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Yamaha EF12000DE Owner's Manual PDF

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Summary of Content for Yamaha EF12000DE Owner's Manual PDF

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OWNER'S MANUAL

EF12000DE

LIT-19626-01-22

Generator

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INTRODUCTION Congratulations on your purchase of your new Yamaha. This manual will provide you with a good basic understanding of the operation and maintenance of this machine. If you have any questions regarding the operation or maintenance of your machine, please consult a Yamaha dealer.

YAMAHA MOTOR CO,LTD. MADE IN JAPAN

IDENTIFICATION NUMBER RECORDS Record your Primary I.D., and serial numbers in the spaces provided, to assist you in ordering spare parts from a Yamaha dealer. Also record and keep these I.D. num- bers in a separate place in case your machine is stolen.

MACHINE IDENTIFICATION The machine serial number is stamped in the location as shown.

NOTE : The first three digits of these numbers are for model identification; the remain- ing digits are the unit production num- ber. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer.

PRI-I.D. CODE

MODEL

SERIAL No.

PRI-I.D. NUMBER

EF12000DE OWNERS MANUAL

2005 by Yamaha Motor Corporation, U.S.A. 1st Edition, October 2004

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited. Printed in Japan.

P/N LIT-19626-01-22

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PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MACHINE.

Particularly important information is dis- tinguished in this manual by the follow- ing notations.

-

The Safety Aler t Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instruc- tions could result in severe injury or death to the engine operator, a bystander, or a person inspecting or repairing the engine.

A CAUTION indicates special precau- tions that must be taken to avoid dam- age to the engine.

NOTE :

A NOTE provides key information to make procedures easier or clearer.

NOTE :

9 Yamaha continually seeks advance- ments in product design and quali- ty. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor dis- crepancies between your engine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.

9 This manual should be considered a permanent part of this engine and should remain with this engine when resold.

WARNING

WARNING

CAUTION :

851-005

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Check that following acces- sories come with your Yamaha Generator.

(1) Owners manual

(2) Wheel mounting parts (See page 38.)

(3) Servicing tools

(4) Battery mounting bracket (See page 13.)

Be sure to replenish with engine oil. (See page 11 for details.)

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CONTENTS

LIMITED WARRANTY (EF-SERIES)......................................................1

LOCATION OF IMPORTANT LABELS ..................................................3

SAFETY INFORMATION ........................................................................4

EXHAUST FUMES ARE POISONOUS.............................................4

FUEL IS HIGHLY FLAMMABLE AND POISONOUS .......................4

ENGINE AND MUFFLER MAY BE HOT...........................................4

ELECTRIC SHOCK PREVENTION ..................................................5

CONNECTION NOTES .....................................................................6

CONNECTION...................................................................................6

EXTENSION CORD NOTES .............................................................6

CONTROL FUNCTION...........................................................................8

PRE-OPERATION CHECK...................................................................11

CHECK ENGINE OIL ......................................................................11

CHECK FUEL..................................................................................12

BATTERY INSTALLATION..............................................................13

CHECK COMPONENT PARTS.......................................................15

CHECK GENERATOR SURROUNDINGS......................................15

OPERATION .........................................................................................16

STARTING THE ENGINE................................................................16

USING ELECTRIC POWER............................................................17

STOPPING THE GENERATOR.......................................................22

WATTAGE INFORMATION ...................................................................23

VOLTAGE DROP IN ELECTRIC EXTENSION CORDS..................24

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MAINTENANCE SCHEDULE...............................................................25

DAILY INSPECTION........................................................................25

PERIODICAL MAINTENANCE.......................................................25

HOW-TO MAINTENANCE.................................................................27

ENGINE OIL CHANGE ...................................................................27

ENGINE OIL FILTER REPLACEMENT ..........................................27

SERVICING AIR CLEANER............................................................28

CLEANING AND ADJUSTING SPARK PLUG ...............................29

CLEANING FUEL STRAINER ........................................................29

FUEL HOSE REPLACEMENT........................................................30

CHECKING CARBON BRUSH .......................................................30

BATTERY-Replenishing the battery fluid.....................................31

SPARK ARRESTER........................................................................32

PREPARATION FOR STORAGE..........................................................33

BATTERY ........................................................................................34

TROUBLESHOOTING..........................................................................35

SPECIFICATIONS ................................................................................36

WIRING DIAGRAM...............................................................................37

OPTIONAL PARTS...............................................................................38

HOW-TO INSTALL THE WHEEL.................................................38

FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY...........39

EMISSION CONTROL SYSTEM WARRANTY STATEMENT ..............41

LIMITED WARRANTY ON EMISSION CONTROL SYSTEMS ............42

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1

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2

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3

3

2

5

1

3

2

1 5

4

6

6

4

REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. THIS ENGINE MEETS EMISSION STANDARDS FOR ****U.S. EPA REGULATIONS FOR SMALL NON-ROAD ENGINES (EMISSION COMPLIANCE PERIOD OF 1000 HOURS) AND **** CALIFORNIA SI SORE's. YAMAHA MOTOR CO.,LTD.

ENGINE FAMILY- DISPLACEMENT 653 cm3 IMPORTANT ENGINE INFORMATION EM

EH63 .64 .65

*****.******

LOCATION OF IMPORTANT LABELS Please read the following labels carefully before operating this machine.

NOTE :

Maintain or replace safety and insutruction labels, as necessary.

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4

743-002

743-003

743-005

743-004

743-006

743-007

G-380

SAFETY INFORMATION

G-381

EXHAUST FUMES ARE POISONOUS 9 Never operate the engine in a closed area or it

may cause unconsciousness and death within a short time. Operate the engine in a well ven- tilated area.

G-382

FUEL IS HIGHLY FLAMMABLE AND POISO- NOUS 9 Always turn off the engine when refuelling. 9 Never refuel while smoking or in the vicinity of

an open flame. 9 Take care not to spill any fuel on the engine or

muffler when refuelling. 9 If you swallow any fuel, inhale fuel vapor, or

allow any to get in your eye(s), see your doctor immediately. If any fuel spills on your skin or clothing, immediately wash with soap and water and change your clothes.

9 When operating or transporting the machine, be sure it is kept upright. If it tilts, fuel may leak from the carburetor or fuel tank.

G-383

ENGINE AND MUFFLER MAY BE HOT 9 Place the machine in a place where pedestri-

ans or children are not likely to touch the machine.

9 Avoid placing any flammable materials near the exhaust outlet during operation.

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5

743-008a

a

743-009

743-010

743-011

743-012

q

9 Keep the machine at least 1 m (3 ft) from buildings or other equipment, or the engine may overheat.

a 1 m (3ft)

9 Avoid operating the engine with a dust cover.

G-384

ELECTRIC SHOCK PREVENTION 9 Never operate the engine in rain or snow.

9 Never touch the machine with wet hands or electrical shock will occur.

9 Be sure to ground (earth) the generator.

NOTE: Use ground (earth) lead of sufficient current capaci- ty.

1 Lead diameter

Ground (earth) Lead Diameter:

0.12 mm (0.005 in)/ampere EX:

10 Ampere 1.2mm (0.05 in)

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6

743-013

q

w

q

w

G-385

CONNECTION NOTES 9 Avoid connecting the generator to commercial

power outlet. 9 Avoid connecting the generator in parallel with

any other generator. 1 Correct 2 Incorrect

G-440

CONNECTION

G-387

EXTENSION CORD NOTES 9 When using an extension cord, its total length

should not exceed 60 meters for cross section of 1.5 mm square and 100 meters for cross section of 2.5 mm square.

9 This extension cord should be protected by a tough flexible rubber sheath (IEC 245) or the equivalent to withstand mechanical stresses.

Before the generator can be connected to a build- ings electrical system, a licensed electrician must install an isolation (transfer) switch in the build- ings main fuse box. The switch is the connection point for generator power and allows selection of generator or main line power to the building. This will prevent the generator from charging the main power line (backfeeding) when the main power supply has failed or has been turned off for line repair. Backfeeding can electrocute or injure line maintenance personnel. Also, generator and build- ing electrical system damage can occur when nor- mal operating power returns if unit is used without an isolation switch.

WARNING

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7

Notes on installation 1. If you provide the generator with wheels, always be sure to place the genera-

tor on a level surface, locking the wheel with the stopper and / or chocking the wheels.

2. Select a place which allows you to maintain and inspect the generator, which is no exposed to contamination used by exhaust gas.

If you are planning to install the generator without its wheels attached, take into consideration being able to make oil changes efficiently.

3. In ground connection, be sure to use the designated ground terminal.

(A grounding cable is not included in the set of accessories.)

4. During use, be sure not to disconnect the battery.

5. While the power is on, do not unplug the unit or disconnect cables from the terminals.

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8

CONTROL FUNCTION

TANK CAP FUEL TANK

AIR CLEANER

SPARK PLUG CAP

FUEL COCK

CONTROL PANEL

BATTERY

STOPPER

MUFFLER

CONNECTOR FOR REMOTE CONTROL

SPARK PLUG CAP

OIL FILLER CAP

OIL GAUGE

ELECTRIC STARTER

OIL DRAIN PLUG

OIL FILTER

FUEL GAUGE

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9

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10

Automatic bulb checking When the starter switch is turned to the "START" from the "STOP" position, the oil pressure warning lamp flashes only once to check the bulb.

If it does not flash, ask a Yamaha dealer to inspect the electrical circuit.

Fail-safe Function of ECU (Electronic Control Unit) When the remote control unit is connected, the engine will not start unless

both starter switch on the control panel and the engine switch on the remote control unit are switched on.

If the engine does not run for 3 seconds when the starter switch is turned to the "START" position on either the generator or the remote control unit, the starter motor will stop automatically.

If the engine does not start for 21 seconds when the starter switch is turned to the "START" position on either the generator or the remote control unit, the starter motor will stop automatically.

NOTE :

If the engine stalls, check the engine oil level or contamination. Add or change oil, and restart. (See page 11 for more details.) Check the fuel level and the fuel cock because the same result can be expect- ed when the fuel runs out.

If the engine runs over 4500 rpm for 7 seconds, the engine stops automatically and the oil pressure warning lamp flashes for 3 minutes.

Oil Pressure Monitoring System The engine is equipped with an oil pressure sensor (of a hydraulic pressure detection type).

If this sensor detects the oil pressure below the specified level, it stops the engine automatically. Then, the oil pressure warning lamp flashes for 3 minutes and goes off.

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11

PRE-OPERATION CHECK

UPPER LEVEL

LOWER LEVEL

OIL GAUGE

OIL GAUGE

UPPER LEVEL

LOWER LEVEL

CHECK ENGINE OIL Before checking or refilling oil, be sure gener- ator is located on stable and level surface with engine stopped.

1) Remove oil level gauge and check the engine oil level.

2) If oil level is below the lower level "L" refill with suitable oil (see table) to upper level "F" after removing the engine oil filler cap.

3) Change oil if contaminated. (See "How-To" Maintenance.)

Recommended engine oil : Use class "SE" (API classification) oil or a higher grade oil according to the table below. SAE 10W-30 is recom- mended for general, all-temperature use. If single viscosity oil is used, select the appropriate viscosity for the average temperature in your area.

Oil capacity1.55 L (1.36 lmp qt, 1.64 US qt)

NOTE : The engine is equipped with an oil sensor

unit (hydraulic pressure detection type) that will automatically stop the engine if oil in the crank case is reduced below the specified level. Should the engine be automatically stopped, be sure to check the amounts of fuel and oil.

When the oil is reduced below the specified level, add new oil to the upper limit. Since the oil sensor will not detect the deteriora- tion of oil, visually check the quality or determine it by the specified time and then change the oil if necessary. (Refer to page 27.)

OIL FILLER CAP

Ambient temperature

-20 -4

-10 14

0 32

10 50

20 68

30 86

40C 104F

Single grade

Multigrade

5W 10W

20W #20

#30 #40

YAMALUBE 4 (10W-30)

10W-40

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12

1) Check fuel level at fuel level gauge.

2) If fuel level is low, refill with unleaded automotive gasoline.

This engine is certified to operate on automotive unleaded gasoline.

3) Be sure the fuel filter screen is insert- ed.

Fuel tank capacity : 44 L (9.68 lmp gal, 11.62 US gal)

Fuel filter screen Tank cap

Fuel gauge

EMPTY FULL

E F

CHECK FUEL

NOTE :

The full level of fuel is the upper surface of the fuel filter.

Be sure to add the fuel in small amounts as the fuel level approaches to the full fuel level mark.

Recommended fuel : Un leaded automotive gasoline of octane rating RON87 or higher.

"LEVEL" MARK

FUEL LEVEL LINE

Continuous operation time in normal use (rated load)

60 Hz Approx. 8.2 hours

Do not refuel while smoking or near open flame or other such potential fire hazards. Otherwise fire accident may occur.

WARNING

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13

Installation

1) Turn the starter switch to the "STOP" position to prevent accidental short circuit- ing.

2) Attach terminals to a lead-acid battery already charged. Mount the battery onto the position as specified below, with its terminals facing inward.

3) Insert each long bolt through the specified hole, its tip pointing outward.

4) Put the supporting arm on the long bolts and tighten with the butterfly nuts. (Push the lead-acid battery all the way inward.)

5) Arrange the wiring so that it won't be damaged by possible vibration caused by the engine.

6) Only after checking that the engine's starter key is in the "STOP" position, securely connect the cable with a red, to the positive (+) terminal first. And then connect the other cable to the negative (-) terminal.

Make sure you review each warning in order to prevent fire hazard. Do not refill tank while engine is running or hot. Close fuel cock before refueling with fuel. Be careful not to admit dust, dirt, water or other foreign objects into fuel. Do not fill above the top of the fuel filter (marked "LEVEL") or the fuel may

overflow when it heats up later and expands. Wipe off spilt fuel thoroughly before starting engine. Keep open flames away.

Should the connection be made in incorrect manner, the engine will be dam- aged.

CAUTION :

WARNING

AE00231

BATTERY (See page 31 for more details) Check the fluid level and fill if necessary. Use only distilled water if refilling is necessary.

Recommended Battery Lead-acid battery : A capacity of 12V-32Ah or larger.

For the generators used in low temperature below -5C(23F), 12V-40Ah or larger battery is recommended.

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14

RED CABLE

RED CABLE

LESS THAN 260 mm (10.2 in)

LESS THAN 170 mm (6.7 in)

LESS THAN 205 mm (8.1 in)

Butterfly nut Long bolt Accessory Supporting arm parts Terminals and nut

Red cable: to the positive (+) terminal

Black cable: to the negative () terminal

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15

CHECK COMPONENT PARTS Check following items before starting engine:

Fuel leakage from fuel hose, etc. Bolts and nuts for looseness. Components for damage or breakage. Generator not resting on or against any adjacent wiring.

CHECK GENERATOR SURROUNDINGS

Make sure you review each warning in order to prevent fire hazard. Keep area clear of inflammables or other hazardous materials. Keep generator at least 1 meter (3 feet) away from buildings or other struc-

tures. Only operate generator in a dry, well ventilated area. Keep exhaust pipe clear of foreign objects. Keep generator away from open flame. No smoking! Keep generator on a stable and level surface. Do not block generator air vents with paper or other material.

WARNING

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16

OPERATION

(3) Turn the starter switch to the "START"

position.

Take your hand off the switch immedi- ately after the engine starts.

If the engine fails to start, release the switch, wait a few seconds, than try again. Each attempt should be as short as possible to preserve the bat- tery. Do not crank the engine more than 10 seconds on any one attempt.

NOTE :

A fail-safe function equipped on this gen- erator prevents the starter from cranking the engine within 0.5 second after the engine has been stopped.

STARTING THE ENGINE

CLOSE

CLOSE

OPEN

(1) Make sure that the economy switch and AC switch (no-fuse breaker) are off.

(2) Turn the fuel cock lever to the vertical (open) position.

STOP ON

START

ON

OFF

ECONOMY

SW AC SW

ON

OFF

ON

OFF

Check the oil level before each operations. (See page 11) Perform the specified daily inspection to see if it is in normal condition.

CAUTION :

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17

In the following occasion, two or three trials may be required for starting the engine :

(1) The very first starting of a new generator.

(2) After the refueling of the engine which has been stopped due to fuel short- age.

(3) Starting after the oil filter change.

USING ELECTRIC POWER CONTROL PANEL

STOP ON

START

AC

ECONOMY SW

HOUR METER

ECONOMY SWITCH

OIL PRESSURE WARNING LAMP

PILOT LAMP

VOLTAGE METER

AC RECEPTACLE EARTH (GROUND) TERMINAL

STARTER SWITCH

AC SWITCH NO-FUSE BREAKER

20 A 20 A 30 A30 A 50 A

ON

OFF

ON

OFF

AC SW

120V 120 / 240V

ON

OFF

Make sure that the appliance is switched OFF before connecting it to the generator.

Do not move the generator while it is running.

Be sure to ground the generator if the connected appliance is grounded. Failure to ground unit may lead to electrical shock.

WARNING

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18

ON

OFF

ECONOMY

SW AC SW

ON

OFF

ON

OFF

(1) AC APPLICATION

(a) Ground the generator, using the ground terminal located at the side of the panel.

(b) Before starting the engine, check that the economy switch and AC switch of the generator and the power switches of the appliances are turned off.

(c) Connect the plugs of the appliances to the receptacles before starting the engine.

(d) Start the engine and check that the voltage meter indicates the rated volt- age.

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19

TABLE 1

TWIST

up to 30A

up to 30A

up to 20A NEMA 5-20R

NEMA L5-30R

NEMA L14-30R

NEMA 5-20P

NEMA L5-30P

NEMA L14-30P

GFCI (Ground Fault Circuit Interrupter) Receptacle, duplex (REC1)

Locking Receptacle (REC2)

Locking Receptacle (REC3)

Style Ampere Receptacle AC plug Description

up to 50A HUBBELL CS6369

HUBBELL CS6365C

Locking Receptacle (REC4)

To take power out from the TWIST LOCK RECEPTACLE, insert the plug into the receptacle, and turn it clock- wise to the lock position.

Be sure to ground the generator if the connected electrical device Is grounded.

WARNING

The duplex 120V receptacle is protected by a GFCI (Ground Fault Circuit Interrupter). GFCI shuts off the output current from the duplex 120V recepta- cle when a ground fault occurs in the generator or the appliance. Please note that other receptacles are not protected by GFCI.

CAUTION :

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20

(e) Turn the AC switch (no fuse breaker) to on and check to see that the pilot lamp is on.

(f) Turn on the switch of the appliance.

AC SW

ON

OFF

ON

OFF

NOTE :

The AC switch (no-fuse breaker) turns off automatically when the load exceeds the generator rated output.

When the AC switch (no-fuse breaker) turns off during operation, the genera- tor is over loaded or the appliance is defective. Stop the generator immedi- ately, check the appliance and / or gen- erator for overloading or detect and have repaired as necessary by Yamaha dealer or service shop.

CAUTION :

GFCI RECEPTACLE TEST

After starting the engine, check the GFCI for proper functioning by the following test procedure.

Push yellow TEST button, The red RESET button will pop out exposing the word TRIP. Power is now off at the outlets protected by the GFCI, indicating that the device is func- tioning properly.

If TRIP dose not appear when testing, do not use the gen- erator. Call a qualified electrician.

To restore power, push RESET button.

If the RESET button pops out during operation, stop the generator immedi- ately and call a qualified electrician for checking generator and the appli- ances.

WARNING

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21

ECONOMY SWITCH

ECONOMY SWITCH automatically reduces engine speed when load is OFF, and automatically increases engine speed to rated r.p.m. when load is ON. ECONOMY SWITCH provides fuel economy and low noise operation at no-load running.

(1) HOW TO USE ECONOMY SWITCH

Start the engine with ECONOMY SWITCH off.

ON

OFF

ECONOMY

SW

(2) CHECKING THE OPERATION

When ECONOMY SWITCH does not operate normally, please check following :

Overloaded ? Please make it sure that the generator is not overload.

NOTE :

The ECONOMY SWITCH must be turned to "OFF" to increase engine speed to rated rpm when using a load of 0.04A or less.

The ECONOMY idling speed is 2,400 2,700 rpm.

NOTE :

Most induction loads such as electric motors require three to five times more wattage than their ratings during starting. This starting wattage should not exceed the rated output of the generator for prop- er operation of ECONOMY SWITCH.

Turn ECONOMY SWITCH off when the ECONOMY SWITCH does not work normally under the rated output.

NOTE :

Warm up the engine without a load for a few minutes.

Turn ECONOMY SWITCH on.

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22

STOPPING THE GENERATOR (1) Turn off the power switch of the elec-

tric equipment.

(2) Turn the economy switch and AC switch (no-fuse breaker) to off.

(3) Unplug the cord from receptacle of the generator.

CLOSE

CLOSE

OPEN

(4) Allow the engine to run at no-load for about 3 minutes to cool down before stopping.

(5) Turn the starter switch to the STOP position.

(6) Close the fuel cock.

STOP ON

START

NOTE :

It is normal that the engine speed goes up for a moment when you turn the starter switch to "STOP" while the Economy switch is in the "ON" position.

ON

OFF

ECONOMY

SW AC SW

ON

OFF

ON

OFF

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23

Some appliances need a "surge" of energy when starting. This means that the amount of electrical power needed to start the appliance may exceed the amount needed to maintain its use. Electrical appliances and tools normally come with a label indicating voltage, cycles/Hz, amperage (amps) and electrical power needed to run the appliance or tool. Check with your nearest dealer or service center with questions regarding power surge of certain appliances or power tools.

Electrical loads such as incandescent lamps and hot plates require the same wattage to start as is needed to maintain use.

Loads such as fluorescent lamps require 1.2 to 2 times the indicated wattage during start-up.

Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.

Electrical motors require a large starting current. Power requirements depend on the type of motor and its use. Once enough "surge" is attained to start the motor, the appliance will require only 50% to 30% of the wattage to continue running.

Most electrical tools require 1.2 to 3 times their wattage for running under load during use. (For example, a 9,000 watt generator can power a 3,200 to 7,000 watt electrical tool.)

Loads such as submersible pumps, air conditioners and air compressors require a very large force to start. They need 3 to 5 times the normal running wattage in order to start. (For example, a 5,000 watt generator would only be able to drive a 1,800 to 3,100 watt pump.)

If the power consumption of electrical appliances exceeds the operating range or if there is short circuit or other problems in the appliances, the AC breaker could trip "OFF" or the rotation of the generator could be abnormally reduced. In this case, stop the generator to see if the power consumption of the appli- ances is too large and if there is a problem in the appliances.

The frequency (the number of the generators rotation) was adjusted before the time of shipment. Changing the frequency could result in the generators break- down, so refrain from changing it.

WATTAGE INFORMATION

7UX-9-17 04.11.25 11:12 AM 23

24

To determine the total wattage required to run a particular electrical appliance or tool, multiply the voltage figure of the appliance/tool by the amperage (amps) fig- ure of same. The voltage and amperage (amps) information can be found on a name plate which is normally attached to electrical appliances and tools.

VOLTAGE DROP IN ELECTRIC EXTENSION CORDS When a long electric extension cord is used to connect an appliance or tool with the generator, a certain amount of voltage drop occurs in the extension cord which lessens the effective voltage available to the appliance or tool. The chart below has been prepared to illustrate the approximate voltage loss when an extension cord of 300 feet (approx. 100 meters) is used to connect an appliance or tool to the generator.

Applications Applicable Wattage (W)

60 Hz

Incandescent lamp, Heater 9,500

Fluorescent lamp, Electric tool 4,700

Pump, Compressor 2,400

Nominal cross

section

A.W.G. Gauge

No.

Allowable current

No.of strands / strands dia.

Resistance Current Amp.

No./mm /100mmm2 No. A 1A 3A 5A 8A 10A 12A 15A

0.75 18 7 30/0.18 2.477 2.5V 8V 12.5V

V o

lt ag

e d

ro p

1.27 16 12 50/0.16 1.486 1.5V 5V 7.5V 12V 15V 18V

2.0 14 17 37/0.26 0.952 1V 3V 5V 8V 10V 12V 15V

3.5 12 to 10 23 45/0.32 0.517 1.5V 2.5V 4V 5V 6.5V 7.5V

5.5 10 to 8 35 70/0.32 0.332 1V 2V 2.5V 3.5V 4V 5V

NOTE :

The above wattage chart is general guide only. Refer to your specific appliance for correct wattage.

When you use two or more alternating current outlets at a time, be careful that the sum of the appliances' power consumption does not exceed the value speci- fied in the above chart.

7UX-9-17 04.11.25 11:12 AM 24

25

MAINTENANCE SCHEDULE

DAILY INSPECTION Before running the generator, check the following service items:

Excessive vibration,noise

Clean air cleaner element

Safe surroundings

Enough clean engine oil

Leakage of gasoline and engine oil

Loose or broken bolts and nuts

Enough gasoline

PERIODIC MAINTENANCE Periodic maintenance is vital to safe and efficient operation of your generator. Check the table below for periodic maintenance intervals. IT IS ALSO NECESSARY FOR THE USER OF THIS GENERATOR TO CONDUCT THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION- RELATED PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL SYS- TEM EFFECTIVE.

The emission control system consists of the following parts :

The maintenance schedule indicated in the table is based on the normal generator operation. Should the generator be operated in extremely dusty condition or in heavier loading condition, the maintenance intervals must be shortened depending on the contamination of oil, clogging of filter elements, wear of parts, and so on.

(1) Carburetor and internal parts

(2) Cold start enrichment system, if applicable

(3) Intake manifold, if applicable

(4) Air cleaner elements

(5) Spark plug

(6) Magneto or electronic ignition system

(7) Spark advance/retard system, if applicable

(8) Exhaust manifold, if applicable

(9) Hoses, belts, connec- tors, and assemblies

7UX-9-17 04.11.25 11:12 AM 25

26

*Note 1 : Initial oil change should be performed after first twenty (20) hours of operation. Thereafter change oil every hundred (100) hours. Before changing oil, check for a suitable way to dispose of old oil. Do not pour it down into sewage drains, onto garden soil or into open streams. Your local zoning or environmental regulations will give you more detailed instruc- tions on proper disposal.

*Note 2 : As to the procedures for these items, please refer to the SERVICE MANUAL or consult your nearest Yamaha dealer.

*Note 3 : More frequent oil changing, oil filter replacement and air cleaner service on replacement may be necessary depending on operating conditions. This would include dusty environment, high ambient temperature, heavy engine loading.

Periodic Maintenance Schedule table

Maintenance Items Every 8 hours (Daily)

Every 20

hours

Every 200

hours

Every 500

hours

Every 1000 hours

Clean generator and check bolts and nuts (Daily)

Check and refill engine oil (Refill daily to upper level)

Change engine oil (*Note 1 and 3) (Initial)

Check battery electrolyte fluid level

Clean spark plug

Clean air cleaner

Clean fuel strainer

Replace air cleaner element (*Note 3)

Clean and adjust spark plug and electrodes

Replace engine oil filter (*Note 1 and 3) (Initial)

Clean and adjust carburetor (*Note 2)

Remove carbon from cylinder head (*Note 2)

Every 50

hours

Clean engine base (oil pan) (*Note 2)

Check and adjust valve clearance (*Note 2)

Replace spark plug

Replace fuel lines (Yearly)

Overhaul engine (*Note 2)

Check and replace carbon brushes

Spark arrester

(Every 100 hours)

(Every 100 hours)

7UX-9-17 04.11.25 11:12 AM 26

27

"HOW-TO" MAINTENANCE

OIL FILTER

ENGINE OIL CHANGE Initial oil change After 20 hours of operation

Thereafter Every 100 hours of operation

1. When changing oil, stop the engine and loosen the drain plug.

2. Re-install the drain plug before refilling oil.

3. Refer to the recommended oil table on page 11.

4. Always use the best grade and clean oil. Contaminated oil, poor quality oil and shortage of oil cause damage to engine or shorten the engine life.

OIL CAPACITY : 1.55 L (1.36 lmp qt, 1.64 US qt)

ENGINE OIL FILTER REPLACEMENT Initial engine oil filter replacement

should be performed after 20 hours of operation. Thereafter replace the engine oil filter every 200 hours.

When installing a new oil filter, apply oil to O-ring, attach the oil filter in position and tighten 2/3 turns by hand or with wrench after touching the O-ring to the sealing surface of engine.

Run the engine for a minute ; stop the engine and check for oil leakage around the oil filter and recheck the oil level.

OIL DRAIN PLUG (ON BOTH SIDE)

OIL FILLER CAP

To prevent injury, pay attention to the spilled hot engine oil when replacing engine oil filter.

CAUTION :

7UX-9-17 04.11.25 11:12 AM 27

28

AIR CLEANER COVER

KNOB

SERVICING AIR CLEANER A dirty air cleaner element will cause starting difficulty, power loss, engine mal- functions, and shorten engine life extremely.

Always keep the air cleaner element clean. Replace the air cleaner element set more often in dusty environments.

The air cleaner paper inner element and urethane foam outer element can be removed after removing knob and air cleaner cover. When installing, set the paper element and urethane foam on the air cleaner base. Check that the grommet is in position, and then install the cover with knob tightened securely.

Urethane Foam cleaning Wash and clean the urethane foam in kerosene. Saturate in a mixture of 3 parts kerosene and 1 part engine oil, and then squeeze to remove excess oil. Clean or replace the urethane foam ele- ment every 50 hours. (more often in dusty environments)

Paper element Clean by tapping gently to remove dirt and blow off dust. Never use oil. Clean or replace the paper element every 50 hours of operation, and replace element set every 200 hours or once a year.

GROMMET

ELEMENT

URETHANE FOAM

BASE

7UX-9-17 04.11.25 11:12 AM 28

29

0.7 to 0.8 mm (0.028" to 0.031")

CLEANING FUEL STRAINER Dirt and water in the fuel are removed by the fuel strainer.

(a) Remove the strainer cup and throw away water and dirt.

(b) Clean the screen and strainer cup with gasoline.

(c) Tightly fasten the cup to main body, making sure to avoid fuel leak.

CLEANING AND ADJUSTING SPARK PLUG (a) Unplug the high-voltage cables (locat-

ed at the outlet panel and lead-acid battery).

(b) Using the supplied plug wrench and handle, turn it counterclockwise until it comes off.

(c) Clean the area around the mounting hole.

(d) Clean the electrodes if they are dirty. Adjust the clearance to 0.7-0.8 mm (0.028-0.031in). Replace it with a new one if the abrasion has developed to the degree where a flat surface can- not be obtained on its projection. If the electrodes turn black, also inspect the air cleaner.

(e) Attach and tighten the plug with the specified torque : 25 to 30 Nm (2.5 to 3.0 kg-m).

( f ) After checking that the contact area inside the plug cap is not corroded, connect the high-voltage cables.

Spark plug

NGK BPR5ES

7UX-9-17 04.11.25 11:12 AM 29

30

CHECKING CARBON BRUSH If the brush become excessively worn, its contact pressure with the slip ring changes and causes a roughened surface on the slip ring, resulting in irregular gen- erator performance.

Check the brush every 500 hours or if generator performance is irregular.

If the brush is 5 mm (0.20") long or less, replace it with a new one.

(a) Remove the brush cover.

(b) Disconnect the wire connector and remove the brush.

(c) Carefully note the brush direction and relative position with the slip ring when installing new brush.

15 to 5 mm (0.6" to 0.2")

BRUSH

BRUSH HOLDER

BRUSH COVER

BRUSH HOLDER

FLANGE BOLT

SCREW

FUEL HOSE REPLACEMENT

Replace the fuel hose every 1,000 hours or every year. If fuel hose leak is found, replace the fuel hose immediately.

Take extreme caution when replacing fuel hose ; gasoline is flammable.

WARNING

7UX-9-17 04.11.25 11:12 AM 30

31

AE00481

BATTERY Replenishing the battery fluid 1. Check the fluid level. The level should

be between the upper and lower level marks.

1 Upper level 2 Lower level

2. Add only distilled water if necessary.

762-035

q

w

762-036

762-012

Battery electrolyte is poisonous and dangerous. It contains sulfuric acid and can cause severe burns. Avoid contact with skin, eyes or clothing.

ANTIDOTE:

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: Flush with water for 15 min- utes and get prompt medical atten- tion.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

WARNING

Normal tap water contains minerals which are harmful to a battery; there- fore, refill only with distilled water.

CAUTION :

7UX-9-17 04.11.25 11:12 AM 31

32

SPARK ARRESTER

SPARK ARRESTER In a dry or wooded area, it is recommendable to use the engine with a spark arrester. Some areas require the use of a spark arrester. Please check your local laws and regulations before operating your engine.

The spark arrester must be cleaned regularly to keep it functioning as designed. A clogged spark arrester :

Prevents the flow of exhaust gas Reduces engine output Increases fuel consumption Makes starting difficult

If the engine has been running, the muffler and the spark arrester will be very hot. Allow the muffler to cool before cleaning the spark arrester.

How to remove the spark arrester 1. Remove the flange bolts from the

muffler cover and remove the muffler cover.

2. Remove the special screw from the spark arrester and remove the spark arrester from the muffler.SPARK

ARRESTER SCREEN

MUFFLER

SCREW

SPARK ARESSTER SCREEN Clean the spark arrester screen Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen.

The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged.

Install the spark arrester, and muffler protector in the reverse order of disassembly.

7UX-9-17 04.11.25 11:12 AM 32

PREPARATION FOR STORAGE

The following procedures should be followed prior to storage of your generator for a period of 6 months or longer.

Drain fuel from fuel tank and strainer (cup) carefully by disconnecting the fuel line. Gasoline left in the fuel tank will eventually deteriorate making engine-starting difficult.

Drain fuel from the carburetor by loos- ening the drain screw on the carburetor float chamber , or run the engine at no-load until it stops.

Disconnect the terminal of the battery.

Change engine oil.

Check for loose bolts and screws, tighten them if necessary.

Clean generator thoroughly with oiled cloth. Spray with preservative if avail- able. NEVER USE WATER TO CLEAN GENERATOR !

Store generator in a well ventilated, low humidity area.

Screw for Drain

33

7UX-9-17 04.11.25 11:12 AM 33

AE00633

BATTERY 1. Remove the battery.

2. Check the fluid level. Add only distilled water if necessary. (See page 31 BATTERYReplenishing the battery fluid)

3. After checking the fluid level, charge the battery.

4. Store the battery in a cool, dark and dry place. Do not store the battery in an excessively warm or cold place [i.e., less than 0C (30F) or more than 30C (90F)].

5. Check battery condition with a hydrometer monthly, and charge as necessary.

Disconnect the negative lead first, then the positive lead from the battery. Connect the positive lead first, then the negative lead to the battery when

installing the battery. Never smoke or make and break connections at the battery while charging.

Sparks may ignite the battery gas. Be sure the battery terminals are tight and that the battery vent tube is prop-

erly routed and is securely attached to the battery.

WARNING

Do not disconnect the battery during engine operation. Avoid operating the generator with the battery removed.

CAUTION :

34

7UX-9-17 04.11.25 11:12 AM 34

TROUBLESHOOTING

When generator engine fails to start after several attempts, or if no electricity is available at the output receptacles, check the possible causes in accordance with the following table. If your generator still fails to start or generate electricity, con- tact your nearest Yamaha dealer or authorized service center for further informa- tion or corrective procedures.

Possible causes

Problem

Lo w

b at

te ry

B lo

w n

fu se

D et

er io

ra te

d fu

el F ue

l p ip

in g

C lo

gg in

g of

A ir

cl ea

ne r

C lo

gg in

g of

C oo

lin g

ai r

in ta

ke

Lo w

o il

le ve

l

F au

lty s

pa rk

p lu

g

O ve

rlo ad

b y

co nn

ec te

d ap

pl ia

nc e

In co

rr ec

t o r

po or

c on

ne ct

io n

of w

ire s

In su

ffi ci

en t c

ap ac

ity o

f e xt

en si

on c

ab le

Starter will not run

Le ak

ag e

Starter runs, but Engine will not start.

C lo

gg in

g

D ur

in g

op er

at io

n Rotation decreased Unstable rotation

Breaker turned off

C ar

bo n

br us

he s

ar e

ex ce

ss iv

el y

w or

n

Low power

The starter motor will not run : Wait for more than 0.5 second after the engine is stopped and then turn the

starter switch to the "START" position. If a remote control unit is connected, check if both starter switch on the control

panel and the engine switch on the remote control unit are switched on.

The engine stopped and the oil pressure warning lamp flashed for three minutes. Check the following.

No fuel in the fuel tank Supply fuel Fuel cock not open Turn on fuel cock No sufficient engine oil Add or change engine oil

35

7UX-9-17 04.11.25 11:12 AM 35

SPECIFICATIONS

Model

Remote controller terminal (Auto choke)

Standard

EF12000DE

A lt

er n

at o

r

Type

Rated voltage

Brush, Self-exciting, 2-pole, Single phase

611 mm (24.1 in) [758 mm (29.8 in)]*1

Rated frequency 60 Hz

771 mm (30.4 in) [856 mm (33.7 in)]*1

120V / 240V

Rated output 9500 VA

Maximum output 12000 VA

Large

Power factor 1.0

Width

Voltage regulator

High

A.V.R type

E n

g in

e

Model EH65D

Type Twin cylinder, Air-cooled, 4-stroke, Overhead valve engine

Displacement 653 cm3

Fuel Automotive Unleaded Gasoline

Oil capacity 1.55 L (1.36 lmp qt, 1.64 US qt)

Starting system Electric starter

Fuel tank capacity 44 L (9.68 lmp gal, 11.62 US gal)

Rated continuous operation per a tankful of fuel

Rated Approx. 8.2 hours

D im

en si

on

826 mm (32.5 in)

Dry weight 141 kg (310.8 lb) [149 kg (328.5 lb)]*2

*1: [ ] shows dimensions with castors. *2: [ ] shows dry weight with castors installed.

Rated current 79.2 A / 39.6 A

Valve clearance (Intake & Exhaust)

0.0039 0.0008 in (0.1 0.02 mm) Note : Adjust the valve clearance while the engine is cold.

Emissions durability period (California only)

500 hours

36

7UX-9-17 04.11.25 11:12 AM 36

WIRING DIAGRAM

5 3 2

4

(AC output)

(AVR)

1

CONTROL BOX

Fuel cut

Ignition coil

Auto choke (Bimetal)

Electric starter

Oil pressure switch

Regulator

Magnetic switch

Charge coil

Exciting coil

- +

Battery 12V Grn

Grn/Y

Org

Gry

Blk

R

Starter switch

to earth terminal

ST Relay

Connector (Remote control)

Gry

R15

B lk

15

Grn

W Blk/W

Gry

Gry

Blk

(AC 120V)

R

Blk/W Blk

R

Grn/Y Grn/Y

Grn

Grn

Org OrgR

Org

LBlu

LBlu

Brn Y

Org

R

W

W

W

W W

W W

OFF -M +M B L.IG ST

ON START

R/W

Idle solenoid 1

Electronic control unit

2

13

3

12

4

11

5

10

6

9 8 7

B lk

Y Y

B lk

R

Blk

Grn/Y

Grn/Y Economy switch

Idle control

unit

Oil pressure warning lamp

(Red)

LGrn

Org

Blk

Blk R

Blu

Blk

B lk

R

R

W

W

W

LGrn

Grn/Y Grn/Y

Grn/Y

Brn

CONTROL BOXGENERATOR

Fuse

Y Y

No-fuse breaker

V ol

tm et

er

H ou

r m

et er

P ilo

t l am

p

VHr PL

Earth(Ground) terminal

Field Winding

A C

W in

di ng

1 A

C W

in di

ng 2

AVR

w w

Id le

co

nt ro

l un

it

AC otuput receptacle(120V)

REC2

AC output receptacle (120V) REC1

AC output receptacle (120/240V) REC3

AC output receptacle (120/240V) REC4

Engine Exciting coil

to Idle control unitto Starter

switch

Grn/Y

W Brn

Blk

(4P)

LGrn Blk

LGrn W

Brn

G rn

/Y

BrushBrush

Auxiliary Winding for Condenser

Connector Remoto control

Wiring color cord

LGrn R/W Blk/RBlk Black Brn/W Brown/White R Red

Blk/W Black/White Grn Green W White Blu Blue Grn/W Green/White Y Yellow LBlu Light blue Org Orange Pik Pink Brn Brown Gry Gray Grn/Y Green/Yellow

: : : : :

: : : : :

: : : : :

: : :

Light green Red/White Black/Red

37

7UX-9-17 04.11.25 11:12 AM 37

OPTIONAL PARTS

"HOW-TO" INSTALL THE WHEEL (1) Checking of supplied accessories

(2) Tool preparation

Hoist or square bar (100 mm (3.94 in) by 100 mm (3.94 in), length : 700 mm (27.56 in))

Plier

Spanner or socket wrench (12 mm (0.472 in)), 2 units

(3) Installation procedures

(a) Raise the generator by about 100 mm (3.94 in), with hoist or with square bar put under the bottom panel.

(b) Attach wheel mounting parts , ,stopper , using clamp , and wheel , to wheel shaft . Then check that wheel is rotated smoothly. If moving turns out to be too complicat- ed, assemble them together using grease. (4 locations / 2 pieces)

(c) Bend the tip of according to the shape of wheel shaft as possible.

(d) Attach the assembled shaft to the foundation plate of the engine, using , , and .

(e) Attach the other shaft to the foundation plate of the generating unit, using and . ( is not used.) The tightening torque of bolts should be 20 to 25 Nm (2.0 to 2.5 kg-m).

REMOTE CONTROL UNIT

When the remote control unit is connected, the engine will not start unless both starter switch on the control panel and the engine switch on the remote control unit are switched on.

If you provide the generator with wheels, always be sure to place the generator on a level surface, locking the wheel with the stopper and /or chocking the wheels.

WARNING

38

7UX-9-17 04.11.25 11:12 AM 38

FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY

EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California

Yamaha Motor Corporation, U.S.A. (herein YAMAHA) warrant(s) to the initial retail purchaser and each subsequent owner, that this Nonroad engine (herein engine) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S. Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period.

For the components listed under PARTS COVERED, the dealer or service center authorized by YAMAHA will, at no cost to you, make the necessary diagnosis, repair, or replacement neces- sary to ensure that the engine complies with applicable U.S. EPA regulations.

EMISSISON COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and con- tinues for a period of 2 years.

PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty. Some of the parts listed below may require scheduled maintenance and are warranted up to the first sched- uled replacement point for that part. (1) Fuel Metering System (3) Ignition System

(i) Carburetor and internal parts (and/or (i) Spark plugs. pressure regulator or fuel injection system) (ii) Magneto or electronic ignition system.

(ii) Air/fuel ratio feedback and (iii) Spark advance/retard system, if applicable. control system, if applicable. (4) Exhaust manifold, if applicable

(iii) Cold start enrichment system, if applicable. (5) Miscellaneous Items Used in Above Systems (iv) Regulator assy (gaseous fuel, if applicable) (i) Electronic controls, if applicable

(2) Air Induction System (ii) Hoses, belts, connectors, and assemblies. (i) Intake manifold, if applicable (iii) Filter lock assy (gaseous fuel, if applicable) (ii) Air filter.

OBTAINING WARRANTY SERVICE To obtain warranty service, take your engine to the nearest Authorized Yamaha distributor or dealer. Bring your sales receipts indicating date of purchase for this engine. The dealer or ser- vice center authorized by YAMAHA will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order. All parts and acces- sories replaced under this warranty become the property of YAMAHA.

WHAT IS NOT COVERED * Conditions resulting from tampering, misuse, improper adjustment (unless they were made

by the dealer or service center authorized by YAMAHA during a warranty repair), alteration, accident, failure to use the recommended fuel and oil, or not performing required mainte- nance services.

* The replacement parts used for required maintenance services. * Consequential damages such as loss of time, inconvenience, loss of use of the engine or

equipment, etc. 39

7UX-9-17 04.11.25 11:12 AM 39

* Diagnosis and inspection charges that do not result in warranty-eligible service being per- formed.

* Any non-authorized replacement part, or malfunction of authorized parts due to use of non- authorized parts.

OWNERS WARRANTY RESPONSIBILITIES As the engine owner, you are responsible for the performance of the required maintenance list- ed in your owners manual. YAMAHA recommends that you retain all receipts covering mainte- nance on your engine, but YAMAHA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the engine owner, you should however be aware that YAMAHA may deny warranty cover- age if your engine or a part has failed due to abuse, neglect, improper maintenance or unap- proved modifications.

You are responsible for presenting your engine to the nearest dealer or service center autho- rized by YAMAHA when a problem exists.

If you have any questions regarding your warranty rights and responsibilities, you should con- tact the Yamaha Customer Relations Department at 1-800-962-7926 for the information.

THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYS- TEM WARRANTY MAINTENANCE AND REPAIRS

You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine. YAMAHA reserves the right to deny warranty coverage if the engine has not been properly maintained. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep maintenance records.

MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A DEALER OR SERVICE CENTER AUTHORIZED BY YAMAHA MOTOR CORPORATION, U.S.A.. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM.

If other than the parts authorized by YAMAHA are used for maintenance replacements or for the repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by YAMAHA in their performance and durability.

HOW TO MAKE A CLAIM All repair qualifying under this limited warranty must be performed by a dealer or service center authorized by YAMAHA. In the event that any emission-related part is found to be defective during the warranty period, you shall notify Yamaha Customer Relations Department at 1-800- 962-7926 and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed.

40

7UX-9-17 04.11.25 11:12 AM 40

Emission Control System Warranty Statement

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Yamaha Motor Corporation, U.S.A. (herein YAMAHA) are pleased to explain the emission control system warranty on your 2005 and later Small Off- Road engine(herein "engine"). In California, the engine must be designed, built and equipped to meet the State's stringent anti-smog standards. YAMAHA must warrant the emission control system on your engine for the periods of time described below, provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system may include parts such as the carburetor or fuel-injection system, and the ignition system. Also included may be hoses, belts,connectors and other emission-related assemblies. Where a war- rantable condition exists, YAMAHA will repair your engine at no cost to you including diagnosis, parts and labor.

MANUFACTURER'S WARRANTY COVERAGE:

The 2005 and later engines are warranted for two (2) years. If any emission related part on your engine is defective, the part will be repaired or replaced by YAMAHA.

OWNER'S WARRANTY RESPONSIBILITIES:

-As the engine owner, you are responsible for the performance of the required mainte- nance listed in your Owner's Manual. YAMAHA recommends that you retain all receipts covering maintenance on your engine, but YAMAHA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte- nance.

-As the engine owner, you should ,however, be aware that YAMAHA may deny you war- ranty coverage if your engine or a part has failed due to abuse, neglect, improper main- tenance or unapproved modifications.

-You are responsible for presenting your engine to a dealer, distributor or warranty sta- tion authorized by Yamaha Motor Corporation, U.S.A. P.O.BOX 6555, Cypress, California 90630, U.S.A. (herein YAMAHA) as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should con- tact the Yamaha Customer Relations Department at 1-800-962-7926.

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LIMITED WARRANTY on Emission Control Systems

- California Only - YAMAHA warrants to the owner of the 2005 and later engine that the engine (1) has been designed, built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Resources Board, and (2) is free from defects in materials and workmanship that could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below.

A. COMMENCEMENT DATE The warranty period begins on the date the engine is delivered to a first retail purchaser.

B. LENGTH OF COVERAGE YAMAHA warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of a war- ranted emission-related part for a period of two (2) years after the date of delivery to the first retail purchaser.

C. WHAT IS COVERED: 1. REPAIR OR REPLACEMENT PARTS

Repairs and replacement of any warranted part will be performed at no charge to you by an authorized dealer, distributor or a warranty station. You may contact the Yamaha Customer relations Department at 1-800-962-7926 to obtain the name of the nearest appropriate loca- tion where your warranty repairs are performed.

2. WARRANTY PERIOD This warranty continues for a period of two (2) years and applies only to the repair, replace- ment or adjustment of the component parts that are not scheduled for replacement as required maintenance. Further, component parts which are scheduled only for regular inspection to the effect of "repair or replace as necessary" are warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part.

3. DIAGNOSIS You will not be charged for diagnostic labor that leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or warranty station.

4. DAMAGES If a warranted part failed causing damage to other engine components, consult a warranty station.

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D. WHAT IS NOT COVERED 1. This limited warranty does not cover any part which malfunctions, fails or is damaged due to

failure to follow the maintenance and operating instructions set forth in the 2005 and later Owner's Manual including:

(1) improper or inadequate maintenance of any warranted parts

(2) improper installation, adjustment or repair of the engine or of any warranted part unless per- formed by an authorized dealer

(3) failure to follow recommendations on fuel use contained in the 2005 and later Owner's Manual

(4) repairs performed outside of the authorized warranty service facilities

(5) use of parts which are not authorized by YAMAHA.

2. Add-on or modified parts This warranty does not cover any part that malfunctions, fails or is damaged due to alter- ations by changing, adding to or removing parts from the engine.

3. Expenses incurred by processing warranty claims YAMAHA, any authorized dealer, distributors and warranty station shall not be liable for any loss of use of the engine, for any alternative usage, for any damage to goods, loss of time or inconvenience.

E. HOW TO FILE A CLAIM All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or warranty stations authorized by YAMAHA . In the event that any emission-related part is found to be defective during the warranty period, you must notify Yamaha Customer Relations Department at 1-800-962-7926 and you will be advised of the appropriate warranty service facilities where the warranty repair is to be performed.

F. WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be performed by the authorized dealer who sold you the engine, although warranty service will be performed by any authorized dealers, distributors and warranty stations anywhere in the United States. When warranty repair is needed, the engine must be brought to an authorized dealer, distributorship or warranty station's place of business during normal business hours. In all cases, a reasonable time, not to exceed 30 days, must be allowed for the warranty repair to be completed after the engine is received by the authorized dealer, distributor or service station.

G. MAINTENANCE, REPLACEMENT AND REPAIR OF EMISSION-RELATED PARTS Only warranted engine replacement parts approved by YAMAHA should be used in the perfor- mance of any warranty maintenance or repairs on emission-related parts. If other than autho- rized parts are used for maintenance, replacement or repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized parts in performance and durability. YAMAHA, however, assumes no liability under this warranty with respect to parts other than authorized parts. The use of non- authorized replacement parts does not invalidate the warranty on other components unless the non-authorized parts cause damage to warranted parts.

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H. PARTS COVERED UNDER THE CALIFORNIA EMISSIONS WARRANTY (1) Fuel Metering System

(i) Carburetor and internal parts (and/or pressure regulator or fuel injection system)

(ii) Air/fuel ratio feedback and control system, if applicable.

(iii) Cold start enrichment system, if applicable.

(iv) Regulator assy (gaseous fuel, if applicable)

(2) Air Induction System

(i) Intake manifold, if applicable

(ii) Air filter.

(3) Ignition System

(i) Spark plugs.

(ii) Magneto or electronic ignition system.

(iii) Spark advance/retard system, if applicable.

(4) Exhaust manifold, if applicable

(5) Miscellaneous Items Used in Above Systems

(i) Electronic controls, if applicable

(ii) Hoses, belts, connectors, and assemblies.

(iii) Filter lock assy (gaseous fuel, if applicable)

I. MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2005 and later Owner's Manual and to retain proof that inspection and maintenance services are performed at the times when recommended. YAMA- HA will not deny a warranty claim solely because you have no record of maintenance; howev- er, YAMAHA may deny a warranty claim if your failure to perform required maintenance result- ed in the failure of warranted part. The proof which you maintain should be given to each sub- sequent owner of the engine. You are responsible for performing the scheduled maintenance described below based on the procedures specified in the 2005 and later Owner's Manual. The scheduled maintenance below is based on a normal engine operating schedule.

PROCEDURE INTERVAL

1) Change engine oil : Initial 20 hours and every 100 hours afterward

2) Clean air cleaner (element) : Every 50 hours

3) Replace air cleaner element : Every 200 hours

4) Clean and adjust spark plug and electrodes : Every 200 hours

Note: More frequent maintenance may be necessary under dusty, dirty or severe conditions.

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7UX-9-17 04.11.25 11:12 AM 47

7UX-9-17 hyoshi 04.10.13 11:19 AM 4

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Manualsnet FAQs

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