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Service Manual em 10000

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230 views

Service Manual em 10000

Uploaded by

Martin
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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—M10000-ET12000 INTRODUCTION CONTENTS This manual covers service and repair procedures for Honda EM10000+ET 12000 Generators. ‘SPECIFICATIONS Al information contained in this manual is based on the lat- et product information available atthe time of printing. We reserve the right to make changes at anytime without notice [No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic, mechanical, photocopying, recording, or other- wise, without prior written permission of the publisher. This includes tex, figures, and tables. ‘As you read this manual, you wil find information thats pre- ceded by a INOTICE! cymbol. The purpose of this message is to help prevent damage to the generator, other property, (oF the environment. SAFETY MESSAGES Your safety, and the safety of others, are very important. To help you make informed decisions, we have provided safe- ty messages and other safety information throughout this ‘manuel, Of course, itis not practical or possible to wam you ‘about all the hazards associated with servicing this genera tor. You must use your own good judgment. You will find important safety information in a variety of forms, including ‘+ Safety Labels — on the engine cover. + Safety messages — Preceded by a safety alert symbol Nand one of three signal words, DANGER, WARNING, or CAUTION. ‘These signal words mean: WEN You WILL bo KILLED or SERIOUSLY HURT if you dont folow instructions. MENU You CAN bo KILLED or SERIOUSLY HURT if you dont follow instructions PNEUIINE You CAN be HURT if you dont follow instructions, + Instructions — how to service this generator correctly and. safely, Honda Motor Co., Ltd. ‘SERVICE INFORMATION MAINTENANCE BATTERY MAINTENANCE COVER/CENTER BEAM FUEL TANK/FUEL VALVE AIR CLEANER/MUFFLER CONTROL BOX GENERATOR ENGINE REMOVALINSTALLATION FAN COVERIFLYWHEELIGNITION COILS CONTROL BASE/GOVERNOR FUEL PUMPICARBURETOR STARTER MOTOR CYLINDER HEADS/VALVES CRANKCASE/CRANKSHAFT/PISTONS WHEEL (OPTIONAL PART) Cc oe re ee I) a INDEX —M10000-ET12000 1. SPECIFICATIONS 1. SPECIFICATIONS. 14 2. CHARACTERISTICS 12 3. PERFORMANCE CURVES 1-4 4, DIMENSIONAL DRAWING. 17 5. WIRING DIAGRAM 18 2, SERVICE INFORMATION THE IMPORTANCE OF PROPER SERVICING 24 2. IMPORTANT SAFETY PRECAUTIONS .... 2-1 3, SERVICE RULES 22 4. SYMBOLS USED IN THIS MANUAL 23 5. SERIAL NUMBER LOCATIONS: 23 6. MAINTENANCE STANDARDS 24 7. TORQUE VALUES 26 8, SPECIAL TOOLS. 28 9, TROUBLESHOOTING 29 a. ENGINE 29 b. IGNITION SYSTEM 244 ©. FUEL CUT SYSTEM 247 d. COVER SAFETY SYSTEM (€T12000 only) 249 fe. STARTING SYSTEM 220 {. CHARGING SYSTEM 221 g. LUBRICATION SYSTEM 222 h. GENERATOR 223 10.CABLE & HARNESS ROUTING. 231 3. MAINTENANCE 1, MAINTENANCE SCHEDULE at 2. ENGINE OIL, 32 3, ENGINE OIL FILTER 33 4, AIR CLEANER a4 5. SPARK PLUGS 36 6. BATTERY 36 7. VALVE CLEARANCE a7 8, SEDIMENT CUP 39 9. GOVERNOR 39 10.FUEL TUBES 340 4, BATTERY 1, BATTERY 44 2. BATTERY CHARGING 42 5, MAINTENANCE COVERICENTER BEAM 1, MAINTENANCE COVERICENTER BEAM . 5-1 6. FUEL TANK/FUEL VALVE 4. FUEL TANK et 2. FUEL VALVE 63 7. AIR CLEANER/MUFFLER 1. AIR CLEANER 2. AIR DUCTS 3, MUFFLER, 8. CONTROL BOX 1. CONTROL BOX 2. CONTROL PANEL, ‘9, GENERATOR 1, REAR HOUSING/STATOR 2, ROTOR/FRONT HOUSING 10.ENGINE REMOVALINSTALLATION 1, ENGINE REMOVAL 2, FRAME/BOTTOM RUBBERS: 3, ENGINE INSTALLATION 11.FAN COVER/FLYWHEEL/IGNITION COILS 1. FAN COVER 2. COOLING FAN/FLYWHEEL/ IGNITION COILS CHARGE COILISIDE PLATES BREATHER COVER 12.CONTROL BASE/GOVERNOR 1, CONTROL BASE/GOVERNOR ARM 13.FUEL PUMP/CARBURETOR 1. FUEL PUMP 2. CARBURETOR 14.STARTER MOTOR 1, STARTER MOTOR 15.CYLINDER HEADS/VALVES 1, CYLINDER HEADS 2. VALVE GUIDE REPLACEMENT 3, VALVE SEAT RECONDITIONING. 16.CRANKCASE/CRANKSHAFT/PISTONS. 1. CRANKCASE COVER, 2. OIL PUMP/GOVERNOR 3, CRANKSHAFT/CAMSHAFT/ CYLINDER BLOCK 4, PISTONS 5. VALVE LIFTERIOIL LEVEL SWITCH ‘17. WHEEL (OPTIONAL PART) 1, WHEEL (OPTIONAL PART) 7 72 74 at 89 on 96 10-4 10-3 10-4 14-2 116 118 124 134 13.2 144 15-4 158 159 164 16-3 166 16-12 16-15 17-4 —M10000-ET121 1. SPECIFICATIONS 1, SPECIFICATIONS 2. CHARACTERISTICS, 4, DIMENSIONAL DRAWING 5. WIRING DIAGRAM 3, PERFORMANCE CURVES Bore x Stroke Maximum horsepower 1. SPECIFICATIONS * DIMENSIONS AND WEIGHTS ‘Model - M1000 712000 Description code EATS EAUS Type a RG a RG ‘Overall length 973 mm (38.3 in) ‘Overall wiath 552 mm (21-7 in) ‘Overall height 637 mm (25.1 in) Dry weight 150 kg (834 Ibs) Carb weight 175.2 kg (886 Ibs) * ENGINE Model GX620KT Description code | 6c Type 7 — stroke, overhead vaive, 90° V-win —__| Displacement 614 om? (87.5 cu in) 77 x 66 mm (3.0 x26 in) 14.9 KW 20 PS) at 3,600 mi* (pm) [Lubrication sysiem Max. torque 44.1 Nim (4.5 kgfm, 32.5 Ibtft) at 2,500 min (rpm) Compression ratio 83:1 Cooling system Forced-air cooling Ignition system | Transistorized magneto ignition lanition ining 20° BTDC (Fixed) | Spark plug ZGRSA (NGK), J16CR-U (DENSO) — Carburetor Horizontal, buttertly valve type Air leaner Dual element ype Governor s—s—~—| FUEL FILTER restricted, »[ Clean or replace: P. 6-1 FUEL PUMP restricted | —+[ Replace: P. 13-1 >| FUEL PUMP DIAPHRAGM TUBE [Replace or reconnect P. 13-1 damaged or disconnected (Reemee onrcronnee = |>[ CARBURETOR fauity. | >| Disassemble and inspect. 13-4 | [RuEL eur soLENOD aay. | [apace 108 ‘Troubleshooting: P. 2-17, |»{ GOVERNOR out of adjustment | —>[ Adjust: P39 |e [ IGNITION SYSTEM mattunction. | ——»[ Troubleshooting: P. 2-14 | -(aseion SOUT ate —]} —+ [reece] L=[TGNITION COIL AIRGAP | —_»l Adjust: P. 11-5 Inoonect IGNITION SWITCH tay. | —»[Inapoct P12 SPARK PLUG fay | [inspect F3-5 | »[OIL ALERT SYSTEM malfunction. | ——>[ Troubleshooting: P. 2-16 }»[OIL LEVEL SWITCH fauity. | >| Inspect: P. 16-17 > [OIL ALERT UNIT uty. | —»[Troubleshootng: F216 +d -£T12000 Only » [COVER SAFETY SYSTEM matunaton, | >| Troubleshootng:P.2-70 | s»[ TERMINAL COVER SWITCH fauty. | —»[ Inspect P. 8-11 EM10000-ET12000 Engine lacks VALVE CLEARANCE incorect | —»{aast P67 power >» [ CARBURETOR fauty || Dissssembieandinepect P. 184 |—>[ GOVERNOR out of adjustment. | —>[Aduse P38 |» [SPARK PLUGIS) faut | —>[Repiace: P35 |—»[ IR GLEANER reseed | [ean orroplace: 3-4 inspect and recondition: P. 15-9 VALVE, VALVE SEAT wom or >| amat | |= [OYLINDER, PISTON, PISTON RING |» Disassemble and inspect wom. P.16-12 theu, 16-14 Engine speed too | ——»| CARBURETOR faulty | —»[ Disassemble and inspect: P. 13-4 Tow or too high |»[ GOVERNOR out of adjustment. |-_——»[ Adjust: P. 39 | sLTGNITION COILS) faulty. | —+Tnspect: P. 11-4 Engine speed does (CARBURETOR faulty | [Disassemble and inspect: P. 13-4 not stabilize, > [GOVERNOR out of adjustment. | —»f adjust P88 of IGNITION COIL(S) faulty. }—>{ Inspect: P. 2-10 —M10000-ET12000 + Hard Stating 1 Check that the starter motor should turn with the ignition switch turned to START position. T Starter motor turns. Y 2. Check the AC terminal cover. T Closed y [/3. Check the engine oil level T Sulficient oil a “4. Check the fuel level in the tank. Sulficient fuel in the tank ' '5 Loosen the carburetor drain screw and check whether fuel reaches the carbure- tor. os Reaching the carburetor ' 6. Remove the spark plugs and check for wet or fouled electrode, Normal [7 Perform spark test Good ‘spark iy '& Check compression of each ayn 212) Normal y Reinstall the spark plugs securely and restart the engine according tothe starting procedure, Starter motor —>! {does not tum. | Open >| Low il evel —>{ No fuel in ——> the tank |— Not reaching —>/ the carburetor Oy wet ——>| No spark or —>| ‘weak sparks Compression —>{ is too high. Compression —>| is oo low. Perform "e. STARTING SYSTEM" troubleshooting (P. 2-20) ‘lose the AG terminal cover securely. | ‘Add the recommended ol ‘Add fuel ‘Check for blockage of the fuel line, fuel fiter ‘or fuel pump, ‘Check for blockage of the carburetor port and Nozzle, or check the fuel cut solenoid for prop er operation ‘+ Clean the electrodes and restart being sure thal the choke is not closed to much. + If flooding is severe, check the carburetor float valve Perform “b. IGNITION SYSTEM’ troubleshooting (P. 2-14) Check for carbon deposits in the combustion chamber. | ‘+ Check that the valve clearance is correct * Check for defective cylinder head gasket, valves or valve seats. (Check that the cylinder head is correctly tightened. CCheck for worn piston, piston rings or oylinder. 2-11 EM10000-ET12000 + Engine Start but Then Stalls. “Check the fuel evel in the tank. the tank Sufficient fuel in the tank y 2.Loasen the carburetor drain screw and No fuel in Not reaching —»{ Check for blockage ofthe fuel line, fuel fiter >[ Add fuel “Inspect the carburetor and intake mani- fold mounting bolts for looseness, and carburetor gaskets and intake manifold | ety ‘gaskets for damage, Normal 5.Check compression of each cylinder. | | Normal Reise he spark plugs secure and procedure. a * _ * Cylinder Compression Test 1) Remove the both spark plugs. 2) Install a compression gauge (commercially available) to the spark plug hole, 3) Tum the starter motor unt stable compression obtained. * Do not operate the starter motor more than 5 seconds at one try If stable compression is not obtained within 5 seconds, stop the starter motor and wait 10 - 20 sec: fonds and repeat operation again. | 059-0183 MPa (60-85 kgllcme, 85 - 121psi) Cylinder compression ‘check whether fuel reaches the carburetor.| the carburetor | oF fuel pump. Reaching the carburetor es ‘3. Check the fuel cut solenoid for proper — Abnormal ——»{ Perform *c. FUEL CUT SYSTEM" ‘operation (P. 13-8), troubleshooting (P. 2-17). Normal ¥ Loose bolts or > Rtighten the carburetor mounting bots | damaged gas- ne nt te ithe ‘Compression —»{ Check for carbon deposits in the combustion is too high. Compression —»{ + Check that the valve clearance is correct, is too low. or intake manifold mounting bots, they * Install the carburetor gaskets and intake manifold gaskets correctly. + Replace the carburetor gasket or intake manifold gasket, i they are damaged. chamber. * Check for defective cylinder head gasket, valves or valve seats. + Check that the cylinder head is correctly tightened * Check for wom piston, piston rings or oylinder. ‘COMPRESSION GAUGE (Commercially available) 2-12 —M10000-ET12000 + Abnormal Engine Speed (Engine Speed Too High, Too Low, or Not Stabilized) 1. Check the governor adjustment is cor. | rect Correct 1 y 2. Check the valve clearance, Tl Correct ¥ 8. Remove the spark plugs and check the electrodes for carbon deposits and plug ge. Normal y 4, Check for the blockage in the main jet or |_—__ nozzle of the carburetor. Normal y '. Ghesk the fuel cut solencid for proper Operation (P. 13-6). Normal ¥ 6. Inspect the carburetor and intake mani- {fold mounting bolts for looseness, and ‘carburetor gaskets and intake manifold {gaskets for damage. [geste er eemege Normal ¥ 7. Check compression of each cylinder (P. 212) 8 Normal Ty. Reinstall the spark plugs securely and |ftaig enone sesorana oe trang procedure, Incorrect. ——»[ Adjust the governor (P. 3-9) Incorrect. ——>{ Adjust the valve clearance (P. 37). Abnormal »{ Glean the electrodes and adjust the plug gap. Foplace the spark plug f necessary, Clogged [Disassemble and clean, Replace if necessary. ‘Abnormal ——»{ Perform “c. FUEL CUT SYSTEM" lroubleshooting (P. 2-17) Loose bolts or —»{ Retighien the carburetor mounting bolts or damaged gaskets Compression Is too high. — Compression —»| is too low. intake manifold mounting bolts, if they are loose, + Install the carburetor gaskets and intake ‘manifold gaskets correctly. + Fleplace the carburetor gasket or intake manifold gasket, if hey are damaged >| Check for carbon deposits in the combustion chamber. ‘Check thatthe valve clearance is correct * Check for detective cylinder head gasket, valves or valve seats, + Check that the cylinder head is correctly tightened. + Check for wom piston, piston rings or eyin- ser. 2-13 E—M10000-ET12000 b. IGNITION SYSTEM -ET12000 onily-—-—- ( sc'reeuint coven + System Diagram Sire | (ON: Cover open) 1 iLL} | | cay ee | es, @ ox ii3l, 5 oe ewieS Lew L TTS TIE ence g r eS aise ee 'GuTON 5100 7 ovcne conraoe Sires + Yo” Faaearness SIRT ese 5 3 H hon here I nos 3 BORG BROWN fac] [ic] a WELLOWO. ORANGE e Star Bo Bue o> Leone ve = oni 6 GREEN [tg Llu GREEN + [ + T 8 R RED P| PINK ane mae oeceve. — [i wntre— Gr ena + IGEN Con + RAMEN COL = SwitcH woo 9,1 (R164 Sean PLUS Soankcrtug + Spark Test 1) Tum the fuel valve to the OFF position and drain the ‘gasoline from the carburetor. AWARNING Gasoline is highly flammable and explosive. {fignited, gasoline can bum you severely. * Be sure there is no spilled fuel near the engine, ‘Unbumt gas can ignite if ts left in the cylinder. * Release the unbumt gas from the cylinder before testing + Place the spark plug away from the spark plug hole. 2) Remove the spark plug caps and spark plugs 8) Turn the starter motor for 5 seconds to release the unbumed gas from the cylinders. 4) Attach a spark plug to the spark plug cap. '5) Tum the ignition switch to the ON position. Ground the negative (—) electrode (i.e. threaded part) of the spark plug against the cylinder head bolt and operate the elec- tric starter to check whether sparks jump across the electrodes. 66) Remove the spark plug from the spark plug cap and install the spark plug to the spark plug cap of the other cylinder. Perform the spark test 2-14 E—M10000-ET12000 ‘+ No Spark at Spark Plug 1 Disconnect the C17 connector (Backd Blue) from the ol alert unit wire inside of the connector cover beside the starter, motor and retest 17 CONNECTOR {BLACKIBLUE) WIRE No spark ¥ 2, Check the spark plug gap, and adjust it necessary. Perform the spark tes. ————— No spark or weak spark Y [ 3. Perform spark test again using anew spark plug, No spark Y 4. Check for voltage leakage caused by jamaged high tension wire. Normal i y 8, Disconnect the blackired wire C20 con- ‘nector inside of the connector cover beside the starter motor and retest. ¢20 CONNECTOR (BLACKIRED) ENGINE STOP DIODE WIRE, Spark ¥ Check the engine stop diode (P. 11-8). If the engine stop diode is normal, check the ignition coils, and replace if necessary. Spark >| Perform troubleshooting “Oil Alert Malfunction* (P. 2-16) | Incorrect ——»[ Adjust the governor (P. 3-9), Good spark ——»{ Replace the spark plug(s). ‘Abnormal »[ Replace the ignition coil (P. 112). — No spark >! EM10000: Gheck the ignition switch. if the ignition switch is normal, replace or repair the wire hamess, ET12000: Perform the troubleshooting “. COVER SAFETY SYSTEM" (P. 2-19) 2-15 E—M10000-ET12000 * Oll Alert Malfunction 1. Check the engine oil level T ‘Sufficient oil en 2. Disconnect the oil level switch wire C18 (Yellow) and 19 (Green)) connectors. Check for continuity between the ol level ‘switeh wite connectors. OL LEVEL, SWITCH WIRE NY / No continuity | {8 Drain the engine oll and check for cont- ruity between the oil level switch wire connectors, aires SWITCH WIRE Continuity y Faaplace the oil alert unt (P. 14). Low oil evel —>| Continuity ——>| |— No continuity —»| ‘Add recommended oll(P. 3-2) Replace the oil level switch (P. 16-5). Replace the oll level switch (P. 165) 2-16 —M10000-ET12000 c. FUEL CUT SYSTEM ‘+= System Diagram £71200 oniy—-—-— ‘AG TERMINAL COVER | @ recnren | i SwitcH {ONCover open) ey on, | § 5 [iT Lon £5 on on—[:2Lan-+ Lent eww. cow Sr. i wf FUEL CUT SOLENOID NN IguiTon (GN Hoot rojo. evane contr. surres (Ste Ndi ess) vaneraewess ine aeness SIT BLAGK Ter BROWN. [YELLOW [O- ORANGE By/BuE ub /UGHT BLUE G GREEN [tg UGHT GREEN R [RED (PINK W WATE 16 GAA oo + Fuel Cut Solenoid Malfunction (After burn, Engine stall or does not start) 1 Check the fuel cut solenoid (P. 13-6). ree Normal | 2. Check the fuel cut solenoid circuit Disconnect the fuel cut solenoid connectors (C18 and C16) Check for continuity between the Green/White and Green/Red wire terminals of the engine wire hamess with the ignition switch OFF. | — Abnormal Positive probe cis ce [Negative probe GreenvRed Greenwrite [ C15 GreeniRed Continuity C16 Green Write = —— + Use a Rx 1 scale of a commercially available multimeter ‘and the meter shows current flow from negative (-) to post tive (4), —— Normal y “a Goto P. 2-8. GREEN/RED ‘Abnormal Y ® Goto P. 2-18. Foplace the fuel cut solenoid (P. 13: FUEL CUT SOLENOID WIRE 2-17 From P. 2-17, a) 3, Ghesk the OG winding (P. 8-4), | — Abnormal ——» Replace the stator (P. 94). Normal (Check AC output normal, replace or repair the wire har- If abnormal, go toh. GENERATOR" troubleshooting (P. 2:23) From P. 2-17. @) Normal T12000 Only — (8-11) Norma Normal a Foplace or repair the wire hamess. 4. Check the AC terminal cover switch B | Abnormal ——m! Replace the cover switch B (P. E—M10000-ET12000 a ee ‘8. Check the ignition switch (P.6-12). | — Abnormal ——»{ Replace the ignition switch (P. 8-9 and 10). Replace the rector (P. 6-9 or 10) '5. Check the reciiier (P. 8-11). |— Abnormal —>| 2-18 —M10000-ET12000 d. COVER SAFETY SYSTEM (ET12000 only) + System Diagram RECTIER_ AGTERMINAL COVER [GN Corer open) evone See LEE ‘gumon f t — Sunrex Nozwern To No. iT) aaa | SSR sf wee YELLOW [0 [ORANGE 5 Babu feo ue LUE GREEN tg | ew eneeN Roneo. we na 20ern hte FUEL cur Wi wHITE ‘ar GRAY SBME | BNI ee ae) + System Inspection ‘Tur te ignition switch to OFF and disconnect the @® con- | ~ Abnormal —»[ Check the AC Terminal cover — ecto. wich A(P. 6-11). the cover Check for continuity beyween the No. 10 (BlacK/Yellow) and Switch is normal, replace or ‘No, 10 (Green) terminals of the connecter of he contol ‘epaire the contol wire hamess Wire harness withthe ignition swteh ON. ‘There should be continuity with the AG terminal cover ‘osed and no continuty wth the cover open Viewed fom terminal side Normal y 2 Check for continuly Beyween the No. 8 (GreeiWhite connect | — Abnormal —» Check the AG terminal cover ostveterster probe) and No.9 (GreenVFed connect nega: switch B (P- 6-11). the cover {ve tester probe) terminals ofthe @® connector ofthe cont Switch is normal, check th rec Wire hamecs with te ignition switch ON. and the conta wie harness. Use'a Rx 1 sal of a commercially avallable multimeter Freplace or repair if necassary. and the meter shows current flow fom negative () to pos ive ( e ‘There shouldbe continuity E withthe AC terminal cover vals [as closed and no continuity L214 1940 ‘with the cover open. Positive (@y NEGATIVE ropa (@) PROBR Viewed from terminal side Normal ‘Systems OK, wa —| is compete 2-19 E—M10000-ET12000 e. STARTING SYSTEM + System Diagram ee sonra, . » Bowes Meese ‘gun 2 ‘SWITCH g Fett 6 | Grae © tee wcnene Biman” eee cic SEE" iy oe Ue lugares BASo enreny tre oR * Starter Motor Does Not Turn 1. Ghesk the fuse (10A). Burt out »[ Replace the fuse (104). Good — y__ 2. Check the battery (P. $6). — Under charge — Good a 3. Ghesk the starter magnetic switch’ ]—— Abnormal -—»| Replace the magnetic switch/solenoid (P. 14- solenoid (P. 14-4), 2) Normal 4. Check the starter motor (P. 14-1 for per- | Abnormal ——»{ Replace or repair the starter motor (P. 14-1 formance tes). thru, 14-5), Normal 5. Check the ignition switch (P. 8-12). ‘Abnormal ——»{ Replace the ignition switch (P. 8-9 or 10). Normal Replace or repair the wire hamess. 2-20 —M10000-ET12000 f. CHARGING SYSTEM + System Diagram 31 BLACK [Br [BROWN Y | YELLOW [0 | ORANGE Bu BLUE | Lb | LIGHT BLUE G|GREEN tg | LIGHT GREEN R/RED (P| PINK W/ WHITE [er] GRAY CHAACECOL chor & or0s + Battery Under Charged 1. Check the fuse (10A). T Good Y a8 4 (Stanten maanenic iS 8 Stren TeAMINA E BATTERY Burnt out >| REGULATOR! RECTIFIER re alilalie vi! contro. 3 vnnenarness IGNITION Swircr Feplace the fuse (10) 2. Check the charge coil (P. 11-7), Normal ‘8. Cheek the ignition switch (P. T Normal ¥ 4. Check the regulatorireciir (P, 0-5), T Normal __ Y Foplace or repair the wire hamess. Abnormal >| ‘Abnormal aplaoe charge coil (P. 11-6) Abnormal »[ Replace the regulatorirectier (P. 2-21 E—M10000-ET12000 g. LUBRICATION SYSTEM + Symptom and Possible Causes [Low oil pressure | —-—»[OIL POW fay —>[npoat F164 > [OIL FILTER SCREEN resvcted, | ——»[ Inspect P.163 >>| OIL FILTER CARTRIDGE restricted. xf Replace: P. 3-3 ‘| * Oil Pressure Test 1) Make sure that the engine ol evel is correct. 2) Remove the sealing plug, 3) Install the ol pressure gauge attachment to the sealing plug installed hole TORQUE: 8 Nim (0.9 kgfm, 6.6 Int) = SSO pay OIL PRESSURE GAUGE Tighten the oll pressure gauge attachment tothe spect- fied torque. Do not ovenighten the oil pressure gauge | °7606-S000001 ‘attachment to avoid damaging the threads of the crankcase, 4) Connect the oil pressure gauge tothe ol pressure gauge attachment, lL. PRESSURE GAUGE 5) Start the engine and let it run approximately 10 minutes. | ATTACHMENT ‘Measure the oil pressure when the engine has reached | 07406-0030000 ‘normal operating temperature. ops Standard | 196 KPa ilpressure | (2.0 kgflom2, 28.4 psi) a 6) Remove the oil pressure gauge and attachment, 7) Clean the threads of the sealing plug and plug hole. Apply liquid sealant (Honda bond 4 or equivalent) and then tighten the sealing plug to the specified torque using Apply liquid sealant ‘a torque wrench TORQUE: 9 Nm (0.9 kgf, 6.5bF) (NOTICE) Tighten the sealing plug to the specified torque. Do not overtighten the sealing plug to avoid damaging the threads of the crankcase. 2-22 EM10000-ET12000 h. GENERATOR ‘+ System Diagram EM10000 Manion Fe a vital oo 2-23 E—M10000-ET12000 + Generator Test Points EM10000 ‘Sensor winding ‘Sensor winding Stator side connector Viewed from terminal side minal arrangement: Color | Remarks 1 [Light green’) Exciter winding White 3 |Light green/| Exciter winding White 4 |ReaWhite | DC winding 6 |ReaiWhite | DC winding ET12000 ‘Stator side connector viewed from terminal side Terminal arrangement: Viewed from terminal side ‘Terminal arrangement: (No] Color | Remarke NNo] Color | Remarks 1 Red | Sensor winding U) 2 | White | Sensor winding (V) 3 Black | Sensor wining (0) “4 [Bie | Sensor winding (W) @ Stator side connector 1 [Light green) Exciter winding White 3 | Light green!) Exciter winding white 1723 (POSITIVE BRUSH TERMINAL) ‘T24 (NEGATIVE BRUSH TERMINAL) 132 31 723 (POSITIVE BRUSH TERMINAL) ‘T24 (NEGATIVE BRUSH TERMINAL) 128 @ [ReaWwhite [DC winding 6 |RediWhite [DC winding 2-24 —M10000-ET12000 ‘+ Abnormal Output (none, low, or high) at Receptacle EG High voltage and electrical current present. Touching the non-insulated portions of the meter leads or gener- ator wiring can cause shock or electrocution. Wear insulated gloves and avoid handling non-insulat- 4 wiring, ‘Before troubleshooting, make sure that the circuit breaker is in the ON positon, {Remove te genertor end cover and hspect the | — Discotored —»[ Replace the stator P 9-2) Stor winding or ascoloraton ae 77a Aa STATOR WINDING [2 Ghoak he engine speed | — anormal —»[ Aust tho governor 39) Standard no load speed: 3,000 100 mint (rpm) T Normal ¥ ‘3, M1000: ET 12000: Check the main winding voltage between T21 and ‘Check the main winding output voltage between 728, ‘Tze terminals with the engine running at standard no —T27, 126, and Tes terminals with the engine running load speed, at slandard no load speed. Standard voltage Standard voltage: ‘T22 (White) — 721 (Brown): RG type: RG type: 230:+34 VAC. 728 (Black) — 127 (Blue): 290-494 VAC | Riype : 2203433 VAC 728 (Black) — T26 (White): 230-434 VAC 728 (Black) —725 (Rea) 25034 VAC ‘ype: 28 (Black) — T27 (Blue): 220-433 VAC 728 (Black) — 126 (White): 220:+33 VAC 728 (Black) — T25 (Reed): | 220-433 VAC = \ 728 (BLACK) 5 v a7 (eLue)— {NS 726 (WHITE) 725 (RED) (BROWN) 4 7 T T Normal { Sip sad cin cindy pen he oo cow. 228 SROAE Reads apse tp cla 2-25 EM10000-ET12000 From P. 2:25 | 4. Check the brush voltage between T23 (+) and "T24 (-) terminals withthe engine running at stan- dard no load speed ‘Standard voltage: 32:4 VOC 123 (4) (REDWHITE) | — Normal {Goto step @(P. ‘Abnormal q 5. Stop the engine. Check the brush voltage with the ignition switch ON. Perform this check quickly because power is. shut off approximately 15 seconds after the ign tion switch turned OFF. Standard voltage: 11 - 14 V (battery voltage) 409 (REDWHITE) (BLACK/WHITE) Abnormal “Tum the ignition switch OFF. Remove the control pana. Check for voltage Between the No. 1 {WhiterBie +) and No. 2 (Green -) terminals of the © connector ofthe contol wire hamess withthe igniton swatch ON ‘There should be battery voltage. y Goto P. 227. GREEN() © WHITEPBLUE (+) If there is battery voltage, goto step 10. I there is no vottage, check the ignition switch, fuse and open cicult in wire hamess. Replace or repair as necessary. 2-26 —M10000-ET12000 From P. 2.26. ' 6. Tum the ignition switch OFF, disconnect the brush terminals and remove the brush holder. ‘Clean and inspect the sip rings. Check for field winding resistance at the sip rings. Standard resistance: 49 - 590 SUP RINGS Normal y 7. Closely inspect the brushes for length, t ‘movement, continuity between the brush tip and terminal, and for unusual wear. Brush length: At least 9.5 mm (0.3 in) ‘There should be contiuity between the: outer brush and T23 terminal, and inner brush ‘and 724 terminal 2 Mt eres »| a 7 Goto P, 2.28. ‘Abnormal Replace the rotor (P. 8-6), ‘Abnormal ——» [ Replace the brush holder (P. 2-27 EM10000-ET12000 From P. 2-27. y ‘8. EMA0000: Disconnect the @ and @ connectors and T21 and 722 terminals. Measure the resistance between the terminals of the stator winding. Standard resistance Main winging ‘Sensor winding (® connector ‘Tat — T32 terminals: 0.2 - 0.42 No. 1 — No, 2 terminals 0.059 Max Exciter winding (@ connector No. 1 — No. 3 terminals: 1.6 - 209 132 T1200: Disconnect the @ and @ connectors and 725, 126, 127 and 728 terminals. Measure the resistance between the terminals ofthe stator winging Standard resistance: Main winding: ‘Sensor winding (@ connector 138 — 135 ferminals: 06-082 No. 3—No. 1 terminals: 0.08@Max. 738 — 136 terminals: 06-0.8 2 No. 3— No. 2 terminals: 0.08@Max. ‘138 — T37 terminals: 0.6 -0.8 2 No. 3— No. 4 terminals: 0,08@Max. Exciter winding (@ connector No. 1 —No, 3 terminals: 20 -2.5 2 | Replace the stator (P. 9-2), Goto P. 2.29. Sau 2-28 —M10000-ET12000 From P. 2.28. ¥ ‘8. Connect a known good 12V battery to the brush terminal (battery positive to T23 and negative to T24 terminals). Measure the voltage between the terminals of the stator winding with the engine running at no load speed, Standard voltage: M0000: Main winding: Sensor winding (@ connector T31 — T32 terminals: No. 1 —No. 2 terminals: 8:1 VAC RG type: 103-15 VAC Riype: 96:14 VAC Exciter winding (@® connector); No. 1 No.3 terminals: 33:5 VAC Sensor winding (@® connector): Er12000; Nov Ne Moma 1 VAC ing: No, 3— No. 2 terminals: 61 VAC RG Type: 738 —T35 terminals: 111416 VAC CT ENTS 738 — 736 terminals: 11116 VAC ‘738 — T37 terminals: 111216 VAC FiType: 738 — 135 terminals: 105415 VAC 738 — 736 terminals: 105215 VAC rrael ‘138 — 137 terminals: 10515 VAG 137 Exciter winding (@ connector): No. 1 — No, 3 terminals: 48:47 VAC 96 735 Abnormal Goto P. 2-30, Replace the stator (P. 9-2) 2-29 E—M10000-ET12000 From P. 2.29. a ® connectors from the AVR, ‘Measure the resistance of the stator winding at the wire hamess side connectors. M1000: T1200: ‘Standard resistance: Standard resistance: Exciter winding (@ connector): Exciter winding (@ connector): No, 1 —No. 3 terminals: 0.2 - 0.49 No. 1—No. $ terminals: 20-25 @ ‘Sensor winding (@ connector) Sensor winding (@ connector No. 2— No. 1 terminals: 0.052 Max. No. 2—No. 1 terminals: 0.08 QMax. No. 2—No. 8 terminals: 0.08 QMax. Field winding (® connector): No. 2—No. 4 terminals: 0.08 QMax. No. 1 — No. 2 terminals: 49 - 599 Field winding (@ connector) No, 1—No. 2 terminals: 49 - 599 AVR 10.Connect the all terminals and connectors to the generator. Remove the control box. Disconnect the ©, @ and on a @ ic GREEN/ LIGHT Q ay WHITE GREEN) Silat lol “ lal ns mn acomnre GREEN © LIGHT @ suse Say wots, QI ou al ae | ae ‘Viewed from terminal side | ¥ ¥ 2-30 E—M10000-ET12000 10. CABLE & HARNESS ROUTING CABLE BANDS (CHOKE CABLE CABLE STRAP BATTERY GROUND CABLE STARTER CABLE ‘CONTROL WIRE HARNESS ‘CABLE BANDS BATTERY GROUND CABLE STARTER CABLE WHITE TAPED MARKS Camp the white taped places ot the starter cable and battery ground cable, 2-31 —M10000-ET12000 12 (0 e 4is5 1|| oh 2| Control wire harness side connectors, Viewed from terminal side HARNESS CLIPS CONTROL WIRE HARNESS CABLE STRAP HARNESS CLIP: FUSE BOX HARNESS CLIP. ENGINE WIRE: HARNESS. WIRE HARNESS BANDS BATTERY GROUND CABLE STARTER CABLE 2-32 EM10000-ET12000 eos, OIL ALERT UNIT FUEL CUT SOLENOID WIRE. STARTER MAGNETIC ENGINE STOP. SWITCHISOLENOID. DIODE WIRE ENGINE WIRE (CHARGE COIL WIRE HaRNess ———_\ v4 ‘CORD TUBE HARNESS BAND (2) — XK RE ‘STARTER CABLE BATTERY GROUND > / eaBle HARNESS CLIP SwiTcH Wine NaRNEss BAND ou ALERT unr HARNESS CLIP wine lt Lever SwircH WIRE a TH ase10" : enone stop |_| sranrer | (Cee DIODE WIRE: CABLE | j |) eeteReeny | Lererroreuue ENGNE wRE HARNESS i i (GREEN) 20 LACKED) {To.Gnos) | \ ENGINE i wine il-se | cuarcecon NSS | 4 cietarany FUEL cur #2) crstoneswnen) }|.4— S0LENo wine j BATTERY GROUND STARTER CABLE CABLE 4 | 2-33 E—M10000-ET12000 M1000 Controt wire hamess side connectors Viewed from terminal side 729 (REDIWHITE) 724 (BLACKMHITE) GND? (YELLOW/GREEN) WIRE TIE HARNESS BAND “T2e (WHITE) 32 (Stator side) WIRE TIE Tat (Stator side) T21 (BROWN) REGULATOR/RECTIFIER 2-34 EM10000-ET12000 +7120 @ @ @® Control wire harness side connectors. Viewed from terminal side "728 (REDIWHITE) 24 (BLACKMWHITE) {GND2 (GREEN) HARNESS BAND WIRE TIE REGULATORRECTIFIER 2-35 E—M10000-ET12000 + EM10000 1 © 3 aft Git Mes Control wire harness side connectors viewed from terminal side Control wire harness side connectors ‘viewed from terminal side ‘CONTROL WIRE HARNESS IGNITION swiTcH HOUR METER WIRE BAND (2) CABLE TIE (2) RECTIFIER E Ts 1. (erown) (nie) ‘T11 (BROWN) 6 (veLLow VouTMETER SheEN) Ac RECEPTACLE (2) ae AC RECEPTACLE fear an) N01 (GROUND TERMINAL) (YELLOWIGREEN) AC RECEPTACLE (@a0v 20a) CIRCUIT BREAKER, 2-36 —M10000-ET12000 “ee @ @® @ 2 aay wa soiree comic tt circum WIRE BAND (2) BREAKER | Jonmon swircH CONTROL WIRE RECTIFIER Peco ® RARNESS CABLE TIE (3) T7 QWHITE) T6 (RED) r = f 7 lo @ iy acoureut Ra | foun (OTERMINALS. of METER (THREE PHASE) oS abt \ ® -\—— Z = 7 Za IU ) 13 od ° S (GREEN) OL 14 Reo) O yp © T2(warre ; ) \° ° g ; q ons 17 To AVR, S (BLACK) (BLUE) ‘19 (RED) S Tae qwurre) THs (RED) / vio (neem / M2 Tal our (GREEN) / (wnirey/ (BLACK) Vour 11 (BLACK) ACK/ YELLOW) AC TERMINAL COVER. caruacw YEON SRY Ct Qoovaay GND1 (GROUND TERMINAL) 1 (GREEN) >= (C4(GREEN/ WHITE) AC TERMINAL CO\ SWITCH B Not used. 3 (RED) (GREEN) VER 2-37 EM10000-ET12000 CONTROL WIRE HARNESS ® emroooo @® © im ep & 9 @ ewn2000 Control wire harness side connectors viewed from terminal side 2-38 —M10000-ET12000 FUEL TUBE Tube insertion length: 20-25 mm (0.8 1.0 in) TUBE CLIPS FUEL HOSE ‘CARBURETOR DRAIN TUBE Route the carburetor ‘TUBE CLIP drain ube as shown. FUEL HOSE RUBBER Set the fuel hose rubber at 805 mm (8.1:+02 in) from the tube end. 80:5 mm @1202 in) ‘TUBE CLIP FUEL HOSE There must be § mm (02 in) or ‘mate of the clearance to the end tthe frame. CARBURETOR DRAIN TUBE FUEL TUBE Insert the fuel tube up To the base ofthe joint 2-39 EM10000-ET12000 ‘TUBE CLAMP D8.5 FUEL HOSE FUEL TUBE A WIRE CLIP FUEL CUT SOLENOID WIRE See P. 239, HOSE CLIP FUEL TUBE B TUBE CLIP 810 (4) ENGINE STOP DIODE WIRE DIAPHRAGM TUBE WIRE CLAMP IL ALERT UNIT BREATHER TUBE No. 1 IGNITION coll, CHARGE cont” ENGINE STOP DIODE WIRE, ‘See P. 2-33 CHARGE COIL WIRE FUEL CUT SOLENOID WIRE 2-40 EM10000-ET12000 AIR CLEANER CASE HOSE CLIP FUEL TUBE A DIAPHRAGM TUBE == FUEL TUBE B ‘Seo P. 239 FUEL CUT ‘SOLENOID CARBURETOR DRAIN TUBE. ‘CARBURETOR DRAIN TUBE No. 2 IGNITION COIL, rn ‘S Eaine stop ENGINE STOP WIRE CLAMP TUBE CLIP DIODE WIRE, DIODE WIRE a 0! 20-30 mm (@-1.2In) ‘CARBURETOR DRAIN TUBE 2-41 E—M10000-ET12000 2-42 EM10000-ET12000 3. MAINTENANCE 1. MAINTENANCE SCHEDULE 6. BATTERY 2. ENGINE OIL 7. VALVE CLEARANCE 3. ENGINE OIL FILTER 8. SEDIMENT CUP | 4. AIR CLEANER 9. GOVERNOR | 5. SPARK PLUGS 10. FUEL TUBES ie MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (1) \._ Perform at every indicated month or \. operating hour interval, whichever | noo aaa eng Chock evel | Change [eagiw ter ——Rrglans Air cleaner ‘Check Glan pace Spa pa Check dat ‘Sediment cup Combustion chamber Fuel tank and filter Fuel tubes (1) For commercial use, log hours of operation to determine proper maintenance intervals (2) Service more frequently when used in dusty areas. (G) Replace paper element type only First. | Every Each | month 3 months |6 months use or or 20 brs Every or 00 hrs. ‘After every 500 his. Every year 3-1 E—M10000-ET12000 2. ENGINE OIL Oil Change Drain the engine oll while the engine is warm. Warm engine oil drains quickly and completely. 1) Place a suitable container under the drain bolt. ‘Place wooden blocks under the generator to make ‘clearance between the generator frame and ground for inserting an cil pan. 2), Remove the oil filer cap, drain bolt and sealing washer, and allow the cil to drain completely Used engine oll contains substances that have been identified as carcinogenic. If repeatedly left in ‘contact with the skin for prolonged periods, it may ‘cause skin cancer. Wash your hands thoroughly with soap and water as soon as possible after contact with used engine oil + Please dispose of used engine oil in a manner that is ‘compatible withthe environment. We suggest that you take it in a sealed container to your local waster dis: posal site, or service station for reclamation. Do not throw it in the trash, pour it on the ground, drown a. drain 3) Make sure the sealing washer isin good condition and replace it with new one if necessary. Reinstall the drain bolt and sealing washer, and tighten the drain bolt to the specified torque. TORQUE: 39 N-m (40 kgm, 29 lott) 4) Fill the engine with the correct amount of the recom: ‘mended cil Recommended |Use a 4-stroke motor oil that meets_| engine oll, or exceeds the requirements for API service classification SH or SJ. Engine oi Without oi itr replacement capaciy Approximately 1.1 £ 11.18 US at, 097 Imp at | Wit oi iter replacement Approximately. 14 (1.48 US at, 1.23 Imp qi) ‘+ SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the recom- ‘mended range. ry AMBIENT TEMPERATURE OIL FILLER CAP ‘SEALING WASHER 100 3-2 —M10000-ET12000 5) Remove the oil level gauge and wipe itclean with a cloth. 6) Reinstall the oil level gauge and check the oil level shown on the ol level gauge. If near or below the lower limit mark, add to the upper limit mark with the recommended oil 3. ENGINE OIL FILTER Oil Filter Replacement 41) Drain the engine oil (P. 3-2), 2) Place a rag under the ol fiter to trap oil leakage. 3) Remove the oil fiter using the oi fiter wrench and lt the remaining oll drain out * Dispose of the oll fier in a manner that is compatible withthe environment. TooL: Ol fter wrench O7HAA-Ps70101 4) Apply a thin coat of engine oil tothe oil iter O-ring. '5) Screw on the new oil iter uni the O-ring contacts the oll fiter base, then tighten the oil fiter an addtional 7/8 turns Using the oil fiter wrench, TORQUE: 22 Nim (2.2 kghm, 16 Ibtft) 6) Fil the engine with the specified amount of recommend ‘ed engine oil (P. 3-2) 7) Start the engine and run it fora few minutes, then stop ‘the engine and check for oll leaks inthe ol fiter cartridge area, Check the oll level and add the recommended engine oil to the upper limit mark if necessary. OWL LEVEL GAUGE UPPER |<—Lower OIL FILTER WRENCH O7HAA-PS7O101 3-3 E—M10000-ET12000 4, AIR CLEANER Cleaning A diy air cleaner element restricts a flow to the carburetor, reducing engine performance. If the generator Is operated in dusty areas, clean the air cleaner more often than speci- fied in the MAINTENANCE SCHEDULE (P. 3-1). \NoTIce) Operating the engine without an air cleaner element or with a damaged air cleaner element, wil allow dirt to enter the engine, causing rapid engine wear. 41) Remove the maintenance cover. 2) Unsnap the cover clips and then remove the air cleaner cover. 3) Remove the paper air cleaner element from the air cleaner case and remove the foam air cleaner element {rom the air cleaner cover. 4) Carefully check both elements for holes or tears and replace if necessary. 5) Clean both elements, i they are to be reused. Foam element: Clean in warm soapy water, rinse and ‘allow it dry thoroughly, or clean with a high flash point ‘solvent and allow it dry. Do not put oil to the foam ele- ment Paper element: Tap the element several times on a hard surface to remove dir, or blow compressed air (not ‘exceed 207 KPa, 2.1 kgticm?, 90 psi) through the ole- ‘ment from the clean side that faces the engine. Never try to brush off dit; brushing will force dit into the fibers of the paper element. 68) Wipe dit from the inside of the air cleaner case using a moist rag. Be careful to prevent dit from entering the air duct that leads to the carburetor. 7) Place the foam element onto the air cleaner cover. 8) Install the paper element on the air cleaner case and install the air cleaner cover. Set the cover clips securely. 9) Reinstall the maintenance cover. AIR CLEANER COVER FOAM ELEMENT. PAPER ELEMENT. COVER CLIP (4) FOAM ELEMENT: Wash and rinse, PAPER ELEMENT: Dry thoroughly. 3-4 —M10000-ET12000 5. SPARK PLUGS Inspection Ifthe engine has been running, the engine is very hot. Allow itto cool before proceeding 1) Remove the spark plug caps and remove the spark plugs using the spark plug wrench, 2) Visually inspect the spark plug. Discard the plug if the insulator is cracked, chipped or has excessive carbon builtup. 8) Measure the plug gaps with a wire type feeler gauge. If necessary, adjust the gap by bending the side electrode, ‘Standard spark | ZGREA (NGK) ‘JH6CR-U (DENSO) Spark plug gap | 0.7 - 0.8 mm (0.028 - 0.031 in) 4) Make sure the sealing washers are in good condition and replace if necessary. 5) install the spark plugs fingertight to seat the washer, then tighten with a spark plug wrench to compress the seal- ing washer. * If reinstall the used spark plug, tighten 1/8 - 1/4 turn after spark plug seats. + If install a new spark plug, tighten 1/2 turn after the ‘spark plug seats, \Norice) +The spark plugs must be securely tightened. An improper tightened spark plug can become very hot ‘and may damage the engine. + Overightening the spark plug can damage the threads in the cylinder head. 6) Reinstall the spark plug caps. —M10000-ET12000 6. BATTERY PUG Hydrogen gas from batteries are highly flammable and explosive, + Koop heat, sparks, and flame away. Inspection 1) Disconnect the battery negative (-) cable first. Then open the positive terminal cover and disconnect the positive (4) cable from the battery. 2) Loosen the 6 mm flange nuts and remove the battery sotting plate. '3) Remove the battery and check the battery case for dam- ‘age or cracks. Replace if necessary 4) Check the electrolyte level in each cel If the levels iow, remove the battery and add distiled water to bring the level to the UPPER level. Do not filthe battery above the UPPER level ine. If over- filled, electrolyte may overflow and corrode the genera- tor components. Immediately wash off any spiled elec- trolyt. 5) Check the electrolyte gravity of each cell with a hydrom- ter. Ee The battery electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. + Antidote: | EXTERNAL - Flush with water. INTERNAL - Drink large quantities of water or milk. | Follow with milk of magnesia, beaten egg, or veg- table oll. Call a physician immediately. + Eyes: Flush with water and get prompt medical attention. Specific gravity | 1.270 - 1.290 at 20°C (68' F) 6) Check the battery terminals for corrosion. Clean as nec- essary, 7) Install the battery and tighten the battery setting plate. Connect the battery positive (+) cable tothe battery pos- itive terminal, then connect the negative (-) cable to the battery negative terminal. Coat the battery terminals with ‘grease. ‘6 mm FLANGE NUT (2) NEGATIVE () POSITIVE (+) TERMINAL, TERMINAL, | BATTERY SETTING PLATE BATTERY 3-6 E—M10000-ET12000 7. VALVE CLEARANCE Valve clearance inspection and adjustment must be per- formed with the engine cold Inspection 1) Remove the maintenance cover. 2) Remove the fuel hose from the tube clip, '8) Open the wire band and release the contro wire harness land choke cable. 4) Disconnect the @ and « connectors (engine wire har- ‘ness and control panel wire harness connectors) 5) Open the hamess clip and release the engine wire har- ness from the clip and remove the fuse holder from the ‘control box. 66) Remove the right and left side covers (P. 6-3). 7) Remove the control box mounting four 6 x 12 mm flange bolts, and slide the control box assembly through the front guard pipe and place it on the fuel tank as shown. '8) Remove the fan cover (P. 11-1), 9) Remove the head cover bolt, and remove the cylinder head cover and gasket. ‘CABLE BAND CONTROL BOX HARNESS CLIP ENGINE WIRE, FUSE HOLDER HARNESS. = IRE CHOKE CABLE CYLINDER HEAD COVER, AND GASKET \ weab cover | 3-7 —M10000-ET12000 10) Remove the spark plugs. 11)Tum the crankshaft until the No. 1 piston comes TDC at ‘compression stroke (both vaives closed). + The "T* mark on the cooling fan should align with the * mark on the right cylinder. 12) Check the intake and exhaust valve clearances at No. 1 linder by inserting a eeer gauge betwoen the vale Stem ard focker ar TN | 0.18:50.08 mm (0.00667-0.0008 in} EX | 0.20:£0.02 mm (0.0079 0.0008 in Valve clearance 19)Tum the crankshaft 270 degrees to put the No. 2 cylin- der at TDC of compression stroke, and check the intake and exhaust valve clearances of the No. 2 cylinder. + The "T* mark on the cooling fan should align with the ‘mark on the left cylinder. Adjustment I adjustment is necessary, proceed as follows: 41), Hold the rocker arm pivot and loosen the pivot lock nut 2) Turn the rocker arm pivot to obtain the specified valve clearance, 3) Hold the rocker arm pivot and tighten the lock nut to the specified torque. TORQUE: 10 Nem (1.0 kgtm, 7 ltt) 4) Recheck the valve clearance after tightening the lock ut '5) After adjustment, reinstall the cylinder head cover and tighten the head cover bolt. TORQUE: 9 Nim (0.9 kgm, 6.6 Ibt*t) 6) Install the removed parts inthe reverse order of removal ‘O° MARK ARK. LOCKER ARM PIVOT LOCK NUT LOCKER ARM. VALVE CLEARANCE, VALVE STEM LOCKER ARM LOCK NUT LOCKER ARM PivoT 3-8 E—M10000-ET12000 8. SEDIMENT CUP Cleaning AWARNING ‘Gasoline is highly flammable and explosive. You can be bummed or seriously injured when handling fuel + Keep heat, sparks, and flame away. + Handle fuel only outdoors, + Wipe up spills immediately. oT) ‘Turn the fuel valve to the OFF postion and remove the sediment cup. 2) Clean the sediment cup. 8) Check the O-ring for good concition and replace it nec- essary. 4) Install the O-ring and sediment cup. Tighten the sedi- ment cup to the specified torque 5) After installing the sediment cup turn the fuel valve tothe ‘ON position and check for fuel leaks. 9, GOVERNOR Adjustment 1) Remove the maintenance cover. 2) Remove the air cleaner case (P. 7-1). '3) Loosen the govemor arm nut and move the govemor arm to fuly open the thro. 4) Holding the carburetor throtle valve fully open, turn the governor arm shatt as far as it will go in the same direc- tion as the govemor arm moved to open the throtle (counterclockwise) 5) Tighten the govemor arm nut to the specified torque TORQUE: 11 Nim (1.1 kgm, 8 bff) 6) Install the air cleaner (P. 7-1). Start the engine and allow itto warmup to normal operating temperature. Check the engine speed at no load Standard engine speed | 3,000: 100 min (pm) 7) Adjust the engine speed if necessary by tuming the adjusting screw. THROTTLE VALVE SHAFT GOVERNOR ARM SHAFT GOVERNOR ‘ARM NUT | —M10000-ET12000 10. FUEL TUBES Inspection Gasoline is highly flammable and explosive. You can be bumed or seriously injured when handling fuel + Koop heat, sparks, and flame away. + Handle fuel only outdoors. + Wipe up spills immediately. 1) Check the fuel tubes for deteriofation, cracks or signs of leakage. For engine block fuel tubes, remove the the air cleaner ‘and inspect the fuel tubes. 2) Replace the fuel tubes if necessary. Replacement ‘Between the fuel valve and the carburetor: 1) Tum the fuel valve to the OFF positon and then replace the fuel hose. 2) After replacing the fuel hase, check for leaks and make sure the area is dry before stating the engine. * Between the fuel tank and fuel valve: 4) Drain the gasoline from the fuel tank, and then replace the fuel tube. 2) After replacing the fuel tube, check for leaks and make ‘sure the area is dry before stating the engine. FUEL TANK See P. 1941 FUEL HOSE FUEL TUBE FUEL VALVE 3-10 EM10000-ET12000 4. BATTERY BATTERY 2.BATTERY CHARGING 1. BATTERY a, REMOVAL/INSTALLATION PG Hydrogen gases from batteries are highly flammable and explosive. + Keep heat, sparks and flame away. + When removing the battery, disconnect the negative (-) ‘terminal frst, then disconnect the positive (+) terminal ‘When installing the battery, connect the positive (+) terminal first, then connect t battery. ‘negative (-) terminal to the * Check the battery terminals for corrosion. Clean as necessary. Coat the battery terminals with grease, BATTERY GROUND CABLE NEGATIVE (-) TERMINAL POSITIVE (+) TERMINAL, BATTERY SETTING PLATE eG) S v > me (6mm FLANGE NUT(2) BATTERY SETTING BOLT (—) ——— BATTERY TRAY BATTERY INSPECTION: P. 3.6 CHARGING: P. 4-2 1 —M10000-ET12000 2. BATTERY CHARGING AWARNING Hydrogen gases from batteries are highly flammable and explosive. Yo can be burned or serious injured when charging battery, + Keep heat, sparks and flame away. 1) Remove the battery (P. 4-1) 2) Remove the caps trom each cell, Verify that the ‘electrolyte level is between the upper and lower level marks, 3) Connect the charger positive (+) cable to the battery positive (+) terminal and charger negative cable to the battery negative (-) terminal. 44) Charge the battery until the battery electrolyte gravity is 1.270 - 1.290 at 20°C (68 F) The battery electrolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. + Antidote: EXTERNAL - Flush with water. INTERNAL - Drink large quantities of water or milk Follow with mik of magnesia, beaten egg, or vegetable oil. Call a physician immediately + Eyes: Flush with water and get prompt medical attention, * Discontinue charging if the electrolyte temperature exceeds 45°C (117°F). * Connect and disconnect the charging cables while power is tuned OFF at the charger. * Quickly charging should only be dune in an ‘emergency; slow charging is preferred. 26A 18 hours Charging curent | Charging time 5) After charging the battery reinstall the caps. 6) Install the battery (P. 4-1). gis 1B 2s fa 122 eae (CHARGING TIME (HOUR) | 4-2 Em1o000-eT12000 5, MAINTENANCE COVER/CENTER BEAM 1 MAN TUNE COVERCENTER BEM ] 1. MAINTENANCE COVER/CENTER BEAM a. DISASSEMBLY/REASSEMBLY w/ BRACKET (OPTIONAL) v9 vucen PLATE @ = we a Be — HANGER HOOK (OPTIONAL) MARTENANCE COVER — = ye wanes COVER a @) $5. eS Sx emmseueraprina senewly ——_|_ ics a Ss —e =! 5 COVER GROMMET (4) RUBBER CUSHION (4) s & \\) Ae —M10000-ET12000 5-2 E—M10000-ET12000 1, FUEL TANK a. DISASSEMBLY/REASSEMBLY Gasoline is highly flammable and explosive. You can be bumed or seriously injured when handling | tuet | + Keop heat, sparks, and flame away. * Handle fuel only outdoors. * Wipe up spill immediately. * Before removing the fuel tank, completely drain the ‘gasoline from the fuel tank to a suitable container. 6, FUEL TANK/FUEL VALVE FUEL TANK INSTALLATION: Wash to femove sediment and dry fongy bac ttm SOREW era FUEL TANK CAP FUEL GAUGE FUEL TANK STRAINER eetnnee anexer INSTALLATION: 7 Renn. clean the e 4 ex Son and check fo cam Replace necessary. 2 we 6 mm WASHER (4) f i INSTALLATION: $ aa aul as chown EES — pater ee ' FUEL TANK SIDE INSTALLATION: Seroon and check tr canage TyBE CLIP B10 Frolace i necessary eI) Tube insertion length: 20-25 mm (0.8- 1.0 in) FUEL TUBE FUEL TUBE ASSEMBLY: P. 6-2 ‘TUBE HOLDER BRACKET 5 mm FLANGE NUT (2) ‘See P. 6-3 for fue! tube connection, 6-1 + SUPPORTER RUBBER INSTALLATION 1) Set the supporter rubber on the fuel tank side ofthe fuel tube by aligning the edge of the supporter rubber with the starting point of straight of the fuel tube as shown, 2) Install the tube protector as shown, 3) Wrap them with vinyl tape to hold them as shown. 4) Install the supporter rubber on the fuel valve side as shown and wrap the tube protector and supporter rubber with the vinyl tape as shown, FUEL FUEL TUBE FUEL TANK SIDE \ SS a ‘STARTING POINT OF STRAIGHT 45-20.mm (8-08 im) —

REAR DUCT 7-2 E—M10000-ET12000 + UPPER DUCT AND REAR DUCT INSTALLATION 41) Setthe upper duct on the lower duct and fuel tank brack- et and loosely install the two 6 x 12 mm flange bolts (* land A mark) 2) Loosely instal the eight 6 x 12 mm flange bolts (* mark). 3) Install the rear duct and loosely install the seven 6 x 12 mmm (* mark) and two 6 x 16 mm (** mark lange bolt. 4) Tighten the two 6x 16 mm flange bolts ("* mark) secure- vy. 5) Tighten all the other 6 x 12 mm (* mark) flange botts securely. 6x16) UPPER DUCT FUEL TANK BRACKET REAR DUCT Lower buct 7-3 —M10000-ET12000 3, MUFFLER a. DISASSEMBLY/REASSEMBLY ‘The muffler becomes very hot during operation and remain hot for a while after stopping the engine. Be careful not to touch the muffler while its hot, Aliow it to cool before proceeding 41) Remove the following - maintenance cover and center beam (P. 5+1). + fuel tank (P. 6-1). + air ducts (P. 7-2). Lower puct 6x16(2) puct seaL_ LEFT EXHAUST PIPE RIGHT EXHAUST PIPE y 2 4 o 9 @ 0.9. GG @ 0) @ @ J 2a Nm 24 kgm, 18 lit) ‘8 mm FLANGE NUT (4) 24 Nm (24 kgf, 18 IBF) EXHAUST PIPE GASKET (4) INSTALLATION: Do not reuse. Replace with new one when reassembly. MUFFLER INSTALLATION: P. 75 Remove any carbon deposit in the mutier by lighty tapping ‘around it with plastic hummer. fe 4 mm waster (2) ~~ ax @ 7-4 —M10000-ET12000 + MUFFLER INSTALLATION 1) Loosely install the loft and right exhaust pipes with new exhaust pipe gaskets. 2) Set the mufle/exhaust pipes assembly to the cylinder head using new exhaust pipe gaskets and loosely install the & mm flange nuts. 8) Install the two 8 x 30 mm flange bolts and 8 mm wash- ers loosely, 4) Tighten the 8 mm flange nuts mounting the exhaust pipes to the muffier to the specified torque. * Tighten the left or right exhaust pipe mounting nuts, then the other side pipe mounting nut TORQUE: 24 Nim (2.4 kof, 18 IbFt) '5) Tighten the 8 mm flange nut mounting the exhaust pipes to the cylinder head to the specified torque, TORQUE: 24 Nim (2.4 kgf, 18 Ibft) 6) Tighten the muffler mounting 8 x 30 mm flange bolt securely. LEFT EXHAUST ‘amm FLANGE NUT (4) or 2a Nem (24 kgf, 18 BFA) RIGHT EXHAUST PIPE eae ‘amm FLANGE NUT (4) 28 Nem (2.4 kghm, 18 EA) ‘8 mm WASHER (2) 8x30(2) E—M10000-ET12000 EM10000-ET12000 8. CONTROL BOX 1. CONTROL BOX 2. CONTROL PANEL 1. CONTROL BOX a. REMOVAL 1), Remove the following: = maintenance cover and center beam (P. 5-1) + fuel tank (P. 6-1) ~ air cleaner case (P. 7-1). Cover the intake port with sealing tape not to allow dirt enter the carburetor. 2) Remove the generator end cover, and open the wire band, + Replace the hamess band if itis cut 8) Disconnect the connectors @®, @ and @, and terminals T21, 122, 723, T24 T25, 126, 127, 128 and GND2. “me | 5x 14mm. SELF-TAPPING SCREW Ne 4x8 mm WASHER ‘SCREW (2) 6 x 12 mm WASHER, SCREW mm SPRING (GENERATOR END caren WASHER (2) 6 x8 mm SCREW @) 712000 5x14@) 5.2 Nem (0.5 kgfm, 3.8 ibtfty HARNESS: BAND. 6x12mm WASHER, SCREW 6x8mm_ ~~ 6mm SPRING SCREW (4) WASHER (4) 8-1 E—M10000-ET12000 4) Open the three cable bands (White) and one cable strap (Black) and release the control wire hamess and choke cable. '5) Loosen the cable clamp bolt and cable joint screw and disconnect the choke cable from the choke lever on the con- trol base. 66) Remove the fuel tube from the hose clip on the control box. 7) Disconnect the connectors @ and ©. '8) Remove the fuse box from the control box and open the hasness clip and release the engine wire harness. CABLE BAND (White) CONTROL WIRE. HARNESS: (CHOKE CABLE CABLE CLAMP CONTROL BASE JOINT SCREW ‘CABLE STRAP (Black) HARNESS CLIP CHOKE CABLE ENGINE WIRE HARNESS, FUSE HOLDER FUEL HOSE ‘CABLE BANDS (WHITE) ‘TUBE CLIP; 8-2 —M10000-ET12000 9) Remove the four 6 x 25 mm flange bolts and left and Fight side covers. 10) Remove the mounting bolts and remove the control box as an assembly with the control panel + EM10000 shown, 712000 is similarly. CONTROL BOX ASSEMBLY ‘DISASSEMBLY/REASSEMBLY: Ped 6x12) LEFT CONTROL PANEL GUARD — > ——~ noir contnot PANEL GUARD RIGHT SIDE COVER, LEFT SIDE COVER 6 mm WASHER (4) 6 x25(4) 8-3 —M10000-ET12000 b. DISASSEMBLY + See P. 8-1 thru. 8-3 for control box removal + EM10000 shown, ET 12000 is similarly. 1) Open the harness clip and release the diverged wire harness connected tothe engine wire hamess. 2) Remove the two bots and open the contol box. 3) Disconnect the AVR connectors @, @, @ and @. 4) Pullthe control wire hamess and choke cable from the contol box and remove the control box. CONTROL PANEL HARNESS CLIP (2) [ DIsASsEMBLY/ ] , REASSEMBLY: P09, 10 | CHOKE CABLE GROMMET 6x 12(SH) @ 8X 16mm WASHER BOLT (2) CONTROL BOX ‘TUBE CLIP AVR UNIT INSPECTION: P. 65, 6 EM10000-ET12000 c. INSPECTION + AVR Check the AVA. by measuring the resistance between the terminals according tothe table below. Use a Rx scale ofa commercially available multimeter and the meter shows curent ow from negative (-) probe to positive (+) probe. + EM10000 2 2 © wares ( } t uci” ude Re BLUE GREEN BROWN BROWN GREEN) GREEN/ RED! BLACKS WHITE = WHITE WHITE WHITE ‘Viewed from terminal side Measuring range: Rx k Positive probe (+) Connector No. ®@ _@ ® Terminal No i 2a [3 4 po { J2l2 Lge | ug | FB] wire color writer | Green | Brown | Brown | green | green’ | Red | Black’ ie ‘Blue Sine | awe | Write. | White 3) 1 WhiterBive = |= |= | | | 5 | 6 § © [2 Green ee >) = e 8 8 16 7 2 1| Brown = co 26 = = © 3 $/© [pom ee ==} =| = = 1| Light green/White ~ 70, ~ oo 110, 75 100 © 2] Light oreenwhite | c= 7 | = © | 10 [= 78 | 100 1) Reawhite = | 4 |= |= | 7 | 70 60 | ©] Blackwnite = 5 = oo 100, 100. 55 ~ 8-5 E—M10000-ET12000 * ET12000 2 ewe 2 eiack © wo eh he FS BLUE GREEN . Reo’ BLACK! WHITE RED GREEN GREEN = WHITE WHITE Viewed from terminal side Measuring range: R xk Positive probe (+) _ ‘Connector No. © eo | © Terminal No. a[tets te tstetitets ye 22 Light | Light 312] wirecoor | White’ Green | Biue | Black | White | Red | green! | green’ | Red! | Black! BE Blue Sire | rave | White | White =), 4] Whitefaiue 7 2 |e «s|s| 7m) | 4) 9% g|© 2) Green 5 [eo |e |» || s8 | 8 | a5 | 36 57 [1] Blue eo [| [=| 8 | 80 | 60 [= | | = | © Bo 2) Back Pe [0 a 2/3] white o | o |e 8 | 30 | = | «= | = | 2 | [al Red e | |e 8 | o> ~|o | oo || [1 {ont greenvwnite | co | G0 |e | | | wm || 490 | 4 | 100 2| Light greenwnite | © | 90 | @ | | w | » | 190 [~~ | 4 | 100 @ 1 Rearwnte © | 7 | | | |» | 9 | 0 _| 90 2 BlackWhits | | 90 | | | «© | » | 10) 10) 3 | d. ASSEMBLY ‘Assembly is the reverse order of removal. ‘ Pass the control wire harness and choke cable through the control box. Route the control wire hamess and choke cable and connect the AVR connectors @), @, @ and ©. + Wire Harness Connection AVR 8x 16 mm WASHER BOLT(2) CONTROL WIRE HARNESS. (CHOKE CABLE GROMMET 8-6 —M10000-ET12000 e. INSTALLATION Installation is the reverse order of removal * Replace the wire te andlor hamess band with new ones, if they are cut when removal, and secure the wires. * Clamp the wire hamess, cable and fuel tube securely * Wire Connection To Generator + EM10000 123 a4 BRUSH (+) TERMINAL BRUSH (-) TERMINAL (Reawhite) (Blackie) 4x 8 mm WASHER SCREW (2) ‘5.x 14mm SELF-TAPPING SCREW 6 x 12 mm WASHER SCREW Gno2 (YellowGreen) HARNESS BAND wires a8 shown. TaTALLATOR = Repl e hamose oreeeren ‘ Ae corel y ares See pe Oo) pepenes ae ne aie / coed @ 2P CONNECTOR (Brown and Brown) Tze i ‘AC OUTPUT TERMINAL (White) i | m2 Ac ouTpUT ‘TERMINAL 4P CONNECTOR (Brown) (Groen, Light groon, Gray, and Gray) 6x 8 mm SCREW (2), 6 mm SPRING WASHER (2) 8-7 —M10000-ET12000 + £712000 23 BRUSH (+) TERMINAL (Rearwnite) 124 BRUSH (-) TERMINAL, (Blackwite) 4x 8 mm WASHER SCREW (2) 5 x 14 mm SELF-TAPPING SCREW WIRE TIE INSTALLATION: Frpiace the wire te that Gno2 (Green) HARNESS BAND is cut and secure the ites as shown, @ 6P CONNECTOR (Light green’Whita, Light fgreen/White, RedWhite ‘and Red”white) = Ac ourpuT. ‘TERMINAL (Biack) @ 4P CONNECTOR 127 (Red, Blue, Black land White) TERMINAL (Bivo) 26 ‘AC OUTPUT @ TERMINAL (White) 4P CONNECTOR (Green, Light green, Gray, land Gray), AC OUTPUT. TERMINAL (Fed) 68 mm SCREW (4), ‘6 mm SPRING WASHER (4) 8-8 —M10000-ET12000 2. CONTROL PANEL a. DISASSEMBLY 1), Remove the control box and control panel as an assembly (P, 8-1 thru. 8-3). 2) Remove the two 6 x 12 mm flange bolts and separate the control box from the control panel 8) Disconnect the AVR connectors, 4) Pullout the control wire hamess and choke cable from the control box and remove the control panel + EM10000 aeaniOn Sore 5x16 mm WASHER INSPECTION: 6-12] SCREW) CHOKE CABLE NUT \ HOUR METER INSPECTION: 6-13 ‘AG CIRCUIT BREAKER CONTROL PANEL §p)-——nsrecrow: rea PLATE 6x 15 mm WASHER 3. oo BOLT 2 A ot %o RECTIFIER 7 ; INSPECTION: P.6-12 x © <—— 4 mm FLANGE , NUT (10) AC RECEPTACLE (608-250v) VOLTMETER INSPECTION: P. 6-13 | 4x6 mm SCREW (2) (CHOKE CABLE ° 4x10mm ‘SCREW (10) ‘AC RECEPTACLE (2) (208-250v) GROUND TERMINAL ‘AC RECEPTACLE, SET (@0A-250V) {GROUND TERMINAL BOLT ee HARNESS: 8-9 E—M10000-ET12000 + T1200 2ote ae 5.x 16 mm WASHER INSPECTION: P. 6:13 ‘SCREW (2) {AC CIRCUIT BREAKER [INSPECTION P.6-11 | RECTIFIER IGNITION switch [ INSPECTION: P. 6-12 (CHOKE CABLE NUT. 3 mm FLANGE NUT (2) ee INSPECTION: P. 8-12 CONTROL PANEL PLATE 6x 14 mm WASHER, BOLT / 4mm FLANGE VOLTMETER Brahe INSPECTION: P. 6-13 Cr. S/ « 3x6 mm WASHER RECEPTACLE ‘SCREW (4) (@) (20a-250v) (For AC circuit breaker) 9 ‘COVER SWITCH A COVER SWITCH B INSPECTION: P. 6-11 INSTALLATION: P. 6-15, 3x25 mm SCREW Ses washer > @ (CHOKE CABLE 4x 12mm SCREW (8) (For AC receptac GROUND TERMINAL, BOLT 6x28 mm ero WIRE BAND (2) ‘TERMINAL SET AC TERMINAL COVER | DISASSEMBLY/ | REASSEMBLY: P. 0-11 CABLE TIE (2) CONTROL WIRE 4x8 mm WASHER HARNESS. SCREW (6) (For circuit breaker terminal) 8-10 —M10000-ET12000 + AC TERMINAL COVER (ET12000 only) AC TERMINAL SET (a) ‘TERMINAL COVER BRACKET AC TERMINAL a erat ‘6 mm SPRING WASHER (4) an 6 mm FLANGE NUT @) AC TERMINAL Cover ser 'mm FLANGE NUT @) AC CABLE GUIDE b. INSPECTION + COVER SWITCHS (ET12000 only) ‘Check for continuity between the C1 and C2 (Switch A), C3 and C4 (switch 8) terminals, ‘There should be continuity wi the AC terminal cover open and no continuity with the cover closed. ‘The cover switch A is connected Green and Black/Yellow wires ‘The cover switch B is connected Red and GreeWhite wires + RECTIFIER = —— Check or continuity between the terminal according tothe table below necririen Peslve probe [Terminal | Wega probe \| 1 [2 | 4 elt ey ey oo 8 [2 carry ——| airy Con Els Continuity) <= = ela Contniy| == [= + Use a Rx 1 scale of a commercially available mutimeter {and the meter shows current flow from negative (-) to pos- itive (4). Ifthe meter shows current flowing one way and rot the other way around, the diode is good. 8-11 + AC CIRCUIT BREAKER, Ew10000 1) Disconnect the wire terminals. 2) Check for continuity between the terminals. ‘There should be continuity with ON and no continuity with OFF. T1200 1) Disconnect the wire terminals. 2). Check for continuity between the T3 and T6, T4 and 17, 75 and TS terminals. ‘There should be continuity with ON and no continuity with OFF. “IGNITION SWITCH 1) Disconnect the 8P connector @) 22). Check for continuity between the terminals of the switch wire connecter according to the table below. O-O: Continuity ffemmane[ 1] 2]9]4] 5] 6] 7] 8 | We eB Peston \ "eto ore [on [sm] | EM10000-ET12000 CIRCUMT BREAKER, IGNITION swiTcH Viewed from terminal side 8-12 —M10000-ET12000 + HOUR METER 1) Disconnect the 2P connector @ 2) Connect a 12 V battery positive (+) lead to the No. 1 (WhiterYellow) and negative (-) lead to the No. 2 (Yellow'Green) terminals ‘The hour meter should operate. Replace the hour meter necessary. + VOLTMETER + Output voltage is normal but volmeter needle does not swing: 1) ‘Start the engine and check whether there is voltage at the voltmeter terminal. lard voltage [RG ype: 280-34 VAC eee R type: 220-03 VAC. 2) If there is specified voltage at the terminal, replace the voltmeter. op obo fa Viewed from 2 Za 3 8-13 EM10000-ET12000 c. ASSEMBLY ‘Assembly isthe reverse order of disassembly. * Wire Connection + EM10000 @e CONTROL WIRE HARNESS WIRE BAND (2) IGNITION SWITCH CABLE TIE (2) INSTALLATION: FRoplace the wire band recTirien | that is cut and sooure the wires as shown, CHOKE CABLE To contr bo Ped VOLTMETER GREEN) (Brown) (7° MARK) ‘AC RECEPTACLE ‘AC RECEPTACLE (2) Gav) (@30v 60a) GND! (GROUND TERMINAL) AC RECEPTACLE (Yellow/Green) (@50v 30a) CIRCUMT BREAKER E—M10000-ET12000 + £712000 Ts Ta (whitey fae 13 (RED) ms joicur that eul'and secure | | BREAKER the vtes as shown IGNITION switcH Te (@Lue) ® CONTROL WIRE RECTIFIER 7 (WHITEY T6 (RED) HARNESS C » » y \ ( © C _ o_ CABLE TIE 3) oe ef Na ny HOUR ‘Ac ourpur / # © TERMINALS Oo METER (THREE PHASE) 2. 4 re al @ — Zz i a) ( ob} lo © < m3 lo| @ : (GREEN) T1 (RED) gs » pb) fone 72 (WHITE) e é b) 2 ° o , q 2 o ons Ti ‘To AVR, od (BtacK) (BLUE) re (RD) “T16 (WHITE) T15 (RED) 2 18 Your cwarre) 115 0) 7” vio oREEM) /TRirey/ Tack) your , TH (BLACK) C2 (BLACK! YELLOW) COVER SWITCH A 9 Not used. ores (GND1 (GROUND TERMINAL) (Green) 1 (GREEN) CA(GREEN/ WHITE) COVER SWITCH B Not used. 3 (RED) 8-15 E—M10000-ET12000 8-16 EM10000-ET12000 9. GENERATOR 1. REAR HOUSING/STATOR a. DISASSEMBLY/REASSEMBLY 1) Remove the following parts: = battery (P. 4-1) - maintenance cover and center beam (P. 5-1) fuel tank (P. 6-1) - air ducts and muller (P. 7-2 thru, 7-4) 2) Remove the generator end cover and disconnect the control wire hamess. M1000 ‘CONTROL WIRE HARNESS 5x 14mm. SELF-TAPPING SCREW GENERATOR END i COVER 4x8 mm WASHER ‘SCREW (2) HARNESS BAND 6x 12mm screw sem = [52Nm @5kghm, 38 BEM : 127 1725 135 68mm SCREW (4) mm SPRING WASHER (4) —M10000-ET12000 3) Install the engine hangers to the cylinder head as shown. ‘Attach a chain hoist tothe engine hangers and pul the chain tight to suppor the engine. Or place wooden blocks under the front housing to support the generator/engine assembly, (NOTICE ‘+ Always remove the brush holder before removing the rear hhousing. If the rear housing is removed with the brush holder attached, damage to the brush holder will occur, “+ Place the stator with the core side down. Do not place with the coil side down, ENGINE HANGER STATOR | RENOVALINSTALLATION: STATOR COVER ‘The stator is heavy. Take care not to get inured during installationremoval ofthe stator. _( + Flomove/nsall the stator by winding ‘a commercially available lifting strap around testator and iting up 28 INsPECTION:P.o4 LIFTING STRAP. ‘SPRING WASHER (2) 6x15 mm. Wane ‘TERMINAL BRACKET Bout Cy 6 x 15 mm WASHER Barre) ~e een en 2 Barre) TERMINAL BLOCK TeRMNAL | CONNECTION: ‘10mm FLANGE LPos mre Stim REGULATOR 8x20mm (as igh, 25 bit) RECUATOM aSheR BOLT minal 6x45) 5x 14mm INSPECTION Seucrapena Pos DON eOKgim. eb) | SLE 9-2 E—M10000-ET12000 + REAR HOUSINGISTATOR INSTALLATION 1) Assemble the rear housing and stator with the 6 x 45 mm flange bot. 2) Install the stator and rear housing assembly tothe front housing + Take care not to damage the stator coll and rotor coil ‘+ MAIN COIL TERMINAL CONNECTION Install the main coil terminals by aligning the marked num- bers as shown. REAR HOUSING 6x45 (2) M0000 732 (3 MARK) 31 (1 MARK) 738 (0 MARK) ‘737 (W MARK) 796 (V MARK) 735 (U MARK) 9-3 b. INSPECTION + STATOR (Check the stator coll. If the colls are bumt or discolored, replace the stator. Measure the resistance between the coil terminals. This test can be performed with stator mounted. Main winding: Between the terminals: M1000: T31 (1) — 732 (2):02 -04 2 712000; T38(0) — 137 (Wy: 06-08 @ 38 (0) — 796 (V): 06 -0.8 38 (0) — 795 (U):06-0.8 2 ‘Sensor winding (@ connector): Between the terminals: M1000: No. 1 (Brown) — No. 2 (Brown): 0.05 @ Max ET12000: No. 3 (Black) — No. 1 (Red): 0.08 2 Max. No. 3 (Black) — No. 2 (White): 0.08 © Max No. 8 (Black) — No. 4 (Blue): 0.08 @ Max Exciter winding (® connector): Between the terminals: M1000: No. 1 (Light greer/White) — No. 3 (Light greer/rite) 16-209 712000: No. 1 (Light green/White) — No. 3 (Light green/Wite): 20-252 DC winding (@ connector): Between the terminals: No. 4 (Red’White) — No. 6 (Red’White): 03-05 @ E—M10000-ET12000 9-4 —M10000-ET12000 + REGULATOR/RECTIFIER Check for continuity between the terminals according tothe table below. Positive on probe Pink | Yellow | 1 | Pink 5200 & 2 |Yelow | 5200 @ | 3 |Green | 10102 | 990 2 [4 [Black | 1800 2 | 800 9 + Use a Rxt scale of a commercially available muti meter, land the meter shows current flow from negative (-) o pos” itive (+). If the meter shows current flowing one way and rot the other way around, the diode is good. * This table shows reference values, + BRUSH HOLDER Check the brushes for free movement. Replace if neces- sary, ‘Measure the brush length. ‘Standard ‘Service limit 155 mm (0.61 in) 95 mm (0.37 in) (Check for continuity between the brush and terminal ‘There should be continuity between the outer brush and T23 positive (+) terminal and between the inner brush and 724 negative (-) terminal ‘Tea NEGATIVE, TERMINAL INNER BRUSH oureR BRUSH BRUSH LENGTH SERVICE LIMIT 985 mm (0.37 in) EM10000-ET12000 2. ROTOR/FRONT HOUSING a. DISASSEMBLY/REASSEMBLY 1) Remove the rear housing and stator (P. 9-1). * After removing the stator, support the rotor with wood- ‘en block under the rotor FRONT HOUSING INSTALLATION Install with the "UP* mark facing up. aA 8x25 (4) FRONT HOUSING BRACKET 5x14 mm SELF ao TAPPING SCREW (3) 6x12) GENERATOR DUCT 10mm WASHER COOLING. FAN PLATE, 410x278 mm HEX. BOLT REMOVALINSTALLATION: COOLING FAN orn 55 Nim (56 kgf, 41 loft) 5 BEARING Take care notte camage he STOPPER FING fan blade. INSTALLATION: ‘Alig the projected part of the stopper ring withthe mark on ‘REMOVAL: the Dearing. aan PROJECTION sropren — ( ) AIG ( INSPECTION: 9-6 —M10000-ET12000 + ROTOR REMOVAL 1), Wrap the rag around the rotor and hold the rotor using a commercially available strap wrench as shown. Loosen the 10 x 278 mm hex. bolt 2) Remove the 10 x278 mm hex. bolt and 10 mm washer. 3) Place a wooden block and shop towel under the rotor and remove the rotor using the sliding shaft and sliding hammer weight, TooLs: Sliding shaft, 12 mm 0736-0010101 Sliding hammer weight 07741-0010201 + ROTOR INSTALLATION 1) Clean off oil or grease from the taper of the crankshaft and the tapered hole in the rotor. 2) Install the rotor onto the crankshaft and loosely install the 10 x 278 mm hex. bolt and 10 mm washer. 8) Wrap the rag around the rotor and hold the rotor using a ‘commercially available strap wrench as shown. Tighten the 10 x 278 mm hex. bot to the spectied torque. TORQUE: 55 N'm, (5.6 kghm, 41 tft) 10 x 278 mm HEX. BOLT 07736-0010101, SLIDING HAMMER WEIGHT 07741-0010201 10x 278 mm HEX. BOLT STRAP WRENCH (Commercially available) SLIDING SHAFT, 12 mm 9-7

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