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A Few Words About SafetySERVICE INFORMATIONThe service and repair information contained in this manual is intended for use by qualified, professional technicians. Attemptingservice or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damagethis Honda product or create an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some proceduresrequire the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is notrecommended by Honda must determine the risks to their personal safety and the safe operation of this product.

If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommendthat you do not use replacement parts of inferior quality.

For Your Customers SafetyProper service and maintenance are essential to the customers safety and the reliability of this product. Any error or oversightwhile servicing this product can result in faulty operation, damage to the product, or injury to others.

For Your SafetyBecause this manual is intended for the professional service technician, we do not provide warnings about many basic shop safetypractices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledgeof safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.

Some of the most important general service safety precautions are given below. However, we cannot warn you of everyconceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you shouldperform a given task.

Important Safety PrecautionsMake sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing andusing safety equipment. When performing any service task, be especially careful of the following:

Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skillsrequired to perform the tasks safely and completely.

Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work aroundpressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.

Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severeburns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make surethat the hoist hook is securely attached to the product.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This willhelp eliminate several potential hazards:

Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. Burns from hot parts. Let the engine and exhaust system cool before working in those areas. Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.

Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful whenworking around gasoline or batteries.

Use only a nonflammable solvent, not gasoline, to clean parts. Never store gasoline in an open container. Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

Improper service or repairs can create an unsafecondition that can cause your customer or others tobe seriously hurt or killed.

Follow the procedures and precautions in thismanual and other service materials carefully.

Failure to properly follow instructions andprecautions can cause you to be seriously hurt orkilled.Follow the procedures and precautions in thismanual carefully.

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How to use this manual

SPECIFICATIONS

SERVICE INFORMATION

MAINTENANCE

TROUBLESHOOTING

FUEL SYSTEM

GOVERNOR

GENERATOR/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

OTHER ELECTRICAL

MUFFLER

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD

CYLINDER BLOCK

WIRING DIAGRAMS

INDEX

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INTRODUCTIONThis manual covers the service and repair procedures for the Honda EC3600K1/EC5000K1/ECT7000K1/ECT7000P1 generators.

All information contained in this manual is based on the latest product information available at the time of printing. We reserve theright to make changes at anytime without notice.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic,mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, andtables.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to helpprevent damage to this Honda product, other property, or the environment.

SAFETY MESSAGESYour safety and the safety of others are very important. To help you make informed decisions, we have provided safety messagesand other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazardsassociated with servicing these products. You must use your own good judgement.

Honda Motor Co., Ltd.SERVICE PUBLICATION OFFICE

Date of Issue: August, 2011

You will find important safety information in a variety of forms, including: Safety Labels on the product. Safety Messages preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you dont follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you dont follow instructions.

You CAN be HURT if you dont follow instructions.

Instructions how to service these products correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION AREBASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HondaMotor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUTINCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUTWRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OFMAINTENANCE ON Honda PRODUCTS.

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SERVICE RULES Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Hondas design

specifications may damage the unit. Use the special tools designed for the product. Install new gaskets, O-rings, etc. when reassembling. When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless

a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before assembly. After assembly, check all parts for proper installation and operation. Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the

threads and ruin the hole.

Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. Theuse of incorrect tools and fasteners will damage the unit.

SYMBOLSThe symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining tothese symbols, it will be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use the recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use marine grease (water resistant urea based grease).

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use automatic transmission fluid.

x ( ) Indicates the diameter, length, and quantity of metric bolts used.page 1-1 Indicates the reference page.

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ABBREVIATIONSThroughout this manual, the following abbreviations are used to identify the respective parts or systems.

Abbreviatedterm

Full term

ACG Alternator API American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center ATF Automatic Transmission Fluid ATT Attachment AVR Automatic Voltage Regulator BAT BatteryBDC Bottom Dead Center BTDC Before Top Dead Center BARO Barometric PressureCKP Crankshaft PositionComp. CompleteCMP Camshaft PositionCYL Cylinder DLC Data Link Connector D-AVR Digital Automatic Voltage Regulator EBT Engine Block TemperatureECT Engine Coolant TemperatureECM Engine Control ModuleEMT Exhaust Manifold TemperatureEOP Engine Oil PressureEX ExhaustF Front or ForwardGND GroundHO 2S Heated Oxygen sensor IAB Intake Air BypassIAC Idle Air ControlIAT Intake Air TemperatureI.D. Inside diameter IG or IGN IgnitionIN IntakeINJ InjectionL. LeftMAP Manifold Absolute PressureMIL Malfunction Indicator LampO.D. Outside Diameter OP Optional PartPGM-FI Programmed-Fuel InjectionP/N Part Number Qty QuantityR. RightSAE Society of Automotive EngineersSCS Service Check SignalSTD StandardSW SwitchTDC Top Dead Center

Bl Black G Green Br Brown Lg Light greenY Yellow R Red O Orange P PinkBu Blue W White Lb Light blue Gr Gray

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1. SPECIFICATIONS

SERIAL NUMBER LOCATION 1-2

SPECIFICATIONS1-3

DIMENSIONAL DRAWINGS 1-7

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SPECIFICATIONSSPECIFICATIONS

SERIAL NUMBER LOCATIONThe engine serial number is stamped on the cylinder barrel, and the frame serial number is on a label on the engine frame.

Refer to it when ordering parts or making technical inquiries.

EC5000K1 shown:

EC5000K1 shown:

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

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SPECIFICATIONS

SPECIFICATIONSEC3600K1DIMENSIONS AND WEIGHTS

ENGINE

GENERATOR

Model EC3600K1Description code EZDJOverall length 800 mm (31.5 in)

Overall width 550 mm (21.7 in)Overall height 540 mm (21.3 in)Dry weight 60.8 kg (134.0 lbs)Operating weight 64.0 kg (141.1 lbs)

Model GX270T2Description code GCBHTType 4 stroke, overhead valve, single cylinder, inclined by 25Displacement 270 cm 3 (16.5 cu-in)Bore x stroke 77.0 x 58.0 mm (3.03 x 2.28 in)Compression ratio 8.5 : 1

Ignition system CDI (Capacitor Discharge Ignition) magneto ignitionIgnition timing BTDC 10/1,400 min -1 (rpm)Spark plug BPR6ES (NGK), W20EPR-U (DENSO)Lubrication system Forced sprayOil capacity 1.1 liters (1.2 US qt, 1.0 Imp qt)Recommended oil SAE 10W-30 API service classification SE or later Cooling system Forced air Starting system Recoil starter Stopping system Ignition exciter coil circuit openCarburetor Horizontal type, butterfly valve

Air cleaner Dual element typeGovernor Mechanical centrifugalBreather system Flat valve typeFuel used Regular unleaded gasoline with a pump octane rating 86 or higher

Model EC3600K1Type BT FT, GVT, ITT, GVWTDescription code EZDJGenerator type Double electrode field rotation typeExcitation Self-excitationVoltage regulation system Capacitor controlPhase Single phaseRotating direction Counterclockwise (Viewed from the generator)Rated output AC 3400 VARated frequency 50 Hz

AC Rated voltage 115 / 230 V 230 VRated current 30 / 15 A 15 APower factor 1.0 Cos

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SPECIFICATIONSCHARACTERISTICS

Model EC3600K1Type BT FT, GVT, ITT, GVWTVoltagevariation rate

Momentary 25/35 % max. Average 10 % max. Average time 10 sec. max.

Voltage stability 1% max.Frequencyvariation rate

Momentary 25/18 % max. Average 3.5 % max. Average time 10 sec. max.

Frequency stability 1 Hz max.Insulation resistance 10 M min.

AC circuit protector 17 A x 3 17 AInsulation type Type HFuel tank capacity 5.2 liters (1.37 US gal, 1.14 Imp gal)Fuel consumption at rated load 2.32 liters (0.613 US gal, 0.510 Imp gal)/Hr.Max. operating hours at rated load 2.2 Hr.Measured sound power level(2000/14/EC, 2005/88/EC) 96 dB (A)

Guaranteed sound power level(2000/14/EC, 2005/88/EC) 97 dB (A)

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SPECIFICATIONS

EC5000K1/ECT7000K1/ECT7000P1DIMENSIONS AND WEIGHTS

ENGINE

GENERATOR

Model EC5000K1 ECT7000K1 ECT7000P1Type BT, FT, GVT, GVWT, ITT FT, GVT, GVWT, ITT,RGT GVT, GVWT

Description code EZDL EZDPOverall length 800 mm (31.5 in)

Overall width 550 mm (21.7 in)Overall height 540 mm (21.3 in)Dry weight 77.6 kg (171.1 lbs) 80.3 kg (177.0 lbs) 89.3 kg (196.9 lbs)Operating weight 83.1 kg (183.2 lbs) 85.8 kg (189.2 lbs) 94.8 kg (209.0 lbs)

Model GX390T2Description code GCBDTType 4 stroke, overhead valve, single cylinder, inclined by 25Displacement 389 cm 3 (23.7 cuin)Bore x stroke 88.0 x 64.0 mm (3.46 x 2.52 in)Compression ratio 8.2 : 1

Ignition system CDI (Capacitor Discharge Ignition) magneto ignitionIgnition timing BTDC 10/1,400 min -1 (rpm)Spark plug BPR6ES (NGK), W20EPR-U (DENSO)Lubrication system Forced sprayOil capacity 1.1 liters (1.2 US qt, 1.0 Imp qt)Recommended oil SAE 10W-30 API service classification SE or later Cooling system Forced air Starting system Recoil starter Stopping system Ignition exciter coil circuit openCarburetor Horizontal type, butterfly valve

Air cleaner Dual element typeGovernor Mechanical centrifugalBreather system Flat valve typeFuel used Regular unleaded gasoline with a pump octane rating 86 or higher

Model EC5000K1 ECT7000K1 ECT7000P1Type BT FT, GVT, GVWT,ITT

FT, GVT, GVWT,ITT, RGT GVT, GVWT

Description code EZDL EZDPGenerator type Double electrode field rotation typeExcitation Self-excitationVoltage regulation system

Capacitor controlCompound

throughtransformer

AVR (AutomaticVoltage

Regulator)Phase Single phase Single phase/Three phaseRotating direction Counterclockwise (Viewed from the generator)Rated output AC 4500 VA 3600/6500 VARated frequency 50 Hz

AC Rated voltage 115/230 V 230 V 230/400 VRated current 39.0/19.5 A 19.5 A 16.0/9.5 A

Power factor 1.0 Cos 1.0/0.8 Cos

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SPECIFICATIONSCHARACTERISTICS

Model EG5000K1 ECT7000K1 ECT7000P1Type

BT FT, GVT,GVWT ITTFT, GVT,

GVWT, ITT,RGT

GVT, GVWT

Voltagevariation rate

Momentary 25/35 % max. Average 10 % max. Average time 10 sec. max.

Voltage stability 1 % max.Frequencyvariation rate

Momentary 25/18 % max. Average 3.5 % max. Average time 10 sec. max.

Frequency stability 1 Hz max.Insulation resistance 10 M min.

AC circuit protector 17 A x 3,25 A, 30 A

17 A x 2,25 A 17 A, 25 A 10 A, 17 A

16 A (3-pole+ neutral)

Insulation type Type HFuel tank capacity 6.1 liters (1.61 US gal, 1.34 Imp gal)Fuel consumption at rated load 2.94 liters (0.777 US gal, 0.647 Imp gal)/Hr. 3.15 liters (0.832 US gal, 0.693Imp gal)/Hr.Max. operating hours at rated load 2.1 Hr. 1.9 Hr.Measured sound power level(2000/14/EC, 2005/88/EC) 96 dB (A)Guaranteed sound power level(2000/14/EC, 2005/88/EC) 97 dB (A)

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SPECIFICATIONS

DIMENSIONAL DRAWINGSUnit: mm (in)ECT7000K1 shown:

550 (21.7)

540 (21.3)

800 (31.5)

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2. SERVICE INFORMATION

MAINTENANCE STANDARDS2-2

TORQUE VALUES 2-4

LUBRICATION & SEAL POINT 2-5

TOOLS2-6

HOW TO READ CONNECTORDRAWINGS2-9

FRAME/ENGINE CABLE/HARNESSROUTING 2-10

FUEL TUBE ROUTING 2-27

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SERVICE INFORMATIONSERVICEINFORMATION

MAINTENANCE STANDARDSENGINEEC3600K1

Unit: mm (in)Part Item Standard Service limit

Engine Engine speed 3,200 150 min -1 (rpm)

Cylinder compression1.31 MPa (13.4 kgf/cm 2, 191 psi)/1,400 min -1 (rpm)

Cylinder Sleeve I.D. 77.000 77.017 (3.0315 3.0322) 77.17 (3.038)Cylinder head Warpage 0.10 (0.004)Piston Skirt O.D. 76.975 76.985 (3.0305 3.0309) 76.85 (3.026)

Piston-to-cylinder clearance 0.015 0.042 (0.0006 0.0017) 0.12 (0.005)Piston pin bore I.D. 18.002 18.008 (0.7087 0.7090) 18.042 (0.7103)

Piston pin Pin O.D. 17.994 18.000 (0.7084 0.7087) 17.950 (0.7067)Piston pin-to-piston pin bore clearance 0.002 0.014 (0.0001 0.0006) 0.08 (0.003)

Piston rings Ring sideclearance

Top 0.030 0.060 (0.0012 0.0024) 0.15 (0.006)Second 0.030 0.060 (0.0012 0.0024) 0.15 (0.006)

Ring end gap Top 0.200 0.350 (0.0079 0.0138) 1.0 (0.04)Second 0.350 0.500 (0.0138 0.0197) 1.0 (0.04)Oil (side rail) 0.20 0.70 (0.008 0.028) 1.0 (0.04)

Ring width Top 1.160 1.175 (0.0457 0.0463) 1.150 (0.0453)Second 1.160 1.175 (0.0457 0.0463) 1.150 (0.0453)

Connecting rod Small end I.D. 18.005 18.020 (0.7089 0.7094) 18.07 (0.711)Big end I.D. 33.025 33.039 (1.3002 1.3007) 33.07 (1.302)Big end oil clearance 0.040 0.064 (0.0016 0.0025) 0.12 (0.005)Big end side clearance 0.1 0.4 (0.004 0.016) 1.0 (0.04)

Crankshaft Crankpin O.D. 32.975 32.985 (1.2982 1.2986) 32.92 (1.296)Runout 0.1 (0.004)

Valves Valveclearance

IN 0.15 0.02 EX 0.20 0.02

Valvestem O.D.

IN 6.575 6.590 (0.2589 0.2594) 6.44 (0.254)EX 6.535 6.550 (0.2573 0.2579) 6.40 (0.252)

Valve guideI.D. IN/EX 6.600 6.615 (0.2598 0.2604) 6.66 (0.262)

Guide-to-stemclearance

IN 0.010 0.040 (0.0004 0.0016) 0.11 (0.004)EX 0.050 0.080 (0.0020 0.0031) 0.13 (0.005)

Valve seat width 1.0 1.2 (0.04 0.05) 2.1 (0.08)Valve spring free length 39.0 (1.54) 37.5 (1.48)Valve spring perpendicularity 1.5

Camshaft Camshaft O.D. 15.966 15.984 (0.6286 0.6293) 15.92 (0.627)Cam height IN 31.845 32.245 (1.2537 1.2695) 31.22 (1.229)

EX 31.566 31.966 (1.2428 1.2585) 31.26 (1.231)Cylinder barrel Camshaft holder I.D. 16.000 16.018 (0.6299 0.6306) 16.05 (0.632)Crankcasecover

Camshaft holder I.D. 16.000 16.018 (0.6299 0.6306) 16.05 (0.632)

Spark plug Gap 0.70 0.80 (0.028 0.031) Ignition coil Air gap 0.20 0.60 (0.008 0.024) Carburetor Main jet # 88

Float height 13.2 (0.52) Pilot screw opening 2 turns out

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SERVICE INFORMATIONEC5000K1/ECT7000K1/ECT7000P1

Unit: mm (Part Item Standard Service limit

Engine Engine speed 3,150 150 min -1 (rpm)

Cylinder compression 1.29 MPa (13.2 kgf/cm2, 187 psi)/

1,400 min -1 (rpm)

Cylinder Sleeve I.D. 88.000 88.017 (3.4646 3.4652) 88.17 (3.471)Cylinder head Warpage 0.10 (0.004)

Piston Skirt O.D. 87.975 87.985 (3.4636 3.4640) 87.85 (3.459)Piston-to-cylinder clearance 0.015 0.042 (0.0006 0.0017) 0.12 (0.005)Piston pin bore I.D. 20.002 20.008 (0.7875 0.7877) 20.042 (0.7891)

Piston pin Pin O.D. 19.994 20.000 (0.7872 0.7874) 19.950 (0.7854)Piston pin-to-piston pin bore clearance 0.002 0.014 (0.0001 0.0006) 0.08 (0.003)

Piston rings Ring sideclearance

Top 0.030 0.060 (0.0012 0.0024) 0.15 (0.006)Second 0.030 0.060 (0.0012 0.0024) 0.15 (0.006)

Ring end gap Top 0.200 0.350 (0.0079 0.0138) 1.0 (0.04)Second 0.350 0.500 (0.0138 0.0197) 1.0 (0.04)Oil (side rail) 0.20 0.70 (0.008 0.028) 1.0 (0.04)

Ring width Top 1.160 1.175 (0.0457 0.0463) 1.150 (0.0453)Second 1.160 1.175 (0.0457 0.0463) 1.150 (0.0453)

Connecting rod Small end I.D. 20.005 20.020 (0.7876 0.7882) 20.07 (0.790)Big end I.D. 36.025 36.039 (1.4183 1.4189) 36.07 (1.420)

Big end oil clearance 0.040 0.064 (0.0016 0.0025) 0.12 (0.005)Big end side clearance 0.1 0.4 (0.004 0.016) 1.0 (0.04)

Crankshaft Crankpin O.D. 35.975 35.985 (1.4163 1.4167) 35.93 (1.415)Runout 0.1 (0.004)

Valves Valveclearance

IN 0.15 0.02 EX 0.20 0.02

Valvestem O.D.

IN 6.575 6.590 (0.2589 0.2594) 6.44 (0.254)EX 6.535 6.550 (0.2573 0.2579) 6.40 (0.252)

Valve guideI.D. IN/EX 6.600 6.615 (0.2598 0.2604) 6.66 (0.262)

Guide-to-stemclearance

IN 0.010 0.040 (0.0004 0.0016) 0.11 (0.004)

EX 0.050 0.080 (0.0020 0.0031) 0.13 (0.005)

Valve seat width 1.0 1.2 (0.04 0.05) 2.1 (0.08)

Valve spring free length 39.0 (1.54) 37.5 (1.48)Valve spring perpendicularity 1.5

Camshaft Camshaft O.D. 15.966 15.984 (0.6286 0.6293) 15.92 (0.627)Cam height IN 32.398 32.798 (1.2755 1.2913) 32.10 (1.264)

EX 31.885 32.285 (1.2553 1.2711) 31.59 (1.244)Cylinder barrel Camshaft holder I.D. 16.000 16.018 (0.6299 0.6306) 16.05 (0.632)Crankcasecover Camshaft holder I.D. 16.000 16.018 (0.6299 0.6306) 16.05 (0.632)

Spark plug Gap 0.70 0.80 (0.028 0.031) Ignition coil Air gap 0.20 0.60 (0.008 0.024) Carburetor Main jet # 105

Float height 13.2 (0.52) Pilot screw opening 2-1/8 turns out

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SERVICE INFORMATION

STANDARD TORQUE VALUES

LUBRICATION & SEAL POINT

Item Thread dia. (mm) Torque valuesNm kgfm lbfft

Screw 4 mm 2.1 0.21 1.55 mm 4.3 0.44 3.26 mm 9.0 0.92 6.6

Bolt and nut 5 mm 5.3 0.54 3.9

6 mm 10 1.0 78 mm 22 2.2 1610 mm 34 3.5 2512 mm 54 5.5 40

Flange bolt and nut 5 mm 5.3 0.54 3.96 mm 12 1.2 98 mm 23 2.3 1710 mm 40 4.0 30

SH (Small head) flange bolt 6 mm 9.0 0.92 6.6CT (Cutting threads) flange bolt (Retightening) 5 mm 5.4 0.55 4.0

6 mm 12 1.2 9

Material Location RemarksEngine oil Camshaft cam profile and journal

Valve lifter stem, stem end and slipper Valve stem sliding surface and stem endValve rocker arm tappet surface and pivotRocker arm pivot threads and pivotCylinder barrel inner surfaceCylinder head bolt threads and seating surfacePiston outer surfacePiston ring whole surfacePiston pin whole surfaceCrankpin and gearsConnecting rod big and small endConnecting rod special bolt threads and seating surfaceBalancer weight gear and journal (Except EC3600K1)Governor weight holder gear and sliding surfaceGovernor shaft journalGovernor arm shaftFlywheel special nut threads and seating surfaceCylinder head bolt threads and seating surfaceO-ring whole surface

Multi-purpose grease Oil seal lipRecoil starter case projectionStarter return spring inner hookRecoil starter ratchet sliding surfaceSpring retainer sliding surface

Threebond 2430 or equivalent Recoil starter center bolt threadsLOCTITE 638 Pilot screw limiter capLocking agent Cover/AVR unit torx screw threads

Control unit torx screw threads

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SERVICE INFORMATION

TOOLSFloat level gauge07401-0010000

Valve guide reamer, 6.612 mm07984-ZE20001

Remover weight07741-0010201

Valve guide driver, 6.6 mm07942-6570100

Attachment, 32 x 35 mm07746-0010100

Attachment, 52 x 55 mm07746-0010400

Attachment, 62 x 68 mm07746-0010500

Attachment, 72 x 75 mm07746-0010600

Driver, 22 mm I.D.07746-0020100

Driver attachment, 20 mm I.D.07746-0020400

Driver, 40 mm I.D.07746-0030100


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SERVICE INFORMATION


Pilot, 15 mm07746-0040300

Pilot, 30 mm07746-0040700

Pilot, 35 mm07746-0040800

Pilot, 14 mm07746-0041200

Driver 07749-0010000

Seat cutter, 27.5 mm (45 EX)07780-0010200

Seat cutter, 29 mm (45 IN)07780-0010300

Seat cutter, 35 mm (45 IN)07780-0010400

Seat cutter, 33 mm (45 EX)07780-0010800

Flat cutter, 28 mm (32 EX)07780-0012100

Flat cutter, 30 mm (32 IN)07780-0012200

Flat cutter, 35 mm (32 IN)07780-0012300

Flat cutter, 33 mm (32 EX)07780-0012900

Interior cutter, 30 mm (60 IN/EX)07780-0014000

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SERVICE INFORMATION

Interior cutter, 37.5 mm (60 IN/EX)07780-0014100

Bearing remover shaft, 15 mm07936-KC10500

Attachment, 45 x 50 mm07946-6920100

Flywheel puller set07935-8050004

Cutter holder, 6.6 mm07781-0010202

Generator shaft holder 07AAA-ZP4GTS1

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SERVICE INFORMATION

HOW TO READ CONNECTOR DRAWINGSConnector drawings show the terminal arrangement, terminal No., number of pins and the shape of terminal (male or female).

Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors areshown for the dedicated connectors.

The double frame connectors represent the male connectors and the single frame connectors represent the female connectors.

Both the male and female connectors are shown by viewing them from the terminal side.

FEMALE CONNECTOR

MALE CONNECTOR

VIEWING DIRECTION

VIEWING DIRECTION

FEMALE CONNECTOR DRAWING

(SINGLE FRAME)

Female connector viewed from theterminal side.

CONNECTOR No.

MALE CONNECTOR DRAWING

(DOUBLE FRAME)

Male connector viewed from theterminal side.

LOCK

CONNECTOR No.TERMINAL ARRANGEMENT

The connector drawing shows the terminal arrangement ofthe connector with the lock of the connector toward up.

TERMINAL No.The system drawing shows the No.9 terminal of theconnector.

LOCK

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SERVICE INFORMATION

FRAME/ENGINE CABLE/HARNESS ROUTINGENGINE STOP SWITCH SIDE:

To engine stop switch To ignition coil

To oil level switch

Y

R BlINSIDE

ENGINE STOP SWITCH

ENGINE WIREHARNESS

OIL LEVEL SWITCH

HARNESS CLIP

ENGINE STOPSWITCH CORD

HARNESS CLIP

R Bl

Y

OIL LEVELSWITCH WIRE

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SERVICE INFORMATION

GROUND CABLE

GROUND TERMINAL

GROUND CABLEGROUND TERMINAL

Terminalnumber

Wire color

Y/G

Y/G

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SERVICE INFORMATION

GENERATOR/COVER SIDE (EC3600K1)FT, GVT, GVWT, ITT TYPE

COVER SIDE

STATOR SIDE

RECEPTACLE TERMINAL

GROUND TERMINAL

EXCITER WINDING CONNECTOR

EXCITER WINDINGCONNECTOR

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

CIRCUIT PROTECTOR CONNECTOR


MAIN WINDING 4P CONNECTOR

Terminalnumber

Wire color

1

2

3

4

R

W

G

Y

Terminalnumber

Wire color

1

2

3

4

R

Y

G

Y

Terminalnumber

Wire color

Terminalnumber

Wire color

Y/G

Terminalnumber

Wire color

G

R

Y/G

Y/G

R

G

G

G

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SERVICE INFORMATION

CONTROL BOX SIDE (EC3600K1):BT TYPE


RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL



RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

CIRCUIT PROTECTORCONNECTOR (Upper side)

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

GROUND TERMINAL

VOLTAGE SELECTORSWITCH CONNECTOR (Upper side)

VOLTAGE SELECTOR SWITCH CONNECTOR (Upper side)

VOLTAGE SELECTOR SWITCH CONNECTOR (Upper side)


Terminalnumber

Wire color

G

G

W

W

W

W

Bl

R

W

G

R

W

Terminalnumber

Wire color

R

Y/G

G

Bl

W

Y/G

Bl

W

Y/G

Terminalnumber

Wire color

Y/G

VOLTAGE SELECTOR SWITCH CONNECTOR (Lower side)

CIRCUIT PROTECTOR CONNECTOR (Upper side)CIRCUIT PROTECTOR CONNECTOR (Lower side)VOLTAGE SELECTOR SWITCH CONNECTOR (Lower side)

CIRCUIT PROTECTORCONNECTOR (Lower side)

VOLTAGE SELECTORSWITCH CONNECTOR (Lower side)

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SERVICE INFORMATION

CONTROL BOX SIDE (EC5000K1):FT, GVT, GVWT TYPE

RECEPTACLETERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

MAIN WINDING TERMINAL (Lower side)

JUMP WIRE TERMINAL (Upper side)

RECEPTACLE TERMINAL (Upper side)

RECEPTACLE TERMINAL (FT type only)



CIRCUIT PROTECTORTERMINAL (Upper side)




CIRCUIT PROTECTOR CONNECTOR (Upper side)


Terminalnumber

Wire color Wire color Terminalnumber

Terminalnumber


Terminalnumber

Wire color

G

WY

R

G

Y

Y

R

G

GG

G

G

G

R

Y/GG

R

Y/G

G

Y

Y/G

R

G

Y/G

GROUND TERMINAL

CIRCUIT PROTECTORCONNECTOR (Lower side) MAIN WINDING TERMINAL (Lower side)



JUMP WIRE TERMINAL (Upper side)

CIRCUIT PROTECTOR CONNECTOR (Lower side)


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SERVICE INFORMATIONITT TYPE

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLETERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL





GROUND TERMINAL

RECEPTACLETERMINAL (Upper side)

CIRCUIT PROTECTOR TERMINAL (Upper side)

JUMP TERMINAL (Upper side)

JUMP TERMINAL (Upper side)

Terminalnumber


Wire color Terminalnumber

Terminalnumber

Wire color

G

W

Y

R

G

Y

Y

G

G

G

G

R

R

Y/G

G

R

Y/G

G

Y/G


CIRCUIT PROTECTORCONNECTOR (Lower side)

MAIN WINDINGTERMINAL (Lower side)




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SERVICE INFORMATIONBT TYPE

RECEPTACLETERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

VOLTAGE SELECTOR

SWITCH TERMINAL

VOLTAGE SELECTORSWITCH TERMINAL






RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

CIRCUIT PROTECTORCONNECTOR











RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINALRECEPTACLE TERMINAL




GROUND TERMINAL






R

Y/G

G

R

Y/G

G

W

Y

Y/G

W

G

Y

R

Y

G G

YG

G

G

G

Y

Y

Y

Y

Y/G

W

R

W

Y/G

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SERVICE INFORMATIONBT, FT, GVT, GVWT, ITT TYPE



MAIN WINDING TERMINAL





G

W

Y

R

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SERVICE INFORMATION

MAIN/EXCITER WINDING 6P CONNECTOR


STATOR SIDE

TRANSFORMER SIDE

BRUSH HOLDER CONNECTOR

TRANSFORMERWINDING TERMINAL



TRANSFORMER WINDING TERMINAL

TRANSFORMERWINDING TERMINAL



TRANSFORMER WINDING CONNECTOR





G

R

Y

Y

G

R

Y

Terminalnumber

Wire color

R

G

Bl

R

G

Bl

Terminalnumber

Wire color

R

G

Bl

R

G

Bl

Terminalnumber

Wire color

G

R

Bl

G

R

Bl

1

2

3

4

5

6

1

2

3

4

5

6

DIODE CONNECTOR

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SERVICE INFORMATION

GENERATOR SIDE (ECT7000K1)

STATOR SIDE

TRANSFORMER SIDE

BRUSH HOLDER

MAIN/EXCITER WINDING 6P CONNECTOR

Terminalnumber

Wire color

R

G

Bl

R

G

Bl

Terminalnumber

Wire color

R

G

Bl

R

G

Bl

1

2

3

4

5

6

1

2

3

4

5

6

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SERVICE INFORMATION

CONTROL PANEL SIDE (ECT7000P1):

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL

RECEPTACLE TERMINAL


Br

Bu

Y/G

W

Bu

Y/G

Bl


W

Bl

Y/G

Bu

Br

Bu

Y/G

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SERVICE INFORMATION

CIRCUIT BREAKER TERMINAL








Terminalnumber

Wire color

Br

W

Bl

Bu

Br

W

Bu

Bl

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SERVICE INFORMATION

FIELD WINDING BRUSH HOLDER SIDE (ECT7000P1)

FIELD WINDING CONNECTOR

FIELD WINDING CONNECTOR

Terminalnumber

Wire color

R

Gr

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SERVICE INFORMATION

FUEL TUBE ROUTING

FUEL TUBE

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3. MAINTENANCE

MAINTENANCE SCHEDULE3-2

ENGINE OIL LEVEL CHECK3-3

ENGINE OIL CHANGE3-4

AIR CLEANER CHECK/CLEANING/REPLACEMENT3-5

SEDIMENT CUP CLEANING 3-6

SPARK PLUG CHECK/ADJUSTMENT/REPLACEMENT3-7

SPARK ARRESTER CLEANING3-8

VALVE CLEARANCE CHECK/ADJUSTMENT 3-8

COMBUSTION CHAMBER CLEANING 3-9

FUEL TANK AND FILTER CLEANING 3-10

FUEL TUBE INSPECTION3-10

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MAINTENANCEMAINTENANCE

MAINTENANCE SCHEDULE

(1) Service more frequently when used in dusty areas.

(2) For commercial use, log hours of operation to determine proper maintenance intervals.

ITEM Perform at everyindicated month oroperating hour interval,whichever comes first.

REGULAR SERVICE PERIOD (2)Refer

topageEach use

Firstmonth

or 20 hrs.

Every3 monthsor 50 hrs.

Every6 months

or 100 hrs.

Every yearor 300 hrs.

Engine oil Check level 3-3Change 3-4

Air cleaner Check 3-5Clean (1)

Sediment cup Clean 3-6Spark plug Checkadjust

3-7ReplaceSpark arrester Clean 3-8Valveclearance

Checkadjust 3-8

Combustionchamber Clean After every 1,000 hrs. 3-9

Fuel tank &filter

Clean 3-10

Fuel tube Check Every 2 years (Replace if necessary) 3-10

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MAINTENANC

ENGINE OIL LEVEL CHECK

Check the engine oil level with the engine stopped.

Place the engine on a level surface.

Remove the oil filler cap/dipstick [1] and wipe thedipstick clean.

Insert the oil filler cap/dipstick in the oil filler neck, butdo not screw it in.Remove the oil filler cap/dipstick and check the oil level.

If the oil level is near or below the lower level [2] on thedipstick, fill with the recommended engine oil to theupper level (top of the oil filler neck) [3].

Oil is a major factor affecting performance and servicelife. Use 4-stroke automotive detergent oil.

SAE 10W-30 is recommended for general use. Other

viscosities shown in the chart may be used when theaverage temperature in your area is within therecommended range.

Check that the O-ring [4] is in good condition, replace itif necessary.

Apply engine oil to the O-ring.

Reinstall the oil filler cap/dipstick securely.

RECOMMENDED ENGINE OIL:SAE 10W-30API service classification SE or later

[2]

SAE VISCOSITY GRADES

AMBIENT TEMPERATURE

[3

[1]

[4]

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MAINTENANCE

ENGINE OIL CHANGE

Drain the used engine oil while the engine is warm.Warm oil drains quickly and completely.

Place a suitable container [1] under the engine oil drainbolt (12 x 15 mm) [2].

Remove the oil filler cap/dipstick [3], drain bolt, sealingwasher (12 mm) [4] and drain the engine oil into thesuitable container.

Please dispose of used engine oil in a manner that iscompatible with the environment. We suggest you takeused oil in a sealed container to your local recyclingcenter or service station for reclamation. Do not throw itin the trash, pour it on the ground, or down a drain.

Install the engine oil drain bolt (12 x 15 mm) and newsealing washer (12 mm).Tighten the drain bolt to the specified torque.

With the engine on a level surface, fill therecommended engine oil to the upper level (page 3-3) .

Install the oil filler cap/dipstick.

Recheck the engine oil level (page 3-3) .

Make sure there are no engine oil leaks.

Used engine oil contains substances that havebeen identified as carcinogenic.If repeatedly left in contact with the skin forprolonged periods, it may cause skin cancer.Wash your hands thoroughly with soap and wateras soon as possible after contact with used engineoil.

TORQUE:22.5 Nm (2.3 kgfm, 17 lbfft)

ENGINE OIL CAPACITY:1.1 liters (1.2 US qt, 1.0 Imp qt)

[3]

[1]

[2] [4]

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MAINTENANC

AIR CLEANER CHECK/CLEANING/REPLACEMENT

A dirty air cleaner element will restrict air flow to thecarburetor, reducing engine performance. If the engineis operated in dusty areas, clean the air cleaner moreoften than specified in the MAINTENANCE

SCHEDULE.

Operating the engine without the air cleaner element or with the filter installed loosely will allow dirt to enter theengine, causing rapid engine wear. Install the air cleaner element securely.

Remove the air cleaner cover nut [1] and air cleaner cover [2].

Remove the wing nut [3], grommet [4] and air filter assembly.

Separate the paper element [5] from the foam element[6].

Carefully check both filters for holes or tears andreplace if damaged.

Clean the filters if they are to be reused.

Clean the foam element [1] in warm soapy water, rinse

and allow to dry thoroughly, or clean with a high flushpoint solvent [2] and allow to dry thoroughly.

Dip the form element in clean engine oil [3] andsqueeze out all the excess oil.

Excess oil will restrict air flow through the form elementand may cause the engine to smoke at startup.

Tap the paper element [1] several times on a hard

surface to remove dirt, or blow compressed air (notexceeding 207 kPa, 2.11 kgf/cm 2, 30 psi) through thepaper element from the inside.

Never try to brush off dirt; brushing will force dirt into thepaper fibers.

Assemble the air cleaner in the reverse order of disassembly.

[1]

[2]

[3]

[5]

[6]

[4]

[2] [

[1]

[1]

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MAINTENANCE

SEDIMENT CUP CLEANING

Turn the fuel valve lever [1] to the "OFF" position.

Remove the sediment cup [2] and the O-ring [3].

Remove the cup filter [4] while releasing the tabs [5].

Clean the sediment cup and the cup filter withnonflammable solvent and allow them to dry thoroughly.

Install the cup filter as the direction shown in theillustration.

Install a new O-ring and tighten the sediment cup to thespecified torque.

Check the installation part of the sediment cup for anysign of fuel leakage.

Gasoline is highly flammable and explosive.You can be burned or seriously injured whenhandling fuel. Keep heat, sparks, and flame away.

Handle fuel only outdoors. Wipe up spills immediately.

TORQUE:3.9 Nm (0.40 kgfm, 2.9 lbfft) ON

UNDER VIEW:

BOSS

OFF

CARBURETOR

BOSS

[1]

[3]

[2]

[4]

[5][5]

[5]

[5]

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MAINTENANC

SPARK PLUG CHECK/ADJUSTMENT/REPLACEMENT

Remove the spark plug cap [1], and then remove thespark plug [2] using a spark plug wrench [3].

Visually inspect the spark plug. Replace the plug if theinsulator [1] is cracked or chipped.

Remove carbon or other deposits with wire brush.

Check the sealing washer [2], center electrode [3] andside electrode [4] for damage.

An incorrect spark plug can cause engine damage.Use the recommended spark plug or an exact equivalent.

Replace the spark plug if the sealing washer isdamaged.

Measure the plug gap with a thickness gauge. If themeasurement is out of the specification, adjust bybending the side electrode.

Install the spark plug finger tight to seat the washer,then tighten it to the specified torque.

A loose spark plug can become very hot and can

damage the engine. Overtightening can damage thethreads in the cylinder head.

Install the spark plug cap securely.

If the engine has been running, the engine will bevery hot. Allow it to cool before proceeding.

[3] [1]

[2]

SPECIFIED SPARK PLUG:BPR6ES (NGK), W20EPR-U (DENSO)

SPARK PLUG GAP: 0.70 0.80 mm (0.028 0.031 in)

TORQUE:18 Nm (1.8 kgfm, 13 lbfft)

[2]

[1]

0.70 0.80 mm(0.028 0.031 in)

[3]

[4]

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MAINTENANCE

SPARK ARRESTER CLEANING

Remove the muffler protector (page 11-2) .

Remove the two screws (5 x 8 mm) [1] and sparkarrester [2].

Clean the carbon deposits from the spark arrester screen [3] with a wire brush [4].

Check the spark arrester screen for damage. If thescreen is damaged, replace the spark arrester.

Install the spark arrester in the reverse order of removal.

VALVE CLEARANCE CHECK/ADJUSTMENT

Valve clearance inspection and adjustment must be performed with the engine cold.

Disconnect the breather tube [1].Remove the head cover bolt [2] and head cover [3].Check the head cover packing [4] for damage or deterioration and replace it if necessary.

The engine and the muffler becomes very hotduring operation and remains hot for a while afterstopping the engine. Be careful not to touch themuffler while it is hot. Allow it to cool before

proceeding.

[3]

[4]

[2]

[1]

[2][1]

[4] [3]

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MAINTENANCDisconnect the spark plug cap from the spark plug.

Set the piston near top dead center of the cylinder compression stroke (both valves fully closed) by pullingthe recoil starter slowly. When the piston is near topdead center of the compression stroke, the " " mark [1]and cut-out [2] on the starter pulley will align with thetop hole [3] on the recoil starter case [4].

If the exhaust valve is opened, use the recoil starter toturn the crankshaft one additional turn and align the " "mark on the starter pulley with the top hole on the recoilstarter case again.

Insert a thickness gauge [1] between the valve rocker arm [2] and valve stem [3] to measure the valveclearance.

If adjustment is necessary, proceed as follows.

Hold the rocker arm pivot [4] and loosen the rocker armpivot lock nut [5].

Adjust by turning the rocker arm pivot until there is aslight drag on the thickness gauge.

Hold the rocker arm pivot and retighten the pivot locknut to the specified torque.

Recheck the valve clearance, and if necessary, readjustthe clearance.

Installation is in the reverse order of removal.

COMBUSTION CHAMBER CLEANINGRemove the cylinder head (page 13-4) .

Clean any carbon deposits from the combustionchamber [1].

Install the cylinder head (page 13-4) .

[[3]

[2] [

VALVE CLEARANCE:IN: 0.15 0.02 mmEX: 0.20 0.02 mm

TORQUE: 10 Nm (1.0 kgfm, 7 lbfft)

[1]

[4]

To increase valve clearance: screw out.To decrease valve clearance: screw in.

[3] [2]

[5]

[1]

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MAINTENANCE

FUEL TANK AND FILTER CLEANING

Remove the fuel tank (page 5-3) .

Remove the fuel tank joint [1].

Remove the O-ring [2] from the fuel tank joint.

Wash the fuel tank joint in nonflammable or high flashpoint solvent.

Inspect the fuel filter screen [3] to be sure it isundamaged.

Clean the fuel tank [4] with nonflammable or high flashpoint solvent and allow to dry thoroughly.

Check to be sure new O-ring is in place, and install thefuel tank joint.

Tighten the fuel tank joint to the specified torque.

Install the fuel tank (page 5-3) .

Make sure there are no fuel leaks.

FUEL TUBE INSPECTION

Check the fuel tube [1] for damage, fuel leakage,corrosion, and other abnormalities.

Check that the fuel tube is not interfering with theneighboring parts.

Replace the fuel tube if there is damage, fuel leakageor, corrosion (page 5-3) .

Gasoline is highly flammable and explosive.You can be burned or seriously injured whenhandling fuel. Keep heat, sparks, and flame away.


TORQUE:2.0 Nm (0.20 kgfm, 1.5 lbfft)

[4]

[1]

[2]

[3]

Gasoline is highly flammable and explosive.You can be burned or seriously injured whenhandling fuel. Keep heat, sparks, and flame away. Wipe up spills immediately. Handle fuel only outdoors.

[1]

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4. TROUBLESHOOTING

BEFORE TROUBLESHOOTING4-2 TROUBLESHOOTING 4-2

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TROUBLESHOOTINGTROUBLESHOOTING

BEFORE TROUBLESHOOTING Check that the connectors are connected securely. Check for sufficient fresh fuel in the fuel tank. Check the engine oil level. Read the circuit tester's operation instructions carefully, and observe the instructions during inspection.

TROUBLESHOOTINGHARD STARTING

Perform the spark test (page 8-4).

Wet

Spark

No spark

Dry

Clogged

Normal

Check the spark plug (page 3-7).

Check the air cleaner element (page 3-5).

If spark plug is correct, dry the electrodes, andthen restart the engine, taking care that the chokevalve is not closed too much.

If the engine does not start and the electrodes arewet again, check the carburetor float valve (page5-9).

Perform the IGNITION SYSTEMTROUBLESHOOTING (page 8-2).

Disassemble the carburetor to clean thecarburetor ports, jets, and nozzles (page 5-7).

Clean the air cleaner element.

Go to page 4-3.

Pull the recoil starter and check whether theengine cranks.

If the recoil starter operates correctly whenremoved but cannot be pulled when installedon the engine, disassemble the engine andrepair or replace the faulty part(s) (page 14-4).

Cranks

Cannot be cranked

Clean

Fuel is not reaching thecarburetorLoosen the carburetor drain screw, and check the

fuel flow from the fuel tank.Check for clogged fuel tube (page 3-11).Check for clogged fuel tank joint (page 3-10).

Fuel is reachingthe carburetor

If the engine is stalled in a cold weather

application, check for a frozen clog in the breathertube.

If the recoil starter operates correctly whenremoved but is hard to pull when installed onthe engine, check the decompressor operationof the camshaft (page 14-15).

Check the recoil starter (page 9-6).

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TROUBLESHOOTING

Normal

Compressionis too high

Compressionis too low

Perform the cylinder compression test (page 13-6).

Check the valve clearance (page 3-8) and thenperform the cylinder compression test.

If the cylinder compression is too high, removecarbon deposits in the combustion chamber (page3-9).

Check the valve clearance (page 3-8), and thenperform the cylinder compression test.If the cylinder compression is too low, perform aleak down test.If there is air leakage in the engine, check thefollowing:

Valve spring free length (page 13-8) Valve seat width (page 13-7) Valve face irregularly worn (page 13-8) Decompressor operation (page 14-15) Piston ring side clearance (page 14-12)

Piston ring width (page 14-11) Piston ring end gap (page 14-12) Piston skirt O.D. (page 14-10) Cylinder sleeve I.D. (page 14-9)

Restart the engine according to the startingprocedure.

From page 4-2

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TROUBLESHOOTING

ENGINE SPEED DOES NOT STABILIZE

Check the air cleaner element (page 3-5). Clean the air cleaner element.

Check the valve clearance (page 3-8).

Remove the spark plug and check the electrodesfor carbon and proper gap (page 3-7).

Check the main jet for blockage (page 5-8).

Check for air leaking between the carburetor andengine block. Is it normal?

Check the cylinder compression (page 13-6).

Check for worn piston, piston rings, or cylinder(page 14-9).

Check for carbon deposits in the combustionchamber (page 3-9).

Check around the air intake tract and carburetor;replace the insulator and/or gasket if necessary.

Disassemble and clean the carburetor.

Inspect the spark plug and adjust the spark pluggap. Replace if necessary.

Adjust the valve clearance.

Clogged

Abnormal

No

High cylindercompression

Low cylindercompression

Yes

Clear

Normal

Clean

Normal

Normal

Abnormal

Clogged

Check the ignition coil air gap (page 8-4). Adjust the ignition coil air gap.

Check the ignition coil (page 8-5).

Replace the ignition coil if abnormalities arefound, and recheck.

Normal

Abnormal

Check the valve clearance (page 3-8).Check that the cylinder head is correctlytightened (page 13-4).

Check for defective cylinder head gasket,valves, or valve seats (page 13-5).

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TROUBLESHOOTING

ENGINE DOES NOT STOP WHEN ENGINE STOP SWITCH IS TURNED OFF

ENGINE DOES NOT STOP WHEN ENGINE OIL LEVEL IS LOW

Check for engine wire harness connecting theengine stop switch and the ignition coil forcontinuity.

Replace or repair the engine wire harness.

Check the engine stop switch (page 10-11). Abnormal

Normal

Check the ignition coil (page 8-5).Replace the ignition coil if necessary, and recheck.

Replace the engine stop switch (page 7-14).

No continuityENGINE WIRE HARNESS

R

Bl

Normal

Check for continuity between the oil level switchconnector and the engine ground.

Replace the oil level switch (page 14-4).Continuity

No continuity

Check the engine wire harness between the oillevel switch and the ignition coil for continuity.

Replace the ignition coil (page 8-3).

Replace or repair the engine wire harness.No continuity

Continuity

ENGINE WIRE HARNESS

Y

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5. FUEL SYSTEM

TOOL 5-2

FUEL TANK REMOVAL/INSTALLATION 5-3

AIR CLEANER REMOVAL/INSTALLATION5-4

CARBURETOR REMOVAL/INSTALLATION5-5

CARBURETOR DISASSEMBLY/ASSEMBLY5-6

CARBURETOR BODY CLEANING 5-8

CARBURETOR INSPECTION 5-8

PILOT SCREW REPLACEMENT 5-9

CHOKE SET REPLACEMENT 5-10

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FUEL SYSTEMFUELSYSTEM

TOOLFloat level gauge07401-0010000

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FUEL SYSTEM

FUEL TANK REMOVAL/INSTALLATION

Turn the fuel valve lever to the "ON" position.

Loosen the drain screw (6 x 8 mm) and drain the fuelinto a suitable container.

After installation, route the fuel tube to the carburetor properly (page 2-27) .

Gasoline is highly flammable and explosive.You can be burned or seriously injured whenhandling fuel. Keep heat, sparks and flame away.


FUEL TANK CAP: NOTE 3

FUEL TANK CAP PACKING: NOTE 6

FUEL TANK STRAINER: NOTE 4CUT-OUTS: NOTE 7

FUEL TANK: NOTE 1

TANK MOUNTING RUBBER (2)

BOLT (6 x 10 mm) (4)

FUEL TANK BOLT(8 x 25 mm) (2)24 Nm (2.4 kgfm, 18 lbfft)

FUEL TANK NUT (8 mm) (2)24 Nm (2.4 kgfm, 18 lbfft)

CLIP (B8) (2)

FUEL TUBE:NOTE 2, 5

O-RING

TANK MOUNTING RUBBER A (2)

TANK MOUNTING NUT (2)

FUEL TANK JOINT: NOTE 12.0 Nm (0.20 kgfm, 1.5 lbfft)

DRAIN SCREW

(6 x 8 mm)

FUEL VALE LEVER

NOTE 1 FUEL TANK AND FILTER CLEANING page 3-10NOTE 2 FUEL TUBE INSPECTION page 3-10

NOTE 3 When reassembly, make sure that air vent hole is clean and unclogged.Blow with compressed air if necessary.

NOTE 4 When reassembly, make sure that the strainer is clean and undamaged.

NOTE 5 When reassembly, check for crack or deterioration before installation andreplace if necessary.

NOTE 6 Check the tank cap packing for wear or damage. Replace it if necessary. NOTE 7 When reassembly, align the cut-outs.

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FUEL SYSTEM

AIR CLEANER REMOVAL/INSTALLATION

When installation, route the breather tube properly(page 2-11) .

FOAM ELEMENT: NOTE 1 AIR CLEANER COVER NUT

AIR CLEANER COVER

WING NUT

GROMMET

PAPER ELEMENT: NOTE 1ELBOW PACKING:NOTE 2

NOISE SILENCER

BREATHER TUBE:NOTE 2

AIR CLEANER ELBOWNUT (6 mm) (2)9.0 Nm (0.90 kgfm, 6.6 lbfft)

AIR CLEANER ELBOW: NOTE 3, 4 CARBURETOR SPACER: NOTE 5

BOLT/WASHER(6 x 22 mm)

COLLAR

CHOKE LEVER: NOTE 3

FUEL VALVE LEVER: NOTE 3

ELBOW COLLAR (2)

NOTE 1 AIR CLEANER CHECK/CLEANING/REPLACEMENT page 3-5NOTE 2 Before installation, check for cracks or deterioration.

NOTE 3 Remove and install with the choke lever in the "ON" position and fuel valvelever in the "OFF" position as shown.

NOTE 4 Before installation, clean the inside with compressed air. NOTE 5 Note the installation direction.

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FUEL SYSTEM

CARBURETOR REMOVAL/INSTALLATION

Pinch the fuel tube with the fuel tube clamp and thendisconnect it from the carburetor.

Remove the air cleaner elbow (page 5-4) .

Gasoline is highly flammable and explosive.You can be burned or seriously injured whenhandling fuel. Keep heat, sparks and flame away. Handle fuel only outdoors. Wipe up spills immediately.

CHOKE LEVER: NOTE 5

CARBURETOR: NOTE 2

INSULATOR GASKET: NOTE 6

CARBURETOR GASKET:NOTE 6

CARBURETOR INSULATOR:NOTE 3, 4

CLIP (B8)

FUEL TUBE CLAMP(Commercially available)

FUEL TUBE

GOVERNOR ROD: NOTE 1

HIGH TENSION CORD

FUEL VALVE LEVER

NOTE 1 GOVERNOR ROD REMOVAL/INSTALLATION page 5-6NOTE 2 CARBURETOR DISASSEMBLY/ASSEMBLY page 5-6NOTE 3 Before installation, blow out of the passages with compressed air. NOTE 4 After installation, clamp the high tension cord securely.

NOTE 5 The short peg on the choke lever can be used to plug the end of the fueltube.

NOTE 6 Note the installation direction.

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FUEL SYSTEM

GOVERNOR ROD REMOVAL/INSTALLATIONPull the carburetor toward a point where the groove [1]in the throttle arm [2] lines up with the governor rod [3],and lift the rod out of its hole and unhook the throttlereturn spring [4].

Installation is in the reverse order of removal.

CARBURETOR DISASSEMBLY/ASSEMBLY

[4]

[3]

[1]

[2]

Gasoline is highly flammable and explosive.You can be burned or seriously injured whenhandling fuel. Keep heat, sparks and flame away. Handle fuel only outdoors. Wipe up spills immediately.

To prevent serious eye injury, always wear safetygoggles or other eye protection when usingcompressed air.

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FUEL SYSTEMRemove the carburetor (page 5-5) .

SET COLLAR

SPRING

PILOT JET: NOTE 9

O-RING

UPPERSIDE

UPPERSIDE

20

LIMITER CAP

PILOT SCREW: NOTE 4

FLOAT PIN

FLOAT: NOTE 2, 7

FLOAT CHAMBER: NOTE 9

O-RING

SET SCREWGASKET

SET SCREW (8 x 10 mm) DRAIN SCREW (6 x 8 mm)

DRAIN SCREWGASKET

FLOAT VALVE SPRING

FLOAT VALVE: NOTE 3

THROTTLE STOP SCREW

SEDIMENT CUP: NOTE 6

O-RING

CUP FILTER: NOTE 6

SPRING PIN (2 x 12 mm)

CHOKE LEVER

PAN SCREW(3 x 6 mm) (2)

FUEL VALVE PACKING

FUEL VALVELEVER

FUEL VALVE SPRING

LEVER SETTINGPLATE

CARBURETOR BODY: NOTE 1

MAIN NOZZLE:NOTE 8

MAIN JET: NOTE 9

CHOKE VALVEPLATE: NOTE 5

NOTE 1 CARBURETOR BODY CLEANING page 5-8NOTE 2 FLOAT LEVEL HEIGHT page 5-8NOTE 3 FLOAT VALVE page 5-9NOTE 4 PILOT SCREW REPLACEMENT page 5-9NOTE 5 CHOKE SET REPLACEMENT page 5-10NOTE 6 SEDIMENT CUP CLEANING page 3-6NOTE 7 After installation, check for smooth movement. NOTE 8 Before installing, clean thoroughly with low pressure compressed air. NOTE 9 Install the float chamber to the carburetor body at an angle as shown.

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FUEL SYSTEM

CARBURETOR BODY CLEANING

Some commercially available chemical cleaners arevery caustic. These cleaners may damage plastic

parts such as the O-ring, the float and the float seat of the carburetor. Check the container for instructions. If you are in doubt, do not use these

products to clean Honda carburetors. High air pressure may damage the carburetor body.

Use low air pressure (30 psi or less) when cleaning passages and ports.

Clean the carburetor body with non-flammable solvent.

Clean thoroughly the following passages and ports withlow-pressure compressed air.

Pilot screw hole [1] Pilot jet hole [2] Pilot air jet [3] Main air jet [4] Transition ports [5] Pilot outlet [6] Main nozzle holder [7] External vent port [8]

CARBURETOR INSPECTIONFLOAT LEVEL HEIGHT

Place the carburetor in the position as shown. Measurethe distance between the float top and carburetor bodywhen the float just contacts the float valve withoutcompressing the valve spring.

If the measured float height is out of specification,check the float valve and the float valve spring (page 5-9) .

If the float valve and the float valve spring are normal,replace the float (page 5-6) .

To prevent serious eye injury, always wear safetygoggles or other eye protection when usingcompressed air.

[8]

[5]

[6]

[3]

[1]

[4]

[7][2]

TOOL:Float level gauge [1] 07401-0010000

FLOAT HEIGHT:13.2 mm (0.52 in)

[1]

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FUEL SYSTEMFLOAT VALVECheck the float valve [1] and its seat [2] for wear or contamination.

Before installation, check for wear or a weak spring [3].

Check the operation of the float valve.

PILOT SCREW REPLACEMENTThe limiter cap is an emission-related part.

Leave the pilot screw [1] and limiter cap [2] in placeduring carburetor cleaning. Remove only if necessaryfor repair of the carburetor.Removal of the limiter cap requires breaking the pilotscrew.

A new pilot screw and limiter cap must be installed.

When the limiter cap has been broken off, remove thebroken pilot screw.

Place the spring on the replacement pilot screw, andinstall it on the carburetor.Turn the pilot screw [1] in until it is lightly seated, thenturn the screw out the required number of turns.

Apply LOCTITE 638 to the inside of a new limiter cap[2], and then install the cap so its stop prevents the pilotscrew from being turned counterclockwise.

Be careful to avoid turning the pilot screw while

installing the limiter cap. The pilot screw must stay at itsrequired setting.

OK CLEAN REPLACE

[2][1]

[3]

CARBURETOR BODY

[2]

[Pilot screw breaks at narrow point.

Pilot screw opening:EC3600K1:

2 turns outEC5000K1/ECT7000K1/ECT7000P1:

2-1/8 turns out

[2]

[1] [2]

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6. GOVERNOR

GOVERNOR ARM REMOVAL/INSTALLATION6-2

GOVERNOR ADJUSTMENT 6-3

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GOVERNORGOVERNOR

GOVERNOR ARM REMOVAL/INSTALLATION

Remove the following:

Fuel tank (page 5-3) Air cleaner elbow (page 5-4)

After installation, adjust the governor arm (page 6-3) .

BOLT (6 x 12 mm) (3)

CONTROL BASE

GOVERNOR SPRING: NOTE 3, 4

GOVERNOR ARM: NOTE 1

NUT (6 mm)

GOVERNOR ARM BOLT

THROTTLE RETURNSPRING: NOTE 2

GOVERNOR ROD: NOTE 2

INSULATOR (Except EC3600K1)

NOTE 1 GOVERNOR ADJUSTMENT page 6-3NOTE 2 GOVERNOR ROD REMOVAL/INSTALLATION page 5-6

NOTE 3 When reassembly, install the spring with the long end side toward thecontrol base.

NOTE 4 Hook the governor spring to the governor arm as shown.

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GOVERNO

GOVERNOR ADJUSTMENTRemove the fuel tank (page 5-3) .

Loosen the nut (6 mm) [1] on the governor arm bolt [2],and move the governor arm [3] to fully open(counterclockwise) the throttle.

Rotate the governor arm shaft [4] as far as it will go inthe same direction as governor arm moved to open thethrottle.Tighten the nut securely.

Install the fuel tank (page 5-3) .

Use a tachometer with graduations of 50 min -1 (rpm) or smaller that will accurately indicate a 50 min -1 (rpm)change.

Warm up the engine.

Stop the engine and connect a tachometer according tomanufacturers operating instruction.

Restart the engine and bring the engine to its standardspeed with the throttle lever.

Adjust the throttle control screw [5] so that the throttlecannot be moved past this point.

ENGINE SPEED:EC3600K1:

3,200 150 min -1 (rpm)EC5000K1/ECT7000K1/ECT7000P1:

3,150 150 min -1 (rpm)

[2]

[

[5]

[4]

[1]

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7. GENERATOR/CHARGING SYSTEM

TOOLS7-2

GENERATOR SYSTEM DIAGRAM 7-3

BEFORE TROUBLESHOOTING7-9

GENERATOR SYSTEMTROUBLESHOOTING7-9

FAN COVER REMOVAL/INSTALLATION7-14

COOLING FAN/FLYWHEEL REMOVAL/INSTALLATION7-15

GENERATOR REMOVAL 7-18

COMPOUNDING TRANSFORMERDISASSEMBLY/ASSEMBLY(ECT7000K1)7-25

WINDING INSPECTION7-26

BRUSH HOLDER INSPECTION (ECT7000K1,ECT7000P1) 7-36

DIODE INSPECTION(EXCEPT ECT7000P1) 7-37

COMPOUNDING TRANSFORMER AIR GAPCHECK/ADJUSTMENT (ECT7000K1) 7-38

ROTOR BEARING INSPECTION 7-39

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GENERATOR/CHARGING SYSTEMGENERATOR/CHARGING SYSTEM

TOOLSDriver attachment, 20 mm I.D.07746-0020400


Driver, 22 mm I.D.07746-0020100

Driver, 40 mm I.D.07746-0030100

Flywheel puller set07935-8050004

Generator shaft holder 07AAA-ZP4GTS1

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GENERATOR SYSTEM DIAGRAMEC3600K1FT, GVT, GVWT, ITT Type:

BLACKYELLOWBLUEGREENRED

VIOLETVWHITE

BEIGEBeGRAYPINKLIGHT GREELIGHT BLUEORANGEBROWN

WRGBuYBl

Gr PLgLbOBr

COLOR COMB : GROUND/MARKING

GENERATOR BLOCK

M1W M2W

FWEXW CAPACITOR35 microF

GND3

EARTHTERMINAL

C4

C5

3

1

2

3

4

C6 C7

CIRCUIT PROTECTOR17A-230V THERMAL

SOCKETSCHUKO 16A-230VBLUE COLORCHILDREN PROTECT

T2

T1

T3

SOCKETFRENCH 16A-230VBLUE COLOR

CHILDREN PROTECT

SOCKETFRENCH 16A-230VBLUE COLOR

CHILDREN PROTECT


AC OUTLET EC3600-ITT type

AC OUTLET EC3600-FT type AC OUTLET EC3600-GVT typeEC3600-GVWT type

CONTROL BOX BLOCK

T2T1

T3

T6T4

T5

C6 C7


a

c

b

a

c

b

a

c

b

C6 C7


T6

T4

T5

T1

T2

T3

SOCKETEEC 16A-230VBLUE COLOR


G(G)

G(G)G(G)

T6

T4

T5

Y / G

Y / G

R R

GG

Y / G

R G

Y / G

R G

Y/G

(R)

Y/G

(R)

Y/G

(R)

R

W

Y

G

R

Y

G

Y / G

G

G

Y / G

R R

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GENERATOR/CHARGING SYSTEMBT Type:

EXW


VIOLETVWHITE

BEIGEBeGRAYPINKLIGHT GREENLIGHT BLUEORANGEBROWN

WRGBuYBl

Gr PLgLbOBr


GENERATOR BLOCK

M1W M2W

CAPACITOR22 microF

GND4EARTHTERMINAL

C15

C16

4

1

2

3

4

C8 C9


AC OUTLET EC3600-BT type/115V

AC OUTLET EC3600-BT type/230V

CONTROL BOX BLOCK

115V-0-230VVOLT CHANGE SW(115V POSITION)

1

23

4

56

C51

C50

C49

C48

C47

C46

T7 T9

T8

SOCKET

EEC 16A-230VBLUE COLOR

C10

T15

T14

T13T12

T11

T10

C11

2 x CIRCUIT PROTECTOR17A-115V THERMAL

2 x SOCKETEEC 16A-115VYELLOW COLOR

C12

C13

FW

G

W

(R)

(G)

R

W

BlBl

G

R

W

Y

G

R

W

W

G W

R (G)

Y/G

W

W

W

W

Bl Bl

Y/G

Y/G (Bl)

Y/G Y/G

Bl

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EC5000K1FT, GVT, GVWT, ITT Type:


VIOLETV

WHITE

BEIGEBe

GRAYPINKLIGHT GRLIGHT BLUORANGEBROWN

WRGBuYBl

Gr PLgLbOBr


T25

T24T26

T28

T27 T29

T38T36

T37

T35

T33

T34

T30

T31

T32

C19 C20C25

C27

C28

C26

C23C21

C22 C24




AC OUTLET EC5000-FT type AC OUTLET EC5000-ITT type

2 x SOCKETFRENCH 16A-230VBLUE COLORCHILDREN PROTECT




a

c

b

a

cb

2 x CIRCUITPROTECTOR17A-230VTHERMAL

T16

T18

T17

T19

T20

T22

T21

T23

GENERATOR BLOCK

a

c

b

M1W M2WEARTHTERMINAL

GND5

FW

C18

C17

EXW CAPACITOR35 microF

CONTROL BOX BLOCK

C19

C21

C22

C20

2 x CIRCUIT PROTECTOR17A-230V THERMAL

2 x SOCKETSCHUKO 16A-230VBLUE COLORCHILDREN PROTECT


AC OUTLET EC5000-GVT typeEC5000-GVWT type

T24 T25

T26

T27

T28

T29

C23

C24

Y / G Y

/ G

Y / G

G

R Y / G

R

Y / G

(R)

Y/G

(R)

Y/GY/G

(G) G G

G

(G) G

G

G

G

G G

R R

R R R

Y / G

Y / G

W

G (G) G

GG

Y

R

R R

(R)

G

Y

R

G G

Y/G

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GENERATOR/CHARGING SYSTEMBT Type:


VIOLETVWHITE


WRGBuYBl

Gr PLgLbOBr


GND5

3 56

B

A

1 24

D

C

T39

T41

T40

T42

T16

T18

T17

T19

C18

C17

GENERATOR BLOCK

M1W

FW

EXW

M2W

CAPACITOR35 microF

C44

C45

C42

C43

T48T43

T55

T56

T57

T58

T61

T59

T60

T44

T50

T51T49

T53

T54T52

T45 C38 C39

C36 C37

T46

T47

C40 C41VOLTAGE SWITCH115V-0-230V






SOCKETEEC 32A-115VYELLOW COLOR

SOCKETEEC 16A-115VYELLOW COLOR

EARTHTERMINAL

AC OUTLET EC5000-BT type / 230V

AC OUTLET EC5000-BT type / 115V

CONTROL BOX BLOCK

1150

230 A B C D

0115

230

VOLTAGE SWITCH

W

GY Y

(Y) Y

G

W

R R

WW

G

Y

R

W

Y / G

GG

G GG

R

W

Y / G

Y / G

Y / G

Y / G

(R)

Y/GY/G

G

R

Y Y

Y

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ECT7000K1

1 CONT

ROLBOXBLOCK

T76

T75

T77T73

T72 T74

C66

C65 C66C65

C66

C65

C51 C53

C52 C54

C55 C57

C56 C58

C59

C60

C61

C62

C63

C64


2 x SOCKETFRENCH 16A-230VBLUE COLORCHILDREN PROTECT

2 x SOCKETSCHUKO 16A-230VBLUE COLORCHILDREN PROTECT

T74T72

T73

T82

T78

T79T80

T81


SOCKETEEC 16A-400VRED COLOR

T75

T76T77

T72

T73T74

T62 T63

T66

T64

T67T65

T68

T69

T70

T71

GND6

EARTHTERMINAL

CURRENT TRANSFORMER

DIODE

FW

EX1W

EX2W

EX3W

GENERATOR BLOCK AC OUTLET 230V ECT7000-GVT typeECT7000-GVWT typeECT7000-RGT type

AC OUTLET 230V ECT7000-FT type AC OUTLET 230V ECT7000-ITT type



AC OUTLET 400V

PROTECTOR SWITCH3x10A-400V THERMAL

BLACKYELLOWBLUE

GREENRED

VIOLETVWHITE

BEIGEBeGRAYPINKLIGHT GREEN

LIGHT BLUEORANGEBROWN

WRG

BuYBl

Gr PLgLbOBr

COLOR COMB : GROUND/MARKINGc c

c

a

b

a

b

a

b

3

5

4

6

1

2

M1W

M2W

M3W

R

(R) (R)R

R

R

Bu

Bu

Bu

Bu

Bu

(Bu)

( Y / G )

Y / G

R

(R)RR

R(Bu)

Y / G

RBu

Bu

Bu(Neutral)

Bu

R

G

R

G

R

G

R

G

R

R

(Y)

(Y)

(Y)

Bl

G

R

Bl

Y / G

Y / G

G

R

Bl

G

R

Bl

G

R

Bl

G

R

Bl

Y

Y

G

R

Bl

Y

G

G

R B l

R

B l

Y/G

Y/G (Y/G)

Y/G

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ECT7000P1

GND7

GENERATOR BLOCK CONTROL BOX BLOCK

AC OUTLET 400V AC OUTLET 230V

AC thermal circuit breaker 16A

T93T96

T97T95

T99

T100

T98

T102

T103

T101

T94T90

T82

T83

T84

T85

T86

T87

T88

T89

T91

T92

400V/16A 230V/16A 230V/16A 230V/16A

FW

F1 F2

MW


VIOLETVWHITE


WRGBuYBl

Gr PLgLbOBr


C67

C68

1 2 3 4 5 6

3

2

1

6

4

5

2

3

AVR UNIT

Y/G

Y/G

U

V

W

Br

W

Bl

Br

W

Bl

Bl

Bu

Bu

Bu

Gr

R

Y / G

Y / G Y

/ G Y / G

Y / G

Y R G r Y Y

B u

B u

B u

B u

B r

B r

W B l W

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BEFORE TROUBLESHOOTING Check that the connectors and terminals are connected securely. Read the circuit testers operation instructions carefully, and observe the

instructions during inspection.

GENERATOR SYSTEM TROUBLESHOOTINGNO OR LOW AC OUTPUTEC3600K1, EC5000K1

Normal

Normal

Abnormal

Go to page 7-10.

Normal

Normal

Normal

Abnormal

Abnormal

Abnormal

Measure the main winding AC voltage(EC3600K1: page 7-26, EC5000K1: page 7-27).

Stop the engine and disconnect the condenserconnectors and connect them to a new condenserand measure the main winding AC voltage.

Check the circuits between the generator andreceptacles.

Measure the exciter winding AC voltage at thecondenser connector terminals (EC3600K1: page7-32, EC5000K1: page 7-33).

Replace the condenser (EC3600K1: page 7-18,EC5000K1: page 7-19).

Replace the stator (EC3600K1: page 7-18,EC5000K1: page 7-19).

Connect a 12 V battery to the condenserconnector terminals for a few secondes tomagnetize the rotor.

Let the generator run for a few minutes to ensuregood re-magnetization of the rotor.

Check the engine speed (page 6-3).

STANDARD:

Measure the AC voltage at the receptacles.

EC3600K1: 3,200 150 min -1 (rpm)EC5000K1: 3,150 150 min -1 (rpm)

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ECT7000K1

Abnormal

Abnormal

Normal

From page 7-9

Abnormal

Normal

Stop the engine and measure the field windingresistance (page 7-30).

Replace the rotor (EC3600K1: page 7-18,EC5000K1: page 7-19).

Check the diode (page 7-37). Replace the diode (EC3600K1: page 7-18,EC5000K1: page 7-19).

Measure the exciter winding resistance(EC3600K1: page 7-32, EC5000K1: page 7-33).

Replace the stator (EC3600K1: page 7-18,EC5000K1: page 7-19).

Normal

Go to page 7-12.

Abnormal

Normal

Normal

Go to page 7-11.

Normal

Abnormal

Abnormal

Measure the main winding AC voltage at thecoupling plate (page 7-28).

Check the engine speed (page 6-3).STANDARD: 3,150 150 min -1 (rpm)

Measure the DC voltage at the brush holder (page7-30).

Check the circuits between the generator andreceptacles.

Stop the engine and check the diode (page 7-37). Replace the faulty diode (page 7-20).

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From page 7-10

Normal

Abnormal

Normal

Normal

Normal

Abnormal

Abnormal

Abnormal

Abnormal

Normal

Disconnect the Red and Green wire connectorsfrom diode as shown.Connect a 12 V battery (+) terminal to the Red

wire connector and (-) terminal to the Green wireconnector.

The generator is normal.Let the generator run for a few minutes to ensuregood re-magnetization of the rotor.

Measure the exciter winding AC voltage betweenthe Yellow wire connectors.

Phase - phase: 56 68 V

Replace the stator (page 7-20).

Measure the exciter winding AC voltage at the 6Pconnector terminals (thin wire side).Phase - phase: 56 68 V

Stop the engine and disconnect the battery.Measure the exciter winding resistance (page 7-33).

Replace the stator (page 7-20).

Measure the main winding AC voltage at the 6Pconnector (thick wire side).Phase - phase: 215 265 V

Replace the transformer (page 7-20).


Measure the output AC voltage at the couplingplate (page 7-28).Phase - neutral: 135 165 VPhase - phase: 225 275 V

Abnormal

Abnormal

Normal

Measure the field winding resistance (page 7-30). Replace the rotor (page 7-20).

Check the brush holder (page 7-36). Replace the brush holder (page 7-20).

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ECT7000P1

Abnormal

Abnormal

Normal

From page 7-10

Measure the main winding resistance (page 7-29). Replace the stator (page 7-20).

Measure the transformer resistance of the mainwinding side (page 7-35).


Measure the main winding AC voltage (page 7-29).

Normal

Abnormal

NormalCheck the circuits between the generator andreceptacles.


Stop the engine and check the brush holder (page7-36).

Replace the brush holder (page 7-21). Abnormal

Normal

Measure the field winding resistance (page 7-31). Replace the stator (page 7-21). Abnormal

Normal

Connect the 12 V battery to the brush holderterminals and measure the AC voltage at the 6Pconnector (page 7-29).

Normal

Abnormal Replace the stator (page 7-21).

Replace the AVR (page 10-3).

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HIGH AC OUTPUT (ECT7000K1)

UNSTABLE AC OUTPUT

Measure the AC voltage. of each main winding (page 7-26) of each exciter winding (page 7-32)

Replace the stator (page 7-20).Voltages are not balanced

Voltages are balanced

Adjust the transformer air gap (page 7-38).

Check the loose or poor connection at theconnectors and terminals.

Normal


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FAN COVER REMOVAL/INSTALLATION

After installation, route the wire harness properly (page2-10) .

BOLT (6 x 12 mm) (5)FAN COVER

TUBE CLIP

ENGINE STOP SWITCH SCREW(3 x 6 mm) (2)

ENGINE STOP SWITCH:NOTE 1

0.45 Nm (0.046 kgfm, 0.33 lbfft)

NOTE 1 ENGINE STOP SWITCH INSPECTION page 10-11

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COOLING FAN/FLYWHEEL REMOVAL/INSTALLATION

When disassembling and reassembling, take care not to damage the fan blade.

Remove the ignition coil (page 8-3) .

After installation, perform the "IGNITION COIL AIRGAP CHECK/ADJUSTMENT" (page 8-4) .

WOODRUFF KEY (25 x 18 mm): NOTE 3

FLYWHEEL: NOTE 1, 2

COOLING FAN: NOTE 2

STARTER PULLEY(Except EC3600K1):NOTE 2

STARTER PULLEY(EC3600K1)

FLYWHEEL SPECIAL NUT (16 mm)

128 Nm (13.1 kgfm, 94 lbfft)

170 Nm (17.3 kgfm, 125 lbfft)

EC3600K1:

Except EC3600K1:

NOTE 1 FLYWHEEL REMOVAL page 7-16NOTE 2 FLYWHEEL INSTALLATION page 7-16

NOTE 3 After installing the flywheel, check to be sure that the woodruff key is still inits slot on the crankshaft.

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FLYWHEEL REMOVALHold the flywheel [1] with a commercially available strapwrench [2] and remove the special nut (16 mm) [3].

Take care not to damage the cooling fan with the strapwrench.

Remove the starter pulley [4] and cooling fan [5].

Hold the flywheel [1] with a commercially available strapwrench [2].

Remove the flywheel by using the special tool.

Do not hit the flywheel with a hammer.

FLYWHEEL INSTALLATIONClean the tapered surface [1] of dirt, oil, grease, andother foreign material before installation.

Be sure there are no metal parts or other foreignmaterial on the magnet part [2] of the flywheel.

Set the woodruff key (25 x 18 mm) [3] in the key groove[4] of the crankshaft securely.

Install the flywheel [5] by aligning the key slot [6] withwoodruff key on the crankshaft.

The flywheel may push the woodruff key (25 x 18 mm)out of its slot; check after installation.

Attach the cooling fan [1] to the flywheel [2] by aligningthe three projections of the cooling fan with the holes of the flywheel.

Attach the starter pulley [3] by aligning the hole of the

pulley with the projection at the center of the coolingfan.

[3]

[1]

[2][4] [5]

TOOL:Flywheel puller set [3] 07935-8050004

[1] [3][2]

[4]

[3]

[5]

[6]

[1]

[2]

[3]

[2] Align

Align

[1]

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GENERATOR/CHARGING SYSTEM Apply engine oil to the threads and seating surface of the special nut (16 mm) [1], and loosely tighten the nut.

Hold the flywheel [2] with a commercially available strapwrench [3], and tighten the nut to the specified torque.

TORQUE:EC3600K1: 128 Nm (13.1 kgfm, 94 lbfft)Except EC3600K1: 170 Nm (17.3 kgfm, 125 lbfft)

[

[1] [3]

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GENERATOR/CHARGING

Documents

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