Yamaha EF1000 Service Manual

EF1000 
Service Manual 
7FL-28197-11  

FOREWORD 
This manual was written by the  Yamaha Motor 
Company  primarily for use by Yamaha dealers and 
their 
qualified mechanics. It is not possible to put 
an entire  mechanics  education into one manu­
al, so it is assumed that persons  using this book 
to perform  maintenance  and repairs  on  Yamaha 
generator  have a basic  understanding 
of the 
mechanical precepts 

and  procedures  inherent 
to 
generator repair technology. Without such 
knowledge, attempted repairs or service to this 
model...

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ILLUSTRATED SYMBOLS 
(Refer to the illustration) 
Illustrated symbols CD to @ are designed as 
thumb tabs to indicate the chapters number 
and  content. 

INDEX 
GENERAL INFORMATION 
PERIODIC INSPECTIONS 
AND ADJUSTMENTS 
ENGINE 
ELECTRICAL 
SPECIFICATIONS 
111 
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CONTENTS 
CHAPTER 1 
GENERAL 
INFORMATION 
MACHINE  IDENTIFICATION ..................... 1-1 
IMPORTANT  INFORMATION ................... 1-2 
SPECIAL TOOLS AND TESTERS ............. 1-5 
CHAPTER  2 
PERIODIC INSPECTIONS 
AND ADJUSTMENTS 
INTRODUCTION ....................................... 2-1 
MAINTENANCE  INTERVALS CHART ...... 2-1 
PERIODIC MAINTENANCE/ 
LUBRICATION  INTERVALS ...................... 2-1 
BODY COVER/FUEL TANK ...................... 2-3 
JOB INSTRUCTION CHART................ 2-3 
ENGINE...

VALVE INSPECTION ............................  3-7 
VALVE SEAT INSPECTION ..................  3-8 
PUSH ROD INSPECTION 

.................... 3-10 
CYLINDER HEAD INSTALLATION ...... 3-10 
PISTON,CAMSHAFT,CRANKCASE, 
CRANKSHAFT 
......................................... 3-11 
JOB INSTRUCTION CHART  ................  3-12 
CRANKSHAFT  REMOVAL ................... 3-13 
CAMSHAFT AND VALVE LIFTER 
INSPECTION 
........................................  3-13 
CRANKCASE INSPECTION ................. 3-14...

CHAPTER 4 
ELECTRICAL 
ELECTRICAL COMPONENTS ................. .4-1 
CIRCUIT DIAGRAM ..................................  4-2 
IGNITION SYSTEM .................................. 4-3 
TROUBLESHOOTING CHART ............ 4-3 
GENERATOR SVSTEM .............................  4-7 
TROUBLESHOOTING CHART ............ 4-7 
INSPECTION ........................................  4-9 
CHAPTER 5 
SPECIFICATIONS 
GENERAL SPECIFICATIONS .................... 5-1 
MAINTENANCE SPECIFICATIONS .......... 5-2 
TIGHTENING...

MACHINE IDENTIFICATION ~~~~. 
790-027 
1-1 
GENERAL INFORMATION 
MACHINE IDENTIFICATION 
ENGINE SERIAL NUMBER 
The engine  serial number CD is stamped  into the 
rear  cover. 
NOTE: ________________________ ___ 
The first three digits of these numbers are 
for model identification; the remaining digits 
are the unit production number. 
STARTING  SERIAL NUMBER 
I EF1000 7FL I 0400101-
NOTE: --------------------------
Designs and specifications  are subject to change 
without notice.  

IMPORTANT INFORMATION 
[ __ ] 
1-2 
IMPORTANT  INFORMATION 
PREPARATION FOR REMOVAL AND 
DISASSEMBLY 
NOTES  ON SERVICE 
1. Fire  prevention 
When servicing  the engine, always keep  away 
from fire. 
2.  Right 
tools 
Be sure to use  the right special tool for the 
job to guard  against  damage. 
3. 
Oil, grease  and sealers 
Be sure to use  genuine  Yamaha oils, greases 
and 
sealers, or the equivalents. 
4.  Expendable  parts 
Always replace gaskets, 0-rings, cotter pins, 
and 
circlips with new parts...