter.
Check to see if the needle swings and then returns,
replace it if it does not.
Some models are equipped with a voltage adjuster
that should be tested per the Service Manual’s
specifications.
It is a variable resistor that should show a smooth
rise in resistance as the knob is turned from one end
of it’s scale to the other.
If the voltage adjuster shows an open circuit through-
out the scale or at any one point in the scale, it
should be replaced.
It should also be replaced if the resistance is out of
specification.
Next, remove the rotor assembly to test the rotor ROTOR RECTIFIER TEST
rectifiers, the exciter armature coil and the main field
coil.
Unsolder the coils from the rotor rectifiers, noting
where the wires go for reference when it comes time
to reattach them, and test the diodes in the same
manner as on the non-AVR model. There should be
continuity in one direction but not the other.
2-12

And last, test the Exciter Armature Coil resistance EXCITER ARMATURE COIL
and short to ground. RESISTANCE TEST
Then the Main Field Coil resistance and short to MAIN FIELD COIL RESISTANCE TEST
ground.
If the problem was not with any of these compo-
nents, it will then be necessary to replace the AVR
circuit board.
Correctly following these procedures, should have
revealed the problem in one of these areas.
2-13

Theory for AVR Type Generators with

Brushes
This type of generator unit is used in Yamaha’s
EDL6500S diesel generator. It is still a self-exciting BRUSH TYPE AVR GENERATOR
type generator, but uses a brush and slip ring set up
to complete the loop that turns the rotor into a large
magnet.
Generation of electricity begins when a small per-
manent magnet inside the rotor begins to spin inside
the sub-coil. That AC voltage is then sent to the AVR
circuit board, where it is full wave rectified into DC
voltage.
The DC voltage is then sent from the AVR board to
the main field coil in the rotor, through the brushes
and magnetizes the rotor. This causes the main coil
in the stator to suddenly increase voltage to the
rated output.
Troubleshooting Procedures for AVR

Type with Brushes
The troubleshooting procedure is very similar to the
other types. The big difference with this type is that
it is not necessary to remove the rotor from the gen-
erator assembly to test it. This is because there are
no diodes soldered inside and the windings can be
tested through the slip rings
Once again we’ll quickly go through the steps that
we’ve already covered and detail the new ones a
little more closely.
First verify the problem. If the voltage is a little low,
make sure that the engine RPM is correct. On this
model, the RPM should be set at 3,250.
This is be done by using the special photoelectric
tachometer that is designed for diesel engines.
Follow the directions with the tachometer for proper
usage and this models Service Manual for proper
adjustment procedures.
If there is still little or no voltage from the receptacle,
then check for 120 volts AC between the red and
white wires and 120 volts AC between the brown
and blue wires on the generator unit.
If the voltage is good, check the wiring and the con-
trol box. If not, proceed to testing the generator.
Disconnect all of the wires from the generator unit,
in preparation for the tests.
2-14

Check for resistance in the main coil, this model is Testing Procedures for Models
0.33 ohms, +10%, between the red and white wires EquipPed with DC Circuitry
and the same between the brown and blue wires.
As mentioned with the EDL6500S, some other
Then check the resistance in the sub-coil for 0.97 Yamaha models also have DC 12 volt capabilities.
ohms, +10%, between the light green/red and the
green wires in the 4 pin connector. Models such as the early model non-inverter EF1000,
produce this voltage by tapping off of the main coil
There is also a battery charge coil inside the stator and using a full wave rectifier to convert the AC volt-
assembly. If the complaint is everything works good, age to DC.
except the battery keeps going dead. Check the
resistance between the two blue/white wires that are On models like this, if the problem is only with the
in the 2 pin connector for 0.1 ohms, +10%. DC portion of generator, it probably has a bad recti-
fier.
If everything checks out OK there, test all three of
those coils for a short to ground. And if it still checks Test the rectifier according to the specific model’s
out, test for them being shorted together. Be sure to Service Manual.
check between the main coil and the sub coil, the Because the DC circuit uses the main coil to provide
main coil and the battery charge coil and the sub coil it’s voltage, a problem with the AC side will more
and the battery charge coil. than likely result in a problem with the DC side as
If the problem was not found in the stator assembly, well.
then we’ll move on to the rotor. As with the other coils, test for normal resistance,
Remove the brush assembly and inspect them for short to ground and shorted to the sub-coil. If it is
wear. The standard length is 12.5mm and the wear part of the main coil it cannot be shorted to the main
limit is 9mm. Replace them and retest the generator coil, but be sure to check the Service Manual for the
if they’re below the wear limit. If they check OK, then model you are working on.
we’ll test the rotor windings resistance while the
brushes are off.
Place the meter leads on the two slip rings that the
brushes ride on. The reading should be 55.1 ohms,
+10%.
If that is OK, test it for being shorted to ground by
placing one meter lead on one of the slip rings and
the other meter lead on the core of the rotor.
You should have an open circuit. Any resistance
reading would mean the windings are contacting the
core and the rotor must be replaced.
The last test will be the AVR circuit board. First rein-
stall the brush assembly, but do not connect the wire
leads. Disconnect the emergency relay unit and
start the engine.
Apply 12 volts DC to the brush terminals with the “+”
to “+” terminal and the “-” to “-” terminal.
Check the sub coil voltage between the light green/
red and the green wires for 53 volts AC. If the voltage
is correct, then the AVR board is bad and should be
replaced.
As with the AVR and Non-AVR models, one of these
tests should reveal the problem.
2-15

2-16

2-17

TROUBLESHOOTING YAMAHA INVERTER GENERATORS
This guide has troubleshooting flow charts and information to help the Service Department technician cor-
rectly diagnose electrical output and engine running problems. Many diagnostic procedures are the same for
all Yamaha inverter generators, and differences among generators are noted. However, this guide is meant as
a familiarization tool and should not be substituted for the appropriate service manual. Test specifications vary
from model to model, so these numbers are in Section 3 of this book.
Determining if a Problem is
Generator or Engine Related
One item of importance when troubleshooting a generator is differentiating between an electrical problem with
the generator and a mechanical problem with the engine.
It is important we remember that the generator depends on the engines ability to maintain a specific speed,
for it to provide a constant current output.
Be sure you have not overlooked the possibility that the reason the generator does not have the proper output,
is because the engine has lost it’s ability to keep up with the generator’s needs.
A typical scenario for this may be that the generator’s output is OK with no load or a light load, but the output
decreases or becomes erratic as the load increases. Providing that given load would not normally exceed the
rated output.
2-18

Inverter Generator Diagnostics
2-19

2-20

ELEC Diagnostics
Inverter Generator
IGNITION SYSTEM
*
2
1
2) Secondary coil resistance
9 Connect the pocket tester (Ω × 1k) to the
secondary terminal.
Tester (+) lead → High-tension cord 1

Tester (–) lead → Ground terminal 2
Secondary coil resistance:

Refer11.5
to Service
kΩ ±Data
20%Section
at 20 for°C
Specifications
(68 °F)
MEETS OUT OF
SPECIFICATION SPECIFICATION Replace the ignition coil.
5. Air gap
9 Measure the thickness between the magnet
rotor and ignition coil.
Air gap:
Refer to Service
0.5 ± 0.1 mmData Section
(0.02 for
± Specifications
0.004 in)
MEETS OUT OF
SPECIFICATION SPECIFICATION Adjust the air gap.
6. Engine switch
9 Disconnect the engine switch coupler in the
control box.
9 Connect the pocket tester (Ω × 1k) to the
engine switch terminal. 1
B/W
B
Tester (+) lead → Black/white terminal 1 2
Tester (–) lead → Black terminal 2
Switch “ON” → Continuity

Switch “STOP” → No continuity
CONTINUITY NO CONTINUITY
Replace the engine switch,
*
2-21
5-6

7VV10-05 02.10.7 1:41 PM Page 7

IGNITION SYSTEM ELEC
* å ∫
7. Oil level switch 2 2

9 Remove the oil level switch from the bottom
of the crankcase.
Refer
Refertotomodels Service Manual CAMSHAFT
“CRANKSHAFT2, for removal
procedure.
AND ROCKER ARM” in CHAPTER 3. 1
1
9 Connect the pocket tester to the oil level
switch for continuity.
Tester (+) lead → Blue lead 1

Tester (–) lead → Ground 2
å Continuity → Correct
∫ No continuity → Correct
Replace the oil level switch.
8. Wire harness
9 Check the terminal of the connector for con-
tamination, rust, or disconnection.
GOOD NO GOOD
Correct or replace the connector.
Replace the speed limiter.
GOOD
Replace the TCI unit.
2-22
5-7

GENERATOR SYSTEM ELEC Diagnostics
Inverter Generator
GENERATOR SYSTEM
TROUBLESHOOTING CHART
WEAK OR NO ACOR
WEAK CURRENT: DUAL AC COIL (EF1000iS)
NO AC CURRENT
Start the engine.

Check the overload warning light. Check the overload warning light.
DOES NOT TURN ON TURNS ON TURNS ON DOES NOT TURN ON
Start the engine.

Check the pilot light.
DOES NOT TURN ON TURNS ON Check the pilot light.
Rated engine speed inspection.

9 Operate the engine with no load.
9 Set the economy switch to “OFF”. Check the throttle control system.
5,000 r/min Refer to “THROTTLE CONTROL SYSTEM” in
GOOD OUT OF SPECIFICATION CHAPTER 6.
Magnetic force is weak.

AC coil 1 AC voltage inspection
9 Connect Brown-Green (R-S), Green-Brown (S-T),
Replace the magneto rotor.
and Brown-Brown (R-T) leads.
9 Start the engine, then measure the voltage. (Tester
range: AC300V) AC coil 1 resistance inspection
9 Stop the engine.
9 Measure the resistance between Brown-Green
R
(R-S), Green-Brown (S-T), and Brown-Brown (R-T)
AC coil 1 leads. (Tester range: Ω × 1)
S
T R
W Br Br W
Or G Br W AC coil 1
R W Br Br W
AC coil 2
S
T
W Br
S Or G
T R W Br
AC coil 2
AC coil 1 AC voltage:
Refer to Service Data Section for Specifications
130 ~ 260 V at 20 °C (68 °F)
S
TOO LOW T
GOOD
DOES NOT GENERATE
AC coil 1 resistance:
0.47 Ω ± 20% at 20 °C (68 °F)
* SPECIFICATION OUT OF SPECIFICATION
Replace the AC coil 1.
5-8
2-23

ELEC GENERATOR SYSTEM
*
AC coil 2 AC voltage inspection Magnetic force is weak.
9 Connect White-Orange (R-S), Orange-White (S-T),
and White-White (R-T) leads. Replace the magneto rotor.
9 Start the engine, then measure the voltage. (Tester
range: AC120V)
AC coil 2 resistance inspection
9 Stop the engine.
R 9 Measure the resistance between White-Orange
AC coil 1
(R-S), Orange-White (S-T), and White-White (R-T)
leads. (Tester range: Ω × 1)
S
T
W Br Br W R
Or G Br W
R W Br Br W AC coil 1
AC coil 2
S
T
S W Br
T
Or G
R W Br
AC coil 2 AC voltage: AC coil 2

Refer13.5
to Service
~ 23.0DataVSection
at 20 for
°CSpecifications
(68 °F)
S
TOO LOW
GOOD T
DOES NOT GENERATE
AC coil 2 resistance:
0.17 Ω ± 20% at 20 °C (68 °F)
Economy switch continuity inspection SPECIFICATION OUT OF SPECIFICATION
9 Switch “ON” → Continuity
9 Switch “OFF” → No Continuity
Replace the AC coil 2.
Replace the control unit.
2-24
5-9

GENERATOR SYSTEM ELEC
GENERATOR SYSTEM
WEAK OR NO AC CURRENT:
WEAK OR NOSINGLE AC COIL MODELS
AC CURRENT
Start the engine.

Check the overload warning light. Check the overload warning light.
DOES NOT LIGHT ON LIGHT ON LIGHT ON DOES NOT LIGHT ON
Start the engine.

Check the pilot light.
DOES NOT LIGHT ON LIGHT ON Check the pilot light.
No load engine speed inspection.

2,600 r/min Check the throttle control system.
GOOD OUT OF SPECIFICATION Refer to “THROTTLE CONTROL SYSTEM” in
CHAPTER 6.
Main coil AC voltage inspection Magnetic force is weak.

9 Start the engine.
9 Connect the pocket tester to the White leads. Replace the magneto rotor.
9 Measure the voltage. (Tester range: AC 300 V)
Main coil resistance measurement
9 Stop the engine.
9 Measure the resistance between the White leads.
(Tester range: Ω × 1)
W Y
WW Y Y
Main coil AC voltage:

Refer to Service
175 ~ 225Data Section
V at 20 °C for(68
Specifications
°F)
W
TOO LOW W W
GOOD
DOES NOT GENERATE
Main coil resistance:

1.22
Refer Ω ± 20%
to Service at 20 for
Data Section °CSpecifications
(68 °F)
* SPECIFICATION OUT OF SPECIFICATION
Replace the stator assembly.
2-25
5-8

Yamaha Generator Theory GENERATOR
& Diagnostics Guide
SYSTEM ELEC
*
Sub coil AC voltage inspection Magnetic force is weak.
9 Connect the White leads of the sub coil 1.
9 Start the engine, then measure the voltage. (Tester Replace the magneto rotor.
range: AC120V)
Sub coil resistance inspection

W W Or L
W W Or L 9 Stop the engine.
1 9 Measure the resistance between the-White
Orange leads. (Tester range: Ω × 1)
Sub coil AC voltage:

13.0 ~ 18.0 V at 20 °C (68 °F)
TOO LOW W W
GOOD W W
DOES NOT GENERATE 1
Sub coil resistance:

Refer
0.19 Ω ± 20%
to Service Data Section
at 20 for
°CSpecifications
(68 °F)
Replace the control unit. SPECIFICATION OUT OF SPECIFICATION
Replace the stator coil assembly.
2-26
5-9

GENERATOR SYSTEM ELECDiagnostics
Inverter Generator
WEAK OR NO DC CURRENT
Rated engine speed inspection.

9 Set the economy switch to “OFF”. Check the throttle control system.
• Set running
5,000 r/min rpm per Service Manual. Refer to “THROTTLE CONTROL SYSTEM” in
GOOD OUT OF SPECIFICATION model service
CHAPTER 6. manual.
Check the DC circuit breaker.

GOOD DISCONNECTED Replace the DC circuit breaker.
DC coil DC voltage inspection Magnetic force is weak.

9 Connect Blue leads.
9 Start the engine, then measure the voltage. (Tester Replace the magneto rotor.
range: DC 20V)
DC coil resistance inspection

9 Stop the engine.
9 Measure the resistance between Blue leads.
(Tester range: Ω × 1)
L L L L
DC coil DC voltage:
13.5 ~ 23.0 V at 20 °C (68 °F) L L
TOO LOW
GOOD
DOES NOT GENERATE
DC coil resistance:
Refer to Service
0.07 Ω ± 20%Data Section
at 20 for
°CSpecifications
(68 °F)
Replace the rectifier. SPECIFICATION OUT OF SPECIFICATION
Replace the DC coil.
5-10
2-27

ENGINE TRBL
ENGINE
TROUBLETROUBLESHOOTING
SHOOTING
ENGINE
ENGINE DOES NOT START
Check that the oil warn- Check connections between oil warning unit Replace oil
ing light turns ON by and oil level switch. warning
pulling the starter rope. GOOD NO GOOD light, oil
DOSE NOT warning
LIGHT ON
TURN ON unit, or oil
level
switch.
Check engine oil level.
SUFFI- INSUFFI-
Add.
CIENT CIENT
Add.
Check fuel level. Check if fuel is deteriorated.
SUFFI- INSUFFI- GOOD NO GOOD Replace.
CIENT CIENT
Check fuel cock lever

position.
Set to
“ON” “OFF”
“ON”.
Check if fuel flows to fuel

cock. Clean or
GOOD NO GOOD Check if fuel is deteriorated. replace
GOOD NO GOOD fuel pump.
Remove spark plug,
Clean or
attach it to spark plug
replace
cap, and then ground the 9 Check spark plug for dirt and check spark
fuel cock
spark plug to check for plug gap.
spark. 9 Check for voltage leakage due to faulty con-
GOOD WEAK OR nection or broken insulation of the high ten-
SPARK NO SPARK sion cord.
9 Check TCI unit connector for corrosion or
faulty connection.
9 Check the ignition system. Refer to “IGNI-
TION SYSTEM” in CHAPTER 5.
Clean or
* GOOD NO GOOD
replace.
Install a substitute TCI unit to check spark con-

ditions. Replace
GOOD NO GOOD the fuel
TCI unit.
2-28
6-1

TRBL
ENGINE
Check carburetor for

clogged passages or fuel
overflow.
GOOD NOT GOOD Replace. 1
Measure valve clear-
ance.
GOOD
OUT OF
Adjust.
2
SPECIFICATION
Check
using
compression
compression
3
gauge.
OUT OF
4
GOOD
SPECIFICATION
Check valve face and

valve seat for wear.
GOOD WEAR
Resurface
or replace. 5
Check if the marks on
6
the crankshaft and
camshaft are aligned.
Correct or
GOOD NO GOOD
replace.
Check if there is seizure

or wear on the piston, 7
piston ring, or cylinder.
SEIZURE Rebore or
GOOD
OR WEAR replace.
Check the condition of the throttle control sys-

tem. Refer to “THROTTLE CONTROL SYS-
TEM”
TEM”. in Model’s Service Manual.
2-29
6-2

7VV10-06 02.10.4 10:41 AM Page 3

ENGINE TRBL
ENGINE STARTS BUT STALLS
Check fuel level.

SUFFI- INSUFFI-
Add.
CIENT CIENT
Check if fuel cock is

clogged.
GOOD NO GOOD Clean.
Check if fuel hose is

clogged.
GOOD NO GOOD Clean.
9 Check if carburetor 9 Tighten the

retaining nuts are carburetor
loose. bolts
9 Check if there is air securely.
suction due to a dam- 9Replace
aged carburetor joint or carburetor
gasket. joint or gas-
GOOD NO GOOD ket with a
new one.
Measure valve clear-

ance.
OUT OF
GOOD Adjust.
SPECIFICATION
Check compression
using compression
gauge.
OUT OF
GOOD Check piston, piston ring and cylinder.
SPECIFICATION
GOOD NO GOOD Replace.
Check air gap.

Check the condition of the throttle control sys-

tem. Refer to “THROTTLE CONTROL SYS-
TEM”
TEM”. in Model’s Service Manual.
2-30
6-3

7VV10-06 02.10.4 10:41 AM Page 4

ENGINE TRBL
ENGINE SPEED DOES NOT INCREASE
Check if the electric equipment consumes too much

wattage for this generator.
GOOD TOO MUCH Use a generator with a larger capacity.
Check air filter element for dirt.

GOOD NO GOOD Clean.
Check spark plug for dirt and check spark plug gap.
GOOD NO GOOD Clean or adjust.
Check valve clearance.

GOOD NO GOOD Adjust.
Check if main passages such as, the main jet, in the

carburetor are clogged.
GOOD NO GOOD Disassemble or clean.
Check for air suction due to a damaged throttle shaft

seal, carburetor joint, or gasket.
GOOD NO GOOD Disassemble or replace.
Check compression using compression gauge.

Decarbonize combustion chamber if
TOO HIGH
GOOD there are carbon deposits.
TOO LOW
Check valve face and valve seat for wear.

GOOD NO GOOD Resurface or replace.
Check if the marks on the crankshaft and camshaft

are aligned.
GOOD NO GOOD Correct.
Check if there is seizure or wear on piston, piston ring,

or cylinder.
SEIZURE OR Rebore or replace.
GOOD
WEAR
Check
Check the
the condition
condition of
of the
the throttle
throttle control
control system.
system.
Refer
Referto
to “THROTTLE CONTROL
“THROTTLE CONTROL SYSTEM” in
SYSTEM”.
Model Service Manual.
2-31
6-4

ENGINE TRBL
ENGINE SPEED IS UNEVEN
Check fuel level.

SUFFICIENT INSUFFICIENT Add.
Check if fuel is deteriorated.

GOOD NO GOOD Replace fuel.
Check if fuel tank cap is clogged.

Check if fuel cock is clogged.

GOOD NO GOOD Clean.
Check fuel pump operation.

Check spark plug for dirt and check spark plug gap.
GOOD NO GOOD Clean, adjust or replace.
Check valve clearance.

GOOD OUT OF SPECIFICATION Adjust.
While the engine is operating, pull the choke knob

approximately 1/3 to 1/2 way out, and then check the Resurface or replace.
engine operating condition.
STABLE UNSTABLE
Check for air suction due to a damaged throttle shaft

seal, carburetor joint, or gasket.
GOOD NO GOOD Disassemble or replace.
Check if slow or main passages such as, the pilot jet

and main jet, in carburetor are clogged.
GOOD NO GOOD Disassemble or clean.
Check valve face and valve seat for wear.

GOOD NO GOOD Resurface or replace.
Check if there is seizure or wear on piston, piston ring,

or cylinder.
SEIZURE OR Rebore or replace.
GOOD
WEAR
Check
Check thethe condition
condition of
of the
the throttle
throttle control
control system.
system.
Refer
Refer to
to “THROTTLE CONTROL
“THROTTLE CONTROL SYSTEM” in
SYSTEM”.
Model Service Manual.
6-5
2-32

the Model’s Service Manual.

500Ω Terminal: 1-5, 2-4

2-33

THROTTLE CONTROL SYSTEM TRBL
With no load, engine speed does not increase when economy control switch is
set to “OFF”.
With no load, engine speed does not decrease when economy control switch is
set to “ON”.
With load, engine speed does not increase when economy control switch is set to
“ON”.
Check AC output.
Refer to “GENERATOR SYSTEM” in
GOOD NO GOOD the Model’s5. Service Manual.
CHAPTER
Rotate the shaft of the throttle control motor.

GOOD NO GOOD Replace the throttle control motor.
Check economy switch.

GOOD NO GOOD Replace the economy switch.
Check the connections of the wire harness connectors

and couplers, and the wires for an open circuit or short
circuit.
GOOD NO GOOD Correct or replace.
Replace the control motor.
2-34
6-7

ELEC Diagnostics
Inverter Generator
CHARGING SYSTEM
– +
CHARGING SYSTEM
THE BATTERY IS NOT CHARGED
Inspection steps:
1. Fuse 4. Charging coil resistance
2. Battery voltage 5. Rectifier
3. Charging voltage 6. Wire harness (charging system circuit)
NOTE:
• Remove the following part(s) before troubleshooting.
1) Battery bracket
2) Fuel tank
• Use the following special tool(s) for troubleshooting.
Pocket tester: Inductive self-powered tachome-

YU-03112-C, 90890-03112 ter:
YU-8036-B
Engine tachometer:
90890-03113
(90793-80009, 90793-80032)
1. Fuse
• Remove the fuse.
• Connect the pocket tester (Ω × 1) to the NO CONTINUITY
fuse.
• Check the fuse for continuity.
CONTINUITY
Replace the fuse.
2. Battery voltage
• Connect the pocket tester (DC 20 V) to
the battery terminals.
• Measure battery voltage.
Tester positive lead → positive terminal
Tester negative lead →
negative terminal
Battery voltage: OUT OF SPECIFICATION
12.8
Refer V or more
to Service Data Section for Specification
GOOD
• Clean the battery terminals.
* • Recharge or replace the battery.
2-35
4-15

Yamaha Generator Theory &CHARGING
Diagnostics Guide
SYSTEM ELEC – +
* C0NTINUITY
3. Charging voltage È
• Start the engine.
• 3,800 r/min (no load) 1
• Measure the charging voltage.
2
Tester positive lead →
positive terminal 1
negative terminal 2
SWL4120J
È EF3000iSE É
É EF3000iSEB
SWL4120
MEETS SPECIFICATION
Charging voltage:
12 to~ Service
Refer 16 V Data Section for Specification
OUT OF
SPECIFICATION Properly connect the charging system.
4. Charging coil resistance 1

• Disconnect the charging coil connector.
• Connect the pocket tester (Ω × 1) to the
charging coil.
Tester positive lead → White terminal 1
Tester negative lead → Ground 2
2
SWL4130J
Charging coil resistance: OUT OF SPECIFICATION

White-Ground:
Refer0.35 Ω ± Data
to Service 20%Section
at 20for
°CSpecification
(68 °F)
GOOD
Replace the charging coil.
2-36
4-16

CHARGING SYSTEM ELEC – +
* C0NTINUITY
5. Rectifier
• Disconnect the rectifier connector.
• Connect the pocket tester (Ω × 1) to the
rectifier.
• Check the rectifier for continuity.
Normal
White 1
Continuity
Red 2
Red 1 No Continu-
Tester negative lead → ity
White 2
1
NO CONTINUITY
2 Replace the rectifier.

SWL4135
CONTINUITY
DISCONNECTED
6. Wire harness (charging system)
Check the terminal of the connector for
contamination or rust, and the connector
for proper connection.
Correct or replace the connector.
2-37
4-17

Yamaha Generator Theory & STARTING
ELECTRIC Diagnostics Guide
SYSTEM ELEC
ELECTRIC STARTING
ELETRIC STARTING SYSTEM
SYSTEM
THE STARTER MOTOR DOES NOT OPERATE
Inspection steps:
1. Fuse 3. Starter motor
2. Battery voltage 4. Starter relay
NOTE:
9 Remove the following part(s) before troubleshooting.
1) Control panel
9 Use the following special tool(s) for troubleshooting.
Pocket tester: Inductive self-powered tachome-

YU-03112-C, 90890-03112 ter:
YU-8036-B
Engine tachometer:
90890-03113
(90793-80009, 90793-80032)
1. Fuse NO CONTINUITY
9 Remove the fuse.
9 Connect the pocket tester (Ω × 1) to the
fuse.
9 Check the fuse for continuity. Replace the fuse.
CONTINUITY
2. Battery voltage
9 Connect the pocket tester (DC 20 V) to the
battery terminals.
9 Measure battery voltage. OUT OF SPECIFICATION
Tester positive lead → positive terminal
Tester negative lead → negative terminal
Battery voltage: 9 Clean the battery terminals.
12.8
Refer V or more
to Service Data Section for Specification
9 Recharge or replace the battery.
2-38
5-15

ELECTRIC STARTING SYSTEM ELECDiagnostics
Inverter Generator
*
3. Starter motor DOES NOT
MOVE
9 Connect the jumper lead to the starter
relay terminals on the battery side and the Check the battery.
starter motor side. DOES NOT
MOVE
MOVES Repair and/or charge the battery.
Repair and/or replace the starter motor.
w
1 Jumper lead 9 A wire that is used as a jumper lead must
have the equivalent capacity or more as
9 Check the starter motor operation.
that of the battery lead, otherwise the
MOVES jumper lead may burn.
9 This check is likely to produce sparks, so
4. Starter relay be sure that no flammable gas or fluid is
9 Disconnect the engine switch connector. in the vicinity.
9 Connect the jumper lead to the starter
relay connector terminals.
NO CONTINUITY
1 Jumper lead
9 Check the starter motor operation. Replace the starter relay.
MOVES
Replace the engine switch.
5-16
2-39


500Ω Terminal: 1-5, 2-4

2-40

CHOKE CONTROL SYSTEM TRBL
*
Measure the coil resistance between Blue/Yellow- Checking steps:
Black/Red of the thermo sensor. 1. Conect the pocket tester(Ω × 1k) to
(tester range:Ω × 1k) the thermo sensor.
2. Soak the thermo sensor into the
coolant until the 1/3 a of the hexagon
Ω×1k as shown.
3. Slowly heat the coolant,and then let it
cool to the specified temperature indi-
cated.
a
4. Check the thermo sensor for at the
temperatures indicated.
Coil resistance:
2.647-3.021
Refer to Service DatakΩ at 30
Section for °C (86 °F)
Specification
Coil resistance:
0.1859-0.1988
Refer kΩ at 120
to Service Data Section °C (248°F)
for Specification
SPECIFICATION OUT OF SPECIFICATION Replace the thermo sensor.
Check the connections of the wire harness connec-

tors and couplers, and the wires for an open circuit or
short circuit.
GOOD NO GOOD Correct or replace.
Replace the control unit.
2-41
6-8

Current Model Specifications and Wiring Diagrams
CURRENT MODEL
SPECIFICATIONS AND WIRING DIAGRAMS
This section contains relevant service data for all

current Yamaha conventional and inverter genera-
tors. The information is arranged for both the
consumer and industrial series by wattage output -
smallest to largest.
The experienced technician who is familiar with
Yamaha generator maintenance, diagnostic, and
repair procedures can get the necessary specifica-
tions to do the maintenance or repair without going
from one section of the service manual to the next.
However, this section is not designed to replace the
appropriate Service Manual.
Also included in this section are component location
drawings, wiring diagrams, and circuit diagrams.
3-1

7VV10-05 02.10.9 8:36 AM Page 1

CONSUMER SERIES GENERATORS
ELECTRICAL COMPONENTS ELEC
INVERTER GENERATOR EF1000iS
ELECTRICAL
ELECTRICAL COMPONENTS
1 Control unit assembly
5 2 Speed limiter
4 3 Overload warning light (Red)
4 Pilot light (Green)
3
5 Oil warning light (Red)
6 Generator assembly
7 Engine switch
8 Economy switch
9 DC circuit breaker
6 0 AC receptacle (7.5 A × 2)
2
q DC receptacle (12 V-8 A)
w Spark plug cap
e High-tension cable
1 r Ignition coil
t Throttle control motor
y Rectifier
q 0 9 8 7
t
w
1
r
3-2
5-1
CIRCUIT DIAGRAM 1 AC coil 1 (AC)
2 AC coil 2 (AC)
3 DC charge coil
5 Rectifier
R
Br 8 AC receptacle (7.5A × 2)
8
1
Br Br 9 Economy switch
G/Y
EF1000iS WIRING DIAGRAM
S 7
T W Br R R 0 Overload warning light (Red)
Br Br Br Br

G W Br Br W Br W Br
Br Or G Br W Br
W W Br
R R R q DC circuit breaker
W W
R Or W Br Br W W
W
w DC receptacle (12V-8A)
2 6 e Speed limiter
B
S R 9 r TCI unit
T B
R
Y Y
t Engine switch
B/W
L 0 y Oil warning light (Red)
B/W
u Ground terminal
3 L L L L
W q
5 W W
i Control box
o Ground terminal
w
3-3
4 B W p Oil level switch
B a Magneto rotor
L
e B
r s
5-2
Ignition coil
G
Y d Spark plug
R
L L B/W O Y B
O
f Throttle control motor
O
B/W g Engine assembly
G G B/W B t
Y Y
R R Y Y
L L
O O
y G/Y
B/W B/W COLOR CODE
B/W B/W
f L L u
B ........Black
B B B Br .......brown
s G........Green
a i
L.........Blue
p
Or.......Orange
CIRCUIT DIAGRAM
d o
R ........Red
g W .......White
Y ........Yellow
B/W....Black/White
G/Y ....Green/Yellow
ELEC
Current Model Specifications and Wiring Diagram – EF1000iS
7
6
5
4
3
2
1
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Unit EF1000iS
Model code number 7VV2
Dimensions:
Overall length mm (in) 450 (17.7)
Overall width mm (in) 240 (9.5)
Overall height mm (in) 380 (15.0)
Dry weight kg (lb) 12.7 (27.9)
Engine:
Engine type 4-stroke OHV forced air cooled
Cylinder arrangement 1
Displacement L (cm3) 0.050 (50)
Bore × Stroke mm (in) 41.0 × 38.0 (1.61 × 1.50)
Compression ratio 8.2 : 1
Rated output 60 Hz · kW (PS) / 5,000 r / min 1.21 (1.65)
Rated engine speed r / min 5,000
Operating hours 60 Hz · Hrs
W / no load 12.0
W / rated load 4.3
Fuel Unleaded regular gasoline
Fuel tank capacity L (lmp gal, US gal) 2.5 (0.55, 0.66)
Engine oil capacity L (lmp qt, US qt) 0.32 (0.28, 0.34)
Engine recomended oil 4-stroke engine oil API service classification
SE or SF, if not available, SD
Electrical:
Ignition system TCI
Ignition timing BTDC 33°
Spark plug type CR6HSA (NGK)
Spark plug gap mm (in) 0.7 ∼ 0.8 (0.028 ∼ 0.031)
Generator:
Type Multi pole rotating field magnet
Initial excitation Permanent magnet
Driving method Direct connection
Rated power factor 1
7-1
3-4

Current Model Specifications and Wiring Diagram – EF1000iS
Unit EF1000iS
Frequency variation
Instantaneous Less than 1 %
Settling Less than 0.1 %
Settling time
Voltage fluctuation
Less than 7 sec 1
Settling Less than 3 %
Settling time
AC output
Less than 5 sec 2
Rated voltage V 120
Frequency Hz 60
Rated output
Rated current
kVA
A
0.9
7.5
3
Safety device type AC Electronic no fuse breaker
DC Circuit breaker (No fuse breaker)
Rated engine speed
Voltage regulation
r / min 5,000
Voltage feed back system
4
Voltage stability Within ± 4 %
Frequency stability Hz Within ± 1
Rotating speed control
Wave distortion ratio
Throttle motor control type
Less than 2.5 %
5
Number of phase Triple phase
Insulation resistance MΩ Over 10
Insulation type
Receptacle AC
B type
15 A (Duples) × 2
6
DC 8A×1
3-5
7-2

MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Unit Standard Limit
Piston: mm (in)
Piston clearance 0.01 ~ 0.04 (0.0004 ∼ 0.0016) 0.1 (0.004)
Piston skirt “ D ” 40.95 ∼ 40.97 (1.612 ∼ 1.613) 40.94 (1.6118)
Measuring point “ H ” 10 mm (0.4) •••
Piston pin hole inside diameter 10.000 ∼ 10.020 (0.3937 ∼ 0.3945) 10.050 (0.3956)
Piston pin: mm (in)
Piston pin diameter 9.99 ∼ 10.00 (0.3933 ∼ 0.3937) 9.95 (0.3917)
Piston ring: mm (in)
Top ring
Type Barrel face •••
Dimensions “ B × T ” 0.8 × 1.6 (0.03 ∼ 0.06) •••
End gap 0.1 ~ 0.3 (0.0039 ∼ 0.0118) 0.6 (0.0236)
Side clearance 0.06 ~ 0.11 (0.002 ~ 0.004) 0.15 (0.006)
2nd ring
Type Taper •••
Dimensions “ B × T ” 0.8 × 1.7 (0.03 ∼ 0.07) •••
End gap 0.10 ~ 0.3 (0.0039 ∼ 0.0118) 0.6 (0.0236)
Side clearance 0.06 ~ 0.11 (0.002 ~ 0.004) 0.15 (0.006)
OIl ring
Type Solid •••
B
Dimensions “ B × T ” 1.5 × 1.9 (0.059 ∼ 0.075) •••
End gap T 0.2 ~ 0.7 (0.0078 ∼ 0.0275) 0.9 (0.0354)
Cylinder: mm (in)
Inside diameter “ D ” 41.000 ∼ 41.010 (16.14 ∼ 16.15) 41.10 (16.18)
Taper limit ••• 0.05 (0.002)
Warpage limit ••• 0.05 (0.002)
Crankshaft: mm (in)
Big end side clearance “ A ” 0.2 ~ 0.65 (0.008 ~ 0.026) 0.7 (0.028)
Runout “ B ” 0.03 (0.001)
Crank pin diameter “ C ” 15.970 ∼ 15.985 (0.629 ∼ 0.630) 15.940 (0.627)
Connecting rod: mm (in)

Small end diameter “ A ” 10.006 ∼ 10.020 (0.3944 ∼ 0.3945) 10.050 (0.396)
Oil clearance 0.015 ∼ 0.050 (0.0006 ∼ 0.0020) •••
Small end diameter “ B ” 16.000 ∼ 16.015 (0.6299 ∼ 0.6305) 16.050 (0.632)
Oil clearance 0.015 ∼ 0.050 (0.0006 ∼ 0.0020) •••
3-6
7-3

Current Model
MAINTENANCE Specifications and WiringSPEC
SPECIFICATIONS Diagram – EF1000iS
Unit Standard Limit

Camshaft: mm (in)
Camshaft outside diameter
Cam dimension IN EX
“A” 32.65 32.65
(1.29) (1.29)
“B” 28.85 28.85
(1.14) (1.14)
Valve: mm (in)
Valve
Stem diameter “ B ” IN 3.96 ~ 3.98 (0.156 ~ 0.157) 3.92 (0.154)
EX 3.94 ~ 3.96 (0.155 ~ 0.156) 3.90 (0.153)
Valve face contact
width “ D ” IN 0.8 (0.03) 1.8 (0.07)
EX 0.8 (0.03) 1.8 (0.07)
Valve stem runout limit 0.01 (0.0004)
“θ” ••• 90°
Valve guide
Guide inside diameter IN 4.0 (0.157) •••
EX 4.0 (0.157) •••
Valve clearance (cold) IN 0.1 (0.004) •••
EX 0.1 (0.004) •••
Push rod: mm (in)
Runout limit 0.5 (0.02) •••
Valve spring: mm (in)
Free length IN 25.0 (0.984) 24.0 (0.945)
EX 25.0 (0.984) 24.0 (0.945)
Set length IN 15.1 (0.594) •••
EX 15.1 (0.594) •••
Tilt limit ••• 2.0 (0.079)
3-7
7-4

Yamaha GeneratorMAINTENANCE
Theory & Diagnostics Guide
SPECIFICATIONS SPEC
Unit Standard Limit

Carburetor: mm (in)
Type / manufacture BV15-11 / MIKUNI •••
I.D.mark 7VV 00 •••
Bore size Ø 11 (0.433) •••
Main jet #62.5 •••
Main air jet Ø 1.3 (0.051) •••
Pilot air jet Ø 0.9 (0.004) •••
Pilot outlet Ø 0.8 (0.031) •••
Valve seat size Ø 1.5 (0.059) •••
Main nozzle 2H •••
Pilot jet #40 •••
Throttle valve #110 •••
Float height “ H ” 1.5 (0.06) •••
3-8
7-5

MAINTENANCE Specifications and Wiring SPEC
Current ModelSPECIFICATIONS Diagram – EF1000iS
GENERATOR AND ELECTRICAL
Unit Standard Limit

Generator:
AC coil 1 AC voltage (3 phase) (V/r/min) 130 ~ 260 / 5,000 •••
[Br - G (R - S), G - Br (S - T), Br - Br (R - T)
With coupler disconnected]
AC coil 2 AC voltage (3 phase) (V/r/min) 13.5 ~ 23.0 / 5,000 •••
[W - Or (R - S), Or - W (S - T), W - W (R - T)
DC coil DC voltage (V/r/min) 13.5 ~ 23.0 / 5,000 •••
Coil resistance
AC coil 1 (Ω ± 20 %) 0.47 •••
AC coil 2 (Ω ± 20 %) 0.17 •••
[W - Or (R - S), Or - W (S - T), W - W (R - T)
DC coil (Ω ± 20 %) 0.07 (Blue-Blue) •••
Electrical:
Ignition system TCI •••
Ignition timing BTDC 33° •••
Ignition coil
Primary coil resistance (Ω ± 20 %) 0.5 •••
Secondary coil resistance (kΩ ± 20 %) 11.5 •••
Spark plug cap resistance (kΩ) 3.8 ~ 6.3 •••
Spark plug minimum spark gap mm(in) 6 (0.24) •••
7-6
3-9

INVERTER GENERATOR EF2400iS
ELECTRICAL
1 Engine switch
2 2 Speed limiter
3 3 Oil warning light (Red)
1
4 4 Pilot light (Green)
5 Overload warning light (Red)
5 6 AC receptacle (20 A × 2)
7 DC circuit breaker
8 DC receptacle (12 V-8 A)
9 Ground terminal
0 TCI unit
q Control unit assembly
w Rectifier
6 e Generator assembly
7 r Oil level switch
t Spark plug
u y Throttle control motor
u Twin tech (parallel running ter-
8 minal)
9
0 t
e r
y
q
3-10
5-1

CIRCUIT DIAGRAM 1 AC coil
2 DC charge coil
3 Sub coil
4 Rectifier
1 8 Twin tech(parallel running termi-
nal)
Y 9 AC receptacle (20A × 2)
W W Y Y
EF2400iS WIRING DIAGRAM
Y
W Y Br Br
Y 0 Control box

R
G/Y
4 Br q Ground terminal
L R R
2 W W Or L Br Br Br
w Overload warning light (Red)
W W Or L Or Or R 9 e DC receptacle (12V-8A)
3 Or Or R R
L
B
0 7 8 r DC circuit breaker
6 t Engine switch
y Oil warning light (Red)
5 u Speed limiter
i Oil level switch
R
o Magneto rotor
BW
G G Or p TCI unit
Y Y Y
R a
3-115-2
s R G/Y q Spark plug
L L G
Or Or L
s Throttle control motor
G/Y
B/W B/W d Engine assembly
Y
B/W Y Y
w
W
e
B B
B/W G/Y COLOR CODE
B/W B/W B/W
p Or Or Or Or r B ........Black
L Br .......Brown
L L
o B/W G........Green
u Or Or Or
i Y G/Y G/Y t L.........Blue
G/Y
a Or.......Orange
CIRCUIT DIAGRAM
L B/W
Y Y
y R ........Red
d W .......White
Y ........Yellow
B/W....Black/White
G/Y ....Green/Yellow
ELEC Current Model Specifications and Wiring Diagrams – EF2400iS
7
6
5
4
3
2
1
SPECIFICATIONS
Unit EF2400iS
Model code number 7CF2
1 1
Dimensions:
Dry weight kg (lb) 32 (70.5)
2 Engine:
2
3 3
Bore × Stroke mm (in) 66.0 × 50.0 (2.60 × 1.97)
Rated output 60 Hz · kW (PS) / 5,000 r / min 2.5 (3.4)
4 4
1/4 rated load 8.6
W / rated load 5.0
5 5
Fuel tank capacity L (lmp gal, US gal) 6.0 (1.32, 1.59)
Engine oil capacity L (lmp qt, US qt) 0.6 (0.53, 0.63)
Engine recommended oil 4-stroke engine oil API service classification
6 6
(5W-30)
7 7
Electrical:
Ignition system TCI
Ignition timing BTDC 23°±3°
Spark plug type BPR4ES (NGK)
Generator:
3-12
7-1

Current Model Specifications and Wiring Diagrams – EF2400iS
Unit EF2400iS
Frequency variation
Settling Less than 0.1 %
1
Settling time Less than 1 sec
Voltage fluctuation
Settling Less than 3 %
2
AC output
Rated voltage V 120
Frequency Hz 60
3
Rated output kVA 2.0
Rated current A 16.7
4
Voltage regulation Voltage feed back system
Voltage stability Within ± 1 %
Frequency stability Hz Within ± 0.1
5
Rotating speed control Throttle motor control type
Wave distortion ratio Less than 2.5 %
Number of phase Single phase
6
Insulation type B type
Receptacle AC 20 A (Duples) × 2
DC 8A×1
3-13
7-2

SPECIFICATIONS SPEC
ENGINE
Unit Standard Limit
Piston: mm (in)
Piston clearance 0.015 ~ 0.040 (0.0006 ∼ 0.0016) 0.1 (0.004)
Piston skirt “ D ” 66.0 (2.598) 65.9 (2.594)
Measuring point “ H ” 10 mm (0.4) •••
Piston pin hole inside diameter 16.002 ∼ 16.013 (0.6300 ∼ 0.6304) 16.020 (0.6307)
Piston pin: mm (in)
Piston pin diameter 15.995 ∼ 16.000 (0.0.6297 ∼ 0.6299) 15.950 (0.6280)
Top ring
Type Barrel face •••
Dimensions “ B × T ” 1.5 × 2.7 (0.059 ∼ 0.106) •••
End gap 0.2 ~ 0.4 (0.008 ∼ 0.016) 0.9 (0.0354)
Side clearance 0.04 ~ 0.08 (0.0016 ~ 0.0031) 0.1 (0.0039)
2nd ring
Type Taper •••
Dimensions “ B × T ” 1.5 × 2.7 (0.059 ∼ 0.106) •••
End gap 0.2 ~ 0.4 (0.008 ∼ 0.016) 0.9 (0.0354)
Side clearance 0.02 ~ 0.06 (0.0008 ~ 0.0024) 0.1 (0.0039)
OIl ring
Type Solid •••
B
Dimensions “ B × T ” 2.5 × 2.7 (0.098 ∼ 0.106) •••
End gap T 0.2 ~ 0.4 (0.008 ∼ 0.016) 0.9 (0.0354)
Cylinder: mm (in)
Inside diameter “ D ” 66.00 ∼ 66.02 (2.5984 ∼ 2.5990) 66.020 (2.5990)
Taper limit ••• 0.05 (0.002)
Warpage limit ••• 0.05 (0.002)
Crankshaft: mm (in)
Big end side clearance “ A ” 0.2 ~ 0.60 (0.008 ~ 0.024) 0.75 (0.029)
Runout “ B ” ••• 0.04 (0.0016)
Crank pin diameter “ C ” 28.0 (1.102) 27.9 (1.098)

Small end diameter “ A ” 16.006 ∼ 16.020 (0.6301 ∼ 0.6307) •••
Oil clearance 0.006 ∼ 0.025 (0.0002 ∼ 0.0010) •••
Small end diameter “ B ” 28.000 ∼ 28.015 (1.1023 ∼ 1.1029) •••
Oil clearance 0.015 ∼ 0.040 (0.0006 ∼ 0.0016) 0.1 (0.004)
3-14
7-3

SPECIFICATIONS SPEC
Current Model Specifications and Wiring Diagrams – EF2400iS
MAINTENANCE
Unit Standard Limit

Camshaft: mm (in)
Cam dimension IN EX
“A” 26.9 ±0.05 26.68 ±0.05
(1.06 ±0.002) (1.05 ±0.002)
“B” 22.0 ±0.05 22.03 ±0.05
(0.87 ±0.002) (0.87 ±0.002)
Camshaft diameter 14.965 ~ 14.990 14.950
(0.5892 ~ 0.5902) (0.59)
Valve: mm (in)
Valve
Face diameter “ A ” IN 24.0 (0.94) •••
EX 22.0 (0.87) •••
Stem diameter “ B ” IN 5.5 (0.22) •••
EX 5.5 (0.22) •••
Stem length “C” IN 65.9 (2.59) •••
EX 66.2 (2.61) •••
Valve face contact
width “ D ” IN 0.7 (0.03) 1.7 (0.067)
EX 0.7 (0.03) 1.7 (0.067)
Valve stem runout limit ••• 0.01 (0.0004)
“θ” ••• 90°
Valve guide
Guide inside diameter IN 5.5 (0.22) 5.4 (0.21)
EX 5.5 (0.22) 5.4 (0.21)
Stem to guide clearance IN 0.04 ~ 0.06 (0.0016 ∼ 0.0020) •••
EX 0.06 ~ 0.08 (0.002 ∼ 0.003) •••
Valve clearance (cold) IN 0.1 (0.004) •••
EX 0.1 (0.004) •••
Push rod: mm (in)
Runout limit 0.5 (0.02) •••
Free length IN 26.5 (1.04) 25.0 (0.98)
EX 26.5 (1.04) 25.0 (0.98)
Set length IN 21.6 (0.85) •••
EX 21.6 (0.85) •••
Set force IN 4.5 kg (9.9 lb) •••
EX 4.5 kg (9.9 lb) •••
Tilt limit ••• 1.6 (0.06)
3-15
7-4

SPECIFICATIONS SPEC
Unit Standard Limit

Carburetor: mm (in)
Type / manufacture BV20-15 / MIKUNI •••
I.D.mark 7CF 10 •••
Bore size Ø 15 (0.5906) •••
Main jet #86.3 •••
Main air jet Ø 1.8 (0.0709) •••
Pilot air jet Ø 1.1 (0.0433) •••
Pilot outlet Ø 0.9 (0.0354) •••
Main nozzle 31B •••
Pilot jet #35 •••
Float height “ H ” 16.0 (0.63) •••
3-16
7-5

MAINTENANCE
Current Model SPECIFICATIONS SPEC – EF2400iS
Specifications and Wiring Diagrams
Unit Standard Limit

Generator:
Main coil AC voltage (3 phase) (V/r/min) 175 ~ 225 / 2,600 •••
(With the throttle control motor
coupler disconnected)
Sub coil AC voltage (single phase) (V/r/min) 13.0 ~ 18.0 / 2,600 •••
(With the throttle control motor
coupler disconnected)
DC coil DC voltage (V/r/min) 17.0 ~ 23.0 / 2,600 •••
Coil resistance
Main coil (Ω ± 20 %) 1.22 •••
Sub coil (Ω ± 20 %) 0.19 •••
[W - Or (R - S), Or - W (S - T), W - W (R - T)
DC coil (W ± 20 %) 0.12 •••
[W - W (L-L) With 4P coupler
disconnected]
Electrical:
Ignition timing BTDC 23°±3° •••
Ignition coil
Spark plug cap resistance (kΩ) 4.0 ~ 6.0 •••
Spark plug minimum spark gap mm(in) 6 (0.24) •••
7-6
3-17

CONVENTIONAL GENERATOR EF2600
ELECTRICAL
1 Oil warning unit
2 TCI unit
3 Spark plug
4 Condenser
5 Stator assembly
6 Rotor assembly
7 Oil level switch
8 G.F.C.I. receptacle
9 AC switch (NFB)
0 Voltmeter
q Engine switch
w Oil warning light
e AC receptacle
2 3
4
1
6
9
8
e 7
3-18
6

CIRCUIT DIAGRAM
1 Rotor assembly
2 Stator assembly
3 Voltmeter
4 AC switch (NFB)
5 G.F.C.I. receptacle
6 AC receptacle
7 Ground (earth) terminal
8 Engine switch
9 Condenser
EF2600 WIRING DIAGRAM
0 Oil warning unit

q T.C.I unit
4 w Spark plug
1 Br Br
G/Y
Br Br Br
e Oil level switch
Br
6 r Oil warning light
2 V G/Y
R
3
R R 5 R
R R
G G G G G G/Y
G G G G G 9 G/Y
3-19
7
7
G/Y
r 0 8 COLOR CODE
B
B/W Y B ........Black
Br .......brown
L Y B/W B B/W B
G........Green
B L
L.........Blue
B B/W B/W R ........Red
B/W Y ........Yellow
q
B/W....Black/White
B G/Y ....Green/Yellow
CIRCUIT DIAGRAM
e
w
770-053a
ELEC
Current Model Specifications and Wiring Diagrams – EF2600
SPECIFICATIONS
Unit EF2600
Model code number 7CA2
Dimensions:
Engine:
Bore × Stroke mm (in) 66.0 × 50.0 (2.60 × 1.97)
Rated output kW (PS) / 3600 r / min 3.3 (4.4)
Rated engine speed r / min 3600
Operating hours Hrs 9.0
Fuel tank capacityL (lmp gal, US gal) 12.0 (2.64, 3.17)
Engine oil capacityL (lmp qt, US qt) 0.6 (0.53, 0.63)
Engine recommended oil 4-stroke engine oil API service classification
(5W-30)
Engine speed with no load 3,700 ∼ 3,850 r/min

Electrical:
Ignition system TCI
Ignition timing BTDC 23° ± 3° / 3600 r / min
8
3-20

Unit EF2600
Generator:
Type Brush-less, self-exiting, single phase synchronous
generator
AC output
Rated voltage V 120
Frequency Hz 60
Safety device system NFB/G.F.C.I.
Excitation Self magnetization
Initial excitation Residual magnetization
AC voltage fluctuation Less than 10 %
AC frequency variation Less than 5 %
Wave distortion ratio Less than 25 %
Rated power factor 1.0
Number of poles 2
Receptacle AC 20A,125V × 2 (G.F.C.I.) and 20A,125V × 1
3-21
9

SPECIFICATIONS SPEC
ENGINE
Unit Standard Limit
Camshaft: mm (in)
Camshaft outside diameter 14.973 ~ 14.989 14.95 (0.589)
(0.5895 ~ 0.5901)
Camshaft runout limit ••• 0.1 (0.0004)
Cam dimension
“A” 26.9 (1.059) ± 0.05 (0.002) 26.8 (1.055)
± 0.05 (0.002)
“B” 22.025 (0.867) ± 0.05 (0.002) 21.925 (0.863)
± 0.05 (0.002)
Carburetor: mm (in)
Type / Quantity BV20 / 1 •••
I.D.mark 7NJ-10 •••
Bore size Ø 15 (0.590) •••
Main jet #91.3 •••
Main air jet Ø 1.8 (0.071) •••
Pilot air jet Ø 1.1 (0.043) •••
Pilot outlet Ø 0.9 (0.035) •••
Main nozzle 31A •••
Pilot jet #41.3 •••
Float height “ H ” 16 (0.630) •••
Governor arm 3 4
5
1 2
Tension spring attach hole 4 •••
3-22
10

Unit Standard Limit

Generator:
Coil resistance (Ω ± 20 %)
Main coil 0.84 (Red-Brown) •••
Sub coil 1.6 (Green-Green) •••
Rotor coil 1.8 •••
Electrical:
Ignition timing BTDC 23° ± 3° / 3600 r / min •••
TCI
Air gap mm (in) 0.4 ~ 0.6 (0.016 ~ 0.023) •••
11
3-23

SPEC WIRE ROUTING DIAGRAM
WIRE ROUTING DIAGRAM

CONTROL BOX PANEL AND BEHIND CONTROL BOX
1 Engine switch å Control box panel COLOR CODE
2 Oil warning light ∫ Behind the control box panel B ........Black
3 Voltmeter ç Behind the control box Br .......brown
4 AC switch (NFB) G........Green
5 G.F.C.I. receptacle R ........Red
6 AC receptacle Y ........Yellow
7 Condenser B/W....Black/White
8 Oil warning unit G/Y ....Green/Yellow
1 23 4 5 6
å
G
G/Y
∫ Br R G/Y
Br R Br R
B/W
R
B G/Y
Y B/W Br
Br Br
3-24
12

Current Model Specifications and Wiring Diagrams – EF2800i
INVERTER GENERATOR EF2800i
3-25

EF2800i WIRING DIAGRAM
3-26

(5W-30)
3-27

3-28

3-29

3-30

3-31

3-32

Current Model Specifications and Wiring Diagrams – EF3000iSE
+ /B
ELECTRICAL
INVERTER GENERATOR EF3000iSE / B
COMPONENTS
–
ELEC
ELECTRICAL
2 Oil level switch
3 Starter motor
4 Control unit
1 5 Charging coil
6 Starter relay
3
2 7 Rectifier
SWL4010
8 Battery
9 Flywheel magneto
0 Power unit
D A TCI unit
B Spark plug
C C Throttle control motor
B 4 D DC rectifier
A E Main switch
0 F Economy switch
5
G Engine speed limiter/oil level warning unit
9 6 H DC receptacle (12 V, 12 A)
8 7 I AC receptacle (20 A)
4
SWL4020
J AC receptacle (30 A)
K Ground terminal
L Overload warning light (Red)
M Pilot light (Green)
N DC circuit breaker
O Oil level warning light (Red)
E F G H I J
SWL4030
O N M L K
3-33
4-1

SPECIFICATIONS
Unit EF3000iSE/EF3000iSEB
Model code number 7WL2
Dimensions:
Dry weight kg (lb) 67 (147.7) (EF3000iSE)
69 (152.1) (EF3000iSEB)
Engine:
Engine type 4-stroke, OHV, forced air cooled
Bore × Stroke mm (in) 66.0 × 50.0 (2.60 × 1.97)
Compression ratio 8.5:1
Standard compression pressure
kPa (kg/cm2, psi) 400 ~ 600 (4 ~ 6, 57 ~ 85)
Rated output 60 Hz · kW (PS)/3,800 r/min 3.5 (4.7)
1/4 load (economy switch is on) 20.5
Rated load (economy switch is on) 8.0
Fuel tank capacity L (Imp gal, US gal) 13.0 (2.86, 3.43)
Engine oil quantity L (Imp qt, US qt) 0.6 (0.53, 0.63)
Engine oil grade 4-stroke engine oil API service classification
(5W-30)
Electrical:
Ignition system TCI
Gap mm (in) 0.7 ~ 0.8 (0.028 ~ 0.031)
5-1
3-34

SPEC
Current Model Specifications and Wiring Diagrams – EF3000iSE / B
Generator:
Rated power factor 1.0
Frequency variation
Instantaneous Less than 1%
Settling Less than 0.1%
Voltage fluctuation
Settling Less than 3%
AC output
Rated voltage V 120
Frequency Hz 60
DC output
Rated voltage V 12
5
Rated current A 12
Engine speed (no load) r/min 3,800
Rated engine speed r/min 3,800
Economy engine speed (no load) r/min 2,800 ± 50
Voltage stability Within ± 4%
Wave distortion ratio Less than 2.5%
Number of phase
AC output (main coil) Three phase
DC output (subcoil) Single phase
Insulation type B type
Receptacle AC 20 A (Duples) × 1, 30 A × 1
DC 12 A × 1
3-35
5-2

SPEC
ENGINE
Piston: mm (in)
Piston clearance 0.015 ~ 0.040 (0.00059 ~ 0.00157)
<Limit> 0.15 (0.00591)
Piston skirt “D” 65.975 ~ 65.990 (2.5974 ~ 2.5980)
<Limit> 65.9 (2.5945)
Measuring point “H” 10.0 (0.4)
Oversize 1st 66.225 ~ 66.240 (2.6072 ~ 2.6079)
2nd 66.475 ~ 66.490 (2.6171 ~ 2.6177)
Piston pin hole inside diameter 16.002 ~ 16.013 (0.6300 ~ 0.6304)
<Limit> 16.043 (0.6316)
Piston pin: mm (in)
Piston pin diameter 15.995 ~ 16.000 (0.6297 ~ 0.6299)
<Limit> 16.043 (0.6316)
Top ring B
Type T Barrel face
Dimensions “B × T” 1.5 × 2.7 (0.0591 × 0.1063)
End gap 0.20 ~ 0.40 (0.0079 ~ 0.0157)
<Limit> 0.65 (0.0256)
Side clearance 0.04 ~ 0.08 (0.0016 ~ 0.0031)
<Limit> 0.13 (0.0051)
2nd ring B
Type T Taper
Dimensions “B × T” 1.5 × 2.7 (0.0591 × 0.1063)
End gap 0.20 ~ 0.40 (0.0079 ~ 0.0157)
<Limit> 0.75 (0.0295)
Side clearance 0.02 ~ 0.06 (0.0008 ~ 0.0024)
<Limit> 0.12 (0.0047)
Oil ring
Type B Solid
Dimensions “B × T” T 2.5 × 2.8 (0.0984 × 0.1102)
End gap 0.20 ~ 0.70 (0.0079 ~ 0.0276)
<Limit> 0.9 (0.0354)
Cylinder head: mm (in)
Warpage limit 0.05 (0.0020)
Cylinder: mm (in)
Inside diameter “D” 66.005 ~ 66.015 (2.5986 ~ 2.5990)
<Limit> 66.020 (2.5992)
Taper limit 0.05 (0.0020)
3-36
5-3

Crankshaft: mm (in)
Big end side clearance “A” 0.2 ~ 0.6 (0.0079 ~ 0.0236)
<Limit> 0.8 (0.0315)
Runout “B”
<Limit> 0.02 (0.0008)
Crankshaft pin diameter “C” 27.969 ~ 27.984 (1.1011 ~ 1.1017)
<Limit> 27.9 (1.0984)
Small end diameter “A” 16.006 ~ 16.020 (0.6302 ~ 0.6307)
Oil clearance 0.007 ~ 0.018 (0.0003 ~ 0.0007)
Big end diameter “B” 28.000 ~ 28.015 (1.1024 ~ 1.1030)
Oil clearance 0.015 ~ 0.040 (0.0006 ~ 0.0016)
<Limit> 0.1 (0.0039)
Camshaft: mm (in)
Cam dimension IN EX
“A” 26.9 ± 0.05 26.68 ± 0.05
(1.059 ± 0.002) (1.050 ± 0.002)
“B” 22.0 ±0.05 22.025 ± 0.05
(0.866 ± 0.002) (0.867 ± 0.002)
Camshaft journal 14.965 ~ 14.990 (0.5892 ~ 0.5902)

<Limit> 14.950 (0.5886)
Valve: mm (in)
Valve
Face diameter “A” IN 23.9 ~ 24.1 (0.9409 ~ 0.9488)
EX 21.9 ~ 22.1 (0.8622 ~ 0.8701)
Stem diameter “B” IN 5.448 ~ 5.463 (0.2145 ~ 0.2151)
EX 5.440 ~ 5.445 (0.2142 ~ 0.2144)
<Limit> IN 5.418 (0.2133)
EX 5.410 (0.2130)
Stem length “C” IN 65.9 (2.59)
EX 66.2 (2.61)
Valve face contact
width “D” IN 0.9 ~ 1.1 (0.0354 ~ 0.0433)
EX 0.9 ~ 1.1 (0.0354 ~ 0.0433)
<Limit> 1.6 (0.0630)
“θ” 90°
3-37
5-4

Valve guide
Guide inside diameter IN 5.5 (0.22)
EX 5.5 (0.22)
<Limit> IN 5.4 (0.21)
EX 5.4 (0.21)
Stem to guide clearance IN 0.04 ~ 0.06 (0.0016 ~ 0.0024)
EX 0.06 ~ 0.08 (0.0024 ~ 0.0031)
Valve clearance (cold) IN 0.18 ~ 0.22 (0.007 ~ 0.009)
EX 0.18 ~ 0.22 (0.007 ~ 0.009)
Push rod: mm (in)
Runout limit 0.5 (0.02)
Free length IN 26.5 (1.04)
EX 26.5 (1.04)
<Limit> IN 25.2 (0.99)
EX 25.2 (0.99)
Set length IN 21.6 (0.85)
EX 21.6 (0.85)
Set force IN N (kg, lb) 41.9 ~ 46.3 (4.2 ~ 4.6, 92.4 ~ 102.1)
EX N (kg, lb) 41.9 ~ 46.3 (4.2 ~ 4.6, 92.4 ~ 102.1)
Tilt limit Degree/mm (in) 2.5/1.6 (0.06)
Carburetor: mm (in)
Type/manufacturer BV20-15/MIKUNI
I.D. mark 7WL 00
Bore size ø15
Main jet #101.3
Min air jet ø1.8
Pilot air jet ø1.1
Pilot outlet ø0.9
Valve seat size ø1.8
Main nozzle 31B
Pilot jet #37.5
Throttle valve #150
Float height “H” 16.0 (0.63)
Throttle control motor resistance Ω ± 7% 250
3-38
5-5

Generator:
Type/manufacturer GP9822/KOKUSAN DENKI
Main coil AC voltage (3 phase) V 200 ~ 240
Subcoil AC voltage (single phase) V 13.5 ~ 23.0
Coil resistance
Main coil Ω ± 10% 0.79 (Yellow-Yellow)
Subcoil Ω ± 10% 0.17 (Orange-Orange)
Subcoil Ω ± 10% 0.07 (Blue-Blue)
Electrical:
Ignition timing at 3,600 r/min BTDC 23 ± 3°
TCI unit
Primary coil resistance Ω ± 20% 0.5
Secondary coil resistance Ω ± 20% 11.5
Air gap between TCI unit and flywheel
magneto mm (in) 0.5 ± 0.1 (0.020 ± 0.004)
Charge coil resistance Ω ± 20% 0.35 (white-ground)
Spark plug cap resistance kΩ 3.8 ~ 6.3
Minimum spark gap mm (in) 7 (0.28) or more
Battery
Type/manufacturer YTX12-BS/YUASA
Charging amperage and charging time
A × hr 1.2 × 5 ~ 10
Charging voltage V 12.8 or more
Starter motor
Brush length mm (in) 10 (0.39)
<Limit> 3.5 (0.14)
Brush spring force N (g, lb) 5.5 ~ 8.3 (550 ~ 830, 12.1 ~ 18.3)
Commutator diameter mm (in) 22 (0.87)
<Limit> 21 (0.83)
Mica undercut mm (in) 1.5 (0.06)
Fuse
Main A 10 × 1
3-39
5-6

ñ +
COMPONENT LOCATION DIAGRAM

ELECTRICAL
EF4000DE
1 Main switch
2 Economy switch 56 78 9
4
3 Oil warning light
3
4 Voltage meter
2 0A
5 AC switch (120 V, NFB)
6 AC switch (240 V, NFB) 1
7 AC receptacle (120 V-20 A)
8 AC receptacle (120 V-30 A) B
9 AC receptacle (120/240 V-20 A)
0 Stator assembly C
SVW4010
A Rotor assembly
B Ground terminal
C Oil level switch
D Spark plug
E TCI unit
F Condenser
E
G Oil warning unit
H Fuse(10 A)
I Economy idle unit D
J Rectifier
K Rectifier/regulator
L Solenoid valve
SVW4020
F G H I J
K L
G/Y
B/W B
Y R
Br
Br Br
R
B/W R G/Y R
Y Y R
Y Br
Br Br G/Y Br
G/Y
L
L L
SVW4030
3-40
4-1

Current Model Specifications and Wiring Diagrams – YG4000DE
3-41

INVERTER GENERATOR EF4000DE
3-42

(5W-30)
3-43

3-44

3-45

3-46

3-47

3-48

3-49

INVERTER GENERATOR EF4500iSE
3-50

EF4500iSE WIRING DIAGRAM
3-51

3-52

(5W-30)
3-53

3-54

3-55

3-56

3-57

3-58

3-59

3-60

Current Model Specifications and Wiring Diagrams
ñ –
+ EF5200DE
CONVENTIONAL GENERATOR EF5200DE
ELECTRICAL
EF5200DE
1 Main switch
2 Economy switch
3 Oil warning light
4 Voltage meter
0 Exciter field coil
PVX0030
A Stator assembly
B Rotor assembly
C Oil level switch
D Spark plug
E TCI unit
F Resistor
G Oil warning unit
H Rectifier
I AVR
J Condenser
K Economy idle unit
L Ground terminal
PVX0040
M Fuse (10 A)
N Rectifier/regulator
O Solenoid valve
G/Y
PVX0050
3-61

CIRCUIT DIAGRAM COLOR CODE L ............ Blue B/W ........Black/White L/W ........ Blue/White
B ............ Black R ........... Red G/B.........Green/Black R/B ........ Red/Black
EF5200DE
Br........... Brown W........... White G/Y.........Green/Yellow R/W ....... Red/White
G ........... Green Y............ Yellow G/R ........Green/Red
G/Y
G
L L
R G/Y G/Y R G/Y R L
R R R
240V
V G/Y
R R Br Br
120V

Br Br Br
EF5200DE WIRING DIAGRAM
Br Br B
Br
G Y L/W
G Y L/W
Y Y B B
Y Y W W
G G
G G G G W W
G G
G G
B B L G/B R/W
B B B B Y Y
R R B B/W Br R
W W W W
G G STOP
ON
START
B B/W R
B Br
3-62
B R/B R
4
G
B/W Y W B/W R/W Br R/W B B Br
R B/W B/W R
Y R G/R
L Y B/W B
W R B R/W Br
R R B R
G/R B/W R/B R
B/W Y B/W R/W
L
B/W G/R
G/R
R/W L/W B G/R G/R B L/W
W B L/W Y Y L/W B
Y
G/R Y
G/R
B B/W W G/R
B
R
R/W R
G/R B
B
CIRCUIT DIAGRAM
1 Rotor assembly 9 AC receptacle F Rectifier/regulator O Battery

M 2 Stator assembly (125 V-30 A) G Voltage adjuster P Carburetor heater
3 Main coil 0 AC receptacle H AVR Q Starter motor
4 I R
Sub coil (125/250 V-20 A) Condenser Starter relay

5 Exciter field coil A Ground terminal J Economy idle unit S Charging coil
ELEC
6 Voltage meter B Main switch K Oil warning unit T TCI unit

ñ
7 AC switch (NFB) C Remote control terminal L Oil warning light U Spark plug
PVX0090
8 AC receptacle D Rectifier M Solenoid valve V Oil level switch
+
(125 V-20 A) E Fuse (10 A) N Economy switch

Current Model Specifications and Wiring Diagrams – EF5200DE
SPECIFICATIONS
Unit EF5200DE YG5200D
Model code number 7VX2 ←
Dimensions:
Overall length mm (in) 894 (35.2) 670 (26.4)
Overall width mm (in) 520 (20.5) 510 (20.1)
Overall height mm (in) 510 (20.1) 560 (22.0)
Dry weight kg (lb) 87 (191.4) 83 (182.6)
Engine:
Engine type 4-stroke OHV forced ←
air cooled
Cylinder arrangement 1 ←
Displacement L (cm3) 0.301 (301) ←
Bore × Stroke mm (in) 78.0 × 63.0 ←
(3.07 × 2.48)
Compression ratio 8.1 : 1 ←
Rated output 60 Hz ∑kW (PS)/3,600 r/min 5.8 (7.9) ←
Operating hours 60 Hz ∑Hrs 7.6 ←
Fuel Unleaded regular gas- ←
oline
Fuel tank capacity L (Imp gal, US gal) 21.0 (4.62, 5.55) ←
Engine oil capacity L (Imp qt, US qt) 1.1 (0.97, 1.16) ←
(5W-30)
Electrical:
Ignition system TCI ←
Ignition timing at 3,600 r/min BTDC 25 ± 3∞ ←
Spark plug type BPR4ES (NGK) ←
Gap mm (in) 0.7 ~ 0.8 ←
(0.028 ~ 0.031)
3-63

SPEC

Generator:
Type Brushless, self-exciting, ←
single-phase, synchro-
nous generator
Number of phase Single phase ←
Number of poles 2 ←
Excitation Self magnetization ←
Initial excitation Residual magnetiza- ←
tion
Driving method Direct connection ←
Rated power factor 1.0 ←
Frequency variation Less than 5% ←
Voltage fluctuation Less than 10% ←
AC output
Rated voltage V 120/240 ←
Frequency Hz 60 ←
Rated output kVA 4.5 ←
Rated current A 37.5/18.8 ←
Safety device type NFB (No fuse breaker) ←
Rated engine speed r/min 3,600 ←
Economy idle engine speed r/min 2,350 ←
Voltage regulation AVR ←
Insulation resistance MΩ 10 ←
Insulation class
Stator E class ←
Rotor B class ←
Receptacle
AC 20 A (125 V) × 2,
30 A (125 V) × 1, ←
20 A (250/125 V) × 1
3-64

ENGINE

Piston: mm (in)
Piston clearance 0.024 ~ 0.038 ←
(0.00094 ~ 0.00150)
<Limit> 0.100 (0.0039) ←
Piston skirt ìDî 77.960 ~ 77.980 ←
(3.0693 ~ 3.0701)
<Limit> 77.900 (3.067) ←
Measuring point ìHî 10.0 (0.4) ←
Oversize 1st 78.25 (3.0807) ←
2nd 78.50 (3.0906) ←
Piston pin hole inside diameter 20.000 (0.7874) ←
<Limit> 20.020 (0.7882) ←
Piston pin: mm (in)
Piston pin diameter 19.995 ~ 20.000 ←
(0.7872 ~ 0.7874)
<Limit> 19.950 (0.7854) ←
Top ring
Type Barrel face ←
Dimensions ìB × Tî 1.5 × 3.5 ←
(0.059 × 0.138)
End gap 0.2 ~ 0.4 ←
(0.008 ~ 0.016)
<Limit> 0.9 (0.0354) ←
Side clearance 0.04 ~ 0.08 ←
(0.0016 ~ 0.0031)
<Limit> 0.1 (0.0039) ←
2nd ring
Type Taper ←
(0.059 × 0.138)
End gap 0.2 ~ 0.4 ←
(0.008 ~ 0.016)
<Limit> 0.9 (0.0354) ←
(0.0012 ~ 0.0028)
<Limit> 0.1 (0.0039) ←
Oil ring
Type 3-piece type ←
(0.098 × 0.110)
End gap 0.2 ~ 0.7 ←
(0.008 ~ 0.028)
<Limit> 0.9 (0.0354) ←
3-65

Warpage limit 0.05 (0.002) ←
Cylinder: mm (in)
Inside diameter ìDî 78.000 ~ 78.020 ←
(3.0709 ~ 3.0716)
<Limit> 78.020 (3.0716) ←
Taper limit 0.05 (0.002) ←
Warpage limit 0.05 (0.002) ←
Crankshaft: mm (in)
Big end side clearance ìAî 0.20 ~ 0.65 ←
(0.008 ~ 0.026)
<Limit> 0.8 (0.032) ←
Runout ìBî
<Limit> 0.04 (0.0016) ←
Crank pin outside diameter ìCî 35.969 ~ 35.984 ←
(1.4161 ~ 1.4167)
<Limit> 35.9 (1.4134) ←
Small end diameter ìAî 20.006 ~ 20.020 ←
(0.7876 ~ 0.7882)
Oil clearance 0.006 ~ 0.025 ←
(0.0002 ~ 0.0010)
Big end diameter ìBî 36.000 ~ 36.015 ←
(1.4173 ~ 1.4179)
Oil clearance 0.015 ~ 0.045 ←
(0.0006 ~ 0.0018)
<Limit> 0.1 (0.004) ←
Camshaft: mm (in)
Cam dimension IN EX IN EX
ìAî 32.55 ± 0.05 32.55 ± 0.05 ← ←
(1.28 ± 0.002) (1.28 ± 0.002)
<Limit> 32.40 32.40 ← ←
(1.276) (1.276)
ìBî 26.08 ± 0.05 26.08 ± 0.05 ← ←
(1.03 ± 0.002) (1.03 ± 0.002)
<Limit> 25.93 25.93 ← ←
(1.021) (1.021)
Camshaft journal diameter 15.965 ~ 15.990 ←
(0.6285~ 0.6295)
<Limit> 15.950 (0.6280) ←
3-66

Valve: mm (in)
Valve
Face diameter ìAî IN 32.0 (1.26) ←
EX 27.0 (1.06) ←
Stem diameter ìBî IN 5.948 ~ 5.963 ←
(0.2342 ~ 0.2348)
EX 5.940 ~ 5.955 ←
(0.2339 ~ 0.2344)
<Limit> IN 5.9 (0.23) ←
EX 5.9 (0.23) ←
Stem length ìCî IN 88.1 (3.47) ←
EX 87.9 (3.46) ←
Valve face contact
width ìDî IN 0.7 ~ 0.9 ←
(0.0276 ~ 0.0354)
EX 0.7 ~ 0.9 ←
(0.0276 ~ 0.0354)
<Limit> 1.4 (0.551) ←
Valve stem runout limit 0.01 (0.0004) ←
ìθî 90∞ ←
Valve guide
Guide inside diameter IN 6.000 ~ 6.012 ←
(0.2362 ~ 0.2367)
EX 6.000 ~ 6.012 ←
(0.2362 ~ 0.2367)
Stem to guide clearance IN 0.037 ~ 0.064 ←
(0.00146 ~ 0.00252)
EX 0.045 ~ 0.072 ←
(0.00177 ~ 0.00283)
Valve clearance IN 0.08 ~ 0.12 ←
(0.0031 ~ 0.0047)
EX 0.08 ~ 0.12 ←
(0.0031 ~ 0.0047)
Push rod: mm (in) ←
Runout limit 0.5 (0.02) ←
Free length IN 36.2 (1.4252) ←
EX 36.2 (1.4252) ←
<Limit> IN 34.0 (1.34) ←
EX 34.0 (1.34) ←
Set length IN 29.0 (1.1417) ←
EX 29.0 (1.1417) ←
Set force IN 10 kg (22.0 lb) ←
EX 10 kg (22.0 lb) ←
Tilt limit 1.6 (0.06) ←
10
3-67

Carburetor: mm (in)
Type/manufacture BV26-18/MIKUNI ←
I.D. mark 7RG20 7RT30
Bore size ¯ 18 ←
Main jet #98.8 ←
Main air jet ¯ 1.6 (0.063) ←
Pilot air jet ¯ 0.9 (0.035) ←
Pilot outlet ¯ 1.0 (0.039) ←
Valve seat size ¯ 2.0 (0.079) ←
Main nozzle 53A ←
Pilot jet #62.5 ←
Throttle valve #120 ←
Float height ìHî 14.8 (0.58) 14.3 (0.56)
Carburetor heater resistance (Ω ± 10%) 26 at 23 ∞C (73 ∞F) −
GENERATOR

Generator:
Main coil AC voltage
(with the sub coil coupler connected)
120 V (Br-R) V 130 ~ 140 ←
240 V (Br-L) V 225 ~ 275 ←
(with the sub coil coupler disconnected)
120 V (Br-R) V 20 ~ 30 ←
240 V (Br-L) V 40 ~ 60 ←
Sub coil AC voltage
120/240 V (G-G) V 5~6 ←
Exciter field coil voltage V 14 ←
Coil resistance
Main coil (Br-R) (Ω ± 10%) 0.17 ←
(Br-L) (Ω ± 10%) 0.47 ←
Field coil (rotor assembly) (Ω ± 10%) 30 ←
Sub coil (G-G) (Ω ± 10%) 0.28 ←
Exciter field coil (Ω ± 10%) 4.5 ←
Exciter armature coil (Ω ± 10%) 1.6 ←
11
3-68

ELECTRICAL

Electrical:
Ignition system
Primary coil resistance (Ω ± 20%) 1.2 ←
Secondary coil resistance (kΩ ± 10%) 11.7 ←
Spark plug cap resistance (kΩ) 4.0 ~ 6.0 ←
Air gap between TCI unit and
flywheel mm (in) 0.4 ~ 0.6 ←
(0.0157 ~ 0.0236)
Minimum spark gap mm (in) 6 (0.24) ←
Charging coil resistance (battery charging)
W-Ground (Ω ± 20%) 1.3 −
G/R-Ground (Ω ± 20%) 0.9 −
Economy idle system
Economy idle voltage (DC)
(economy idle unit) V 10 ~ 17 ←
Solenoid valve voltage (DC) V 8 ~ 10 ←
Solenoid valve resistance (Ω ± 10%) 35.5 ←
Electric starting system
Depth of insulator mm (in) 0.4 ~ 0.8 −
(0.0157 ~ 0.0315)
Insulation resistance (MΩ) More than 1 −
Wear limit length mm (in) 8.5 (0.33) −
Starter relay coil resistance (Ω ± 20%) 3.4 −
Battery
Capacity 12 V-26 Ah −
12
3-69

WIRE ROUTING DIAGRAM SPEC
CONTROL BOX PANEL AND BEHIND CONTROL BOX (EF5200DE)
È Condenser
É Negative side is indi-
ECON. cated in black.
SW
ON EF5200DE AC SW
Ê Economy idle unit
20A 30A ON ON
OHV ENGINE
BRUSHLESS
OIL WARNING
Ë Pass the longer
OFF
STOP
ON
START
brown lead through
OFF OFF
the economy idle
120V 120/240V
120V
unit coil.
AC 240V
COLOR CODE
B ............Black
PVX0110
Br ...........Brown
L.............Blue
R ............Red
Y ............Yellow
B/W........Black/White
G/Y ........Green/Yellow
G/Y
A
B
Y
B/W
W
Y R R R L L
Br
Br Br
B/W Br
R
G/Y
L
Y
Y Br
G/Y Br
G/Y
PVX0120
PVX0130
14
3-70

Current Model Specifications and Wiring Diagrams – EF6300iSDE
INVERTER GENERATOR EF6300iSDE
3-71

EF6300iSDE WIRING DIAGRAM
3-72

3-73

3-74

3-75

3-76

ELEC
ELECTRICAL COMPONENTS AND CIRCUIT DIAGRAM
ELECTRICAL
EF6600DE
1 Main switch
2 Economy idle switch 34 5 6789 0 q
3 Oil warning light
4 Voltage meter 2 wer
5 AC switch (120 V-20 A, NFB) 1
7 AC switch (120 V-30 A, NFB) t
q AC switch (240 V, NFB)
w Exciter stator assembly y
e Stator assembly
r Rotor assembly
t Oil level switch
y Spark plug
u TCI unit u
i Resistor
o Oil warning unit
p Rectifier
a AVR i o p a s d f
s Condenser
d Economy idle unit
f Ground terminal
g Fuse (10 A)
h Rectifier/regulator
j Solenoid valve
g
f h j
Y
G
8
3-77

EF6600DE
G/Y
5 L L
R
G/Y R G/Y R G/Y R L
4 R R 8 9
120V
240V
V 7 Br
Br
6 7 7
Br Br 7 0 G/Y
Br Br
s i B q
w
3 Y Y G Y L/W
B B L B B/W R R/W L/R Y
G G Y L/W
GG G W W G u OFF
W W R ON
B G G y START
B B B
W W
Y Y B R L/R
R R R r B/W R/W Y
G G o t

1 G B R/B G/R B B/W B/W B
d a B/W R/W B R R/W R/W R
Y p G/R R L/R Y Y L/R
B/W Y B W
2 R R
B R/W B B R Y
L Y B/W B W R B
Y B/W R/B G/R B/W R/W L/R
G/R
f B/W Y
Y
L
B/W
R/W
B W e
z G/R G/R G/R
G/R L/W B G/R G/R B L/W
; j B
B L/W Y Y L/W B
Y
Y
L/R
9
k L/W
c R
3-78
x g
l M h
Color code
B ..........Black
Br .........Brown
1 Rotor assembly w Engine switch d Economy idle solenoid valve G ..........Green
2 Exciter coil e Rectifier f Economy idle switch Gy ........Gray
3 Sub coil r Remote control terminal g Starter relay L...........Blue
4 Main coil t Fuse (10 A) h Starter motor R ..........Red

5 Stator assembly y Rectifier/regulator j Auto choke coil W .........White
6 Voltage meter u Voltage adjuster k Fuel cut solenoid valve B/W ......Black/White
7 NFB i Condenser l Battery G/R ......Green/White
ELEC
8 AC receptacle (125 V-20 A) o AVR ; Charging coil G/Y.......Green/Yellow

9 AC receptacle (125 V-30 A) p Oil warning unit z T.C.I.unit L/W ......Blue/White
0 AC receptacle (125/250 V-30 A) a Oil warning light x Spark plug R/W......Red/White
q Ground terminal s Economy idle unit c Oil level switch Y ..........Yellow
GENERAL
Current SPECIFICATIONS
Model Specifications SPEC – EF6600DE
and Wiring Diagrams
SPECIFICATIONS
Unit EF6600DE YG6600D YG6600DE
Model code number 7CCB
Dimensions:
Overall length mm (in) 894 (35.2) 670 (26.4) 894 (35.2)
Overall width mm (in) 520 (20.5) 510 (20.1) 520 (20.5)
Dry weight kg (lb) 91 (200.6) 86 (189.6) 93 (205.0)
Noise level: dB(A)/Hzl 74/60
Engine:
Bore × Stroke mm (in) 85.0 × 63.0 (3.35 × 2.48)
Operating hours 60 Hz · Hrs 6.8
Engine oil capacity L (Imp qt, US qt) 1.1 (0.97, 1.16)
(5W-30)
Lubrication system Forced splashing

Air filter system Semi-wet (Urethane foam)
Cooling system Forced air cooling
Ignition system TCI
Starting system Electric and Recoil starter Electric and
recoil starter recoil starter
Stopping system Misfire
Rotating direction Clockwise (from flywheel)
Governor type Centrifugal weight system
Electrical:
Ignition system
Gap mm (in) 0.7 ~ 0.8 (0.028 ~ 0.031)
20
3-79

SPEC
Generator:
Type Brushless, self-exciting, single-phase,
synchronous generator
Number of poles 2
Frequency variation Less than 5%
Voltage fluctuation Less than 10%
AC output
Rated voltage V 120/240
Frequency Hz 60
Rated current A 50.0/25.0
Safety device type NFB (No Fuse Breaker)
Economy idle engine speed r/min 2,350
Voltage regulation AVR
Insulation resistance MΩ More than 10
Insulation class
Stator E class
Rotor B class
Receptacle
AC 20 A (125 V) 20 A (125 V) (Duple) × 2, 30 A
(Duple) × 1, (125 V) × 1, 30 A (250/125 V)
30 A (125 V) ×1
× 1, 30 A
(250/125 V) ×
1
3-80
21

ENGINE
Piston: mm (in)
<Limit> 0.100 (0.0039)
Piston skirt “D” 84.977 ~ 84.998 (3.3456 ~ 3.3464)
<Limit> 84.900 (3.3425)
Oversize 1st 85.25 (3.3563)
2nd 85.50 (3.3661)
Piston pin hole inside diameter 20.000 (0.7874)
<Limit> 20.020 (0.7882)
Piston pin: mm (in)
<Limit> 19.950 (0.7854)
Top ring
Type Barrel face
Dimensions “B × T” 1.5 × 3.6 (0.059 × 0.142)
End gap 0.20 ~ 0.35 (0.008 ~ 0.014)
<Limit> 0.9 (0.035)
Side clearance 0.04 ~ 0.08 (0.0016 ~ 0.0031)
<Limit> 0.1 (0.0039)
2nd ring
Type Taper
Dimensions “B × T” 1.5 × 3.6 (0.059 × 0.142)
End gap 0.20 ~ 0.35 (0.008 ~ 0.014)
<Limit> 0.9 (0.035)
Side clearance 0.03 ~ 0.07 (0.0012 ~ 0.0028)
<Limit> 0.1 (0.0039)
Oil ring
Type B 3-piece type
Dimensions “B × T” T 3.0 × 3.0 (0.118 × 0.118)
End gap 0.20 ~ 0.70 (0.008 ~ 0.028)
<Limit> 0.9 (0.035)
3-81
22

SPEC
Cylinder: mm (in)
<Limit> 85.020 (3.3472)
Crankshaft: mm (in)
<Limit> 0.8 (0.031)
Runout “B”
<Limit> 0.04 (0.0016)
Crank pin outside diameter “C” 35.969 ~ 35.984 (1.4161 ~ 1.4167)
<Limit> 35.9 (1.4134)
Oil clearance 0.006 ~ 0.025 (0.0002 ~ 0.0010)
Oil clearance 0.015 ~ 0.045 (0.0006 ~ 0.0018)
<Limit> 0.1 (0.0039)
Camshaft: mm (in)
Cam dimension
“A” IN 32.55 ± 0.05 (1.281 ± 0.002)
<Limit> 32.40 (1.276)
“A” EX 32.55 ± 0.05 (1.281 ± 0.002)
<Limit> 32.40 (1.276)
“B” IN 26.08 ± 0.05 (1.027 ± 0.002)
<Limit> 25.93 (1.021)
“B” EX 26.08 ± 0.05 (1.027 ± 0.002)
<Limit> 25.93 (1.021)
Camshaft journal diameter 15.965 ~ 15.990 (0.6285 ~ 0.6295)
<Limit> 15.950 (0.6280)
3-82
23

Valve: mm (in)
Valve
Face diameter “A” IN 32.0 (1.26)
EX 27.0 (1.06)
EX 5.940 ~ 5.955 (0.2339 ~ 0.2344)
<Limit> IN 5.9 (0.2323)
EX 5.9 (0.2323)
EX 87.9 (3.46)
Valve face contact
width “D” IN 0.7 ~ 0.9 (0.0276 ~ 0.0354)
EX 0.7 ~ 0.9 (0.0276 ~ 0.0354)
<Limit> IN 1.4 (0.0551)
EX 1.4 (0.0551)
Valve seat contact width IN 0.7 ~ 0.9 (0.0276 ~ 0.0354)
EX 0.7 ~ 0.9 (0.0276 ~ 0.0354)
<Limit> IN 1.4 (0.0551)
EX 1.4 (0.0551)
“θ” 90°
Valve guide
Guide inside diameter IN 6.000 ~ 6.012 (0.2362 ~ 0.2367)
EX 6.000 ~ 6.012 (0.2362 ~ 0.2367)
EX 0.045 ~ 0.072 (0.00177 ~ 0.00283)
EX 0.08 ~ 0.12 (0.0031 ~ 0.0047)
Push rod: mm (in)
3-83
24

EX 36.2 (1.43)
<Limit> IN 34.0 (1.34)
EX 34.0 (1.34)
EX 29.0 (1.14)
Set force IN 10 kg (22.0 lb)
EX 10 kg (22.0 lb)
Tilt limit 1.6 (0.06)
Carburetor: mm (in)
Type/manufacture BV26-20/ BV26-21/ BV26-20/
MIKUNI MIKUNI MIKUNI
I.D. mark 7CT70 7CT20 7CT70
Bore size ø20 ø21 ø20
Main jet #116.3 #98.8 #116.3
Main air jet ø1.4 ø1.6 ø1.4
Pilot air jet ø0.9
Pilot outlet ø0.9 ø1.0 ø0.9
Valve seat size ø1.8 ø2.0 ø1.8
Main nozzle 106 P 53 A 106 P
Pilot jet #50 #63.8 #50
Throttle valve #120
Carburetor heater resistance 26 Ω at 23 °C (73.4 °F)
GENERATOR
Generator:
120 V (Br-R) V 114 ~ 140
240 V (Br-L) V 225 ~ 275
120 V (Br-R) V 20 ~ 30
240 V (Br-L) V 40 ~ 60
Sub coil AC voltage
120/240 V (G-G) V 4 ~ 12
Exciter stator coil voltage V 10 ~ 20
3-84
25

Coil resistance
Main coil (Br-R) (Ω ± 10%) 0.16
(Br-L) (Ω ± 10%) 0.45
Field coil (rotor assembly) (Ω ± 10%) 28
Sub coil (G-G) (Ω ± 10%) 0.35
Exciter stator coil (Ω ± 10%) 45
Exciter rotor coil (Ω ± 10%) 1.7
ELECTRICAL
Electrical:
Ignition system
Ignition timing at 3,600 r/min BTDC 23° ± 3°
Gap 0.7 ~ 0.8 (0.028 ~ 0.031)
Primary coil resistance (Ω ± 20%) 0.6
Secondary coil resistance (KΩ ± 20%) 12
Spark plug cap resistance (KΩ) 3.0 ~ 7.5
Air gap between TCI unit
and flywheel mm (in) 0.5 (0.020)
Minimum spark gap mm (in) 6 (0.24)
W-Ground (Ω ± 20%) 2.3 — 2.3
G/R-Ground (Ω ± 20%) 1.7 1.1 1.7
Economy idle system
(economy idle unit) V 10 ~ 18
Economy idle solenoid valve
voltage (DC) V 10 ~ 18
resistance (Ω ± 10%) 35.5
Depth of insulator mm (in) 0.4 ~ 0.8 — 0.4 ~ 0.8
(0.0157 ~ — (0.0157 ~
0.0315) 0.0315)
Brush spring pressure N (Kgf, lbf) 13 — 13
(1.325, 2.91) (1.325, 2.91)
Insulation resistance (MΩ) More than 0.1 — More than 0.1
Wear limit length mm (in) 6 (0.24) — 6 (0.24)
Holding coil resistance å-∫ (Ω ± 20%) 1.1 — 1.1
Pull-in coil resistance å-ç (Ω ± 20%) 0.5 — 0.5
Battery
Capacity 12 V-26 Ah — 12 V-26 Ah
3-85
26

CONTROL BOX PANEL AND BEHIND CONTROL BOX
EF6600DE
å Condenser ∂ Pass the longer brown COLOR CODE
∫ Negative side is indi- lead through the B ......... Black
cated in black. economy idle unit coil. Br ........ Brown
ç Economy idle unit L .......... Blue
R ......... Red
Y ......... Yellow
B/W ..... Black/White
G/Y ...... Green/Yellow
A
G/Y
B
å ∂ ç
B/W
Br R
Y
Br L L Br
å
Y B/W R R
R
L
Br Br Br
G/Y Br G/Y
Br
Y
Y R Br
B W
G/Y
Br
Br
∫
Y
G
29
3-86

CONTROL PANEL
SERVICE DATA
Clearance Data and Limits
EF12000DE
3-87

EF12000DE
3-88

EF12000DE
3-89

EF12000DE
3-90

EF12000DE
3-91

EF12000DE
3-92

EF12000DE
3-93

Control Box
3-94

3-95

INDUSTRIAL SERIES GENERATORS
ELECTRICAL COMPONENTS ELEC – +
YG2800i ELECTRICAL
1 Control unit
2 Engine switch
3 Economy switch
4 Oil warning unit
5 AC receptacle (20 A, GFCI)
6 AC receptacle (30 A)
7 Ground terminal
8 Overload warning light (Red)
0 Oil warning light (Red)
A Oil level switch PVU0080
B DC circuit breaker
C Spark plug
D Throttle control motor
E Pulser coil
F Magneto rotor
G Stator coil assembly
H AC-CDI unit
I Ignition coil
J DC receptacle (12 V-10 A)
K Rectifier
PVU0090
2 3 8 J 7 5 6
ECON. DC
SW
12V10A
20A TO RESET AC
RESTART ENJINE
BATTERY
GFCI
CHARGE
ONLY RESET
OFF
OVER DC
AC LOAD PROTECTOR
0 9 B AC~
PVU0100
5
3-96

CIRCUIT DIAGRAM 1 Main coil 9 Ground terminal H Ignition coil
2 Sub coil (AC control) 0 DC charge coil I AC-CDI unit
3 Charge coil A Economy switch J Pulser coil
(ignition source) B Overload warning light K Throttle control motor
4 4 Generator assembly C Engine switch L Rectifier
5 Control unit D Oil warning light M DC receptacle
6 Pilot light E Oil warning unit (12 V-10 A)
1 7 AC receptacle (20 A, GFCI) F Oil level switch N DC circuit breaker
8 AC receptacle (30 A) G Spark plug
YG2800i WIRING DIAGRAM

Br Br 8
Y Y Y R Br
R Br
Y Y Y Y Y Y W B 6
R R R
L L R 7 G/Y R G/Y
0 R
L L
L BR 5
2 Or
G/Y Or Or G/Y Or
R Or Or R R
3 G/Y
R R
B R R B B B A G/Y
Gy Y Y B/W Y
B/W 9 9
Br Or Or Or Or Y
3-97
Or B
B/W
R
M
B
B
N
G/Y R R
J B/W R R
C
I
Y Y
D
L B/W
R G/Y B/W
R G/Y B/W R
G G Y
Y Y G/Y W/L B/W L E
K R R B/W
L L G/Y W/L B/W
Or L PVU0110
CIRCUIT DIAGRAM
Or
G/Y
G/Y
B/W COLOR CODE
B ............Black W ...........White
W/L Br ...........Brown Y ............Yellow
G............Green B/W ........Black/White
ELEC
B
Gy ..........Gray G/Y.........Green/Yellow
–
H G F L.............Blue W/L ........White/Blue

Or...........Orange
+
B
R ............Red
Current Model Specifications and Wiring Diagrams – YG2800i
SPECIFICATIONS
Unit YG2800i
Model code number 7VU2
Dimensions:
Engine:
Bore × Stroke mm (in) 66.0 × 50.0 (2.60 × 1.97)
Compression ratio 8.5:1
Rated output 60 Hz · kW (PS)/3,600 r/min 3.3 (4.4)
W/no load 24.9
W/rated load 7.7
(5W-30)
Electrical:
Ignition system AC-CDI (Voltage)
Ignition timing BTDC 23 ± 1°
Gap mm (in) 0.7 ~ 0.8 (0.028 ~ 0.031)
Generator:
Frequency variation
Settling Less than 0.1%
3-98

Unit YG2800i
Voltage fluctuation
Settling Less than 3%
AC output
Rated voltage V 120
Frequency Hz 60
Voltage stability Within ± 1%
Wave distortion ratio Less than 2.5%
Insulation type E type
Receptacle AC 20 A (Duples) × 1, 30 A × 1
DC 10 A × 1
3-99

Unit YG2800i
Piston: mm (in)
<Limit> 0.100 (0.0039)
Piston skirt “D” 66.0 (2.598)
<Limit> 65.9 (2.594)
Oversize 1st 66.25 (2.6083)
2nd 66.50 (2.6181)
Piston pin hole inside diameter 16.002 ~ 16.013 (0.6300 ~ 0.6304)
<Limit> 16.020 (0.6307)
Piston pin: mm (in)
<Limit> 15.950 (0.6280)
Top ring
Type Barrel face
Dimensions “B × T” 1.5 × 2.7 (0.059 × 0.106)
End gap 0.2 ~ 0.4 (0.008 ~ 0.016)
<Limit> 0.9 (0.0354)
Side clearance 0.04 ~ 0.08 (0.0016 ~ 0.0031)
<Limit> 0.1 (0.0039)
2nd ring
Type Taper
Dimensions “B × T” 1.5 × 2.7 (0.059 × 0.106)
End gap 0.2 ~ 0.4 (0.008 ~ 0.016)
<Limit> 0.9 (0.0354)
Side clearance 0.02 ~ 0.06 (0.0008 ~ 0.0024)
<Limit> 0.1 (0.0039)
Oil ring
Type Solid
Dimensions “B × T” 2.5 × 2.7 (0.098 × 0.106)
End gap 0.2 ~ 0.4 (0.008 ~ 0.016)
<Limit> 0.9 (0.0354)
Cylinder: mm (in)
<Limit> 66.020 (2.5990)
3-100

Unit YG2800i
Crankshaft: mm (in)
<Limit> 0.75 (0.029)
Runout “B”
<Limit> 0.04 (0.0016)
Crank pin diameter “C” 28.0 (1.102)
<Limit> 27.9 (1.098)
Oil clearance 0.006 ~ 0.025 (0.0002 ~ 0.0010)
Oil clearance 0.015 ~ 0.040 (0.0006 ~ 0.0016)
<Limit> 0.1 (0.004)
Camshaft: mm (in)
Cam dimension IN EX
“A” 26.9 ± 0.05 26.68 ± 0.05
(1.06 ± 0.002) (1.05 ± 0.002)
<Limit> 26.75 (1.053) 26.53 (1.044)
“B” 22.0 ±0.05 22.03 ± 0.05
(0.87 ± 0.002) (0.87 ± 0.002)
<Limit> 21.85 (0.860) 21.88 (0.861)
Camshaft journal 14.965 ~ 14.990 (0.5892 ~ 0.5902)
<Limit> 14.950 (0.59)
Valve: mm (in)
Valve
EX 22.0 (0.87)
Stem diameter “B” IN 5.5 (0.22)
EX 5.5 (0.22)
<Limit> IN 5.4 (0.21)
EX 5.4 (0.21)
Stem lengtlh “C” IN 65.9 (2.59)
EX 66.2 (2.61)
Valve face contanct
width “D” IN 0.7 (0.03)
EX 0.7 (0.03)
<Limit> 1.7 (0.067)
“θ” 90°
10
3-101

Unit YG2800i
Valve guide mm (in)
Guide inside diameter IN 5.5 (0.22)
EX 5.5 (0.22)
<Limit> IN 5.4 (0.21)
EX 5.4 (0.21)
EX 0.06 ~ 0.08 (0.002 ~ 0.003)
Valve clearance IN 0.1 (0.004)
EX 0.1 (0.004)
Push rod: mm (in)
EX 26.5 (1.04)
<Limit> IN 25.0 (0.98)
EX 25.0 (0.98)
EX 21.6 (0.85)
Set force IN 4.5 kg (9.9 lb)
EX 4.5 kg (9.9 lb)
Carburetor: mm (in)
Type/manufacture BV20-15/MIKUNI
I.D. mark 7VU 10
Bore size ø15
Main jet #88.8
Min air jet ø1.8 (0.0709)
Pilot air jet ø1.1 (0.0433)
Pilot outlet ø0.9 (0.0354)
Valve seat size ø1.8 (0.0709)
Main nozzle 31B
Pilot jet #37.5
Throttle valve #150
11
3-102

Unit YG2800i
Generator:
Main coil AC voltage (3 phase) (V/r/min) 130 ~ 160/2,800
(With the throttle control motor coupler dis-
connected)
Sub coil AC voltage (single phase) (V/r/min) 13.5 ~ 23.0/2,800
(With the throttle control motor coupler dis-
connected)
Coil resistance
Main coil (Ω ± 10%) 0.6 (Yellow-Yellow)
Sub coil (Ω ± 10%) 0.14 (Orange-Orange)
DC charge coil (Ω ± 10%) 0.5 (Blue-Blue)
Electrical:
Ignition system AC-CDI (voltage)
Pulser coil resistance (Ω ± 20%) 185
Ignition timing at 3,800 r/min BTDC 23°
Secondary coil resistance (kΩ ± 20%) 6.7
Charge coil resistance (Ω ± 10%) 0.5
(ignition source)
Spark plug cap resistance (kΩ) 4.0 ~ 6.0
12
3-103

CONVENTIONAL GENERATOR YG4000D
3-104

Current Model Specifications and Wiring Diagrams – YG4000D
3-105

YG4000D WIRING DIAGRAM
3-106

3-107

(5W-30)
3-108

3-109

3-110

3-111

3-112

3-113

3-114

ñ +
CONVENTIONAL GENERATOR YG5200D
YG5200D
1 Engine switch
2 Economy switch
3 Oil warning light
4 Voltage meter
5 AC switch (120 V-20 A, NFB)
6 AC receptacle (125 V-20 A, GFCI)
PVX0060
A AC switch (240 V, NFB)
B Exciter field coil
C Stator assembly
D Rotor assembly
E Oil level switch
F Spark plug
G TCI unit
H Oil warning unit
I Rectifier
J AVR
K Condenser
L Economy idle unit
PVX0070
M Ground terminal
N Solenoid valve
PVX0080
3-115

YG5200D COLOR CODE L ............ Blue B/W ........Black/White R/B ........ Red/Black
B ............ Black R ........... Red G/Y ........Green/Yellow R/W ....... Red/White
Br........... Brown W........... White G/R ........Green/Red
G............ Green Y............ Yellow L/W ........Blue/White
G/Y
G
L L
G/Y R R G/Y R G/Y G/Y R L
R R R
240V
V G/Y
R R Br Br
120V
Br Br Br Br

Br Br
G Y L/W
G Y L/W
Y Y B B
Y Y W W
G G
G G G G W W
G G
G G
B B
B B B B Y Y
W W W W R R
G G
3-116
G
B/W Y
Y
L Y B/W B
B/W Y B B/W
L
B/W
G/R G/R
G/R
L/W B G/R G/R B L/W
B L/W Y Y L/W B
Y
L G/R B/W Y
CIRCUIT DIAGRAM
1 Rotor assembly 8 GFCI (125 V-20 A) B Ground terminal I Oil warning light
2 Stator assembly 9 AC receptacle C Engine switch J Solenoid valve
3 Main coil (125 V-20 A) D Rectifier K Economy switch
ELEC
4 Sub coil 0 AC receptacle E AVR L Oil level switch

5 Exciter field coil (125 V-30 A) F Condenser M Charging coil

ñ
6 Voltage meter A AC receptacle G Economy idle unit N TCI unit
PVX0100
+
7 AC switch (NFB) (125/250 V-20 A) H Oil warning unit O Spark plug

Current Model
Specifications and Wiring Diagrams – YG5200D
SPECIFICATIONS
Model code number 7VX2 ←
Dimensions:
Overall length mm (in) 894 (35.2) 670 (26.4)
Overall width mm (in) 520 (20.5) 510 (20.1)
Dry weight kg (lb) 87 (191.4) 83 (182.6)
Engine:
Engine type 4-stroke OHV forced ←
air cooled
Cylinder arrangement 1 ←
Displacement L (cm3) 0.301 (301) ←
Bore × Stroke mm (in) 78.0 × 63.0 ←
(3.07 × 2.48)
Compression ratio 8.1 : 1 ←
Rated output 60 Hz ∑kW (PS)/3,600 r/min 5.8 (7.9) ←
Operating hours 60 Hz ∑Hrs 7.6 ←
Fuel Unleaded regular gas- ←
oline
Fuel tank capacity L (Imp gal, US gal) 21.0 (4.62, 5.55) ←
Engine oil capacity L (Imp qt, US qt) 1.1 (0.97, 1.16) ←
(5W-30)
Electrical:
Ignition system TCI ←
Spark plug type BPR4ES (NGK) ←
Gap mm (in) 0.7 ~ 0.8 ←
(0.028 ~ 0.031)
3-117

Generator:
Type Brushless, self-exciting, ←
single-phase, synchro-
nous generator
Number of phase Single phase ←
Number of poles 2 ←
Excitation Self magnetization ←
Initial excitation Residual magnetiza- ←
tion
Driving method Direct connection ←
Rated power factor 1.0 ←
Frequency variation Less than 5% ←
Voltage fluctuation Less than 10% ←
AC output
Rated voltage V 120/240 ←
Frequency Hz 60 ←
Rated output kVA 4.5 ←
Rated current A 37.5/18.8 ←
Safety device type NFB (No fuse breaker) ←
Rated engine speed r/min 3,600 ←
Economy idle engine speed r/min 2,350 ←
Voltage regulation AVR ←
Insulation resistance MΩ 10 ←
Insulation class
Stator E class ←
Rotor B class ←
Receptacle
AC 20 A (125 V) × 2,
30 A (125 V) × 1, ←
20 A (250/125 V) × 1
3-118

ENGINE

Piston: mm (in)
Piston clearance 0.024 ~ 0.038 ←
(0.00094 ~ 0.00150)
<Limit> 0.100 (0.0039) ←
Piston skirt ìDî 77.960 ~ 77.980 ←
(3.0693 ~ 3.0701)
<Limit> 77.900 (3.067) ←
Measuring point ìHî 10.0 (0.4) ←
Oversize 1st 78.25 (3.0807) ←
2nd 78.50 (3.0906) ←
Piston pin hole inside diameter 20.000 (0.7874) ←
<Limit> 20.020 (0.7882) ←
Piston pin: mm (in)
Piston pin diameter 19.995 ~ 20.000 ←
(0.7872 ~ 0.7874)
<Limit> 19.950 (0.7854) ←
Top ring
Type Barrel face ←
(0.059 × 0.138)
End gap 0.2 ~ 0.4 ←
(0.008 ~ 0.016)
<Limit> 0.9 (0.0354) ←
(0.0016 ~ 0.0031)
<Limit> 0.1 (0.0039) ←
2nd ring
Type Taper ←
(0.059 × 0.138)
End gap 0.2 ~ 0.4 ←
(0.008 ~ 0.016)
<Limit> 0.9 (0.0354) ←
(0.0012 ~ 0.0028)
<Limit> 0.1 (0.0039) ←
Oil ring
Type 3-piece type ←
(0.098 × 0.110)
End gap 0.2 ~ 0.7 ←
(0.008 ~ 0.028)
<Limit> 0.9 (0.0354) ←
3-119


Valve: mm (in)
Valve
Face diameter ìAî IN 32.0 (1.26) ←
EX 27.0 (1.06) ←
Stem diameter ìBî IN 5.948 ~ 5.963 ←
(0.2342 ~ 0.2348)
EX 5.940 ~ 5.955 ←
(0.2339 ~ 0.2344)
<Limit> IN 5.9 (0.23) ←
EX 5.9 (0.23) ←
Stem length ìCî IN 88.1 (3.47) ←
EX 87.9 (3.46) ←
Valve face contact
width ìDî IN 0.7 ~ 0.9 ←
(0.0276 ~ 0.0354)
EX 0.7 ~ 0.9 ←
(0.0276 ~ 0.0354)
<Limit> 1.4 (0.551) ←
Valve stem runout limit 0.01 (0.0004) ←
ìθî 90∞ ←
Valve guide
Guide inside diameter IN 6.000 ~ 6.012 ←
(0.2362 ~ 0.2367)
EX 6.000 ~ 6.012 ←
(0.2362 ~ 0.2367)
Stem to guide clearance IN 0.037 ~ 0.064 ←
(0.00146 ~ 0.00252)
EX 0.045 ~ 0.072 ←
(0.00177 ~ 0.00283)
Valve clearance IN 0.08 ~ 0.12 ←
(0.0031 ~ 0.0047)
EX 0.08 ~ 0.12 ←
(0.0031 ~ 0.0047)
Push rod: mm (in) ←
Runout limit 0.5 (0.02) ←
Free length IN 36.2 (1.4252) ←
EX 36.2 (1.4252) ←
<Limit> IN 34.0 (1.34) ←
EX 34.0 (1.34) ←
Set length IN 29.0 (1.1417) ←
EX 29.0 (1.1417) ←
Set force IN 10 kg (22.0 lb) ←
EX 10 kg (22.0 lb) ←
Tilt limit 1.6 (0.06) ←
10
3-120

Carburetor: mm (in)
Type/manufacture BV26-18/MIKUNI ←
I.D. mark 7RG20 7RT30
Bore size ¯ 18 ←
Main jet #98.8 ←
Main air jet ¯ 1.6 (0.063) ←
Pilot air jet ¯ 0.9 (0.035) ←
Pilot outlet ¯ 1.0 (0.039) ←
Valve seat size ¯ 2.0 (0.079) ←
Main nozzle 53A ←
Pilot jet #62.5 ←
Throttle valve #120 ←
Float height ìHî 14.8 (0.58) 14.3 (0.56)
Carburetor heater resistance (Ω ± 10%) 26 at 23 ∞C (73 ∞F) −
GENERATOR

Generator:
120 V (Br-R) V 130 ~ 140 ←
240 V (Br-L) V 225 ~ 275 ←
120 V (Br-R) V 20 ~ 30 ←
240 V (Br-L) V 40 ~ 60 ←
Sub coil AC voltage
120/240 V (G-G) V 5~6 ←
Exciter field coil voltage V 14 ←
Coil resistance
Main coil (Br-R) (Ω ± 10%) 0.17 ←
(Br-L) (Ω ± 10%) 0.47 ←
Field coil (rotor assembly) (Ω ± 10%) 30 ←
Sub coil (G-G) (Ω ± 10%) 0.28 ←
Exciter field coil (Ω ± 10%) 4.5 ←
Exciter armature coil (Ω ± 10%) 1.6 ←
11
3-121

ELECTRICAL

Electrical:
Ignition system
Primary coil resistance (Ω ± 20%) 1.2 ←
Secondary coil resistance (kΩ ± 10%) 11.7 ←
Spark plug cap resistance (kΩ) 4.0 ~ 6.0 ←
Air gap between TCI unit and
flywheel mm (in) 0.4 ~ 0.6 ←
(0.0157 ~ 0.0236)
Minimum spark gap mm (in) 6 (0.24) ←
W-Ground (Ω ± 20%) 1.3 −
G/R-Ground (Ω ± 20%) 0.9 −
Economy idle system
(economy idle unit) V 10 ~ 17 ←
Solenoid valve voltage (DC) V 8 ~ 10 ←
Solenoid valve resistance (Ω ± 10%) 35.5 ←
Depth of insulator mm (in) 0.4 ~ 0.8 −
(0.0157 ~ 0.0315)
Insulation resistance (MΩ) More than 1 −
Wear limit length mm (in) 8.5 (0.33) −
Starter relay coil resistance (Ω ± 20%) 3.4 −
Battery
Capacity 12 V-26 Ah −
12
3-122

CONTROL BOX PANEL AND BEHIND CONTROL BOX (YG5200D)
È Condenser
É Negative side is indi-
ECON.
cated in black.
SW
ON YG5200D 20A AC SW
Ê Economy idle unit
20A 30A ON ON
OHV ENGINE
BRUSHLESS
OIL WARNING
OFF ON
Ë Pass the longer
OFF
brown lead through
ON the economy idle
OFF OFF
GFCI 120V unit coil.
120V 120/240V
STOP
AC 240V
Ì Protector
COLOR CODE
PVX0170
B ............Black
Br ...........Brown
L.............Blue
R ............Red
Y ............Yellow
B/W........Black/White
G/Y ........Green/Yellow
G/Y
A
B
Y
Br B G/Y
B/W
Br W
R Br Br Br
B/W Y R
L
B/W R
B Br
Br
Y R L L
R Br
Y
G/Y G/Y Br
Br
Br
G/Y
B
PVX0180
PVX0190
18
3-123

7CC-28197-11 08.2.8 10:44 AM Page 10

ELECTRICAL
CONVENTIONAL COMPONENTS
GENERATOR AND CIRCUIT DIAGRAM
YG6600D ELEC
YG6600D
1 Engine switch
2 Economy idle switch 34 5 6 56 789 0 q
3 Oil warning light
4 Voltage meter
2
1
6 AC receptacle (125 V-20 A, GFCI) wer
t
q AC switch (240 V-25 A, NFB)
w Exciter stator assembly y
e Stator assembly
r Rotor assembly
u
t Oil level switch
y Spark plug
u TCI unit
i Resistor
o Oil warning unit
p Rectifier
a AVR
s Condenser
d Economy idle unit
f Ground terminal
g Solenoid valve i o p a s d f
f g
10
3-124

YG6600D
G/Y
5
L L
R
4 G/Y R G/Y R G/Y R G/Y R L
R R 8 8
120V
240V
V 6 7 Br
Br
7 7
7 Br Br Br 9 7 0 G/Y
Br
o t B q
3 Y Y G Y L/W
B B L
G G Y L/W
GG G W W G r
W W R
B G G
B B B
W W
Y Y
R R R
y
G G

1 G
w
p Y
i
B/W Y
u
2 Y B
L Y B/W B B/W L/R
Y
a B/W Y
Y
L
B/W
B G/R e
G/R G/R
L/W B G/R G/R B L/W
B L/W Y Y L/W B
g Y Y
L/R
d s L/W
11
3-125
h
f
Color code
B ..........Black
Br .........Brown
G ..........Green
1 Rotor assembly 0 AC receptacle (125/250 V- o Economy idle unit Gy ........Gray
2 Exciter field coil 30 A) p Economy idle solenoid valve L...........Blue
3 Sub coil q Ground terminal a Economy idle switch R ..........Red

4 Main coil w Engine switch s Fuel cut solenoid valve W .........White
5 Stator assembly e Rectifier d Charging coil B/W ......Black/White
6 Voltage meter r Voltage adjuster f Spark plug G/R ......Green/White
ELEC
7 NFB t Condenser g T.C.I.unit G/Y.......Green/Yellow

8 AC receptacle (125 V-20 A, y AVR h Oil level switch L/W ......Blue/White
GFCI) u Oil warning unit R/W......Red/White
9 AC receptacle (125 V-30 A) i Oil warning light Y ..........Yellow
SPECIFICATIONS
Model code number 7CCB
Dimensions:
Overall length mm (in) 894 (35.2) 670 (26.4) 894 (35.2)
Overall width mm (in) 520 (20.5) 510 (20.1) 520 (20.5)
Dry weight kg (lb) 91 (200.6) 86 (189.6) 93 (205.0)
Noise level: dB(A)/Hzl 74/60
Engine:
Bore × Stroke mm (in) 85.0 × 63.0 (3.35 × 2.48)
Operating hours 60 Hz · Hrs 6.8
(5W-30)
Lubrication system Forced splashing

Air filter system Semi-wet (Urethane foam)
Cooling system Forced air cooling
Ignition system TCI
Starting system Electric and Recoil starter Electric and
recoil starter recoil starter
Stopping system Misfire
Rotating direction Clockwise (from flywheel)
Governor type Centrifugal weight system
Electrical:
Ignition system
Gap mm (in) 0.7 ~ 0.8 (0.028 ~ 0.031)
20
3-126

Generator:
Number of poles 2
Frequency variation Less than 5%
Voltage fluctuation Less than 10%
AC output
Rated voltage V 120/240
Frequency Hz 60
Rated current A 50.0/25.0
Safety device type NFB (No Fuse Breaker)
Economy idle engine speed r/min 2,350
Voltage regulation AVR
Insulation resistance MΩ More than 10
Insulation class
Stator E class
Rotor B class
Receptacle
AC 20 A (125 V) 20 A (125 V) (Duple) × 2, 30 A
(Duple) × 1, (125 V) × 1, 30 A (250/125 V)
30 A (125 V) ×1
× 1, 30 A
(250/125 V) ×
1
3-127
21

SPEC
ENGINE
Piston: mm (in)
<Limit> 0.100 (0.0039)
Piston skirt “D” 84.977 ~ 84.998 (3.3456 ~ 3.3464)
<Limit> 84.900 (3.3425)
Oversize 1st 85.25 (3.3563)
2nd 85.50 (3.3661)
Piston pin hole inside diameter 20.000 (0.7874)
<Limit> 20.020 (0.7882)
Piston pin: mm (in)
<Limit> 19.950 (0.7854)
Top ring
Type Barrel face
Dimensions “B × T” 1.5 × 3.6 (0.059 × 0.142)
End gap 0.20 ~ 0.35 (0.008 ~ 0.014)
<Limit> 0.9 (0.035)
Side clearance 0.04 ~ 0.08 (0.0016 ~ 0.0031)
<Limit> 0.1 (0.0039)
2nd ring
Type Taper
Dimensions “B × T” 1.5 × 3.6 (0.059 × 0.142)
End gap 0.20 ~ 0.35 (0.008 ~ 0.014)
<Limit> 0.9 (0.035)
Side clearance 0.03 ~ 0.07 (0.0012 ~ 0.0028)
<Limit> 0.1 (0.0039)
Oil ring
Type B 3-piece type
Dimensions “B × T” T 3.0 × 3.0 (0.118 × 0.118)
End gap 0.20 ~ 0.70 (0.008 ~ 0.028)
<Limit> 0.9 (0.035)
3-128
22

Cylinder: mm (in)
<Limit> 85.020 (3.3472)
Crankshaft: mm (in)
<Limit> 0.8 (0.031)
Runout “B”
<Limit> 0.04 (0.0016)
Crank pin outside diameter “C” 35.969 ~ 35.984 (1.4161 ~ 1.4167)
<Limit> 35.9 (1.4134)
Oil clearance 0.006 ~ 0.025 (0.0002 ~ 0.0010)
Oil clearance 0.015 ~ 0.045 (0.0006 ~ 0.0018)
<Limit> 0.1 (0.0039)
Camshaft: mm (in)
Cam dimension
“A” IN 32.55 ± 0.05 (1.281 ± 0.002)
<Limit> 32.40 (1.276)
“A” EX 32.55 ± 0.05 (1.281 ± 0.002)
<Limit> 32.40 (1.276)
“B” IN 26.08 ± 0.05 (1.027 ± 0.002)
<Limit> 25.93 (1.021)
“B” EX 26.08 ± 0.05 (1.027 ± 0.002)
<Limit> 25.93 (1.021)
Camshaft journal diameter 15.965 ~ 15.990 (0.6285 ~ 0.6295)
<Limit> 15.950 (0.6280)
3-129
23

SPEC
Valve: mm (in)
Valve
EX 27.0 (1.06)
EX 5.940 ~ 5.955 (0.2339 ~ 0.2344)
<Limit> IN 5.9 (0.2323)
EX 5.9 (0.2323)
EX 87.9 (3.46)
Valve face contact
width “D” IN 0.7 ~ 0.9 (0.0276 ~ 0.0354)
EX 0.7 ~ 0.9 (0.0276 ~ 0.0354)
<Limit> IN 1.4 (0.0551)
EX 1.4 (0.0551)
Valve seat contact width IN 0.7 ~ 0.9 (0.0276 ~ 0.0354)
EX 0.7 ~ 0.9 (0.0276 ~ 0.0354)
<Limit> IN 1.4 (0.0551)
EX 1.4 (0.0551)
“θ” 90°
Valve guide
Guide inside diameter IN 6.000 ~ 6.012 (0.2362 ~ 0.2367)
EX 6.000 ~ 6.012 (0.2362 ~ 0.2367)
EX 0.045 ~ 0.072 (0.00177 ~ 0.00283)
EX 0.08 ~ 0.12 (0.0031 ~ 0.0047)
Push rod: mm (in)
3-130
24

EX 36.2 (1.43)
<Limit> IN 34.0 (1.34)
EX 34.0 (1.34)
EX 29.0 (1.14)
Set force IN 10 kg (22.0 lb)
EX 10 kg (22.0 lb)
Carburetor: mm (in)
Type/manufacture BV26-20/ BV26-21/ BV26-20/
MIKUNI MIKUNI MIKUNI
I.D. mark 7CT70 7CT20 7CT70
Bore size ø20 ø21 ø20
Main jet #116.3 #98.8 #116.3
Main air jet ø1.4 ø1.6 ø1.4
Pilot air jet ø0.9
Pilot outlet ø0.9 ø1.0 ø0.9
Valve seat size ø1.8 ø2.0 ø1.8
Main nozzle 106 P 53 A 106 P
Pilot jet #50 #63.8 #50
Throttle valve #120
Carburetor heater resistance 26 Ω at 23 °C (73.4 °F)
GENERATOR
Generator:
120 V (Br-R) V 114 ~ 140
240 V (Br-L) V 225 ~ 275
120 V (Br-R) V 20 ~ 30
240 V (Br-L) V 40 ~ 60
Sub coil AC voltage
120/240 V (G-G) V 4 ~ 12
Exciter stator coil voltage V 10 ~ 20
3-131
25

SPEC
Coil resistance
Main coil (Br-R) (Ω ± 10%) 0.16
(Br-L) (Ω ± 10%) 0.45
Field coil (rotor assembly) (Ω ± 10%) 28
Sub coil (G-G) (Ω ± 10%) 0.35
Exciter stator coil (Ω ± 10%) 45
Exciter rotor coil (Ω ± 10%) 1.7
ELECTRICAL
Electrical:
Ignition system
Ignition timing at 3,600 r/min BTDC 23° ± 3°
Gap 0.7 ~ 0.8 (0.028 ~ 0.031)
Secondary coil resistance (KΩ ± 20%) 12
Spark plug cap resistance (KΩ) 3.0 ~ 7.5
Air gap between TCI unit
and flywheel mm (in) 0.5 (0.020)
W-Ground (Ω ± 20%) 2.3 — 2.3
G/R-Ground (Ω ± 20%) 1.7 1.1 1.7
Economy idle system
(economy idle unit) V 10 ~ 18
voltage (DC) V 10 ~ 18
resistance (Ω ± 10%) 35.5
Depth of insulator mm (in) 0.4 ~ 0.8 — 0.4 ~ 0.8
(0.0157 ~ — (0.0157 ~
0.0315) 0.0315)
Brush spring pressure N (Kgf, lbf) 13 — 13
(1.325, 2.91) (1.325, 2.91)
Insulation resistance (MΩ) More than 0.1 — More than 0.1
Wear limit length mm (in) 6 (0.24) — 6 (0.24)
Holding coil resistance å-∫ (Ω ± 20%) 1.1 — 1.1
Pull-in coil resistance å-ç (Ω ± 20%) 0.5 — 0.5
Battery
Capacity 12 V-26 Ah — 12 V-26 Ah
3-132
26

YG6600D
å Condenser ç Economy idle unit ∂ Pass the longer brown COLOR CODE
∫ Negative side is indi- lead through the econ- B ......... Black
cated in black. omy idle unit coil. Br ........ Brown
L .......... Blue
R ......... Red
Y ......... Yellow
L/R ...... Blue/Red
G/Y
A
å ∂ å
B/W
Y Br R
L/R
Y
B/W
å
Br R
Y B/W
B Br L Br
Br
Br Br R
R Br
Y
Y
G/Y
Br R Br Br G/Y L B W
G/Y G/Y
R
Br L Br ∫
Y
G
30
3-133

YG6600DE
å Condenser ç Economy idle unit ∂ Pass the longer brown COLOR CODE
∫ Negative side is indi- lead through the econ- B ......... Black
cated in black. omy idle unit coil. Br ........ Brown
L .......... Blue
R ......... Red
Y ......... Yellow
L/R ...... Blue/Red
G/Y
ç A
å ∂
L/R Y
B/W
Br R
B/W
R/W Y
Br
R
å
R Y B/W
B L Br
Br
Br Br Br
R Br R
Y
Y G/Y
B W
Br L
Br R
G/Y
Br
G/Y
R G/Y Br
L Br ∫
Y
G
31
3-134

ELECTRICAL COMPONENTS AND
Current ModelCIRCUIT DIAGRAM
Specifications ELEC – YG6600DE
–
and Wiring Diagrams
+
YG6600DE
1 Start switch
2 Economy switch
3 Engine switch
4 Oil warning light
5 Voltage meter
7 AC receptacle (125 V-20 A, GFCI)
A AC switch (120 V, NFB) PWV0350
B AC switch (240 V, NFB)

C Exciter stator assembly
D Stator assembly
E Rotor assembly
F Oil level switch
G Spark plug
H TCI unit
I Oil warning unit
J Rectifier
K AVR
L Condenser
PWV0360
M Economy idle unit
N Ground terminal
O Fuse (10 A)
P Rectifier/regulator
Q Solenoid valve
G/Y
PWV0370
3-135
23

YG6600DE
7
YG6600DE
G/Y
G
L
L L G/Y R G/Y R G/Y R G/Y R L

R R R
8
240V
V 6 G/Y
9 0
120V
R R Br Br
3 7
7 Br Br Br Br A
ELECTRICAL
5 1 Br Br
Br
K
WIRING DIAGRAM

B B
G Y L/W J
G Y L/W
I
Y Y B B
4 Y Y W W
G G
G G G G W W
G G
G G
B B
B B B B Y Y
W W W W R R
G G H
C
COMPONENTS
2 L B D
M G E R/W
B R/B R R
G
B/W Y W B/W R/W Br
N R G/R
3-136
24
Y
L Y B/W B B/W L/R
W R B R/W Br R
R R Y B
G/R B/W R/B R
B/W Y R/W
Y
O Y
L
B/W
R/W G/R
G/R
W L/W B G/R G/R B L/W
G/R B L/W Y Y L/W B
Y
G/R Y
B B/W W G/R R/W
B F
G/R B L/R
L/R L/W
V T L/W R
B Q
R
AND CIRCUIT DIAGRAM
X P 1 Rotor assembly D Engine switch Q Carburetor heater COLOR CODE

U 2 Generator assembly E Remote control terminal R Battery B ..............Black L/R........... Blue/Red
W S M 3 Main coil F Rectifier S Starter motor Br .............Brown L/W.......... Blue/White
R 4 Sub coil G Fuse (10 A) T Magnetic switch G ..............Green R/B .......... Red/Black
5 Exciter field coil H Rectifier/regulator U Charging coil L ...............Blue R/W ......... Red/White
6 Voltage meter I AVR V TCI unit R ..............Red
ELEC
7 AC switch (NFB) J Condenser W Spark plug W .............White

8 GFCI (125 V-20 A) K Economy idle unit X Oil level switch Y ..............Yellow
–
9 AC receptacle (125 V-20 A) L Oil warning unit B/W ..........Black/White

0 AC receptacle (125 V-30 A) M Oil warning light G/B...........Green/Black
A AC receptacle (125/250 V-30 A) N Solenoid valve G/Y...........Green/Yellow
+
B Ground terminal O Economy switch G/R ..........Green/Red

C Start switch P Carburetor solenoid valve
PWV0420
EF6600DE YG6600D YG6600DE

7WW2
894 (35.2) 670 (26.4) 894 (35.2)

520 (20.5) 510 (20.1) 520 (20.5)
510 (20.1) 560 (22.0)
90 (198.4) 85 (187.4) 92 (202.8)
4-stroke OHV forced air cooled

1
0.357 (357)
85.0 × 63.0 (3.35 × 2.48)
8.1 : 1
7.1 (9.6)
6.6
Unleaded regular gasoline
21.0 (4.62, 5.55)
1.1 (0.97, 1.16)
4-stroke engine oil API service classification SE or SF, if not available, SD
(5W-30)
Forced splashing
Semi-wet (Urethane foam)
Forced air cooling
TCI
Recoil stater
Misfire
Clockwise (from flywheel)
Centrifugal weight system
BPR4ES (NGK)
0.7 ~ 0.8 (0.028 ~ 0.031)
34
3-137

Brushless, self-exciting, single-phase, synchronous generator
Single phase
2
Self magnetization
Residual magnetization
Direct connection
1
Less than 5%
Less than 10%
120/240
60
6.0
50.0/25.0
NFB (No fuse breaker)
3,600
2,350
AVR
More than 10
E class
B class
20 A (125 V) × 1, 30 A (125 V) × 1,
20 A (250/125 V) × 1 30 A (250/125 V) × 1
3-138
36

0.015 ~ 0.029 (0.0006 ~ 0.0011)

0.100 (0.0039)
84.977 ~ 84.998 (3.3455 ~ 3.3464)
84.900 (3.3425)
10.0 (0.4)
85.25 (3.3563)
85.50 (3.3661)
20.000 (0.7874)
20.020 (0.7882)
19.995 ~ 20.000 (0.7872 ~ 0.7874)

19.950 (0.7854)
Barrel face
1.5 × 3.6 (0.059 × 0.142)
0.20 ~ 0.35 (0.008 ~ 0.014)
0.9 (0.0354)
0.04 ~ 0.08 (0.0016 ~ 0.0031)
0.1 (0.0039)
Taper
1.5 × 3.6 (0.059 × 0.142)
0.20 ~ 0.35 (0.008 ~ 0.014)
0.9 (0.0354)
0.03 ~ 0.07 (0.0012 ~ 0.0028)
0.1 (0.0039)
3-piece type
3.0 ~ 2.8 (0.118 ~ 0.110)
0.20 ~ 0.70 (0.008 ~ 0.028)
0.9 (0.0354)
38
3-139

SPEC
0.05 (0.002)
85.000 ~ 85.020 (3.3465 ~ 3.3472)

85.020 (3.3472)
0.05 (0.002)
0.05 (0.002)
0.20 ~ 0.65 (0.008 ~ 0.026)

0.8 (0.032)
0.04 (0.0016)
35.969 ~ 35.984 (1.4161 ~ 1.4167)
35.9 (1.4134)
20.006 ~ 20.020 (0.7876 ~ 0.7882)

0.006 ~ 0.025 (0.0002 ~ 0.0010)
36.000 ~ 36.015 (1.4173 ~ 1.4179)
0.015 ~ 0.045 (0.0006 ~ 0.0018)
0.1 (0.004)
32.55 ± 0.05 (1.28 ± 0.002)

32.40 (1.276)
32.55 ± 0.05 (1.28 ± 0.002)
32.40 (1.276)
26.08 ± 0.05 (1.03 ± 0.002)
25.93 (1.021)
26.08 ± 0.05 (1.03 ± 0.002)
25.93 (1.021)
15.965 ~ 15.990 (0.6285 ~ 0.6295)
15.950 (0.6280)
3-140
40

32.0 (1.26)
27.0 (1.06)
5.948 ~ 5.963 (0.2342 ~ 0.2348)
5.940 ~ 5.955 (0.2339 ~ 0.2344)
5.9 (0.23)
5.9 (0.23)
88.1 (3.47)
87.9 (3.46)
0.7 ~ 0.9 (0.0276 ~ 0.0354)

0.7 ~ 0.9 (0.0276 ~ 0.0354)
1.4 (0.551)
1.4 (0.551)
0.7 ~ 0.9 (0.0276 ~ 0.0354)
0.7 ~ 0.9 (0.0276 ~ 0.0354)
1.4 (0.551)
1.4 (0.551)
0.01 (0.0004)
90°
6.000 ~ 6.012 (0.2362 ~ 0.2367)

6.000 ~ 6.012 (0.2362 ~ 0.2367)
0.037 ~ 0.064 (0.00146 ~ 0.00252)
0.045 ~ 0.072 (0.00177 ~ 0.00283)
0.08 ~ 0.12 (0.0031 ~ 0.0047)
0.08 ~ 0.12 (0.0031 ~ 0.0047)
0.5 (0.02)
3-141
42

©2009 Yamaha Motor Corporation, U.S.A.
Printed in U.S.A.
LIT-BKTEC-GN-01

DiagnosticsYamaha Ef4500ise (001 218)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DiagnosticsYamaha Ef4500ise (001 218)

Uploaded by

Copyright:

Available Formats

YAMAHA GENERATOR

THEORY & DIAGNOSTICS

Downloaded from www.Manualslib.com manuals search engine

All rights reserved. Any reprinting

Downloaded from www.Manualslib.com manuals search engine

GENERATOR INFORMATION AND THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1

Downloaded from www.Manualslib.com manuals search engine

All models of Yamaha generators run on regular

the outlet without modification of the AC sine wave.

Downloaded from www.Manualslib.com manuals search engine

Air intake Fuel tank cap Fuel gauge

Main switch Economy control switch DC output AC receptacles

Fuel pet cock

Downloaded from www.Manualslib.com manuals search engine

Generator Information and Theory

Power Generation ■ Throttle motor (stepping motor)

Downloaded from www.Manualslib.com manuals search engine

Alternator Recoil starter

Yamaha Generator Theory

AC OUTPUTS Reference information:

Multi-pole Alternator Features

Downloaded from www.Manualslib.com manuals search engine

Yamaha Generator Inverter System

PRINCIPLES OF POWER GENERATION WITH AN INVERTER PORTABLE GENERATOR

*Synchronous Generator — Theory & Troubleshooting

s Generator — Theory & Troubleshooting

For generators with a condensor control

The altered flux line distorts the output sine.

Caution during assembly:

If the engine is difficult to start after the carbure-

Economy switch ON: 2800 rpm (with no load)

Downloaded from www.Manualslib.com manuals search engine

Continuous Running Time The frequency variation of Yamaha inverter gen-

Downloaded from www.Manualslib.com manuals search engine

Instantaneous Frequency Fluctuation & Electronic Breaker

Characteristics of Electronic Breaker

Downloaded from www.Manualslib.com manuals search engine

Control Panel Output Indicator

■ To return the generator to normal output

Downloaded from www.Manualslib.com manuals search engine

• Alternator Cooling fan Fan case

Cooling air inlets

Muffler Generator cooling air inlet

Downloaded from www.Manualslib.com manuals search engine

B/W B/W B/W B/W

8 Ground (Earth) terminal

0 Overload indicator light

B/W B/W B/W B/W

y Oil level gauge

DC 12V circuit is entirely separated from!5AC circuit.

to generate rated DC-output.

Rectifier (for DC output)

Polarity of rectifier 7VU-87105-00

Downloaded from www.Manualslib.com manuals search engine

Battery Charging First-aid procedures: If your skin or clothes

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Power Boost Technology

DC-DC Converter (Power Boost Technology)

Designation of LED Indicators:

Green LED Red LED Designation

Green LED Red LED Designation