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How to use this manual
A Few Words About Safety
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended 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 recommend
that you do not use replacement parts of inferior quality.
For Your Customers Safety
Proper service and maintenance are essential to the customers safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of 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 every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using 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 skills
required 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 around
pressurized 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 severe
burns 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 sure
that 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 will
help 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 when
working 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 unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
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SPECIFICATIONS
1
SERVICE INFORMATION
2
MAINTENANCE
3
TROUBLESHOOTING
4
FUEL SYSTEM
5
GOVERNOR
6
GENERATOR/CHARGING SYSTEM
7
IGNITION SYSTEM
8
STARTING SYSTEM
9
OTHER ELECTRICAL
10
MUFFLER
11
ENGINE REMOVAL/INSTALLATION
12
CYLINDER HEAD
13
CYLINDER BLOCK
14
WIRING DIAGRAMS
15
INDEX
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INTRODUCTION
This 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 the
right to make changes at anytime without notice.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic,
mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and
tables.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to this Honda product, other property, or the environment.
SAFETY MESSAGES
Your safety and the safety of others are very important. To help you make informed decisions, we have provided safety messages
and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated 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 ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE 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. The
use of incorrect tools and fasteners will damage the unit.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these 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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ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbreviated
term
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 Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
D-AVR Digital Automatic Voltage Regulator
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EX Exhaust
F Front or Forward
GND Ground
HO2S Heated Oxygen sensor
IAB Intake Air Bypass
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
Bl Black G Green Br Brown Lg Light green
Y Yellow R Red O Orange P Pink
Bu 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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SPECIFICATIONS
SPECIFICATIONS
SERIAL NUMBER LOCATION
The 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
SPECIFICATIONS
EC3600K1
DIMENSIONS AND WEIGHTS
ENGINE
GENERATOR
Model EC3600K1
Description code EZDJ
Overall 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 GX270T2
Description code GCBHT
Type 4 stroke, overhead valve, single cylinder, inclined by 25
Displacement
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 ignition
Ignition timing
BTDC 10/1,400 min
-1
(rpm)
Spark plug BPR6ES (NGK), W20EPR-U (DENSO)
Lubrication system Forced spray
Oil 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 open
Carburetor Horizontal type, butterfly valve
Air cleaner Dual element type
Governor Mechanical centrifugal
Breather system Flat valve type
Fuel used Regular unleaded gasoline with a pump octane rating 86 or higher
Model EC3600K1
Type BT FT, GVT, ITT, GVWT
Description code EZDJ
Generator type Double electrode field rotation type
Excitation Self-excitation
Voltage regulation system Capacitor control
Phase Single phase
Rotating direction Counterclockwise (Viewed from the generator)
Rated output AC 3400 VA
Rated frequency 50 Hz
AC Rated voltage 115 / 230 V 230 V
Rated current 30 / 15 A 15 A
Power factor 1.0 Cos
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SPECIFICATIONS
CHARACTERISTICS
Model EC3600K1
Type BT FT, GVT, ITT, GVWT
Voltage
variation rate
Momentary 25/35 % max.
Average 10 % max.
Average time 10 sec. max.
Voltage stability 1% max.
Frequency
variation rate
Average 3.5 % max.
Frequency stability 1 Hz max.
Insulation resistance 10 M min.
AC circuit protector 17 A x 3 17 A
Insulation type Type H
Fuel 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/ECT7000P1
DIMENSIONS AND WEIGHTS
ENGINE
GENERATOR
Model EC5000K1 ECT7000K1 ECT7000P1
Type
BT, FT, GVT, GVWT, ITT
FT, GVT, GVWT, ITT,
RGT
GVT, GVWT
Description code EZDL EZDP
Overall 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 GX390T2
Description code GCBDT
Type 4 stroke, overhead valve, single cylinder, inclined by 25
Displacement
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 ignition
Ignition timing
BTDC 10/1,400 min
-1
(rpm)
Spark plug BPR6ES (NGK), W20EPR-U (DENSO)
Lubrication system Forced spray
Oil 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 open
Carburetor Horizontal type, butterfly valve
Air cleaner Dual element type
Governor Mechanical centrifugal
Breather system Flat valve type
Fuel used Regular unleaded gasoline with a pump octane rating 86 or higher
Model EC5000K1 ECT7000K1 ECT7000P1
Type
BT
FT, GVT, GVWT,
ITT
FT, GVT, GVWT,
ITT, RGT
GVT, GVWT
Description code EZDL EZDP
Generator type Double electrode field rotation type
Excitation Self-excitation
Voltage regulation system
Capacitor control
Compound
through
transformer
AVR (Automatic
Voltage
Regulator)
Phase Single phase Single phase/Three phase
Rotating direction Counterclockwise (Viewed from the generator)
Rated output AC 4500 VA 3600/6500 VA
Rated frequency 50 Hz
AC Rated voltage 115/230 V 230 V 230/400 V
Rated 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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SPECIFICATIONS
CHARACTERISTICS
Model EG5000K1 ECT7000K1 ECT7000P1
Type
BT
FT, GVT,
GVWT
ITT
FT, GVT,
GVWT, ITT,
RGT
GVT, GVWT
Voltage
variation rate
Average 10 % max.
Voltage stability 1 % max.
Frequency
variation rate
Average 3.5 % 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 H
Fuel 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, 0.693
Imp 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 DRAWINGS
Unit: mm (in) ECT7000K1 shown:
550 (21.7)
540 (21.3)
800 (31.5)
MEMO
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2. SERVICE INFORMATION
MAINTENANCE STANDARDS2-2
TORQUE VALUES2-4
LUBRICATION & SEAL POINT 2-5
TOOLS2-6
HOW TO READ CONNECTOR
DRAWINGS 2-9
FRAME/ENGINE CABLE/HARNESS
ROUTING 2-10
FUEL TUBE ROUTING 2-27
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SERVICE INFORMATION
SERVICE INFORMATION
MAINTENANCE STANDARDS
ENGINE
EC3600K1
Unit: mm (in)
Part Item Standard Service limit
Engine Engine speed 3,200 150 min
-1
(rpm)
Cylinder compression
1.31 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 side
clearance
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 Valve
clearance
IN 0.15 0.02
EX 0.20 0.02
Valve
stem 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 guide
I.D.
IN/EX 6.600 6.615 (0.2598 0.2604) 6.66 (0.262)
Guide-to-
stem
clearance
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)
Crankcase
cover
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 INFORMATION
EC5000K1/ECT7000K1/ECT7000P1
Unit: mm (in)
Part Item Standard Service limit
Engine Engine speed 3,150 150 min
-1
(rpm)
Cylinder compression
1.29 MPa (13.2 kgf/cm
2
, 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 side
clearance
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 Valve
clearance
IN 0.15 0.02
EX 0.20 0.02
Valve
stem 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 guide
I.D.
IN/EX 6.600 6.615 (0.2598 0.2604) 6.66 (0.262)
Guide-to-
stem
clearance
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)
Crankcase
cover
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
TORQUE VALUES
ENGINE
FRAME
Item
Thread Dia.
and pitch (mm)
Torque values
Remarks
Nm kgfm lbfft
Crankcase cover bolt M8 x 1.25 24 2.4 18
Cylinder head bolt M10 x 1.25 35 3.6 26 Apply engine oil to the threads
and seating surface.
Engine oil drain bolt M12 x 1.5 22.5 2.3 17
Connecting rod special bolt M8 x 1.25 14 1.4 10 Apply engine oil to the threads
Rocker arm pivot bolt M8 x 1.25 24 2.4 18
Rocker arm pivot lock nut M6 x 0.5 10 1.0 7
Spark plug M14 x 1.25 18 1.8 13
Oil level switch joint nut M10 x 1.25 10 1.0 7
Flywheel
special nut
EC3600K1 M16 x 1.5 128 13.1 94 Degrease the crankshaft and
flywheel tapered surface.
Apply engine oil to the threads
EC5000K1/
ECT7000K1/
ECT7000P1
M16 x 1.5 170 17.3 125
Fuel tank bolt M8 x 1.25 24 2.4 18
Fuel tank nut M8 x 1.25 24 2.4 18
Fuel tank joint M10 x 1.25 2.0 0.20 1.5
Air cleaner elbow nut M6 x 1.0 9.0 0.90 6.6
Muffler nut M8 x 1.25 24 2.4 18
Sediment cup 3.9 0.40 2.9
Engine stop switch screw M3 x 1.06 0.45 0.046 0.33
Recoil starter center bolt M5 x 0.8 3.9 0.40 2.9 Apply locking agent
(Threebond 2430 or
equivalent) to the threads
Item
Thread Dia.
and pitch
Torque values
Remarks
mm (in) Nm kgfm lbfft
Generator stud bolt (EC3600K1) M8 24 2.4 18 Degrease the rotor and
crankshaft tapered surface.
Front case bolt (EC3600K1) M8 x 1.25 26 2.7 19
Coupling flange socket bolt
(EC3600K1)
(1/4 20 x 1) 30 3.1 22
Earth bolt (EC5000K1) M5 x 0.8 5.0 0.51 3.7
Coupling plate screw (EC5000K1) M5 x 0.8 5.0 0.51 3.7
Generator support nut
(EC5000K1/ECT7000K1/
ECT7000P1)
M8 x 1.25 24 2.4 18
Ground cable bolt (EC5000K1/
ECT7000K1)
M8 x 1.25 17 1.7 13
Coupling case bolt (EC5000K1/
ECT7000K1)
M8 x 1.25 24 2.4 18
Ventilation grid screw (EC5000K1/
ECT7000K1)
M4 x 1.25 3.0 0.31 2.2
Cap nut (EC5000K1/ECT7000K1) M8 24 2.4 18
Engine mounting nut (EC5000K1/
ECT7000K1/ECT7000P1)
M10 x 1.25 26 2.7 19
Engine mounting nut B
(ECT7000P1)
M8 x 1.25 17 1.7 13
Ground cable nut (ECT7000P1) M8 x 1.25 17 1.7 13
Mounting rubber nut (ECT7000P1) M8 x 1.25 24 2.4 18
Coupling flange bolt (ECT7000P1) (3/8 16 x 1) 38 3.9 28
Coupling flange torx bolt
(ECT7000P1)
M8 x 1.25 24 2.4 18
Rear case torx bolt (ECT7000P1) M8 x 1.25 24 2.4 18
2-5
dummyhead dummyhead
SERVICE INFORMATION
STANDARD TORQUE VALUES
LUBRICATION & SEAL POINT
Item Thread dia. (mm)
Torque values
Nm kgfm lbfft
Screw 4 mm 2.1 0.21 1.5
5 mm 4.3 0.44 3.2
6 mm 9.0 0.92 6.6
Bolt and nut 5 mm 5.3 0.54 3.9
6 mm 10 1.0 7
8 mm 22 2.2 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 5 mm 5.3 0.54 3.9
6 mm 12 1.2 9
8 mm 23 2.3 17
10 mm 40 4.0 30
SH (Small head) flange bolt 6 mm 9.0 0.92 6.6
CT (Cutting threads) flange bolt (Retightening) 5 mm 5.4 0.55 4.0
6 mm 12 1.2 9
Material Location Remarks
Engine oil Camshaft cam profile and journal
Valve lifter stem, stem end and slipper
Valve stem sliding surface and stem end
Valve rocker arm tappet surface and pivot
Rocker arm pivot threads and pivot
Cylinder barrel inner surface
Cylinder head bolt threads and seating surface
Piston outer surface
Piston ring whole surface
Piston pin whole surface
Crankpin and gears
Connecting rod big and small end
Connecting rod special bolt threads and seating surface
Balancer weight gear and journal (Except EC3600K1)
Governor weight holder gear and sliding surface
Governor shaft journal
Governor arm shaft
Flywheel special nut threads and seating surface
Cylinder head bolt threads and seating surface
O-ring whole surface
Multi-purpose grease Oil seal lip
Recoil starter case projection
Starter return spring inner hook
Recoil starter ratchet sliding surface
Spring retainer sliding surface
Threebond 2430 or equivalent Recoil starter center bolt threads
LOCTITE 638 Pilot screw limiter cap
Locking agent Cover/AVR unit torx screw threads
Control unit torx screw threads
2-6
dummyhead dummyhead
SERVICE INFORMATION
TOOLS
Float level gauge
07401-0010000
Valve guide reamer, 6.612 mm
07984-ZE20001
Remover weight
07741-0010201
Valve guide driver, 6.6 mm
07942-6570100
Attachment, 32 x 35 mm
07746-0010100
07746-0010400
07746-0010500
07746-0010600
Driver, 22 mm I.D.
07746-0020100
Driver attachment, 20 mm I.D.
07746-0020400
Driver, 40 mm I.D.
07746-0030100
07746-0030300
2-7
dummyhead dummyhead
SERVICE INFORMATION
07746-0030400
Pilot, 15 mm
07746-0040300
Pilot, 30 mm
07746-0040700
Pilot, 35 mm
07746-0040800
Pilot, 14 mm
07746-0041200
Driver
07749-0010000
Seat cutter, 27.5 mm (45 EX)
07780-0010200
Seat cutter, 29 mm (45 IN)
07780-0010300
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
07780-0012300
07780-0012900
Interior cutter, 30 mm (60 IN/EX)
07780-0014000
2-8
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SERVICE INFORMATION
Interior cutter, 37.5 mm (60 IN/EX)
07780-0014100
Bearing remover shaft, 15 mm
07936-KC10500
07946-6920100
Flywheel puller set
07935-8050004
Cutter holder, 6.6 mm
07781-0010202
Generator shaft holder
07AAA-ZP4GTS1
2-9
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SERVICE INFORMATION
HOW TO READ CONNECTOR DRAWINGS
Connector 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 are
shown 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 the
terminal side.
CONNECTOR No.
MALE CONNECTOR DRAWING
(DOUBLE FRAME)
Male connector viewed from the
terminal side.
LOCK
CONNECTOR No.
TERMINAL ARRANGEMENT
The connector drawing shows the terminal arrangement of
the connector with the lock of the connector toward up.
TERMINAL No.
The system drawing shows the No.9 terminal of the
connector.
LOCK
2-10
dummyhead dummyhead
SERVICE INFORMATION
FRAME/ENGINE CABLE/HARNESS ROUTING
ENGINE STOP SWITCH SIDE:
To engine stop switch To ignition coil
To oil level switch
Y
R Bl
INSIDE
ENGINE STOP SWITCH
ENGINE WIRE
HARNESS
OIL LEVEL SWITCH
HARNESS CLIP
ENGINE STOP
SWITCH CORD
HARNESS CLIP
R Bl
Y
OIL LEVEL
SWITCH WIRE
2-11
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SERVICE INFORMATION
IGNITION COIL SIDE:
HIGH TENSION CORD
BREATHER TUBE
HIGH TENSION CORD
MAIN WIRE
HARNESS SIDE:
GOVERNOR ARM
CYLINDER BARREL RIB
ENGINE WIRE HARNESS
IGNITION COIL
CARBURETOR INSULATOR
IGNITION COIL
4P CONNECTOR
CONTROL BASE ASSY.
Terminal
number
Wire color
1
2
3
4
Bl
R
Y
2-12
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SERVICE INFORMATION
GROUND CABLE
GROUND TERMINAL
GROUND CABLE
GROUND TERMINAL
Terminal
number
Wire color
Y/G
Y/G
2-13
dummyhead dummyhead
SERVICE INFORMATION
GENERATOR/COVER SIDE (EC3600K1)
FT, GVT, GVWT, ITT TYPE
COVER SIDE
STATOR SIDE
RECEPTACLE TERMINAL
GROUND TERMINAL
EXCITER WINDING CONNECTOR
EXCITER WINDING
CONNECTOR
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
CIRCUIT PROTECTOR CONNECTOR
MAIN WINDING 4P CONNECTOR
Terminal
number
Wire color
1
2
3
4
R
W
G
Y
Terminal
number
Wire color
1
2
3
4
R
Y
G
Y
Terminal
number
Wire color
Terminal
number
Wire color
Y/G
Terminal
number
Wire color
G
R
Y/G
Y/G
R
G
G
G
2-14
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SERVICE INFORMATION
GENERATOR SIDE (EC3600K1):
BT TYPE
GROUND TERMINAL
COVER SIDE
STATOR SIDE
Terminal
number
Wire color
1
2
3
4
R
W
G
Y
Terminal
number
Wire color
1
2
3
4
R
W
G
Bl
2-15
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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 PROTECTOR
CONNECTOR (Upper side)
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
GROUND TERMINAL
VOLTAGE SELECTOR
SWITCH CONNECTOR (Upper side)
VOLTAGE SELECTOR SWITCH CONNECTOR (Upper side)
VOLTAGE SELECTOR SWITCH CONNECTOR (Upper side)
Terminal
number
Wire color
G
G
W
W
W
W
Bl
R
W
G
R
W
Terminal
number
Wire color
R
Y/G
G
Bl
W
Y/G
Bl
W
Y/G
Terminal
number
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 PROTECTOR
CONNECTOR (Lower side)
VOLTAGE SELECTOR
SWITCH CONNECTOR (Lower side)
2-16
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SERVICE INFORMATION
CONTROL BOX SIDE (EC5000K1):
FT, GVT, GVWT TYPE
RECEPTACLE
TERMINAL
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 PROTECTOR
TERMINAL (Upper side)
CIRCUIT PROTECTOR
Terminal
number
Wire color Wire color Terminal
number
Terminal
number
number
Terminal
number
Wire color
G
W
Y
R
G
Y
Y
R
G
G
G
G
G
G
R
Y/G
G
R
Y/G
G
Y
Y/G
R
G
Y/G
GROUND TERMINAL
CIRCUIT PROTECTOR
CONNECTOR (Lower side) MAIN WINDING TERMINAL (Lower side)
JUMP WIRE TERMINAL (Upper side)
2-17
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SERVICE INFORMATION
ITT TYPE
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE
TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
CIRCUIT PROTECTOR
GROUND TERMINAL
RECEPTACLE
CIRCUIT PROTECTOR TERMINAL (Upper side)
JUMP TERMINAL (Upper side)
JUMP TERMINAL (Upper side)
Terminal
number
number
Wire color Terminal
number
Terminal
number
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 PROTECTOR
MAIN WINDING
TERMINAL (Lower side)
MAIN WINDING
MAIN WINDING
2-18
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SERVICE INFORMATION
BT TYPE
RECEPTACLE
TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
CIRCUIT PROTECTOR
CONNECTOR
CIRCUIT PROTECTOR
CONNECTOR
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
VOLTAGE SELECTOR
SWITCH TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
CIRCUIT PROTECTOR
CONNECTOR
CIRCUIT PROTECTOR
CONNECTOR
GROUND TERMINAL
Wire color Terminal
number
Wire color Terminal
number
Wire color Terminal
number
Wire color Terminal
number
Wire color Terminal
number
R
Y/G
G
R
Y/G
G
W
Y
Y/G
W
G
Y
R
Y
G G
Y G
G
G
G
Y
Y
Y
Y
Y/G
W
R
W
Y/G
2-19
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SERVICE INFORMATION
BT, FT, GVT, GVWT, ITT TYPE
MAIN WINDING TERMINAL
Wire color Terminal
number
G
W
Y
R
2-20
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SERVICE INFORMATION
GENERATOR SIDE (ECT7000K1)
FT, GVT, GVWT, ITT, RGT TYPE
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE
TERMINAL (Except ITT type)
CIRCUIT BREAKER
CIRCUIT BREAKER CONNECTOR (Upper side)
CIRCUIT BREAKER CONNECTOR (Upper side)
RECEPTACLE
TERMINAL
RECEPTACLE
TERMINAL
RECEPTACLE
TERMINAL
RECEPTACLE TERMINAL
RECEPTACLE
TERMINAL
CIRCUIT BREAKER
RECEPTACLE
CIRCUIT BREAKER
CIRCUIT PROTECTOR
RECEPTACLE
Terminal
number
Wire color
R
Bu
Bu
Y/G
Bu
R
RECEPTACLE
Wire color Terminal
number
Y/G
R
R
G
Bu
Y/G
Terminal
number
Wire color
G
R
Bl
G
R
Bl
R
R
G
Bl
Bl
CIRCUIT BREAKER
CIRCUIT BREAKER CONNECTOR (Lower side)
CIRCUIT BREAKER CONNECTOR (Lower side)
2-21
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SERVICE INFORMATION
MAIN/EXCITER WINDING 6P CONNECTOR
STATOR SIDE
TRANSFORMER SIDE
BRUSH HOLDER CONNECTOR
TRANSFORMER
WINDING TERMINAL
TRANSFORMER WINDING TERMINAL
TRANSFORMER
WINDING TERMINAL
TRANSFORMER WINDING CONNECTOR
Wire color Terminal
number
G
R
Y
Y
G
R
Y
Terminal
number
Wire color
R
G
Bl
R
G
Bl
Terminal
number
Wire color
R
G
Bl
R
G
Bl
Terminal
number
Wire color
G
R
Bl
G
R
Bl
1
2
3
4
5
6
1
2
3
4
5
6
DIODE CONNECTOR
2-22
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SERVICE INFORMATION
GENERATOR SIDE (ECT7000K1)
STATOR SIDE
TRANSFORMER SIDE
BRUSH HOLDER
MAIN/EXCITER WINDING 6P CONNECTOR
Terminal
number
Wire color
R
G
Bl
R
G
Bl
Terminal
number
Wire color
R
G
Bl
R
G
Bl
1
2
3
4
5
6
1
2
3
4
5
6
2-23
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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
Wire color Terminal
number
Br
Bu
Y/G
W
Bu
Y/G
Bl
Wire color Terminal
number
W
Bl
Y/G
Bu
Br
Bu
Y/G
2-24
dummyhead dummyhead
SERVICE INFORMATION
CIRCUIT BREAKER TERMINAL
Terminal
number
Wire color
Br
W
Bl
Bu
Br
W
Bu
Bl
2-25
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SERVICE INFORMATION
AVR UNIT SIDE (ECT7000P1)
CONTROL PANEL
SIDE
STATOR SIDE
STATOR SIDE
GROUND TERMINAL
AVR 6P CONNECTOR
Terminal
number
Wire color
Bl
W
Br
Y/G
Bu
Bu
1
2
3
4
5
6
Terminal
number
Wire color
1
2
3
4
5
6
Bl
W
Br
Y/G
Bu
Bu
Terminal
number
Wire color
R
Gr
Y
Y
Y
1
2
3
4
5
6
2-26
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SERVICE INFORMATION
FIELD WINDING BRUSH HOLDER SIDE (ECT7000P1)
FIELD WINDING CONNECTOR
FIELD WINDING CONNECTOR
Terminal
number
Wire color
R
Gr
2-27
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SERVICE INFORMATION
FUEL TUBE ROUTING
FUEL TUBE
MEMO
dummyhead dummyhead
3-1
3
dummytext
3. MAINTENANCE
MAINTENANCE SCHEDULE3-2
ENGINE OIL LEVEL CHECK3-3
ENGINE OIL CHANGE3-4
AIR CLEANER CHECK/CLEANING/
REPLACEMENT3-5
SEDIMENT CUP CLEANING3-6
SPARK PLUG CHECK/ADJUSTMENT/
REPLACEMENT3-7
SPARK ARRESTER CLEANING 3-8
VALVE CLEARANCE CHECK/
ADJUSTMENT 3-8
COMBUSTION CHAMBER CLEANING 3-9
FUEL TANK AND FILTER CLEANING 3-10
FUEL TUBE INSPECTION 3-10
3-2
dummyhead dummyhead
MAINTENANCE
MAINTENANCE
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 every
indicated month or
operating hour interval,
whichever comes first.
REGULAR SERVICE PERIOD (2)
Refer
to
page
Each use
First
month
or 20 hrs.
Every
3 months
or 50 hrs.
Every
6 months
or 100 hrs.
Every year
or 300 hrs.
Engine oil Check level 3-3
Change 3-4
Air cleaner Check
3-5
Clean (1)
Sediment cup Clean 3-6
Spark plug Checkadjust
3-7
Replace
Spark arrester Clean 3-8
Valve
clearance
Checkadjust
3-8
Combustion
chamber
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
3-3
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MAINTENANCE
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 the
dipstick clean.
Insert the oil filler cap/dipstick in the oil filler neck, but
do 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 the
dipstick, fill with the recommended engine oil to the
upper level (top of the oil filler neck) [3].
Oil is a major factor affecting performance and service
life. Use 4-stroke automotive detergent oil.
SAE 10W-30 is recommended for general use. Other
viscosities shown in the chart may be used when the
average temperature in your area is within the
recommended range.
Check that the O-ring [4] is in good condition, replace it
if necessary.
Apply engine oil to the O-ring.
Reinstall the oil filler cap/dipstick securely.
RECOMMENDED ENGINE OIL:
SAE 10W-30
API service classification SE or later
[2]
SAE VISCOSITY GRADES
AMBIENT TEMPERATURE
[3]
[1]
[4]
3-4
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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 drain
bolt (12 x 15 mm) [2].
Remove the oil filler cap/dipstick [3], drain bolt, sealing
washer (12 mm) [4] and drain the engine oil into the
suitable container.
Please dispose of used engine oil in a manner that is
compatible with the environment. We suggest you take
used oil in a sealed container to your local recycling
center or service station for reclamation. Do not throw it
in the trash, pour it on the ground, or down a drain.
Install the engine oil drain bolt (12 x 15 mm) and new
sealing washer (12 mm).
Tighten the drain bolt to the specified torque.
With the engine on a level surface, fill the
recommended 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 have
been identified as carcinogenic.
If repeatedly left in contact with the skin for
prolonged periods, it may cause skin cancer.
Wash your hands thoroughly with soap and water
as soon as possible after contact with used engine
oil.
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]
3-5
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MAINTENANCE
AIR CLEANER CHECK/CLEANING/
REPLACEMENT
A dirty air cleaner element will restrict air flow to the
carburetor, reducing engine performance. If the engine
is operated in dusty areas, clean the air cleaner more
often 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 the
engine, 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 and
replace 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 flush
point solvent [2] and allow to dry thoroughly.
Dip the form element in clean engine oil [3] and
squeeze out all the excess oil.
Excess oil will restrict air flow through the form element
and 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 (not
exceeding 207 kPa, 2.11 kgf/cm
2
, 30 psi) through the
paper element from the inside.
Never try to brush off dirt; brushing will force dirt into the
paper fibers.
Assemble the air cleaner in the reverse order of
disassembly.
[1]
[2]
[3]
[5]
[6]
[4]
[2] [3]
[1]
[1]
3-6
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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 with
nonflammable solvent and allow them to dry thoroughly.
Install the cup filter as the direction shown in the
illustration.
Install a new O-ring and tighten the sediment cup to the
specified torque.
Check the installation part of the sediment cup for any
sign of fuel leakage.
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when
handling 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]
3-7
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MAINTENANCE
REPLACEMENT
Remove the spark plug cap [1], and then remove the
spark plug [2] using a spark plug wrench [3].
Visually inspect the spark plug. Replace the plug if the
insulator [1] is cracked or chipped.
Remove carbon or other deposits with wire brush.
Check the sealing washer [2], center electrode [3] and
side 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 is
damaged.
Measure the plug gap with a thickness gauge. If the
measurement is out of the specification, adjust by
bending 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 the
threads in the cylinder head.
Install the spark plug cap securely.
If the engine has been running, the engine will be
very 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]
3-8
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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 spark
arrester [2].
Clean the carbon deposits from the spark arrester
screen [3] with a wire brush [4].
Check the spark arrester screen for damage. If the
screen 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 hot
during operation and remains hot for a while after
stopping the engine. Be careful not to touch the
muffler while it is hot. Allow it to cool before
proceeding.
[3]
[4]
[2]
[1]
[2] [1]
[4] [3]
3-9
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MAINTENANCE
Disconnect 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 pulling
the recoil starter slowly. When the piston is near top
dead center of the compression stroke, the " " mark [1]
and cut-out [2] on the starter pulley will align with the
top hole [3] on the recoil starter case [4].
If the exhaust valve is opened, use the recoil starter to
turn the crankshaft one additional turn and align the " "
mark on the starter pulley with the top hole on the recoil
starter case again.
Insert a thickness gauge [1] between the valve rocker
arm [2] and valve stem [3] to measure the valve
clearance.
If adjustment is necessary, proceed as follows.
Hold the rocker arm pivot [4] and loosen the rocker arm
pivot lock nut [5].
Adjust by turning the rocker arm pivot until there is a
slight drag on the thickness gauge.
Hold the rocker arm pivot and retighten the pivot lock
nut to the specified torque.
Recheck the valve clearance, and if necessary, readjust
the clearance.
Installation is in the reverse order of removal.
COMBUSTION CHAMBER CLEANING
Remove the cylinder head (page 13-4).
Clean any carbon deposits from the combustion
chamber [1].
Install the cylinder head (page 13-4).
[1] [3]
[2] [4]
VALVE CLEARANCE:
IN: 0.15 0.02 mm
EX: 0.20 0.02 mm
[1]
[4]
To increase valve clearance: screw out.
To decrease valve clearance: screw in.
[3]
[2]
[5]
[1]
3-10
dummyhead dummyhead
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 flash
point solvent.
Inspect the fuel filter screen [3] to be sure it is
undamaged.
Clean the fuel tank [4] with nonflammable or high flash
point solvent and allow to dry thoroughly.
Check to be sure new O-ring is in place, and install the
fuel 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 the
neighboring parts.
Replace the fuel tube if there is damage, fuel leakage
or, corrosion (page 5-3).
handling fuel.
[4]
[1]
[2]
[3]
handling fuel.
[1]
4-1
4
dummytext
4. TROUBLESHOOTING
BEFORE TROUBLESHOOTING4-2 TROUBLESHOOTING 4-2
4-2
dummyhead dummyhead
TROUBLESHOOTING
TROUBLESHOOTING
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.
TROUBLESHOOTING
HARD 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, and
then restart the engine, taking care that the choke
valve is not closed too much.
If the engine does not start and the electrodes are
wet again, check the carburetor float valve (page
5-9).
Perform the IGNITION SYSTEM
TROUBLESHOOTING (page 8-2).
Disassemble the carburetor to clean the
carburetor ports, jets, and nozzles (page 5-7).
Clean the air cleaner element.
Go to page 4-3.
Pull the recoil starter and check whether the
engine cranks.
If the recoil starter operates correctly when
removed but cannot be pulled when installed
on the engine, disassemble the engine and
repair or replace the faulty part(s) (page 14-4).
Cranks
Cannot be cranked
Clean
Fuel is not reaching the
carburetor
Loosen 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 reaching
the carburetor
If the engine is stalled in a cold weather
application, check for a frozen clog in the breather
tube.
If the recoil starter operates correctly when

removed but is hard to pull when installed on
the engine, check the decompressor operation
of the camshaft (page 14-15).
Check the recoil starter (page 9-6).
4-3
dummyhead dummyhead
TROUBLESHOOTING
Normal
Compression
is too high
Compression
is too low
Perform the cylinder compression test (page 13-
6).
Check the valve clearance (page 3-8) and then
perform the cylinder compression test.
If the cylinder compression is too high, remove
carbon deposits in the combustion chamber (page
3-9).
Check the valve clearance (page 3-8), and then
perform the cylinder compression test.
If the cylinder compression is too low, perform a
leak down test.
If there is air leakage in the engine, check the
following:
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 starting
procedure.
From page 4-2
4-4
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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 electrodes
for carbon and proper gap (page 3-7).
Check the main jet for blockage (page 5-8).
Check for air leaking between the carburetor and
engine 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 combustion
chamber (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 plug
gap. Replace if necessary.
Adjust the valve clearance.
Clogged
Abnormal
No
High cylinder
compression
Low cylinder
compression
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 are
found, and recheck.
Normal
Abnormal
Check the valve clearance (page 3-8).
Check that the cylinder head is correctly
tightened (page 13-4).
Check for defective cylinder head gasket,
valves, or valve seats (page 13-5).
4-5
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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 the
engine stop switch and the ignition coil for
continuity.
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 continuity
ENGINE WIRE HARNESS
R
Bl
Normal
Check for continuity between the oil level switch
connector and the engine ground.
Replace the oil level switch (page 14-4).
Continuity
No continuity
Check the engine wire harness between the oil
level switch and the ignition coil for continuity.
Replace the ignition coil (page 8-3).
No continuity
Continuity
ENGINE WIRE HARNESS
Y
MEMO
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5-1
5
dummytext
5. FUEL SYSTEM
TOOL 5-2
FUEL TANK REMOVAL/INSTALLATION 5-3
AIR CLEANER REMOVAL/
INSTALLATION5-4
CARBURETOR REMOVAL/
INSTALLATION5-5
CARBURETOR DISASSEMBLY/
ASSEMBLY 5-6
CARBURETOR BODY CLEANING 5-8
CARBURETOR INSPECTION 5-8
PILOT SCREW REPLACEMENT 5-9
CHOKE SET REPLACEMENT 5-10
5-2
dummyhead dummyhead
FUEL SYSTEM
FUEL SYSTEM
TOOL
Float level gauge
07401-0010000
5-3
dummyhead dummyhead
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 fuel
into a suitable container.
After installation, route the fuel tube to the carburetor
properly (page 2-27).
handling fuel.
Keep heat, sparks and flame away.
FUEL TANK CAP: NOTE 3
FUEL TANK CAP PACKING: NOTE 6
FUEL TANK STRAINER: NOTE 4
CUT-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)
CLIP (B8) (2)
FUEL TUBE:
NOTE 2, 5
O-RING
TANK MOUNTING RUBBER A (2)
TANK MOUNTING NUT (2)
FUEL TANK JOINT: NOTE 1
2.0 Nm (0.20 kgfm, 1.5 lbfft)
DRAIN SCREW
(6 x 8 mm)
FUEL VALE LEVER
NOTE 1 FUEL TANK AND FILTER CLEANING page 3-10
NOTE 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 and
replace 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.
5-4
dummyhead dummyhead
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 1
ELBOW PACKING:
NOTE 2
NOISE SILENCER
BREATHER TUBE:
NOTE 2
AIR CLEANER ELBOW
NUT (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 3-5
NOTE 2 Before installation, check for cracks or deterioration.
NOTE 3
Remove and install with the choke lever in the "ON" position and fuel valve
lever in the "OFF" position as shown.
NOTE 4 Before installation, clean the inside with compressed air.

NOTE 5 Note the installation direction.
5-5
dummyhead dummyhead
FUEL SYSTEM
CARBURETOR REMOVAL/
INSTALLATION
Pinch the fuel tube with the fuel tube clamp and then
disconnect it from the carburetor.
Remove the air cleaner elbow (page 5-4).
handling fuel.
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 5-6
NOTE 2 CARBURETOR DISASSEMBLY/ASSEMBLY page 5-6
NOTE 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 fuel
tube.
NOTE 6 Note the installation direction.

5-6
dummyhead dummyhead
FUEL SYSTEM
GOVERNOR ROD REMOVAL/
INSTALLATION
Pull 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 throttle
return spring [4].
Installation is in the reverse order of removal.
CARBURETOR DISASSEMBLY/
ASSEMBLY
[4]
[3]
[1]
[2]
handling fuel.
To prevent serious eye injury, always wear safety
goggles or other eye protection when using
compressed air.
5-7
dummyhead dummyhead
FUEL SYSTEM
Remove the carburetor (page 5-5).
SET COLLAR
SPRING
PILOT JET: NOTE 9
O-RING
UPPER
SIDE
UPPER
SIDE
20
LIMITER CAP
PILOT SCREW: NOTE 4
FLOAT PIN
FLOAT: NOTE 2, 7
FLOAT CHAMBER: NOTE 9
O-RING
SET SCREW
GASKET
SET SCREW (8 x 10 mm) DRAIN SCREW (6 x 8 mm)
DRAIN SCREW
GASKET
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 VALVE
LEVER
FUEL VALVE SPRING
LEVER SETTING
PLATE
CARBURETOR BODY: NOTE 1
MAIN NOZZLE:
NOTE 8
MAIN JET: NOTE 9
CHOKE VALVE
PLATE: NOTE 5
NOTE 1 CARBURETOR BODY CLEANING page 5-8
NOTE 2 FLOAT LEVEL HEIGHT page 5-8
NOTE 3 FLOAT VALVE page 5-9
NOTE 4 PILOT SCREW REPLACEMENT page 5-9
NOTE 5 CHOKE SET REPLACEMENT page 5-10
NOTE 6 SEDIMENT CUP CLEANING page 3-6
NOTE 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.
5-8
dummyhead dummyhead
FUEL SYSTEM
CARBURETOR BODY CLEANING
Some commercially available chemical cleaners are
very 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 with
low-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 INSPECTION
FLOAT LEVEL HEIGHT
Place the carburetor in the position as shown. Measure
the distance between the float top and carburetor body
when the float just contacts the float valve without
compressing 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).
compressed 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]
5-9
dummyhead dummyhead
FUEL SYSTEM
FLOAT VALVE
Check 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 REPLACEMENT
The limiter cap is an emission-related part.
Leave the pilot screw [1] and limiter cap [2] in place
during carburetor cleaning. Remove only if necessary
for repair of the carburetor.
Removal of the limiter cap requires breaking the pilot
screw.
A new pilot screw and limiter cap must be installed.
When the limiter cap has been broken off, remove the
broken pilot screw.
Place the spring on the replacement pilot screw, and
install it on the carburetor.
Turn the pilot screw [1] in until it is lightly seated, then
turn 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 pilot
screw from being turned counterclockwise.
Be careful to avoid turning the pilot screw while
installing the limiter cap. The pilot screw must stay at its
required setting.
OK CLEAN REPLACE
[2]
[1]
[3]
CARBURETOR BODY
[2]
[1] Pilot screw breaks at narrow point.
Pilot screw opening:
EC3600K1:
2 turns out
EC5000K1/ECT7000K1/ECT7000P1:
2-1/8 turns out
[2]
[1] [2]
5-10
dummyhead dummyhead
FUEL SYSTEM
CHOKE SET REPLACEMENT
Remove the carburetor (page 5-5).
Pull out the choke valve plate [1].
Remove the choke shaft [2] and install a new choke
shaft.
Insert a new choke valve plate into the slit [3] of the
choke shaft.
Be sure the choke shaft is in the position between the
projections [4] of the choke valve plate.
[4]
[1]
[2]
[1]
[3]
[2]
[4]
6-1
6
dummytext
6. GOVERNOR
GOVERNOR ARM REMOVAL/
INSTALLATION6-2
GOVERNOR ADJUSTMENT 6-3
6-2
dummyhead dummyhead
GOVERNOR
GOVERNOR
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 RETURN
SPRING: NOTE 2
GOVERNOR ROD: NOTE 2
INSULATOR (Except EC3600K1)
NOTE 1 GOVERNOR ADJUSTMENT page 6-3
NOTE 2 GOVERNOR ROD REMOVAL/INSTALLATION page 5-6
NOTE 3
When reassembly, install the spring with the long end side toward the
control base.
NOTE 4 Hook the governor spring to the governor arm as shown.

6-3
dummyhead dummyhead
GOVERNOR
GOVERNOR ADJUSTMENT
Remove 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 in
the same direction as governor arm moved to open the
throttle.
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 to
manufacturers operating instruction.
Restart the engine and bring the engine to its standard
speed with the throttle lever.
Adjust the throttle control screw [5] so that the throttle
cannot be moved past this point.
ENGINE SPEED:
EC3600K1:
3,200 150 min
-1
(rpm)
EC5000K1/ECT7000K1/ECT7000P1:
3,150 150 min
-1
(rpm)
[2]
[3]
[5]
[4]
[1]
MEMO
dummyhead dummyhead
7-1
7
dummytext
7. GENERATOR/CHARGING SYSTEM
TOOLS7-2
GENERATOR SYSTEM DIAGRAM7-3
BEFORE TROUBLESHOOTING7-9
GENERATOR SYSTEM
TROUBLESHOOTING7-9
FAN COVER REMOVAL/
INSTALLATION7-14
COOLING FAN/FLYWHEEL REMOVAL/
INSTALLATION7-15
GENERATOR REMOVAL 7-18
COMPOUNDING TRANSFORMER
DISASSEMBLY/ASSEMBLY
(ECT7000K1) 7-25
WINDING INSPECTION 7-26
BRUSH HOLDER INSPECTION (ECT7000K1,
ECT7000P1) 7-36
DIODE INSPECTION
(EXCEPT ECT7000P1) 7-37
COMPOUNDING TRANSFORMER AIR GAP
CHECK/ADJUSTMENT (ECT7000K1) 7-38
ROTOR BEARING INSPECTION 7-39
7-2
dummyhead dummyhead
TOOLS
07746-0020400
07746-0030300
Driver, 22 mm I.D.
07746-0020100
Driver, 40 mm I.D.
07746-0030100
Flywheel puller set
07935-8050004
Generator shaft holder
07AAA-ZP4GTS1
7-3
dummyhead dummyhead
GENERATOR SYSTEM DIAGRAM
EC3600K1
FT, GVT, GVWT, ITT Type:
BLACK
YELLOW
BLUE
GREEN
RED
VIOLET V
WHITE
BEIGE Be
GRAY
PINK
LIGHT GREEN
LIGHT BLUE
ORANGE
BROWN
W
R
G
Bu
Y
Bl
Gr
P
Lg
Lb
O
Br
COLOR COMB : GROUND/MARKING
GENERATOR BLOCK
M1W M2W
FW
EXW
CAPACITOR
35 microF
GND3
EARTH
TERMINAL
C4
C5
3
1
2
3
4
C6 C7
CIRCUIT PROTECTOR
17A-230V THERMAL
SOCKET
SCHUKO 16A-230V
BLUE COLOR
CHILDREN PROTECT
T2
T1
T3
SOCKET
FRENCH 16A-230V
BLUE COLOR
CHILDREN PROTECT
SOCKET
FRENCH 16A-230V
BLUE COLOR
CHILDREN PROTECT
SOCKET
SCHUKO 16A-230V
BLUE COLOR
CHILDREN PROTECT
AC OUTLET EC3600-ITT type
AC OUTLET EC3600-FT type AC OUTLET EC3600-GVT type
EC3600-GVWT type
CONTROL BOX BLOCK
T2
T1
T3
T6
T4
T5
C6 C7
CIRCUIT PROTECTOR
17A-230V THERMAL
a
c
b
a
c
b
a
c
b
C6 C7
SOCKET
SCHUKO 16A-230V
BLUE COLOR
CHILDREN PROTECT
T6
T4
T5
T1
T2
T3
SOCKET
EEC 16A-230V
BLUE COLOR
CIRCUIT PROTECTOR
17A-230V THERMAL
G (G)
G (G) G (G)
T6
T4
T5
Y
/
G

Y
/
G

R

R

G G
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

7-4
dummyhead dummyhead
BT Type:
EXW
BLACK
YELLOW
BLUE
GREEN
RED
VIOLET V
WHITE
BEIGE Be
GRAY
PINK
LIGHT GREEN
LIGHT BLUE
ORANGE
BROWN
W
R
G
Bu
Y
Bl
Gr
P
Lg
Lb
O
Br
GENERATOR BLOCK
M1W M2W
CAPACITOR
22 microF
GND4
EARTH
TERMINAL
C15
C16
4
1
2
3
4
C8 C9
CIRCUIT PROTECTOR
17A-230V THERMAL
AC OUTLET EC3600-BT type/115V
AC OUTLET EC3600-BT type/230V
CONTROL BOX BLOCK
115V-0-230V
VOLT CHANGE SW
(115V POSITION)
1
2
3
4
5
6
C51
C50
C49
C48
C47
C46
T7 T9
T8
SOCKET
EEC 16A-230V
BLUE COLOR
C10
T15
T14
T13
T12
T11
T10
C11
2 x CIRCUIT PROTECTOR
17A-115V THERMAL
2 x SOCKET
EEC 16A-115V
YELLOW COLOR
C12
C13
FW
G
W
(R)
(G)
R
W
Bl Bl
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
7-5
dummyhead dummyhead
EC5000K1
FT, GVT, GVWT, ITT Type:
BLACK
YELLOW
BLUE
GREEN
RED
VIOLET V
WHITE
BEIGE Be
GRAY
PINK
LIGHT GREEN
LIGHT BLUE
ORANGE
BROWN
W
R
G
Bu
Y
Bl
Gr
P
Lg
Lb
O
Br
T25
T24
T26
T28
T27 T29
T38
T36
T37
T35
T33
T34
T30
T31
T32
C19 C20
C25
C27
C28
C26
C23 C21
C22 C24
CIRCUIT PROTECTOR
25A-230V THERMAL
CIRCUIT PROTECTOR
25A-230V THERMAL
CIRCUIT PROTECTOR
17A-230V THERMAL
AC OUTLET EC5000-FT type AC OUTLET EC5000-ITT type
2 x SOCKET
FRENCH 16A-230V
BLUE COLOR
CHILDREN PROTECT
SOCKET
EEC 16A-230V
BLUE COLOR
SOCKET
EEC 32A-230V
BLUE COLOR
SOCKET
EEC 32A-230V
BLUE COLOR
a
c
b
a
c
b
2 x CIRCUIT
PROTECTOR
17A-230V
THERMAL
T16
T18
T17
T19
T20
T22
T21
T23
GENERATOR BLOCK
a
c
b
M1W M2W
EARTH
TERMINAL
GND5
FW
C18
C17
EXW
CAPACITOR
35 microF
CONTROL BOX BLOCK
C19
C21
C22
C20
2 x CIRCUIT PROTECTOR
17A-230V THERMAL
2 x SOCKET
SCHUKO 16A-230V
BLUE COLOR
CHILDREN PROTECT
CIRCUIT PROTECTOR
25A-230V THERMAL
AC OUTLET EC5000-GVT type
EC5000-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/G Y/G
(G) G G
G
(G) G
G
G
G
GG
R
R
R
R R
Y
/
G

Y
/
G

W
G (G) G
G G
Y
R
R R
(R)
G
Y
R
GG
Y/G
7-6
dummyhead dummyhead
BT Type:
BLACK
YELLOW
BLUE
GREEN
RED
VIOLET V
WHITE
BEIGE Be
GRAY
PINK
LIGHT GREEN
LIGHT BLUE
ORANGE
BROWN
W
R
G
Bu
Y
Bl
Gr
P
Lg
Lb
O
Br
GND5
3 5
6
B
A
1 2
4
D
C
T39
T41
T40
T42
T16
T18
T17
T19
C18
C17
GENERATOR BLOCK
M1W
FW
EXW
M2W
CAPACITOR
35 microF
C44
C45
C42
C43
T48 T43
T55
T56
T57
T58
T61
T59
T60
T44
T50
T51 T49
T53
T54 T52
T45 C38 C39
C36 C37
T46
T47
C40 C41
VOLTAGE SWITCH
115V-0-230V
CIRCUIT PROTECTOR
17A-230V THERMAL
CIRCUIT PROTECTOR
25A-230V THERMAL
CIRCUIT PROTECTOR
17A-230V THERMAL
CIRCUIT PROTECTOR
17A-115V THERMAL
CIRCUIT PROTECTOR
30A-115V THERMAL
SOCKET
EEC 32A-115V
YELLOW COLOR
SOCKET
EEC 16A-115V
YELLOW COLOR
EARTH
TERMINAL
AC OUTLET EC5000-BT type / 230V
AC OUTLET EC5000-BT type / 115V
CONTROL BOX BLOCK
115
0
230
A B C D
0
115
230
VOLTAGE SWITCH
W
G Y Y
(Y) Y
G
W
R
R
W
W
G
Y
R
W
Y
/
G

G G
G G G
R
W
Y
/
G

Y
/
G

Y
/
G

Y
/
G

(R)
Y/G Y/G
G
R
Y Y
Y
7-7
dummyhead dummyhead
ECT7000K1
1 C
O
N
T
R
O
L
B
O
X
B
L
O
C
K
T76
T75
T77
T73
T72 T74
C66
C65 C66 C65
C66
C65
C51 C53
C52 C54
C55 C57
C56 C58
C59
C60
C61
C62
C63
C64
CIRCUIT PROTECTOR
17A-230V THERMAL
2 x SOCKET
FRENCH 16A-230V
BLUE COLOR
CHILDREN PROTECT
2 x SOCKET
SCHUKO 16A-230V
BLUE COLOR
CHILDREN PROTECT
T74 T72
T73
T82
T78
T79
T80
T81
SOCKET
EEC 16A-230V
BLUE COLOR
SOCKET
EEC 16A-400V
RED COLOR
T75
T76
T77
T72
T73
T74
T62 T63
T66
T64
T67 T65
T68
T69
T70
T71
GND6
EARTH
TERMINAL
CURRENT TRANSFORMER
DIODE
FW
EX1W
EX2W
EX3W
GENERATOR BLOCK
AC OUTLET 230V ECT7000-GVT type
ECT7000-GVWT type
ECT7000-RGT type
AC OUTLET 230V ECT7000-FT type AC OUTLET 230V ECT7000-ITT type
CIRCUIT PROTECTOR
17A-230V THERMAL
CIRCUIT PROTECTOR
17A-230V THERMAL
AC OUTLET 400V
PROTECTOR SWITCH
3x10A-400V THERMAL
BLACK
YELLOW
BLUE
GREEN
RED
VIOLET V
WHITE
BEIGE Be
GRAY
PINK
LIGHT GREEN
LIGHT BLUE
ORANGE
BROWN
W
R
G
Bu
Y
Bl
Gr
P
Lg
Lb
O
Br
c 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) R R
R (Bu)
Y
/
G

R Bu
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
RB
l
R
B
l
Y/G
Y/G (Y/G)
Y/G
7-8
dummyhead dummyhead
ECT7000P1
GND7
GENERATOR BLOCK CONTROL BOX BLOCK
AC OUTLET 400V AC OUTLET 230V
AC thermal circuit breaker 16A
T93
T96
T97
T95
T99
T100
T98
T102
T103
T101
T94 T90
T82
T83
T84
T85
T86
T87
T88
T89
T91
T92
400V/16A 230V/16A 230V/16A 230V/16A
FW
F1 F2
MW
BLACK
YELLOW
BLUE
GREEN
RED
VIOLET V
WHITE
BEIGE Be
GRAY
PINK
LIGHT GREEN
LIGHT BLUE
ORANGE
BROWN
W
R
G
Bu
Y
Bl
Gr
P
Lg
Lb
O
Br
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

WB
l
W
7-9
dummyhead dummyhead
Check that the connectors and terminals are connected securely.
Read the circuit testers operation instructions carefully, and observe the
instructions during inspection.
GENERATOR SYSTEM TROUBLESHOOTING
NO OR LOW AC OUTPUT
EC3600K1, 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 condenser
connectors and connect them to a new condenser
and measure the main winding AC voltage.
Check the circuits between the generator and
receptacles.
Measure the exciter winding AC voltage at the
condenser connector terminals (EC3600K1: page
7-32, 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 condenser
connector terminals for a few secondes to
magnetize the rotor.
Let the generator run for a few minutes to ensure
good 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)
7-10
dummyhead dummyhead
ECT7000K1
Abnormal
Abnormal
Normal
From page 7-9
Abnormal
Normal
Stop the engine and measure the field winding
resistance (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 the
coupling plate (page 7-28).
STANDARD: 3,150 150 min
-1
(rpm)
Measure the DC voltage at the brush holder (page
7-30).
receptacles.
Stop the engine and check the diode (page 7-37).
Replace the faulty diode (page 7-20).
7-11
dummyhead dummyhead
From page 7-10
Normal
Abnormal
Normal
Normal
Normal
Abnormal
Abnormal
Abnormal
Abnormal
Normal
Disconnect the Red and Green wire connectors
from diode as shown.
Connect a 12 V battery (+) terminal to the Red
wire connector and (-) terminal to the Green wire
connector.
The generator is normal.
Let the generator run for a few minutes to ensure
good re-magnetization of the rotor.
Measure the exciter winding AC voltage between
the Yellow wire connectors.
Phase - phase: 56 68 V
Replace the stator (page 7-20).
Measure the exciter winding AC voltage at the 6P
connector terminals (thin wire side).
Stop the engine and disconnect the battery.
Measure the exciter winding resistance (page 7-
33).
Measure the main winding AC voltage at the 6P
connector (thick wire side).
Replace the transformer (page 7-20).
Measure the output AC voltage at the coupling
plate (page 7-28).
Phase - neutral: 135 165 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).
7-12
dummyhead dummyhead
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 main
winding side (page 7-35).
Measure the main winding AC voltage (page 7-
29).
Normal
Abnormal
Normal
receptacles.
-1
(rpm)
Stop the engine and check the brush holder (page
7-36).
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 holder
terminals and measure the AC voltage at the 6P
connector (page 7-29).
Normal
Abnormal
Replace the AVR (page 10-3).
7-13
dummyhead dummyhead
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)
Voltages are not balanced
Voltages are balanced
Adjust the transformer air gap (page 7-38).
Check the loose or poor connection at the
connectors and terminals.
Normal
-1
(rpm)
7-14
dummyhead dummyhead
FAN COVER REMOVAL/INSTALLATION
After installation, route the wire harness properly (page
2-10).
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
7-15
dummyhead dummyhead
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 AIR
GAP 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 7-16
NOTE 2 FLYWHEEL INSTALLATION page 7-16
NOTE 3
After installing the flywheel, check to be sure that the woodruff key is still in
its slot on the crankshaft.
7-16
dummyhead dummyhead
FLYWHEEL REMOVAL
Hold the flywheel [1] with a commercially available strap
wrench [2] and remove the special nut (16 mm) [3].
Take care not to damage the cooling fan with the strap
wrench.
Remove the starter pulley [4] and cooling fan [5].
wrench [2].
Remove the flywheel by using the special tool.
Do not hit the flywheel with a hammer.
FLYWHEEL INSTALLATION
Clean the tapered surface [1] of dirt, oil, grease, and
other foreign material before installation.
Be sure there are no metal parts or other foreign
material 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] with
woodruff 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 aligning
the 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 cooling
fan.
[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]
7-17
dummyhead dummyhead
Apply engine oil to the threads and seating surface of
the special nut (16 mm) [1], and loosely tighten the nut.
wrench [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)
[2]
[1] [3]
7-18
dummyhead dummyhead
GENERATOR REMOVAL
Take care not to damage the stator coil and rotor coil
when removing / installing them.
Do not strike any part of the rotor when removing it.
The rotor may be damaged.
When installation, route the wire harness properly
(page 2-10).
When reassembly degrease the rotor and crankshaft
tapered surface.
EC3600K1
Remove the engine (page 12-2).
Remove the control box (page 10-2). BT type:
NUT (8 mm) (4)
WASHER (10 mm) (4)
COUPLING FLANGE SOCKET BOLT (10 x 25 mm) (4)
COUPLING FLANGE
SCREW (4 x 15 mm) (2)
COOLING FAN
FRONT CASE
WASHER (8 mm) (4)
FRONT CASE BOLT
(8 x 16 mm) (4)
GENERATOR STUD BOLT (8 x 185 mm)
ROTOR: NOTE 2, 4
MIDDLE CASE
WASHER (6 mm) (4)
STATOR: NOTE 1, 4
NUT (8 mm)
MOUNTING RUBBER
BOLT (6 x 193 mm) (4)
BOLT (5 x 10 mm) (2)
CAP
END COVER: NOTE 6
WASHER (8 mm)
CAP NUT
SCREW (3 x 10 mm)
CONDENSER
NUT (5 mm) (2)
WASHER (3 mm)
ROTOR BEARING (6203): NOTE 3, 7
DIODE: NOTE 5
NOTE 1 STATOR REMOVAL (EXCEPT ECT7000P1) page 7-22
NOTE 2 ROTOR REMOVAL (EXCEPT ECT7000P1) page 7-22
NOTE 3 BEARING INSTALLATION page 7-24
NOTE 4 WINDING INSPECTION page 7-26
NOTE 5 DIODE INSPECTION (EXCEPT ECT7000P1) page 7-37
NOTE 6 END COVER DISASSEMBLY/ASSEMBLY (EC3600K1 EXCEPT BT TYPE) page 10-9
NOTE 7 ROTOR BEARING INSPECTION page 7-39
7-19
dummyhead dummyhead
EC5000K1
WASHER
(4 mm) (16)
COUPLING PLATE
VENTILATION GRID SCREW (4 x 10 mm) (6)
COOLING FAN
COUPLING CASE
WASHER (10 mm) (4)
BOLT (10 x 25 mm) (4)
STUD BOLT (8 x 253 mm)
ROTOR: NOTE 2, 4
WASHER (8 mm) (4)
WATER SEAL
NUT (8 mm) (4)
BOLT (5 x 14 mm) (4)
BOLT (5 x 10 mm) (4)
CAP
WASHER (8 mm)
CAP NUT
SCREW (4 x 10 mm) (2)
WASHER (5 mm) (2)
CONDENSER
NUT (8 mm)
VENTILATION GRID (2)
MOUNTING RUBBER
CONTROL BOX:
NOTE 7
EARTH BOLT (5 x 10 mm)
COUPLING PLATE SCREW (5 x 15 mm) (2)
NUT (4 mm) (8)
REAR GRID
STATOR:
NOTE 1, 4
RUBBER (2)
CONTROL BOX COVER
ROTOR BEARING (6203):
NOTE 3, 6
DIODE: NOTE 5
COUPLING CASE BOLT (8 x 35 mm) (4)
3.0 Nm (0.31 kgfm, 2.2 lbfft)
5.0 Nm (0.51 kgfm, 3.7 lbfft)
5.0 Nm (0.51 kgfm, 3.7 lbfft)
NOTE 7 CONTROL BOX DISASSEMBLY/ASSEMBLY (EC5000K1) page 10-5
7-20
dummyhead dummyhead
ECT7000K1
WASHER (4 mm) (16)
COUPLING CASE BOLT (8 x 35 mm) (4)
TRANSFORMER
UNIT: NOTE 4, 5
COOLING FAN
WASHER (10 mm) (4)
BOLT (10 x 25 mm) (4)
ROTOR: NOTE 2,5
WASHER (8 mm) (4)
WATER SEAL
NUT (8 mm) (4)
RUBBER (2) BOLT (5 x 14 mm) (4)
BOLT (5 x 10 mm) (4)
CAP
CONTROL BOX COVER
WASHER (8 mm)
CAP NUT
SCREW (4 x 10 mm) (2)
WASHER (8 mm) (4)
VENTILATION GRID (2)
MOUNTING RUBBER
CONTROL BOX:
NOTE 8
BOLT (5 x 10 mm)
SCREW (8 x 20 mm) (4)
NUT (4 mm) (7)
SLIP RING: NOTE 5
BRUSH HOLDER:
NOTE 6
PLATE (3)
STUD BOLT (8 x 253 mm)
NUT (8 mm)
SCREW
(4 x 25 mm)
WASHER (4 mm) (2)
NUT (4 mm)
REAR GRID
STATOR: NOTE 1, 5
NOTE 3, 7
VENTILATION GRID SCREW (4 x 10 mm) (6)
3.0 Nm (0.31 kgfm, 2.2 lbfft)
COUPLING CASE
NOTE 4
COMPOUNDING TRANSFORMER DISASSEMBLY/ASSEMBLY
(ECT7000K1)
page 7-25
NOTE 6 BRUSH HOLDER INSPECTION (ECT7000K1, ECT7000P1) page 7-36
NOTE 8 CONTROL BOX DISASSEMBLY/ASSEMBLY (ECT7000K1) page 10-8
7-21
dummyhead dummyhead
ECT7000P1
Remove the control unit (page 10-3).
WIDE CLAMP
SEAL
COUPLING FLANGE TORX BOLT (8 x 40 mm) (4)
WASHER (8 mm) (4)
COUPLING FLANGE
BOLT (10 x 25 mm) (4)
COUPLING FLANGE
BOLT (5 x 10 mm)
NUT (5 mm)
MOUNTING
RUBBER (2)
ROTOR: NOTE 4
WOODRUFF KEY
(6 x 7.5 mm)
STATOR: NOTE 1, 4, 7
REAR CASE
FAN: NOTE 2
WASHER
TORX SCREW (5 x 10 mm) (4)
WASHER (5 mm) (4)
END COVER
CAP
NUT (2)
STUD BOLT
EXTERNAL CIRCLIP
BRUSH HOLDER: NOTE 5
TORX SCREW/WASHER (6 x 20 mm)
WASHER (10 mm) (4)
O-RING
NOTE 3, 6
[A]
REAR CASE TORX BOLT
(8 x 40 mm) (4)
NOTE 1 GENERATOR REMOVAL (ECT7000P1) page 7-23
NOTE 2 FAN REMOVAL (ECT7000P1) page 7-23
NOTE 5 BRUSH HOLDER INSPECTION (ECT7000K1, ECT7000P1) page 7-36
NOTE 7 When assembly, position the flat part [A] as shown.
7-22
dummyhead dummyhead
STATOR REMOVAL (EXCEPT
ECT7000P1)
EC3600K1: Remove the four bolts (8 x 16 mm), nuts (8 mm) and
washers (8 mm) (page 7-18).
Remove the four bolts (8 x 35 mm), nuts (8 mm) and
washers (8 mm).
EC5000K1 (page 7-19)
ECT7000K1 (page 7-20)
Remove the brush holder (page 7-20).
Remove the stator [1] with a commercially available
puller [2] as shown.
ROTOR REMOVAL (EXCEPT
ECT7000P1)
Remove the recoil starter (page 9-2).
Insert a suitable tool [1] to the square holes [2] of the
starter pulley so that the rotor [3] is held.
Remove the stud bolt/cap nut [4] and washer (8 mm)
[5].
Reinstall the stud bolt/cap nut and turn it in until it is
lightly seated, then turn the screw out the 1 turn.
Take care not to bend the stud bolt
Take care not to damage the sensitive parts
(windings etc.)
Tap the stud bolt/cap nut with a hammer and remove
the rotor.
If this fails, put a spindle (dia. 9 0.1 350 mm long)
(dia. 0.4 0.004 13.8 in long) in the rotor until it
comes into contact with the engine crankshaft.
Holding the rotor firmly, give a short, sharp blow on the
end of the spindle with a hammer.
EC5000K1,
ECT7000K1:
ECT7000K1:
[2] [1]
EC5000K1 shown:
[2] [1]
EC3600K1:
[4] [5]
[3] [1]
[5] [2]
7-23
dummyhead dummyhead
GENERATOR REMOVAL (ECT7000P1)
Recoil starter (page 9-2)
Brush holder (page 7-21)
Remove the four bolts (10 x 25 mm), nuts (10 mm) and
washers (10 mm) (page 7-21)
Insert a suitable tool [1] to the square holes [2] of the
starter pulley so that the rotor is held.
Install the woodruff key (6 x 7.5 mm) [1] to the generator
shaft groove [2].
Fit the special tool [3] onto the generator shaft [4].
Take care not to turn the generator shaft to
counterclockwise to loose. The stud bolt is left hand
threads.
Turn the generator shaft to the clockwise using an
impact wrench fitted with a 41 mm socket to loose the
engine/generator taper coupling with stud bolt (left hand
threads).
FAN REMOVAL (ECT7000P1)
Remove the fan [1] with a commercially available puller
[2] as shown.
[1]
[2]
TOOL:
Generator shaft holder 07AAA-ZP4GTS1
[4] [3] [1]
[2]
[1]
[2]
7-24
dummyhead dummyhead
BEARING INSTALLATION
EXCEPT ECT7000P1
Drive a new bearing [1] with its marked side facing up
until it is fully seated on the end using the special tools.
ECT7000P1
Drive a new bearing [1] with its groove [2] side facing up
TOOLS:
Driver, 22 mm I.D. [2] 07746-0020100
Driver attachment, 20 mm I.D. [3] 07746-0020400
[2]
[3] [1]
TOOLS:
Driver, 40 mm I.D. [3] 07746-0030100
[3]
[1] [4]
[2]
7-25
dummyhead dummyhead
DISASSEMBLY/ASSEMBLY
(ECT7000K1)
The compounding transformer is pre-set in the
factory. Although it is unlikely that this setting will
need to be changed.
Be careful not to damage the magnetic laminations
and keep the metal sheets of the transformer
aligned.
After assembly, adjust the transformer air gap (page
7-38).
Remove the transformer unit (page 7-20).
SCREW (5 x 20 mm) (2)
WASHER (5 mm) (2)
DIODE (2): NOTE 2
WASHER (5 mm) (2)
NUT (5 mm) (2)
NUT
(5 mm) (2)
WASHER (5 mm) (2)
TRANSFORMER PLATE
COUPLING PLATE
SCREW (5 x 15 mm) (2)
TRANSFORMER: NOTE 1, 3
WASHER (6 mm) (4)
WASHER (6 mm) (4)
BOLT (6 x 60 mm) (4)
NUT (4 mm) (3)
WASHER (4 mm)
(6)
BAND
NOTE 1 COMPOUNDING TRANSFORMER WINDING INSPECTION (ECT7000K1) page 7-35
NOTE 3
COMPOUNDING TRANSFORMER AIR GAP CHECK/ADJUSTMENT
(ECT7000K1)
page 7-38
7-26
dummyhead dummyhead
WINDING INSPECTION
MAIN WINDING INSPECTION
EC3600K1
Remove the end cover with the connectors and
terminals connected.
Except BT type (page 7-18)
BT type (page 10-2)
Start the engine and measure the AC voltage between
the main winding 4P connector / (stator
side) terminals with the connector connected according
to the table below.
Stop the engine.
Measure the resistance between the main winding 4P
connector (stator side) terminals according to the table
below.
If the measured resistance is zero or infinity, replace the
stator (page 7-18).
Main winding 4P connector
terminals (stator side)
Voltage (VAC)
No.1 (R) and No.4 (Y)
103 127
No.2 (W) and No.3 (G)
G
W
R
Y
Except BT type:
BT type:
terminals (stator side)
Resistance ()
No.1 (R) and No.4 (Y)
0.41 0.57
No.2 (W) and No.3 (G)
G
W
R
Y
7-27
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EC5000K1
Remove the control box cover (page 7-19).
the coupling plate [1] terminals according to the table
below.
Stop the engine.
Measure the resistance between the coupling plate
terminals (lower side) according to the table below.
stator (page 7-19).
Coupling plate terminals Voltage (VAC)
(R) and (Y)
103 127
(W) and (G)
[1]
G
W
R
Y
Coupling plate terminals Resistance ()
(R) and (Y)
0.33 0.45
(W) and (G)
G
W
R
Y
7-28
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ECT7000K1
the coupling plate [1] terminals according to the table
below.
Phase to neutral:
Phase to phase:
If the measured voltages are out of specification and
balanced, check the transformer air gap (page 7-38).
Stop the engine.
(R) and (R)
207 253 (G) and (G)
(Bl) and (Bl)
(R) and (G)
360 440 (R) and (Bl)
(G) and (Bl)
R G
Bl
Bl
[1]
R
G Bl
R G
Phase to neutral:
Phase to phase:
7-29
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Measure the resistance between the coupling plate [1]
and main/exciter winding 6P connector (stator
side) terminals according to the table below.
stator (page 7-20).
ECT7000P1
Remove the cover/AVR unit (page 10-3) with the AVR
6P connector connected.
the main winding 6P connector (stator side)
terminals with the connector connected according to the
table below.
Stop the engine.
Main/exciter winding 6P
connector (stator side) and
main winding terminals
Resistance ()
No.1 (R) and (R)
0.97 1.33 No.2 (G) and (G)
No.3 (Bl) and (Bl)
[1]
R
G
R
G
Bl
Bl
(stator side) terminals
Voltage (VAC)
No.1 (Bl) and No.5/6 (Bu)
207 253 No.2 (W) and No.5/6 (Bu)
No.3 (Br) and No.5/6 (Bu)
Bl
Br
W
Bu Bu
7-30
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Measure the resistance between the main winding 6P
connector (stator side) terminals according to the
table below.
stator (page 7-21).
FIELD WINDING INSPECTION
EC3600K1/EC5000K1
Check the diode (page 7-37).
Measure the resistance between the diode [1]
terminals.
ECT7000K1
Remove the rear grid (page 7-20).
Start the engine and measure the DC voltage at the
brush as shown.
Stop the engine.
Resistance ()
No.1 (Bl) and No.2 (W)
0.5 0.7 No.2 (W) and No.3 (Br)
No.3 (Br) and No.1 (Bl)
Bl
Br
W
Bu Bu
Resistance ()
EC3600K1 3.55 4.35
EC5000K1 4.4 5.4
EC5000K1 shown: [1]
Field winding wire Voltage (VAC)
R (+) and G () 54 66
R G
7-31
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Measure the resistance between the slip rings.
If the measured resistance is zero or infinity, clean the
slip rings or replace the rotor (page 7-20).
ECT7000P1
Remove the wide clamp (page 7-21).
Disconnect the connectors [1] from the brush holder
terminals.
Connect a 12 V battery (+) terminal to the Red wire side
terminal and () terminal to the Gray wire side
terminal .
the 6P connector terminals (page 7-29)
Stop the engine.
Measure the resistance between the slip rings.
If the measured resistance is zero or infinity, clean the
slip rings or replace the rotor (page 7-21).
Resistance (): 20.2 24.8
Voltage (VAC)
No.1 (Bl) and No.5/6 (Bu)
150 184 No.2 (W) and No.5/6 (Bu)
No.3 (Br) and No.5/6 (Bu)
[1]
Gr R
Resistance (): 23.8 29.2
7-32
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EXCITER WINDING INSPECTION
EC3600K1
Remove the generator end cover with the connectors
and terminals connected.
BT type (page 10-2)
the exciter winding connectors with the connector
connected according to the table below.
Stop the engine and disconnect the exciter winding
connectors.
Measure the resistance between the exciter winding
connectors according to the table below.
stator (page 7-18).
Type
Exciter winding
connector
Voltage (VAC)
Except BT
288 352
BT
Except BT type:
BT type:
Type
Exciter winding
connector
Resistance ()
Except BT
2.6 3.2
BT
Except BT type:
BT type:
7-33
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EC5000K1
the exciter winding connectors with the connector
connected according to the table below.
Stop the engine and disconnect the exciter winding
connectors.
Measure the resistance between the exciter connectors
according to the table below.
stator (page 7-19).
ECT7000K1
the diode [1] connectors according to the table below.
If the measured voltage are out of specification and
balanced, check the transformer air gap (page 7-38).
If the specified voltage is not obtained, measure the AC
voltage at the main/exciter winding 6P connector
terminals.
Stop the engine.
Exciter winding
connector
Voltage (VAC)
288 352
Exciter winding
connector
Resistance ()
4.0 5.0
Diode connectors Voltage (VAC)
(Y) and (Y)
15.7 19.3 (Y) and (Y)
(Y) and (Y)
connector (stator side)
Voltage (VAC)
No.4 (R) and No.5 (G)
73 91 No.5 (G) and No.6 (Bl)
No.4 (R) and No.6 (Bl)
R
G
Bl
Y
Y
Y
[1]
7-34
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Measure the resistance between the main/exciter
winding 6P connector (stator side) terminals
according to the table below.
stator (page 7-20).
connector terminals
(stator side)
Resistance ()
No.4 (R) and No.5 (G)
5.60 6.86 No.5 (G) and No.6 (Bl)
No.4 (R) and No.6 (Bl)
R G Bl
7-35
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WINDING INSPECTION (ECT7000K1)
Measure the main winding side resistance between the
main/exciter winding 6P connector and coupling
plate [1] terminals according to the table below.
Main winding side:
Measure the exciter winding side resistance between
the main/exciter winding 6P connector [1] and diode [2]
connector terminals according to the table below.
Exciter winding side:
compounding transformer (page 7-20).
connector and coupling plate
terminals
Resistance ()
No.1 (R) and (R)
0.97 1.33 No.2 (G) and (G)
No.3 (Bl) and (Bl)
connector and diode
connector terminals
Resistance ()
No.4 (R) and (Y)
1.33 1.81 No.5 (G) and (Y)
No.6 (Bl) and (Y)
R
G
Bl
Bl R
G
Y
Y
Y
Bl
R G
[1]
[2]
Main winding side:
Exciter winding side:
7-36
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BRUSH HOLDER INSPECTION
(ECT7000K1, ECT7000P1)
CONTINUITY INSPECTION
Remove the brush holder.
ECT7000K1 (page 7-20)
ECT7000P1 (page 7-21)
Check the brushes [1] for wear or damage.
Check for continuity between the each brush tip and
wire connectors [2] according to the table below.
There should be continuity.
Check for continuity between the each brush tip [1] and
terminals [3] according to the table below.
There should be continuity.
BRUSH LENGTH MEASUREMENT
(ECT7000K1)
Measure the brush length.
If the brush length is less than the service limit, replace
the brush holder.
ECT7000K1:
Brush tip and connector
Brush tip (G) and connector (G)
Brush tip (G) and connector (G)
Brush tip (R) and connector (R)
Brush tip (R) and connector (R)
ECT7000P1:
Brush tip and terminal
Brush tip (Gr) and terminal (Gr)
Brush tip (R) and terminal (R)
[1]
[2] ECT7000K1:
ECT7000P1: [3]
[1]
SERVICE LIMIT: 5.0 mm (0.20 in)
7-37
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DIODE INSPECTION (EXCEPT
ECT7000P1)
EC3600K1/EC5000K1
EC3600K1: Remove the end cover.
BT type (page 10-2)
Remove the rear grid (page 7-19).
Attach a bulb (12 V - 45 W) [1] to the diode [2] terminals
through a 12 V battery.
Depending on the battery polarity, the bulb should go
on brightly and then, when reversed polarity, go dimmer
(or vice versa).
ECT7000K1
Remove the diode (page 7-25).
Check the continuity between the terminals according
to the table below.
EC5000K1:
EC5000K1 shown: [1]
(+) Tester probe
Y [A] G [B] Y [C] R [D]
() Tester
probe
Y [A]
G [B]
Y [C]
R [D]
[A] [B]
[D] [C]
7-38
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COMPOUNDING TRANSFORMER AIR
GAP CHECK/ADJUSTMENT
(ECT7000K1)
The compounding transformer air gap is pre-set in
the factory. Although it is unlikely that this setting will
need to be changed, the following procedure is given
for guidance and must be carried out by qualified
personnel.
Be careful not to damage the magnetic laminations
and keep the metal sheets of the transformer
aligned.
Connect the voltage meter equipped with wires with
round terminals between a phase [1] and the neutral [2]
on the coupling plate terminals.
Start the engine and measure the voltage.
If the measured voltage is less than the standard
voltage, the air gap is too small.
If the measured voltage is greater than standard
voltage, the air gap is too large.
Adjust the air gap.
Remove the two bolts (6 x 60 mm) [3], and washers (6
mm) [4] at the coupling plate side of transformer.
Move the metal sheets between 0.10 mm and 1.0 mm
apart and retighten the bolts.
Start the engine and measure the voltage.
If the measured voltage is greater than standard
voltage, loosen one bolt and slightly push the metal
sheets towards the windings.
Retighten the bolt and measure the voltage.
If necessary, carry out the same operation on the other bolt.
STANDARD: 207 253 V (VAC)
[4]
[2]
0.10 1.0 mm (0.004 0.04)
[3]
[4]
[1]
7-39
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ROTOR BEARING INSPECTION
Turn the outer race of the rotor bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing inner race fits tightly in the
rotor shaft.
Replace the bearing if necessary.
EC3600K1 (page 7-18)
EC5000K1 (page 7-19)
ECT7000K1 (page 7-20)
ECT7000P1 (page 7-21)
MEMO
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8-1
8
dummytext
8. IGNITION SYSTEM
IGNITION SYSTEM DIAGRAM8-2
BEFORE TROUBLESHOOTING8-2
IGNITION SYSTEM
TROUBLESHOOTING8-2
IGNITION COIL REMOVAL/
INSTALLATION8-3
IGNITION COIL AIR GAP CHECK/
ADJUSTMENT 8-4
SPARK TEST 8-4
SPARK PLUG CAP INSPECTION 8-5
IGNITION COIL INSPECTION 8-5
OIL LEVEL SWITCH INSPECTION 8-6
8-2
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IGNITION SYSTEM
IGNITION SYSTEM
IGNITION SYSTEM DIAGRAM
Check that the connectors are connected securely.
Check for sufficient fresh fuel in the fuel tank.
Read the circuit testers operation instructions carefully, and observe the
instructions during inspection.
Check the engine oil level.
IGNITION SYSTEM TROUBLESHOOTING
NO SPARK AT SPARK PLUG
OIL LEVEL SW ENGINE STOP SW SPARK PLUG IGNITION COIL
FRAME
EARTH
ENGINE
EARTH
GND2 GND1
ENGINE BLOCK
BLACK
YELLOW
BLUE
GREEN
RED
VIOLET V
WHITE
BEIGE Be
GRAY
PINK
LIGHT GREEN
LIGHT BLUE
ORANGE
BROWN
W
R
G
Bu
Y
Bl
Gr
P
Lg
Lb
O
Br
C1 C2
C3
2 1 4 3
O
I
L

A
L
T
E
X
T
(

-

)
E
X
T
(

+

)
L
E
D
1
ENGINE STOP SWITCH
CONNECTION TABLE
EXT( - )
ON
OFF
Y

B
l
R
R

B
l

Y

Replace the engine stop switch (page 7-14).
Check the harness connecting the ignition coil
and the engine stop switch for open or short
circuit and for proper connection (page 4-5).
Normal
Abnormal
Check the engine stop switch (page 10-11).
Check continuity between the oil level switch
connector and engine ground (page 8-6).
Replace the oil level switch (page 14-4).
Check the ignition coil (page 8-5). Replace the ignition coil (page 8-3).
Normal
Normal
Abnormal
Abnormal
Abnormal
8-3
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IGNITION SYSTEM
IGNITION COIL REMOVAL/
INSTALLATION
Air cleaner elbow (page 5-4)
Fan cover (page 7-14)
When installation adjust the ignition coil air gap
(page 8-4).
When installation, route the high tension cord
properly (page 2-11).
IGNITION COIL: NOTE 1, 2, 4
BOLT (6 x 28 mm) (2)
IGNITION COIL 4P CONNECTOR
SPARK PLUG CAP: NOTE 3
HIGH TENSION CORD: NOTE 5
NOTE 1 IGNITION COIL AIR GAP CHECK/ADJUSTMENT page 8-4
NOTE 2 SPARK TEST page 8-4
NOTE 3 SPARK PLUG CAP INSPECTION page 8-5
NOTE 4 IGNITION COIL INSPECTION page 8-5
NOTE 5
Check for cracked or damage insulation and replace the ignition coil if
necessary.
8-4
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IGNITION SYSTEM
IGNITION COIL AIR GAP CHECK/
ADJUSTMENT
Avoid the magnet part of the flywheel when
adjusting.
Adjust the ignition coil air gap equally on both side.
Measure the ignition coil air gap clearance.
If measured clearance is out of specification, adjust the
clearance.
Loosen the two ignition coil bolts (6 x 28 mm) [1].
Insert the thickness gauge [2] of proper thickness
between the ignition coil [3] and flywheel [4].
Push the ignition coil firmly against the flywheel and
tighten the ignition coil bolts securely.
Remove the thickness gauge.
SPARK TEST
Inspect the following before performing the spark test.
Faulty spark plug
Loose spark plug cap
Water in the spark plug cap (Causing the ignition coil
secondary voltage to leak)
Loose ignition coil connector.
Disconnect the spark plug cap [1] from the spark plug
[2].
Connect a known-good spark plug [3] to the spark plug
cap and ground the spark plug to the cylinder head
cover bolt [4].
Turn the engine stop switch to the "ON" position, pull
the recoil starter and check whether sparks jump across
the electrode.
IGNITION COIL AIR GAP:
0.20 0.60 mm (0.008 0.024 in)
0.20 0.60 mm
(0.008 0.024 in)
[3]
[2]
[4]
[1]
0.20 0.60 mm
(0.008 0.024 in)
Drain the fuel from the fuel tank and carburetor
before performing the spark test.
[4] [2] [1]
[3]
8-5
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IGNITION SYSTEM
SPARK PLUG CAP INSPECTION
Measure the resistance of spark plug cap [1] by
attaching one ohmmeter probe to the terminal in the
spark plug cap and the other at the terminal connected
high tension wire.
If measured resistance is out of specification, replace
the spark plug cap.
IGNITION COIL INSPECTION
Disconnect the spark plug cap from the spark plug.
Remove the spark plug cap from the high tension cord
[1].
Disconnect the ignition coil 4P connector [2] from
the ignition coil [3].
Measure the resistance between the terminals and be
sure that the measurements are within the
specifications in the below.
Unit: k
RESISTANCE: 7.5 12.5 k
[1]
1
4
GND
[1]
[2]
2
[3]
(+) Prove
GND
HIGH
TENSION
CORD
Terminal
number
1 2 4
(
)

P
r
o
b
e
GND
6 11 1 10 5 30
HIGH TENSION
CORD
6 11 7 24 12 47
T
e
r
m
i
n
a
l

n
u
m
b
e
r
1
2
5 14 10 26 6 26
4
8-6
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IGNITION SYSTEM
OIL LEVEL SWITCH INSPECTION
SYSTEM INSPECTION
Disconnect the oil level switch wire connector .
Check for continuity between the oil level switch side
(Yellow) terminal and engine ground [1].
There should be no continuity when the engine is full of
oil.
If the correct continuity is not obtained, inspect the oil
level switch.
SWITCH INSPECTION
Remove the oil level switch (page 14-4).
Check for continuity between the oil level switch [1] wire
connector (Yellow) terminal and switch body with
an ohmmeter.
Check the float [2] by dipping the switch into a container
of oil. The ohmmeter reading should go from continuity
to no continuity as the switch is lowered into the oil.
[1]
[1]
LOW OIL LEVEL
(CONTINUITY)
NORMAL OIL LEVEL
(NO CONTINUITY)
[2]
9-1
9
dummytext
9. STARTING SYSTEM
RECOIL STARTER REMOVAL/
INSTALLATION9-2
RECOIL STARTER DISASSEMBLY9-3
RECOIL STARTER ASSEMBLY 9-4
RECOIL STARTER INSPECTION 9-6
9-2
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STARTING SYSTEM
STARTING SYSTEM
RECOIL STARTER REMOVAL/
INSTALLATION
BOLT (6 x 10 mm) (3)
RECOIL STARTER: NOTE 1, 2, 3
NOTE 1 RECOIL STARTER DISASSEMBLY page 9-3
NOTE 2 RECOIL STARTER ASSEMBLY page 9-4
NOTE 3 RECOIL STARTER INSPECTION page 9-6
9-3
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STARTING SYSTEM
RECOIL STARTER DISASSEMBLY
compressed spring.
RECOIL STARTER CENTER BOLT
SPRING RETAINER
FRICTION SPRING
RECOIL STARTER RATCHET (2)
RATCHET SPRING (2)
RECOIL STARTER REAL
RECOIL STARTER ROPE
STARTER RETURN SPRING
RECOIL STARTER CASE: NOTE 1
STARTER GRIP
REINFORCEMENT GRIP
3.9 Nm (0.40 kgfm, 2.9 lbfft)
NOTE 1 RECOIL STARTER ASSEMBLY page 9-4
9-4
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STARTING SYSTEM
RECOIL STARTER ASSEMBLY
Pass the recoil starter rope [1] through the hole [2] of
the recoil starter real [3], and then tie the rope as
shown.
Before installing the recoil starter rope, check for fray or
wear.
Wind the recoil starter rope onto the recoil starter real
counterclockwise.
Hook the outer hook [1] of the starter return spring [2] to
the groove [3] of the recoil starter real [4], and then
install the starter return spring by winding it.
Apply grease to the projection [1] of the recoil starter
case [2] and inner hook [3] of the starter return spring
[4].
Set the recoil starter real [5] to the recoil starter case by
aligning the inner hook of the starter return spring with
the projection of the recoil starter case.
compressed spring.
[2]
10 mm (0.4 in)
[3]
[1]
[1] [2]
[3] [4]
[5] [4]
[3]
[2] [1]
9-5
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STARTING SYSTEM
Apply grease to the two ratchets sliding surface [1].
Install the two ratchets and the two ratchet springs [2] to
the recoil starter real as shown.
Apply grease to the spring retainer [1] sliding surface.
Set the friction spring [2] and spring retainer to the
recoil starter real in the direction as shown.
Apply locking agent (Threebond 2430 or equivalent)
to the threads of the center bolt [3].
Hold the spring retainer and tighten the center bolt to
the specified torque.
Turn the recoil starter real [1] more than 2 turns
counterclockwise to preload the starter return spring.
Be sure to hold the recoil starter real.
Pass the recoil starter rope through hole [1] of the recoil
starter case, the starter grip [2], and reinforcement grip
[3], and then tie the rope as shown.
Check the recoil starter operation (page 9-6).
[2]
[1]
[2]
[1] [3]
[1]
20 mm
(0.8 in)
[1]
[2]
[3]
9-6
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STARTING SYSTEM
RECOIL STARTER INSPECTION
RECOIL STARTER OPERATION
Pull the recoil starter grip several times to inspect that
the ratchets [1] are operated properly (the ratchet ends
come out from the spring retainer [2]).
Install the recoil starter (page 9-2).
STARTER PULLEY
Inspect all of the square holes [1] of the starter pulley [2]
for deformation.
Install the recoil starter (page 9-2).
[2]
[1]
[2]
[1]
10-1
10
dummytext
10. OTHER ELECTRICAL
CONTROL BOX REMOVAL/INSTALLATION
(EC3600K1 BT TYPE) 10-2
CONTROL UNIT REMOVAL/INSTALLATION
(ECT7000P1) 10-3
CONTROL BOX DISASSEMBLY/ASSEMBLY
(EC3600K1 BT TYPE) 10-4
(EC5000K1) 10-5
(ECT7000K1) 10-8
END COVER DISASSEMBLY/ASSEMBLY
(EC3600K1 EXCEPT BT TYPE) 10-9
CONTROL UNIT DISASSEMBLY/ASSEMBLY
(ECT7000P1) 10-10
CIRCUIT PROTECTOR INSPECTION (EXCEPT
ECT7000P1) 10-11
ENGINE STOP SWITCH INSPECTION 10-11
10-2
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OTHER ELECTRICAL
OTHER ELECTRICAL
CONTROL BOX REMOVAL/
INSTALLATION (EC3600K1 BT TYPE)
When installation, route the wire harness properly (page
2-10).
SCREW (4 x 10 mm) (4) CONTROL BOX COVER
NUT (5 mm) (4)
WASHER (5 mm) (4)
CONTROL BOX: NOTE 1
NUT (5 mm) (4)
MOUNTING RUBBER (4)
WASHER (5 mm) (4)
WASHER (5 mm) (4)
WASHER (3 mm)
SCREW (3 x 10 mm)
NUT (5 mm) (4)
CAP
END COVER
BOLT (5 x 10 mm) (2)
NUT (5 mm) (2)
NOTE 1 CONTROL BOX DISASSEMBLY/ASSEMBLY (EC3600K1 BT TYPE) page 10-4
10-3
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OTHER ELECTRICAL
CONTROL UNIT REMOVAL/
INSTALLATION (ECT7000P1)
When installation, route the wire harness properly (page
2-25).
GENERATOR
COVER/AVR UNIT
COVER/AVR UNIT TORX SCREW (5 x 16 mm) (4): NOTE 2
WASHER (5 mm) (4)
PACKING: NOTE 3
CONTROL UNIT
TORX BOLT
(5 x 16 mm) (6): NOTE 2
CONTROL UNIT: NOTE 1
AVR 6P CONNECTOR
PACKING: NOTE 3
NOTE 1 CONTROL UNIT DISASSEMBLY/ASSEMBLY (ECT7000P1) page 10-10
NOTE 2 When reassembly apply locking agent to the threads.
10-4
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OTHER ELECTRICAL
CONTROL BOX DISASSEMBLY/
ASSEMBLY (EC3600K1 BT TYPE)
Remove the control box (page 10-2).
When assembly, route the wire harness properly (page
2-15).
SCREW (4 x 12 mm) (4)
RECEPTACLE
(16 A-115 V)
RECEPTACLE (16 A-230 V)
SCREW (4 x 12 mm) (4)
PACKING: NOTE 2
CONDENSER
CIRCUIT PROTECTOR
(17 A-115 V) (2): NOTE 1
VOLTAGE SELECTOR
SWITCH
PLATE (3)
NUT (3)
PROTECTOR COVER (3)
CONTROL BOX CASE
CONTROL BOX WIRE HARNESS
SCREW (4 x 10 mm)
SCREW (4 x 12 mm) (4)
NUT (4 mm) (2)
WASHER (4 mm)
NUT
PACKING:
NOTE 2
SWITCH COVER
PACKING: NOTE 2
CIRCUIT PROTECTOR
(17 A-230 V): NOTE 1
NOTE 1 CIRCUIT PROTECTOR INSPECTION (EXCEPT ECT7000P1) page 10-11
10-5
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OTHER ELECTRICAL
ASSEMBLY (EC5000K1)
BT TYPE
2-16).
SCREW (4 x 10 mm) (4)
RECEPTACLE
(16 A-115 V)
RECEPTACLE
(32 A-115 V)
SCREW (4 x 10 mm) (4)
PACKING:
NOTE 2
CIRCUIT PROTECTOR
(25 A-230 V): NOTE 1
VOLTAGE SELECTOR SWITCH
PLATE (5)
NUT (5)
PROTECTOR COVER (5)
CONTROL
BOX CASE
SCREW
SCREW (4 x 10 mm) (4)
PACKING: NOTE 2
LEVER STAY
SELECT LEVER
SPECIAL NUT
SWITCH PLATE
SCREW (3)
SWITCH BRACKET
SCREW
(4 x 10 mm) (4)
RECEPTACLE
(16 A-230 V)
PACKING: NOTE 2
WASHER
PACKING:
NOTE 2
CIRCUIT PROTECTOR
(17 A-230 V) (2): NOTE 1
CIRCUIT PROTECTOR
(17 A-115 V): NOTE 1
CIRCUIT PROTECTOR
(30 A-115 V): NOTE 1
10-6
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OTHER ELECTRICAL
FT, GVT, GVWT TYPE
2-16).
FT type shown:
SCREW (4 x 12 mm) (4)
(FT type only)
CIRCUIT PROTECTOR (17 A-230 V) (2): NOTE 1
PLATE (3)
NUT (3)
PROTECTOR COVER (3)
CONTROL BOX CASE
RECEPTACLE (16 A-230 V) (2)
SCREW (4 x 10 mm) (8)
SCREW
(4 x 10 mm) (8)
RECEPTACLE
(16 A-230 V) (2)
PACKING (2):
NOTE 2
GVT, GVWT
type:
PACKING (2):
NOTE 2
PACKING:
NOTE 2
CIRCUIT PROTECTOR
(25 A-230 V): NOTE 1
10-7
dummyhead dummyhead
OTHER ELECTRICAL
ITT TYPE
2-16).
CIRCUIT PROTECTOR (25 A-230 V): NOTE 1
PLATE (2)
NUT (2)
PROTECTOR COVER (2)
CONTROL BOX CASE
SCREW (4 x 12 mm) (4)
RECEPTACLE
(16 A-230 V)
PACKING:
NOTE 2
PACKING: NOTE 2
SCREW
(4 x 12 mm) (4)
10-8
dummyhead dummyhead
OTHER ELECTRICAL
ASSEMBLY (ECT7000K1)
2-20).
GVT, GVWT, RGT type shown:
SCREW
(4 x 16 mm) (2)
RECEPTACLE
(16 A-400 V)
PLATE
NUT
PROTECTOR
COVER
CONTROL BOX CASE
SCREW (4 x 10 mm) (8)
PACKING: NOTE 2
SCREW
(4 x 12 mm) (8)
RECEPTACLE
(16 A-230 V) (2)
PACKING (2):
NOTE 2
FT type:
GUIDE
SEAL
BRACKET
CIRCUIT BREAKER
SCREW (4 x 12 mm) (4)
ITT type:
SCREW (4 x 12 mm) (4)
PACKING (2): NOTE 2
PACKING: NOTE 2
10-9
dummyhead dummyhead
OTHER ELECTRICAL
END COVER DISASSEMBLY/
ASSEMBLY (EC3600K1 EXCEPT BT
TYPE)
Remove the end cover (page 7-18).
2-13).
FT type shown:
PLATE
NUT
PROTECTOR COVER
END COVER
WIRE HARNESS
END COVER
SCREW (4 x 10 mm) (8)
PACKING (2): NOTE 2
GVT, GVWT type:
SCREW (4 x 12 mm) (4)
ITT type:
CAP
SCREW (4 x 10 mm) (8)
PACKING (2): NOTE 2
PACKING: NOTE 2
PACKING: NOTE 2
RECEPTACLE
(16 A-230 V)
SCREW (4 x 10 mm) (4)
10-10
dummyhead dummyhead
OTHER ELECTRICAL
CONTROL UNIT DISASSEMBLY/
ASSEMBLY (ECT7000P1)
Remove the control unit (page 10-3).
2-23).
UNIT CASE
WASHER (5 mm) (4)
NUT (5 mm) (2)
GENERATOR WIRE HARNESS
CONTROL PANEL
TORX SCREW (5 x 12 mm) (10)
CIRCUIT BREAKER
PACKING (3): NOTE 1
RECEPTACLE
(16 A230 V) (3)
BOLT
(4 x 8 mm) (12)
RECEPTACLE (16 A400 V)
BOLT (5 x 20 mm) (4)
CONTROL PLATE
PACKING: NOTE 1
NUT (5 mm) (4)
NUT (4 mm) (12)
WASHER (4 mm) (6)
TORX SCREW
(4 x 12 mm) (6)
SPECIAL BOLT (2)
JUNCTION
RAIL (2)
PACKING: NOTE 1
10-11
dummyhead dummyhead
OTHER ELECTRICAL
CIRCUIT PROTECTOR INSPECTION
(EXCEPT ECT7000P1)
Remove the circuit protector.
EC3600K1 (Except BT type) (page 10-9)
EC3600K1 (BT type) (page 10-4)
EC5000K1 (page 10-5)
ECT7000K1 (page 10-8)
There should be continuity in the ON position (button
in).
Replace the circuit protector if the correct continuity is
not obtained.
ENGINE STOP SWITCH INSPECTION
Disconnect the engine stop switch connectors /
.
Check continuity between the terminals at each switch
position.
If the correct continuity is not obtained, replace the
engine stop switch (page 7-14).
Switch position Continuity
ON Yes
OFF No
MEMO
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11-1
11
dummytext
11. MUFFLER
MUFFLER REMOVAL/INSTALLATION11-2
11-2
dummyhead dummyhead
MUFFLER
MUFFLER
MUFFLER REMOVAL/INSTALLATION
The muffler becomes very hot during operation and
remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot.
Allow it to cool before proceeding.
MUFFLER: NOTE 2
NUT (8 mm) (2)
NUT (8 mm) (3)
EXHAUST PIPE GASKET
SCREW (5 x 8 mm) (2)
SPARK ARRESTER: NOTE 1
MUFFLER PROTECTOR
MUFFLER COVER
COLLAR (2)
SCREW (5 x 25 mm) (2)
Except EC3600K1: EC3600K1:
WASHER (5 mm) (3)
NUT (6 mm) (2)
MUFFLER COVER BASE
SCREW (5 x 8 mm)
SCREW
(6 x 25 mm)
NUT (5 mm) (3): NOTE 3
COVER STAY
STAY COLLAR: NOTE 3 REAR MUFFLER COVER
SCREW (6 x 20 mm) (2)
MUFFLER GASKET
MUFFLER COVER SPACER (3)
NUT (6 mm)
(Except ECT7000P1)
SCREW (6 x 20 mm)
(Except ECT7000P1)
NOTE 1 SPARK ARRESTER CLEANING page 3-8
NOTE 2 Before installation, remove the carbon deposits with a plastic hammer.
NOTE 3
Before tightening securely, install the stay collar to easy installation of the
muffler cover assy.
12-1
12
dummytext
12. ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL/INSTALLATION12-2
12-2
dummyhead dummyhead
EC3600K1
BOLT (8 x 20 mm) (2)
GENERATOR SUPPORT
WASHER (8 mm)
NUT (8 mm) (2)
NUT (8 mm)
NUT (8 mm) (2)
BOLT (8 x 25 mm)
WASHER (8 mm)
WASHER (8 mm)
NUT (8 mm) (2)
SPACER PLATE
ENGINE
NUT (10 mm) (2)
GROUND CABLE
BOLT (8 x 35 mm)
GROUND CABLE
WASHER (8 mm)
MOUNTING RUBBER
(OPPOSITE SIDE OF MUFFLER): NOTE 1
MOUNTING RUBBER
(MUFFLER SIDE): NOTE 1
ENGINE SIDE
54 mm
35 mm
TAB
NOTE 1
Insert the alignment tabs into the holes.
Make sure the rubber is not cracked, hard or worn.
Note the installation direction.
12-3
dummyhead dummyhead
EC5000K1
BOLT (8 x 20 mm) (2)
GENERATOR SUPPORT
WASHER (8 mm)
GENERATOR SUPPORT NUT (8 mm) (2)
NUT (8 mm)
NUT (8 mm) (2)
GROUND CABLE BOLT (8 x 25 mm)
WASHER (8 mm)
WASHER (8 mm)
NUT (8 mm) (2)
SPACER PLATE
ENGINE
ENGINE MOUNTING NUT (10 mm) (2)
GROUND CABLE
BOLT (8 x 35 mm)
GROUND CABLE
WASHER (8 mm)
MOUNTING RUBBER
MOUNTING RUBBER
ENGINE SIDE
54 mm
35 mm
TAB
NOTE 1
12-4
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ECT7000K1
BOLT (8 x 20 mm) (2)
GENERATOR SUPPORT
WASHER (8 mm)
NUT (8 mm)
NUT (8 mm) (2)
GROUND CABLE BOLT (8 x 25 mm)
WASHER (8 mm)
WASHER (8 mm)
NUT (8 mm) (2)
SPACER PLATE
ENGINE
GROUND CABLE
BOLT (8 x 35 mm)
GROUND CABLE
WASHER (8 mm)
MOUNTING RUBBER
MOUNTING RUBBER
ENGINE SIDE
54 mm
35 mm
TAB
NOTE 1
12-5
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ECT7000P1
GROUND CABLE NUT (8 mm)
WASHER (8 mm)
WASHER (8 mm)
GROUND CABLE
SPACER PLATE
MOUNTING RUBBER NUT (8 mm) (2)
BOLT (8 x 25 mm)
ENGINE
WASHER (8 mm)
GROUND CABLE
BOLT (8 x 35 mm)
BOLT (8 x 20 mm) (2)
ENGINE MOUNTING
NUT B (8 mm) (2)
GENERATOR SUPPORT
MOUNTING RUBBER
MOUNTING RUBBER
35 mm
54 mm
TAB
GROUND CABLE NUT (8 mm)
NUT (8 mm)
NOTE 1
MEMO
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13-1
13
dummytext
13. CYLINDER HEAD
TOOLS13-2
CYLINDER HEAD REMOVAL/
INSTALLATION13-4
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY13-5
CYLINDER HEAD/VALVES
INSPECTION 13-6
VALVE GUIDE REPLACEMENT 13-9
VALVE GUIDE REAMING 13-10
VALVE SEAT RECONDITIONING 13-11
13-2
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CYLINDER HEAD
CYLINDER HEAD
TOOLS
Valve guide driver, 6.6 mm
07942-6570100
Seat cutter, 27.5 mm (45 EX)
07780-0010200
07780-0010300
07780-0010400
Seat cutter, 33 mm (45 EX)
07780-0010800
07780-0012100
07780-0012200
07780-0012300
07780-0012900
Interior cutter, 30 mm (60 IN/EX)
07780-0014000
Interior cutter, 37.5 mm (60 IN/EX)
07780-0014100
Cutter holder, 6.6 mm
07781-0010202
13-3
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CYLINDER HEAD
Valve guide reamer, 6.612 mm
07984-ZE20001
13-4
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CYLINDER HEAD
CYLINDER HEAD REMOVAL/
INSTALLATION
Set the piston at top dead center of the cylinder
compression stroke (page 3-8).
Carburetor/carburetor insulator (page 5-5)
Control base (page 6-2)
Muffler (page 11-2)
After installation, perform the following:
Check the valve clearance, and if necessary, adjust
the clearance (page 3-8).
Measure the cylinder compression (page 13-6).
DOWEL PIN (12 x 20 mm) (2)
GASKET
CYLINDER HEAD COVER
CYLINDER HEAD COVER
CYLINDER HEAD: NOTE 1, 3
WASHER
CYLINDER HEAD BOLT (10 x 80 mm) (4): NOTE 2, 4
HEAD COVER PACKING: NOTE 5
CYLINDER HEAD
COVER BOLT
NOTE 1 CYLINDER HEAD DISASSEMBLY/ASSEMBLY page 13-5
NOTE 2
When removal/installation, loosen or tighten the bolts in a crisscross pattern
in 2-3 steps.
NOTE 3
Before installation, remove any carbon deposits from the combustion
chamber and inspect the valve seats.
NOTE 4 When reassembly, apply engine oil to the threads and seating surface.
13-5
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CYLINDER HEAD
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY
Remove the cylinder head (page 13-4).
INTAKE VALVE:
NOTE 2, 7, 8, 11
EXHAUST VALVE:
NOTE 2, 7, 8, 11
VALVE SPRING SEAT
SPARK PLUG: NOTE 6
CYLINDER HEAD: NOTE 2, 5
INTAKE VALVE GUIDE:
NOTE 3, 4
BOLT (CT) (6 x 12 mm)
SHROUD
GUIDE PLATE
VALVE STEM SEAL
ROCKER ARM PIVOT BOLT (2)
ROCKER ARM PIVOT LOCK NUT (2)
ROCKER ARM PIVOT (2):
NOTE 13
VALVE ROCKER ARM (2): NOTE 10, 12
VALVE GUIDE CLIP
INTAKE/EXHAUST VALVE
SPRING RETAINER: NOTE 1
EXHAUST VALVE GUIDE: NOTE 3, 4
VALVE SPRING (2):
NOTE 2
PUSH ROD (2): NOTE 2, 9
NOTE 1 VALVE SPRING RETAINER REMOVAL/INSTALLATION page 13-6
NOTE 2 CYLINDER HEAD/VALVES INSPECTION page 13-6
NOTE 3 VALVE GUIDE REPLACEMENT page 13-9
NOTE 4 VALVE GUIDE REAMING page 13-10
NOTE 5 VALVE SEAT RECONDITIONING page 13-11
NOTE 6 SPARK PLUG CHECK/ADJUSTMENT/REPLACEMENT page 3-7
NOTE 7
Do not interchange the valves. The intake valve is larger than the exhaust
valve.
NOTE 8 Before installation, remove carbon deposits and inspect the valve.
NOTE 9
When reassembly, check both ends for wear and check the rod for
straightness. Be sure the rod ends are firmly seated in the lifters.
NOTE 10
Before installation, check for wear on the pivot bolt, push rod and rocker arm
pivot.
NOTE 11
When reassembly, apply engine oil to the valve stem sliding surface and
stem end.
NOTE 12 When reassembly, apply engine oil to the tappet surface and pivot.
NOTE 13 When reassembly, apply engine oil to the threads and pivot.
13-6
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CYLINDER HEAD
VALVE SPRING RETAINER REMOVAL/
INSTALLATION
Do not remove the valve spring retainers while the
cylinder head is installed to cylinder block, or the valve
will drop into the cylinder.
REMOVAL
Push down and slide the valve spring retainer [1] to the
side so that the valve stem slips through the hole at the
side of the valve spring retainer.
INSTALLATION
Hold the valve so that the valve will not drop.
Push down and slide the valve spring retainer [1] to the
side so that the valve spring retainer is hooked to the
valve stem groove at the center of the valve spring
retainer.
CYLINDER HEAD/VALVES
INSPECTION
CYLINDER COMPRESSION CHECK
Start the engine and warm up to normal operating
temperature.
Stop the engine.
Turn the fuel valve lever to the "OFF" position, and then
remove the drain screw to drain the fuel.
Remove the spark plug (page 3-7).
Pull the recoil starter several times to expel unburned
gas.
Attach a commercially available compression gauge [1]
to the spark plug hole.
Pull the recoil starter forcefully to measure stable
cylinder compression.
CYLINDER HEAD WARPAGE
Remove the carbon deposits from the combustion
chamber (page 3-9).
Check the spark plug hole and valve areas for cracks.
Check the cylinder head warpage using a straightedge
[1] and thickness gauge [2].
If the measurement is more than the service limit,
replace the cylinder head (page 13-5).
Installation
Removal
[1]
CYLINDER COMPRESSION:
EC3600K1:
1.31 MPa (13.4 kgf/cm
2
, 191 psi)/1,400 min
-1
(rpm)
EC5000K1/ECT7000K1/ECT7000P1:
1.29 MPa (13.2 kgf/cm
2
, 187 psi)/1,400 min
-1
(rpm)
[1]
[2] [1]
13-7
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CYLINDER HEAD
VALVE SEAT WIDTH
Remove the carbon deposits from the combustion
chamber (page 3-9).
Inspect each valve face for irregularities.
If necessary, replace the valve (page 13-5).
Apply a light coat of Prussian Blue or erasable felt-
tipped marker ink to each valve seat.
Insert the valve, and snap it using a commercially
available valve lapper [1] closed against its seat several
times.
Be sure the valve does not rotate on the seat.
The transferred marking compound will show any area
of the valve face that is not concentric.
Measure the valve seat width of the cylinder head.
recondition the valve seat (page 13-11).
Check whether the valve seat contact area of the valve
is too high.
If the valve seat is too high or too low, recondition the
valve seat (page 13-11).
VALVE GUIDE I.D.
Ream the valve guide [1] to remove any carbon
deposits before measuring.
Turn the special tool (Valve guide reamer)
clockwise, never counterclockwise.
Continue to rotate the special tool while removing it
from the valve guide.
Measure and record each valve guide I.D.
If the measured valve guide I.D. is more than the
service limit, replace the valve guide (page 13-9).
STANDARD: 1.0 1.2 mm (0.04 0.05 in)
CONTACT TOO HIGH
VALVE SEAT
WIDTH
[1]
TOOL:
Valve guide reamer,
6.612 mm [2] 07984-ZE20001
COMBUSTION
CHAMBER SIDE
VALVE SPRING
SIDE
HANDLE
[2]
[1]
STANDARD: 6.600 6.615 mm
(0.2598 0.2604 in)
13-8
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CYLINDER HEAD
VALVE FACE
Inspect each valve for face irregularities.
VALVE STEM O.D.
Inspect each valve for bending or abnormal stem wear.
Measure and record each valve stem O.D.
If the measurement is less than the service limit,
replace the valve (page 13-5).
GUIDE-TO-STEM CLEARANCE
Subtract each valve stem O.D. from the corresponding
guide I.D. to obtain the stem-to-guide clearance.
If the calculated clearance is more than the service limit,
replace the following:
Valves (page 13-5)
Valve guide (page 13-9)
VALVE SPRING FREE LENGTH
Measure the valve spring free length.
If the measured length is less than the service limit,
replace the valve spring (page 13-5).
VALVE FACE
STANDARD: IN: 6.575 6.590 mm
(0.2589 0.2594 in)
EX: 6.535 6.550 mm
(0.2573 0.2579 in)
SERVICE LIMIT: IN: 6.44 mm (0.254 in)
EX: 6.40 mm (0.252 in)
(0.0004 0.0016 in)
EX: 0.050 0.080 mm
(0.0020 0.0031 in)
EX: 0.13 mm (0.005 in)
STANDARD: 39.0 mm (1.54 in)
13-9
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CYLINDER HEAD
VALVE SPRING PERPENDICULARITY
Measure the valve spring perpendicularity.
If the measured perpendicularity is more than the
service limit, replace the valve spring (page 13-5).
PUSH ROD RUNOUT
Check both ends of the push rod for wear.
Check the push rod for straightness.
If necessary, replace the push rod (page 13-5).
VALVE GUIDE REPLACEMENT
Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
Use a hot plate or oven to heat the cylinder head evenly
to 150C (300F).
Do not use a torch to heat the cylinder head;
warpage of the cylinder head may result.
Do not get the cylinder head hotter than 150C
(300F); excessive heat may loosen the valve seat.
Remove the heated cylinder head from the hot plate
and support it with wooden blocks.
Drive the valve guides [1] out of the cylinder head from
the combustion chamber side.
When driving the valve guides out, be careful not to
damage the cylinder head.
SERVICE LIMIT: 1.5
To avoid burns, use heavy gloves when handling
the heated cylinder head.
TOOL:
Valve guide driver, 6.6 mm [2] 07942-6570100
COMBUSTION
CHAMBER SIDE
[2]
[1]
13-10
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CYLINDER HEAD
Remove the new valve guides from the refrigerator one
at a time as needed.
Install a new clip [1] to a new exhaust valve guide [2].
Drive the exhaust valve guide until the valve guide clip
is fully seated as shown from the valve spring side of
the cylinder head.
Drive a new intake valve guide [4] to the specified
height (measured from the end of the valve guide to the
cylinder head as shown) from the valve spring side of
the cylinder head.
After installing the valve guide, check the guide for
damage.
Replace the valve guide if damaged.
Let the cylinder head cool to room temperature.
Ream the valve guide.
VALVE GUIDE REAMING
For best results, be sure the cylinder head is at room
temperature before reaming valve guides.
Coat the reamer and valve guide with cutting oil.
Rotate the reamer clockwise through the valve guide
the full length of the reamer.
Turn the special tool (valve guide reamer) clockwise,
never counterclockwise.
Continue to rotate the special tool while removing it
from the valve guide.
Thoroughly clean the cylinder head to remove any
cutting residue.
Check the valve guide bore; it should be straight, round
and centered in the valve guide. Insert the valve and
check operation. If the valve does not operate
smoothly, the guide may have been bent during
installation.
Replace the valve guide if it is bent or damaged.
Check the valve guide-to-stem clearance.
TOOL:
Valve guide driver, 6.6 mm [3] 07942-6570100
TOOL:
Valve guide driver, 6.6 mm 07942-6570100
INTAKE VALVE GUIDE INSTALLATION HEIGHT:
EC3600K1:
6.0 mm (0.24 in)
EC5000K1/ECT7000K1/ECT7000P1:
5.0 mm (0.20 in)
EC3600K1: 6.0 mm (0.24 in)
EC5000K1/ECT7000K1/ECT7000P1:
[4]
[3] [1]
[2]
5.0 mm (0.20 in)
TOOL:
Valve guide reamer,
6.612 mm [1] 07984-ZE20001
[1]
HANDLE
COMBUSTION
CHAMBER SIDE
VALVE SPRING
SIDE
13-11
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CYLINDER HEAD
VALVE SEAT RECONDITIONING
Check the valve seat width (page 13-7).
Valve seat cutters/grinders [1] or equivalent valve seat
refacing equipment is recommended to correct a worn
valve seat.
Turn the cutter clockwise, never counterclockwise.
Continue to turn the cutter as you lift it from the valve
seat.
The 32 cutter removes material from the top edge
(contact too high).
The 60 cutter removes material from the bottom edge
(contact too low).
Be sure that the width of the finished valve seat is within
specification.
Make a light pass with the 45 cutter to remove any
possible burrs at the edge of the seat.
After resurfacing the seats, inspect for even valve
seating.
Apply Prussian Blue compound or erasable felt-tipped
marker ink to the valve seat. Insert the valve, and snap
it closed against its seat several times. Be sure the
valve does not rotate on the seat.
The seating surface, as shown by the transferred
marking compound, should have good contact all the
way around.
Thoroughly clean the cylinder head to remove any
cutting residual.
[1]
TOOLS:
Cutter holder, 6.6 mm 07781-0010202
EC36000K1:
Flat cutter, 30 mm (32 IN) 07780-0012200
Flat cutter, 28 mm (32 EX) 07780-0012100
EC5000K1/ECT7000K1/ECT7000P1:
Flat cutter, 35 mm (32 IN) 07780-0012300
Flat cutter, 33 mm (32 EX) 07780-0012900
TOOLS:
EC36000K1:
Interior cutter, 30 mm (60 IN/EX) 07780-0014000
EC5000K1/ECT7000K1/ECT7000P1:
Interior cutter, 37.5 mm
(60 IN/EX)
07780-0014100
STANDARD: 1.0 1.2 mm (0.04 0.05 in)
TOOLS:
EC36000K1:
Seat cutter, 29 mm (45 IN) 07780-0010300
Seat cutter, 27.5 mm (45 EX) 07780-0010200
EC5000K1/ECT7000K1/ECT7000P1:
Seat cutter, 35 mm (45 IN) 07780-0010400
Seat cutter, 33 mm (45 EX) 07780-0010800
VALVE FACE
32
VALVE FACE
60
CONTACT TO STANDARD
VALVE FACE
CONTACT TOO HIGH
VALVE FACE
CONTACT TOO LOW
VALVE FACE
13-12
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CYLINDER HEAD
Lap the valves into their seats, using a commercially
available valve lapper [1] and lapping compound.
After lapping, wash all residual compound off the
cylinder head and valve.
Do not push the valve against the seat with force
during lapping. Apply a light pass with the valve
lapper.
Avoid lapping the valve in the same position as it
causes uneven wear. Lap the valve by turning the
lapper slowly.
Take care not to allow the lapping compound to
enter the gap between the stem and guide.
Adjust the valve clearance after assembly (page 3-8).
[1]
14-1
14
dummytext
14. CYLINDER BLOCK
TOOLS14-2
CRANKCASE COVER REMOVAL/
INSTALLATION14-3
CRANKSHAFT/CAMSHAFT/BALANCER
WEIGHT (EXCEPT EC3600K1)/PISTON
REMOVAL/INSTALLATION14-4
GOVERNOR DISASSEMBLY/
ASSEMBLY 14-6
PISTON DISASSEMBLY/ASSEMBLY 14-7
CYLINDER BLOCK INSPECTION 14-9
BEARING/OIL SEAL REPLACEMENT 14-16
14-2
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CYLINDER BLOCK
CYLINDER BLOCK
TOOLS
Remover weight
07741-0010201
07746-0010100
07746-0010400
07746-0010500
07746-0010600
Driver, 40 mm I.D.
07746-0030100
07746-0030300
07746-0030400
Pilot, 15 mm
07746-0040300
Pilot, 30 mm
07746-0040700
Pilot, 35 mm
07746-0040800
Pilot, 14 mm
07746-0041200
Driver
07749-0010000
Bearing remover shaft, 15 mm
07936-KC10500
07946-6920100
14-3
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CYLINDER BLOCK
CRANKCASE COVER REMOVAL/
INSTALLATION
Drain the engine oil (page 3-4).
Remove the coupling flange (page 7-18).
Remove the front case (page 7-19).
Remove the front case (page 7-20).
Remove the coupling flange (page 7-21).
If the bearing and oil seal are to be replaced, refer to
"BEARING/OIL SEAL REPLACEMENT" (page 14-
16).
If the governor is to be replaced, refer to the
"GOVERNOR DISASSEMBLY/ASSEMBLY" (page
14-6).
EC3600K1:
EC5000K1:
ECT7000K1:
ECT7000P1:
DOWEL PIN (8 x 12 mm) (2)
GASKET
CRANKCASE COVER: NOTE 1
OIL FILLER CAP
EC3600K1: CRANKCASE COVER BOLT (8 x 35 mm) (7)
Except EC3600K1: CRANKCASE COVER BOLT (8 x 40 mm) (7)
OIL FILLER CAP
O-RING (2): NOTE 2
NOTE 1 CYLINDER BLOCK INSPECTION page 14-9
NOTE 2 When reassembly, apply engine oil to the whole surface.
14-4
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CYLINDER BLOCK
CRANKSHAFT/CAMSHAFT/BALANCER
WEIGHT (EXCEPT EC3600K1)/PISTON
REMOVAL/INSTALLATION
Flywheel (page 7-15)
Crankcase cover (page 14-3)
Cylinder head (page 13-4)
If the bearing and oil seal are to be replaced, refer to
"BEARING/OIL SEAL REPLACEMENT" (page 14-16).
THRUST WASHER
O-RING (14 mm)
HOLE
WASHER (12 mm) (2)
MARK
BOLT (6 x 12 mm) (2)
groove
OIL LEVEL SWITCH
JOINT NUT (10 mm)
OIL LEVEL SWITCH: NOTE 4 CONNECTING ROD SPECIAL BOLT (2): NOTE 8
CRANKSHAFT:
NOTE 3, 7, 9
CAMSHAFT:
NOTE 1, 3
WASHER (8.2 x 17 x 0.8 mm)
PISTON: NOTE 2, 3, 5
LOCK PIN (10 mm) : NOTE 11
VALVE LIFTER (2): NOTE 6, 13
GOVERNOR ARM
SHAFT: NOTE 12
HARNESS CLIP
ENGINE OIL DRAIN BOLT
(12 x 15 mm) (2)
22.5 Nm (2.3 kgfm, 17 lbfft)
CONNECTING ROD LOWER END
CYLINDER BARREL: NOTE 3, 10
BALANCER WEIGHT (Except EC3600K1): NOTE 1
NOTE 1 BALANCER WEIGHT/CAMSHAFT INSTALLATION page 14-5
NOTE 2 PISTON DISASSEMBLY/ASSEMBLY page 14-7
NOTE 4 OIL LEVEL SWITCH INSPECTION page 8-6
NOTE 5 When reassembly, install with the index mark toward the push rod hole.
NOTE 6 When disassembly, mark so that the IN and EX sides can be distinguished.
NOTE 7
When reassembly, push in until the bearing touches the crankcase. Be
careful not to damage the oil seal.
NOTE 8 When reassembly, apply engine oil to the threads and seating surface.
NOTE 9 When reassembly, apply engine oil to the crankpin and gears.
NOTE 10 When reassembly, apply engine oil to the inner surface.
NOTE 11
When reassembly, install the lock pin immediately after installing the
governor arm shaft, and move the shaft over against the governor slider.
The lock pin must be installed with the straight side of the lock pin against
the groove of the governor arm shaft.
NOTE 12 When reassembly, apply engine oil to the journal.

NOTE 13 When reassembly, apply engine oil to the stem end and slipper.
14-5
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CYLINDER BLOCK
BALANCER WEIGHT/CAMSHAFT
INSTALLATION
Except EC3600K1: Apply engine oil to the balancer weight [1] gear and
journal.
Install the balancer weight [1] to the cylinder barrel by
aligning the punch marks [2] of the balancer weight and
the crankshaft [3] (marked on the balancer drive gear
[4]).
Apply engine oil to the camshaft [1] cam profile and
journal.
Install the camshaft to the cylinder barrel by aligning the
marks [2] of the camshaft and the crankshaft [3]
(marked on the timing gear [4]).
[1] [3]
[4] [2]
[3] [4]
[2]
[1]
14-6
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CYLINDER BLOCK
GOVERNOR DISASSEMBLY/
ASSEMBLY
Remove the crankcase cover (page 14-3).
GOVERNOR SLIDER: NOTE 2
GOVERNOR HOLDER CLIP: NOTE 3
GOVERNOR WEIGHT (3):
NOTE 4
CRANKCASE COVER: NOTE 1
WASHER (6 mm)
GROOVE
GOVERNOR SHAFT: NOTE 6
GOVERNOR WEIGHT PIN (3)
GOVERNOR WEIGHT HOLDER: NOTE 5, 7
NOTE 2
When reassembly, spread the governor weight to install the governor slider;
then check to be sure slider moves smoothly.
NOTE 3 When reassembly, install firmly into the governor shaft groove.
NOTE 4 When reassembly, check that weights move freely.
NOTE 5 Before installation, check for wear and damage of the gear.
NOTE 6 When reassembly, apply engine oil to the journal.
NOTE 7 When reassembly, apply engine oil to the gear and sliding surface.
14-7
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CYLINDER BLOCK
PISTON DISASSEMBLY/ASSEMBLY
Remove the piston(page 14-4).
PISTON: NOTE 1, 2
LONG END
OIL RING
(COMBINATION
RING)
PISTON PIN CLIP (2)
PISTON PIN: NOTE 2
MAKER MARK
10 mm (0.4 in)
120
120
120
10 mm (0.4 in)
MARK
CONNECTING ROD UPPER END:
NOTE 2
SIDE RAIL
SPACER
TOP RING
SECOND RING
SIDE RAIL
PISTON RING SET: NOTE 2
NOTE 1 PISTON ASSEMBLY page 14-8
14-8
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CYLINDER BLOCK
PISTON ASSEMBLY
Apply engine oil to the piston rings [1] whole surface.
Carefully install the top ring [2] and second ring [3] into
the piston ring grooves [4] with the maker mark [5] side
facing up.
Carefully install the oil ring [6] into the piston ring
groove.
Stagger the piston ring end gaps 120 apart from each
other.
Stagger the side rail end gaps as shown.
Do not confuse the top and second rings.
To install the oil ring, install the spacer [7] first, then
install the side rails [8].
After installation, the piston rings should be free to
rotate in the groove.
Apply engine oil to the piston [1] outer surface.
Apply engine oil to the connecting rod [2] upper and
small end inner surface and big end inner surface.
Apply engine oil to the piston pin [3] whole surface.
Set the connecting rod upper end with the long end
toward the index mark [4] on the piston head.
Install the piston and insert the piston pin through the
piston and connecting rod.
Install two new piston pin clips [5] into the grooves in
the piston pin hole.
Make sure the piston pin clips are seated securely.
Do not align the piston pin clip end gap with the
piston cut-out.
Be careful not to
damage the piston
and rings.
[5] (TOP/SECOND RING)
120
[1]
10 mm (0.4 in)
10 mm (0.4 in)
[6]
[2]
[3]
[8]
[7]
[4]
[8]
[4]
[1]
[2]
[5]
[3]
END GAP
CUT-OUT
[5]
14-9
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CYLINDER BLOCK
CYLINDER BLOCK INSPECTION
CAMSHAFT HOLDER I.D.
CRANKCASE COVER SIDE
Measure the camshaft holder I.D. of the crankcase
cover.
replace the crankcase cover (page 14-3).
Inspect the camshaft O.D. (page 14-14) with this
inspection.
CYLINDER BARREL SIDE
Measure the camshaft holder I.D. of the cylinder barrel.
replace the cylinder barrel (page 14-4).
Inspect the camshaft O.D. (page 14-14) with this
inspection.
CYLINDER SLEEVE I.D.
Measure and record the cylinder I.D. at three levels in
both the X axis (perpendicular to crankshaft) and the
Y axis (parallel to crankshaft). Take the maximum
reading to determine cylinder wear.
replace the cylinder barrel (page 14-4).
Inspect the piston skirt O.D. (page 14-10) with this
inspection.
STANDARD: 16.000 16.018 mm
(0.6299 0.6306 in)
STANDARD: 16.000 16.018 mm
(0.6299 0.6306 in)
EC3600K1:
STANDARD: 77.000 77.017 mm
(3.0315 3.0322 in)
EC5000K1/ECT7000K1/ECT7000P1:
STANDARD: 88.000 88.017 mm
(3.4646 3.4652 in)
TOP
MIDDLE
BOTTOM
X
Y
14-10
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CYLINDER BLOCK
PISTON SKIRT O.D.
Measure and record the piston O.D. at a point 10 mm
(0.4 in) from the bottom of the skirt and 90 degrees to
the piston pin bore.
replace the piston (page 14-7).
Inspect the cylinder sleeve I.D. (page 14-9) with this
inspection.
PISTON-TO-CYLINDER CLEARANCE
Subtract the piston skirt O.D. from the cylinder sleeve
I.D. to obtain the piston-to-cylinder clearance.
replace the piston (page 14-7) and recheck the
clearance.
If the clearance is still more than the service limit with
the new piston, replace the cylinder barrel (page 14-4).
PISTON PIN BORE I.D.
Measure and record the piston pin bore I.D. of the
piston.
replace the piston (page 14-7).
Inspect the piston pin O.D. (page 14-11) with this
inspection.
EC3600K1:
STANDARD: 76.975 76.985 mm
(3.0305 3.0309 in)
EC5000K1/ECT7000K1/ECT7000P1:
STANDARD: 87.975 87.985 mm
(3.4636 3.4640 in)
90
10 mm
(0.4 in)
(0.0006 0.0017 in)
EC3600K1:
STANDARD: 18.002 18.008 mm
(0.7087 0.7090 in)
EC5000K1/ECT7000K1/ECT7000P1:
STANDARD: 20.002 20.008 mm
(0.7875 0.7877 in)
14-11
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CYLINDER BLOCK
PISTON PIN O.D.
Measure and record the piston pin O.D. at three points
(both ends and middle). Take the minimum reading to
determine piston pin O.D.
replace the piston pin.
Inspect the piston pin bore I.D. (page 14-10).
Inspect the connecting rod small end I.D. (page 14-12)
with this inspection.
PISTON PIN-TO-PISTON PIN BORE
CLEARANCE
Subtract the piston pin O.D. from the piston pin bore
I.D. to obtain the piston pin-to-piston pin bore
clearance.
replace the piston pin (page 14-7) and recheck the
clearance.
the new piston pin, replace the piston (page 14-7).
PISTON RING WIDTH
Measure each piston ring width.
If any of the measurements is less than the service
limit, replace the piston rings (top, second, oil) as a set
(page 14-7).
EC3600K1:
STANDARD: 17.994 18.000 mm
(0.7084 0.7087 in)
EC5000K1/ECT7000K1/ECT7000P1:
STANDARD: 19.994 20.000 mm
(0.7872 0.7874 in)
(0.0001 0.0006 in)
STANDARD:
Top/Second: 1.160 1.175 mm
(0.0457 0.0463 in)
SERVICE LIMIT:
Top/Second: 1.150 mm (0.0453 in)
14-12
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CYLINDER BLOCK
PISTON RING SIDE CLEARANCE
Measure the clearance between each piston ring and
ring groove of the piston using a feeler gauge.
If any of the measurements is more than the service
limit, inspect the piston ring width.
If the piston ring width is normal, replace the piston
(page 14-7) and reinspect the clearance.
If necessary, replace the piston rings (top, second, oil)
as a set (page 14-7) and reinspect the clearance.
If any of the measurements is still more than the service
limit with the new piston rings, replace the piston (page
14-7).
PISTON RING END GAP
Before inspection, check whether the cylinder sleeve
I.D. (page 14-9) is within the specification.
Measure each piston ring [1] end gap using a feeler
gauge.
If any measurement is more than the service limit,
replace the piston rings (top, second, oil) as a set (page
14-7).
CONNECTING ROD SMALL END I.D.
Measure the connecting rod small end I.D.
replace the connecting rod (page 14-7).
STANDARD:
Top/Second: 0.030 0.060 mm
(0.0012 0.0024 in)
SERVICE LIMIT:
Top/second: 0.15 mm (0.006 in)
STANDARD:
Top: 0.200 0.350 mm
(0.0079 0.0138 in)
Second: 0.350 0.500 mm
(0.0138 0.0197 in)
Oil (side rail) 0.20 0.70 mm
(0.008 0.028 in)
SERVICE LIMIT:
Top/Second: 1.0 mm (0.04 in)
Oil (side rail) 1.0 mm (0.04 in)
[1]
EC3600K1:
STANDARD: 18.005 18.020 mm
(0.7089 0.7094 in)
EC5000K1/ECT7000K1/ECT7000P1:
STANDARD: 20.005 20.020 mm
(0.7876 0.7882 in)
14-13
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CYLINDER BLOCK
CONNECTING ROD BIG END I.D.
Set the connecting rod lower end to the connecting rod
upper end.
Apply engine oil to the connecting rod bolt threads and
seating surface.
Tighten the connecting rod bolts to the specified torque.
Measure the connecting rod big end I.D.
replace the connecting rod (page 14-7).
CONNECTING ROD BIG END SIDE
CLEARANCE
Measure the clearance between the connecting rod big
end and crankshaft using a feeler gauge.
replace the connecting rod (page 14-7) and recheck the
clearance.
the new connecting rod, replace the crankshaft (page
14-4).
CONNECTING ROD BIG END OIL
CLEARANCE
Clean all oil from the crankpin and connecting rod big
end surface.
Place a piece of plastigauge [1] on the crankpin, install
the connecting rod upper end and the connecting rod
lower end.
Apply engine oil to the connecting rod bolt threads and
seating surface.
Tighten the connecting rod bolts to the specified torque.
Do not rotate the crankshaft while the plastigauge is in
place.
EC3600K1:
STANDARD: 33.025 33.039 mm
(1.3002 1.3007 in)
EC5000K1/ECT7000K1/ECT7000P1:
STANDARD: 36.025 36.039 mm
(1.4183 1.4189 in)
STANDARD: 0.1 0.4 mm (0.004 0.016 in)
[1]
14-14
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CYLINDER BLOCK
Remove the connecting rod and measure the
plastigauge [1] with the plastigauge scale [2].
If the clearance is more than the service limit, inspect
the following:
Connecting rod big end I.D. (page 14-13)
Crankpin O.D. (page 14-14)
If the part that is not within the service limit is replaced,
reinspect the clearance.
CRANKPIN O.D.
Measure the crankpin O.D. of the crankshaft.
replace the crankshaft (page 14-4).
CRANKSHAFT RUNOUT
Remove the crankshaft bearing (page 14-19).
Set the crankshaft on V-blocks and measure the runout
using a dial indicator.
If the measured runout is more than the service limit,
replace the crankshaft (page 14-4).
CAMSHAFT O.D.
Measure the camshaft O.D.
replace the camshaft (page 14-4).
(0.0016 0.0025 in)
[1]
[2]
EC3600K1:
STANDARD: 32.975 32.985 mm
(1.2982 1.2986 in)
EC5000K1/ECT7000K1/ECT7000P1:
STANDARD: 35.975 35.985 mm
(1.4163 1.4167 in)
16 mm
(0.6 in)
16 mm
(0.6 in)
STANDARD: 15.966 15.984 mm
(0.6286 0.6293 in)
14-15
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CYLINDER BLOCK
CAMSHAFT CAM HEIGHT
Measure the cam height of the camshaft.
DECOMPRESSOR WEIGHT
Check for worn and weakened spring.
If the return spring [1] is worn or weakened, replace the
weight return spring.
Check that the decompressor weight moves smoothly.
If the decompressor weight does not move correctly,
RADIAL BALL BEARING
Clean the bearing with solvent and dry it thoroughly.
Turn the inner race (outer race: cylinder barrel side
crankshaft bearing only) of the radial ball bearing with
your finger and check for play.
If the radial ball bearing is noisy or has excessive play,
replace it (page 14-16).
EC3600K1:
(1.2537 1.2695 in)
EX: 31.566 31.966 mm
(1.2428 1.2585 in)
EX: 31.26 mm (1.231 in)
EC5000K1/ECT7000K1/ECT7000P1:
(1.2755 1.2913 in)
EX: 31.885 32.285 mm
(1.2553 1.2711 in)
EX: 31.59 mm (1.244 in)
[1]
14-16
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CYLINDER BLOCK
BEARING/OIL SEAL REPLACEMENT
CRANKCASE COVER
LOCATION
BALANCER WEIGHT BEARING (Except EC3600K1)
Pull out the radial ball bearing [1] using the special
tools.
BALANCER WEIGHT BEARING (6202)
(Except EC3600K1)
EC3600K1:
CRANKSHAFT BEARING (6206)
EC5000K1/ECT7000K1/ECT7000P1:
CRANKSHAFT BEARING (6207)
EC3600K1:
CRANKSHAFT OIL SEAL (30 x 46 x 8 mm)
EC5000K1/ECT7000K1/ECT7000P1:
TOOLS:
Bearing remover shaft,
15 mm [2] 07936-KC10500
Remover weight [3] 07741-0010201
TOOLS:
Attachment, 32 x 35 mm [5] 07746-0010100
Pilot, 15 mm [6] 07746-0040300
Driver [7] 07749-0010000
[3]
[2]
[1]
[7]
[5]
[6]
[4]
14-17
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CYLINDER BLOCK
CRANKSHAFT BEARING
Drive out the bearing [1].
CRANKSHAFT OIL SEAL
Remove the oil seal from the crankcase cover.
Apply grease to the lips of a new oil seal [1].
Drive the oil seal in the position as shown with its flat
surface facing up, using the special tools.
EC3600K1:
TOOLS:
Attachment, 62 x 68 mm [3] 07746-0010500
Pilot, 30 mm [4] 07746-0040700
Driver [5] 07749-0010000
EC5000K1/ECT7000K1/ECT7000P1:
TOOLS:
Attachment, 72 x 75 mm [3] 07746-0010600
Pilot, 35 mm [4] 07746-0040800
Driver [5] 07749-0010000
[1]
[5]
[3]
[4] [2]
EC3600K1:
TOOLS:
Attachment, 45 x 50 mm [2] 07946-6920100
Driver [3] 07749-0010000
EC5000K1/ECT7000K1/ECT7000P1:
TOOLS:
Attachment, 52 x 55 mm [2] 07746-0010400
Driver [3] 07749-0010000
EC5000K1/
ECT7000K1/
ECT7000P1:
2.0 mm (0.08 in)
EC3600K1:
1.0 mm (0.04 in)
[1]
[2]
[3]
14-18
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CYLINDER BLOCK
CYLINDER BARREL
LOCATION
BALANCER WEIGHT BEARING (Except EC3600K1)
Pull out the bearing [1] using the special tools.
EC3600K1:
EC5000K1/ECT7000K1/ECT7000P1:
GOVERNOR ARM SHAFT OIL SEAL (8 x 14 x 5 mm)
(Except EC3600K1)
BALANCER WEIGHT BEARING (6202)
(Except EC3600K1)
TOOLS:
Bearing remover shaft,
15 mm [2] 07936-KC10500
Remover weight [3] 07741-0010201
TOOLS:
Attachment, 32 x 35 mm [5] 07746-0010100
Pilot, 15 mm [6] 07746-0040300
Driver [7] 07749-0010000
[3]
[2]
[1]
[7]
[5]
[6] [4]
14-19
dummyhead dummyhead
CYLINDER BLOCK
GOVERNOR ARM SHAFT OIL SEAL (Except
EC3600K1)
Remove the oil seal from the cylinder barrel.
Drive the oil seal in the position as shown using the
special tools.
CRANKSHAFT OIL SEAL
Remove the oil seal from the cylinder barrel.
Drive the oil seal in the position as shown with its flat
surface side facing up, using the special tools.
CRANKSHAFT
CRANKSHAFT BEARING
Install the flywheel special nut (16 mm) [1] to protect the
crankshaft threads.
Pull off the bearing [2] using a commercially available
bearing puller [3].
Press in a new bearing [4] with its marked side facing
up until it is fully seated on the end using the special
tools and hydraulic press.
TOOLS:
Pilot, 14 mm [2] 07746-0041200
Driver [3] 07749-0010000
0 0.5 mm
(0 0.02 in)
[3] [2]
[1]
EC3600K1:
TOOLS:
Attachment, 45 x 50 mm [2] 07946-6920100
Driver [3] 07749-0010000
EC5000K1/ECT7000K1/ECT7000P1:
TOOLS:
Attachment, 52 x 55 mm [2] 07746-0010400
Driver [3] 07749-0010000
2.0 mm (0.08 in)
[3] [2]
[1]
EC3600K1:
TOOLS:
Driver, 40 mm I.D. [6] 07746-0030100
EC5000K1/ECT7000K1/ECT7000P1:
TOOLS:
Driver, 40 mm I.D. [6] 07746-0030100
[1] [2]
[6]
[5]
[4]
[3]
MEMO
dummyhead dummyhead
15-1
15
dummytext
15. WIRING DIAGRAMS
HOW TO READ A WIRING DIAGRAM &
RELATED INFORMATION15-2
WIRING DIAGRAMS 15-3
15-2
dummyhead dummyhead
WIRING DIAGRAMS
WIRING DIAGRAMS
HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION
The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained
in this section.
HOW TO READ WIRING DIAGRAM
1
2
C1
GND2
T1
T2
1
13
3
9 1 2 5 4 6 7 10
1

2

3

9

2

5

4

7

1
0

1

2

3

4

1

6

1

2

G

G
/
W

G
/
R

G
/
B
l

R
/
W

B
r

B
r

Y

W/ R
Bl / R
G
Bl / R
Bl
(Br)
(Br)
G
( Bl / R)
( Bl / Bu)
(Y)
W/ R
Bl / R
(Bu)
(Bl)
Bl
Y
Bu
R
W
G
R
W
G
R
W
G
( G/ W)
( G/ R)
( G/ Bl )
( R/ W)
(Y)
(Bu)
(R)
(R)
(W)
G

FRAME GND
ENGINE STOP SWITCH
DC RECEPTACLE
(+)
(-)
Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light blue
G Green Lg Light green
R Red P Pink
W White Gr Gray
SYMBOL OF TERMINAL
It shows the shape of each terminal
to identify whether it is a male or
female terminal.
: Connector that relays from a harness to a harness (Circled No. in black background)
: Connector that connects to electrical equipment (Circled No. in white background)
: Connector (Circled C followed with No. in white background)
: Terminal (Circled T followed with No. in white background)
: Ground (Circled GND followed with No. in white background)
TERMINAL No.
Indicates the ground.
(Circled GND followed with
No. in white background)
CONNECTOR/TERMINAL No.
Every connector and terminal has a number to help the users find the location and shape of
the connector and the terminal arrangement by referring to the Connector general layout
drawing and/or the Connector drawing. All the connector/terminal numbers shown in this
service manual are either of those shown in this section.
15-3
dummyhead dummyhead
WIRING DIAGRAMS
WIRING DIAGRAMS
EC3600K1
O
I
L

L
E
V
E
L

S
W
E
N
G
I
N
E

S
T
O
P

S
W
S
P
A
R
K

P
L
U
G
I
G
N
I
T
I
O
N

C
O
I
L
F
R
A
M
E
E
A
R
T
H
E
N
G
I
N
E
E
A
R
T
H
G
N
D
2
G
N
D
1
E
N
G
I
N
E

B
L
O
C
K
B
L
A
C
K
Y
E
L
L
O
W
B
L
U
E
G
R
E
E
N
R
E
D
V
I
O
L
E
T
V
W
H
I
T
E
B
E
I
G
E
B
e
G
R
A
Y
P
I
N
K
L
I
G
H
T

G
R
E
E
N
L
I
G
H
T

B
L
U
E
O
R
A
N
G
E
B
R
O
W
N
W R G B
u
Y B
l
G
r
P L
g
L
b
O B
r
C
O
L
O
R

C
O
M
B

:

G
R
O
U
N
D
/
M
A
R
K
I
N
G
C
1
C
2
C
3
2
1
4
3
O I L A L T
E X T ( - )
E X T ( + )
L E D
1
E
N
G
I
N
E

S
T
O
P

S
W
I
T
C
H
C
O
N
N
E
C
T
I
O
N

T
A
B
L
E
E
X
T
(

+

)
E
X
T
(

-

)
G
E
N
E
R
A
T
O
R

B
L
O
C
K
M
1
W
M
2
W
F
W
E
X
W
C
A
P
A
C
I
T
O
R
3
5

m
i
c
r
o
F
G
N
D
3
E
A
R
T
H
T
E
R
M
I
N
A
L
C
4
C
5
3
1 2 34
C
6
C
7
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
S
O
C
K
E
T
S
C
H
U
K
O

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
H
I
L
D
R
E
N

P
R
O
T
E
C
T
T
2
T
1
T
3
S
O
C
K
E
T
F
R
E
N
C
H

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
H
I
L
D
R
E
N

P
R
O
T
E
C
T
S
O
C
K
E
T
F
R
E
N
C
H

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
H
I
L
D
R
E
N

P
R
O
T
E
C
T
S
O
C
K
E
T
S
C
H
U
K
O

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
H
I
L
D
R
E
N

P
R
O
T
E
C
T
A
C

O
U
T
L
E
T
E
C
3
6
0
0
-
I
T
T

t
y
p
e
A
C

O
U
T
L
E
T
E
C
3
6
0
0
-
F
T

t
y
p
e
A
C

O
U
T
L
E
T
E
C
3
6
0
0
-
G
V
T

t
y
p
e
E
C
3
6
0
0
-
G
V
W
T

t
y
p
e
C
O
N
T
R
O
L

B
O
X

B
L
O
C
K
T
2
T
1
T
3
T
6
T
4
T
5
C
6
C
7
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
ac b ac b
ac b
C
6
C
7
S
O
C
K
E
T
S
C
H
U
K
O

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
H
I
L
D
R
E
N

P
R
O
T
E
C
T
T
6
T
4
T
5
T
1
T
2
T
3
S
O
C
K
E
T
E
E
C

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
O
N
O
F
F
Y
B l
R
R
B l
Y
G

(
G
)

G

(
G
)

G

(
G
)

T
6
T
4
T
5
Y / G
Y / G
R

R

G

G

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
R

G

R

G

Y / G
15-4
dummyhead dummyhead
WIRING DIAGRAMS
BT TYPE
E
X
W
O
N
O
F
F
O
I
L

L
E
V
E
L

S
W
E
N
G
I
N
E

S
T
O
P

S
W
S
P
A
R
K

P
L
U
G
I
G
N
I
T
I
O
N

C
O
I
L
F
R
A
M
E
E
A
R
T
H
E
N
G
I
N
E
E
A
R
T
H
G
N
D
2
G
N
D
1
E
N
G
I
N
E

B
L
O
C
K
B
L
A
C
K
Y
E
L
L
O
W
B
L
U
E
G
R
E
E
N
R
E
D
V
I
O
L
E
T
V
W
H
I
T
E
B
E
I
G
E
B
e
G
R
A
Y
P
I
N
K
L
I
G
H
T

G
R
E
E
N
L
I
G
H
T

B
L
U
E
O
R
A
N
G
E
B
R
O
W
N
W R G B
u
Y B
l
G
r
P L
g
L
b
O B
r
C
O
L
O
R

C
O
M
B

:

G
R
O
U
N
D
/
M
A
R
K
I
N
G
C
1
C
2
C
3
2
1
4
3
O I L A L T
E X T ( - )
E X T ( + )
L E D
1
E
N
G
I
N
E

S
T
O
P

S
W
I
T
C
H
C
O
N
N
E
C
T
I
O
N

T
A
B
L
E
E
X
T
(

+

)
E
X
T
(

-

)
G
E
N
E
R
A
T
O
R

B
L
O
C
K
M
1
W
M
2
W
F
W
C
A
P
A
C
I
T
O
R
2
2

m
i
c
r
o
F
G
N
D
4
E
A
R
T
H
T
E
R
M
I
N
A
L
C
1
5
C
1
6
4
1 2 34
C
8
C
9
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
A
C

O
U
T
L
E
T
E
C
3
6
0
0
-
B
T

t
y
p
e
/
1
1
5
V
A
C

O
U
T
L
E
T
E
C
3
6
0
0
-
B
T

t
y
p
e
/
2
3
0
V
C
O
N
T
R
O
L

B
O
X

B
L
O
C
K
1
1
5
V
-
0
-
2
3
0
V
V
O
L
T

C
H
A
N
G
E

S
W
(
1
1
5
V

P
O
S
I
T
I
O
N
)
1
2
3 4
5
6
C
5
1
C
5
0
C
4
9
C
4
8
C
4
7
C
4
6
T
7
T
9
T
8
S
O
C
K
E
T
E
E
C

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
1
0
T
1
5
T
1
4
T
1
3
T
1
2
T
1
1
T
1
0
C
1
1
2

x

C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
1
1
5
V

T
H
E
R
M
A
L
2

x

S
O
C
K
E
T
E
E
C

1
6
A
-
1
1
5
V
Y
E
L
L
O
W

C
O
L
O
R
C
1
2
C
1
3
Y
B l
R
R
B l
Y
G

W

(
R
)

(
G
)

R

W

B
l

B
l

G

R

W

Y

G

R

W

W

G

W
R

(
G
)

Y
/
G

W W
W W
B
l

B
l

Y / G
Y / G
(
B
l
)

Y
/
G

Y
/
G

B
l

15-5
dummyhead dummyhead
WIRING DIAGRAMS
EC5000K1
B
L
A
C
K
Y
E
L
L
O
W
B
L
U
E
G
R
E
E
N
R
E
D
V
I
O
L
E
T
V
W
H
I
T
E
B
E
I
G
E
B
e
G
R
A
Y
P
I
N
K
L
I
G
H
T

G
R
E
E
N
L
I
G
H
T

B
L
U
E
O
R
A
N
G
E
B
R
O
W
N
W R G B
u
Y B
l
G
r
P L
g
L
b
O B
r
C
O
L
O
R

C
O
M
B

:

G
R
O
U
N
D
/
M
A
R
K
I
N
G
O
I
L

L
E
V
E
L

S
W
E
N
G
I
N
E

S
T
O
P

S
W
S
P
A
R
K

P
L
U
G
I
G
N
I
T
I
O
N

C
O
I
L
F
R
A
M
E
E
A
R
T
H
E
N
G
I
N
E
E
A
R
T
H
G
N
D
2
G
N
D
1
G
N
D
5
E
N
G
I
N
E

B
L
O
C
K
C
1
C
2
C
3
2
1
4
3
O I L A L T
E X T ( - )
E X T ( + )
L E D
1
E
N
G
I
N
E

S
T
O
P

S
W
I
T
C
H
C
O
N
N
E
C
T
I
O
N

T
A
B
L
E
E
X
T
(

+

)
E
X
T
(

-

)
T
2
5
T
2
4
T
2
6
T
2
8
T
2
7
T
2
9
T
3
8
T
3
6
T
3
7
T
3
5
T
3
3
T
3
4
T
2
0
T
2
2
T
2
1
T
2
3
T
2
4
T
2
5 T
2
6
T
2
7
T
2
8
T
2
9
T
3
0
T
3
1
T
3
2
T
1
6
T
1
8
T
1
7
T
1
9
C
1
8
C
1
7
C
1
9
C
2
1
C
2
2
C
2
3
C
1
9
C
2
0
C
2
5
C
2
7
C
2
8
C
2
6
C
2
3
C
2
1
C
2
2
C
2
4
C
2
4
C
2
0
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
2
5
A
-
2
3
0
V
T
H
E
R
M
A
L
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
2
5
A
-
2
3
0
V
T
H
E
R
M
A
L
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
2
5
A
-
2
3
0
V

T
H
E
R
M
A
L
2

x

C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
2

x

C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
C
O
N
T
R
O
L

B
O
X

B
L
O
C
K
G
E
N
E
R
A
T
O
R

B
L
O
C
K
A
C

O
U
T
L
E
T

E
C
5
0
0
0
-
G
V
T

t
y
p
e
E
C
5
0
0
0
-
G
V
W
T

t
y
p
e
A
C

O
U
T
L
E
T

E
C
5
0
0
0
-
F
T

t
y
p
e
A
C

O
U
T
L
E
T

E
C
5
0
0
0
-
I
T
T

t
y
p
e
M
1
W
F
W
E
X
W
M
2
W
2

x

S
O
C
K
E
T
S
C
H
U
K
O

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
H
I
L
D
R
E
N

P
R
O
T
E
C
T
2

x

S
O
C
K
E
T
F
R
E
N
C
H

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
C
H
I
L
D
R
E
N

P
R
O
T
E
C
T
S
O
C
K
E
T
E
E
C

1
6
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
S
O
C
K
E
T
E
E
C

3
2
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
S
O
C
K
E
T
E
E
C

3
2
A
-
2
3
0
V
B
L
U
E

C
O
L
O
R
E
A
R
T
H
T
E
R
M
I
N
A
L
C
A
P
A
C
I
T
O
R
3
5

m
i
c
r
o
F
ac b
ac b
ac b
O
N
O
F
F
Y
B l
R
R
B l
Y
Y / G
Y / G
Y / G
Y / G
Y / G
G

R

Y / G
R

R

Y / G
W
G
(
G
)
G
G
G
YR
R
R
(
R
)
GYR
G
G
Y
/
G

(
R
)
Y
/
G

(
R
)
Y
/
G

Y
/
G

(
G
)
G
G
G
(
G
)
G
G
G
G
G
G
R
R
R
R
15-6
dummyhead dummyhead
WIRING DIAGRAMS
BT TYPE
B
L
A
C
K
Y
E
L
L
O
W
B
L
U
E
G
R
E
E
N
R
E
D
V
I
O
L
E
T
V
W
H
I
T
E
B
E
I
G
E
B
e
G
R
A
Y
P
I
N
K
L
I
G
H
T

G
R
E
E
N
L
I
G
H
T

B
L
U
E
O
R
A
N
G
E
B
R
O
W
N
W R G B
u
Y B
l
G
r
P L
g
L
b
O B
r
C
O
L
O
R

C
O
M
B

:

G
R
O
U
N
D
/
M
A
R
K
I
N
G
O
I
L

L
E
V
E
L

S
W
E
N
G
I
N
E

S
T
O
P

S
W
S
P
A
R
K

P
L
U
G
I
G
N
I
T
I
O
N

C
O
I
L
F
R
A
M
E
E
A
R
T
H
E
N
G
I
N
E
E
A
R
T
H
G
N
D
2
G
N
D
1
G
N
D
5
E
N
G
I
N
E

B
L
O
C
K
C
1
C
2
C
3
2
3
5
6
B A
1
2
4
D C
1
4
3
O I L A L T
E X T ( - )
E X T ( + )
L E D
1
E
N
G
I
N
E

S
T
O
P

S
W
I
T
C
H
C
O
N
N
E
C
T
I
O
N

T
A
B
L
E
E
X
T
(

+

)
E
X
T
(

-

)
T
3
9
T
4
1
T
4
0
T
4
2
T
1
6
T
1
8
T
1
7
T
1
9
C
1
8
C
1
7
G
E
N
E
R
A
T
O
R

B
L
O
C
K
M
1
W
F
W
E
X
W
M
2
W
C
A
P
A
C
I
T
O
R
3
5

m
i
c
r
o
F
C
4
4
C
4
5
C
4
2
C
4
3
T
4
8
T
4
3
T
5
5
T
5
6
T
5
7
T
5
8
T
6
1
T
5
9
T
6
0
T
4
4
T
5
0
T
5
1
T
4
9
T
5
3
T
5
4
T
5
2
T
4
5
C
3
8
C
3
9
C
3
6
C
3
7
T
4
6
T
4
7
C
4
0
C
4
1
V
O
L
T
A
G
E

S
W
I
T
C
H
1
1
5
V
-
0
-
2
3
0
V
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
2
5
A
-
2
3
0
V

T
H
E
R
M
A
L
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
2
3
0
V

T
H
E
R
M
A
L
C
I
R
C
U
I
T

P
R
O
T
E
C
T
O
R
1
7
A
-
1
1
5
V

T
H
E
R
M
A
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15-7
dummyhead dummyhead
WIRING DIAGRAMS
ECT7000K1
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3546 1 2
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15-8
dummyhead dummyhead
WIRING DIAGRAMS
ECT7000P1
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32164 5
O I L A L T
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16-1
16
dummytext
INDEX
A
AIR CLEANER CHECK/CLEANING/REPLACEMENT 3-5
AIR CLEANER REMOVAL/INSTALLATION5-4
B
BEARING/OIL SEAL REPLACEMENT14-16
GENERATOR/CHARGING SYSTEM7-9
IGNITION SYSTEM8-2
TROUBLESHOOTING 4-2
BRUSH HOLDER INSPECTION (ECT7000K1,
ECT7000P1) 7-36
C
CARBURETOR BODY CLEANING 5-8
CARBURETOR DISASSEMBLY/ASSEMBLY5-6
CARBURETOR INSPECTION5-8
CARBURETOR REMOVAL/INSTALLATION5-5
CHOKE SET REPLACEMENT 5-10
CIRCUIT PROTECTOR INSPECTION (EXCEPT
ECT7000P1) 10-11
COMBUSTION CHAMBER CLEANING 3-9
COMPOUNDING TRANSFORMER AIR GAP CHECK/
ADJUSTMENT (ECT7000K1) 7-38
COMPOUNDING TRANSFORMER DISASSEMBLY/
ASSEMBLY (ECT7000K1)7-25
CONTROL BOX DISASSEMBLY/ASSEMBLY (EC3600K1
BT TYPE) 10-4
(EC5000K1) 10-5
(ECT7000K1) 10-8
CONTROL BOX REMOVAL/INSTALLATION (EC3600K1
BT TYPE) 10-2
CONTROL UNIT DISASSEMBLY/ASSEMBLY
(ECT7000P1) 10-10
CONTROL UNIT REMOVAL/INSTALLATION
(ECT7000P1) 10-3
COOLING FAN/FLYWHEEL/REMOVAL/
INSTALLATION7-15
CRANKCASE COVER REMOVAL/INSTALLATION14-3
CRANKSHAFT/CAMSHAFT/BALANCER WEIGHT
(EXCEPT EC3600K1)/PISTON REMOVAL/
INSTALLATION14-4
CYLINDER BLOCK INSPECTION14-9
CYLINDER HEAD DISASSEMBLY/ASSEMBLY13-5
CYLINDER HEAD REMOVAL/INSTALLATION13-4
CYLINDER HEAD/VALVES INSPECTION13-6
D
DIMENSIONAL DRAWINGS1-7
DIODE INSPECTION (EXCEPT ECT7000P1) 7-37
E
END COVER DISASSEMBLY/ASSEMBLY (EC3600K1
EXCEPT BT TYPE)10-9
ENGINE OIL CHANGE3-4
ENGINE OIL LEVEL CHECK3-3
ENGINE REMOVAL/INSTALLATION12-2
ENGINE STOP SWITCH INSPECTION 10-11
F
FAN COVER REMOVAL/INSTALLATION7-14
FRAME/ENGINE CABLE/HARNESS ROUTING2-10
FUEL TANK AND FILTER CLEANING 3-10
FUEL TANK REMOVAL/INSTALLATION 5-3
FUEL TUBE INSPECTION 3-10
FUEL TUBE ROUTING 2-27
G
GENERATOR REMOVAL 7-18
GENERATOR SYSTEM DIAGRAM 7-3
GENERATOR SYSTEM TROUBLESHOOTING 7-9
GOVERNOR ADJUSTMENT 6-3
GOVERNOR ARM REMOVAL/INSTALLATION 6-2
GOVERNOR DISASSEMBLY/ASSEMBLY 14-6
H
HOW TO READ A WIRING DIAGRAM & RELATED
INFORMATION 15-2
HOW TO READ CONNECTOR DRAWINGS 2-9
I
IGNITION COIL AIR GAP CHECK/ADJUSTMENT 8-4
IGNITION COIL INSPECTION 8-5
IGNITION COIL REMOVAL/INSTALLATION 8-3
IGNITION SYSTEM DIAGRAM 8-2
IGNITION SYSTEM TROUBLESHOOTING 8-2
L
LUBRICATION & SEAL POINT 2-5
M
MAINTENANCE SCHEDULE 3-2
MAINTENANCE STANDARDS 2-2
MUFFLER REMOVAL/INSTALLATION 11-2
O
OIL LEVEL SWITCH INSPECTION 8-6
P
PILOT SCREW REPLACEMENT 5-9
PISTON DISASSEMBLY/ASSEMBLY 14-7
R
RECOIL STARTER ASSEMBLY 9-4
RECOIL STARTER DISASSEMBLY 9-3
RECOIL STARTER INSPECTION 9-6
RECOIL STARTER REMOVAL/INSTALLATION 9-2
ROTOR BEARING INSPECTION 7-39
S
SEDIMENT CUP CLEANING 3-6
SERIAL NUMBER LOCATION 1-2
SPARK ARRESTER CLEANING 3-8
SPARK PLUG CAP INSPECTION 8-5
REPLACEMENT 3-7
SPARK TEST 8-4
SPECIFICATIONS 1-3
T
TOOL 5-2
TOOLS
CYLINDER BLOCK 14-2
CYLINDER HEAD 13-2
GENERATOR/CHARGING SYSTEM 7-2
SERVICE INFORMATION 2-6
TORQUE VALUES 2-4
TROUBLESHOOTING 4-2
V
VALVE CLEARANCE CHECK/ADJUSTMENT 3-8
VALVE GUIDE REAMING 13-10
VALVE GUIDE REPLACEMENT 13-9
VALVE SEAT RECONDITIONING 13-11
W
WINDING INSPECTION 7-26
WIRING DIAGRAMS 15-3
INDEX

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0-1

Cylinder Sleeve I.D. 77.000 77.017 (3.0315 3.0322) 77.17 (3.038)

Cylinder Sleeve I.D. 88.000 88.017 (3.4646 3.4652) 88.17 (3.471)

If the recoil starter operates correctly when

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

NOTE 6 Note the installation direction.

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

NOTE 12 When reassembly, apply engine oil to the journal.

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