Yamaha EF2800i Service Repair Manual
DESCRIPTION:
Yamaha EF2800i Service Repair Manual
FOREWORD:
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s edumtion into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha generators have a basic under-, standing of the mechanical precepts and pro-V cedures inherent to generator repair technology. Vifithout such knowledge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company Ltd. is continually striving to further improve all models manufac‘ tured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
MANUAL FORMAT:
The procedures in this manual are organized in a sequential, step-by-step format. The infor- mation has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explana— tions of all cflsassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course.
- Bearings
- Pitting/damage —> Replace.
TABLE OF CONTENTS:
Yamaha EF2800i Service Repair Manual
CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION 1-1
SERIAL NUMBER 1-1
STARTING SERIAL NUMBER 1-1
IMPORTANT INFORMATION 1-2
PREPARATION FOR REMOVAL AND
DISASSEMBLY 1-2
CAUTION ON SERVICE 1-2
NOTES ON SERVICE 1-2
ALL REPLACEMENT PARTS 1-3
GASKETS, OIL SEALS,
AND O-RINGS 1-3
BEARINGS AND OIL SEALS 1-3
SPECIAL TOOLS AND TESTERS 1-4
CHAPTER 2
PERIODIC INSPECTIONS
AND ADJUSTMENTS
INTRODUCTION 2-1
PERIODIC MAINTENANCE/LUBRICATION
INTERVALS 2-1
ENGINE 2-2
ENGINE OIL LEAKAGE
CHECKING 2-2
OIL LEVEL CHECKING 2-2
OIL REPLACEMENT 2-3
FUEL LEAKAGE 2-4
FUEL COCK STRAINER
INSPECTION 2-4
FUEL TANK FILTER 2-5
AIR FILTER ELEMENT 2-6
MUFFLER 2-7
VALVE CLEARANCE
ADJUSTMENT 2-8
COMPRESSION PRESSURE 2-10
RATED ENGINE SPEED 2-11
BREATHER HOSE 2-11
ELECTRICAL 2-12
SPARK PLUG 2-12
ENGINE SWITCH 2-13
ECONOMY SWITCH 2-13
PILOT LIGHT 2-13
RECEPTACLE 2-14
CHAPTER 3
ENGINE
CONTROL PANEL 3-1
CONTROL BOX COVER
AND FUEL TANK 3-3
MUFFLER AND AIR CLEANER 3-4
BREATHER HOSE INSTALLATION 3-5
MUFFLER ASSEMBLY 3-5
CONTROL UNIT AND AC-CDI UNIT 3-6
ENGINE 3-7
CYLINDER HEAD COVER AND CYLINDER
HEAD 3-8
PUSH ROD INSPECTION 3-10
CYLINDER HEAD INSPECTION 3-10
CYLINDER HEAD ASSEMBLY 3-11
BREATHER HOSE ASSEMBLY 3-11
VALVE 3-12
VALVE AND VALVE SPRING
REMOVAL 3-13
VALVE AND VALVE SPRING
INSPECTION 3-13
ROCKER ARM INSPECTION 3-14
VALVE SEAT INSPECTION 3-15
VALVE LAPPING 3-16
VALVE AND VALVE SPRING
ASSEMBLY 3-17
RECOIL STARTER 3-18
RECOIL STARTER
DISASSEMBLY 3-20
RECOIL STARTER INSPECTION 3-20
RECOIL STARTER ASSEMBLY 3-21
GENERATOR 3-23
MAGNETO ROTOR AND STATOR COIL
ASSEMBLY REMOVAL 3-25
MAGNETO ROTOR AND STATOR COIL
ASSEMBLY INSTALLATION 3-26
CRANKCASE COVER
AND CAMSHAFT 3-28
CAMSHAFT INSPECTION 3-29
VALVE LIFTER INSPECTION 3-30
CAMSHAFT ASSEMBLY 3-30
CRANKCASE COVER
INSPECTION 3-30
CRANKCASE COVER
INSTALLATION 3-30
PISTON, CONNECTING ROD, CRANKSHAFT
AND CRANKCASE 3-31
CRANKCASE (CYLINDER)
INSPECTION 3-32
PISTON AND PISTON
PIN INSPECTION 3-32
PISTON RING INSPECTION 3-34
CRANKSHAFT INSPECTION 3-34
CONNECTING ROD OIL
CLEARANCE INSPECTION 3-35
PISTON RING
AND PISTON ASSEMBLY 3-36
CRANKSHAFT ASSEMBLY 3-37
CARBURETOR 3-38
FLOAT HEIGHT INSPECTION 3-40
CHOKE CABLE INSTALLATION 3-41
THROTTLE CONTROL MOTOR 3-41
TROUBLESHOOTING 3-42
ENGINE 3-42
THROTTLE CONTROL SYSTEM 3-48
CHAPTER 4
ELECTRICAL
ELECTRICAL COMPONENTS 4-1
CIRCUIT DIAGRAM 4-2
SWITCHES 4-3
CHECKING SWITCH CONTINUITY 4-3
IGNITION SYSTEM 4-4
TROUBLESHOOTING CHART 4-4
GENERATOR SYSTEM 4-9
TROUBLESHOOTING CHART 4-9
CHAPTER 5
SPECIFICATIONS
GENERAL SPECIFICATIONS 5-1
MAINTENANCE SPECIFICATIONS 5-3
ENGINE 5-3
GENERATOR AND ELECTRICAL 5-6
TIGHTENING TORQUE 5-7
GENERAL TORQUE
SPECIFICATIONS 5-8
DEFINITION OF UNITS 5-8
WIRE ROUTING DIAGRAM 5-9
CONTROL BOX PANEL AND BEHIND
CONTROL BOX 5-9
ENGINE AND GENERATOR 5-10
VIDEO PREVIEW OF THE MANUAL:
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PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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Eric –
Satisfactory