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Yamaha EF1000 Service Manual

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    							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 may render it unfit for use and/or unsafe. 
    Yamaha  Motor 
    Company Ltd. is continually striv­
    ing 
    to further  improve all models manufactured 
    by Yamaha. Modifications and significant 
    changes in specifications  or procedures will be for­
    warded 
    to all Authorized  Yamaha dealers and will, 
    where applicable, appear in future  editions of this 
    manual. 
    NOTE: 
    --------------------------
    This Service Manual contains information 
    regarding periodic maintenance to the emis­
    sion 
    control system. Please read this materi­
    al  carefully. 
    EF1000 
    SERVICE 
    MANUAL 
    ©1995  by Yamaha Motor Co., Ltd. 
    1st  Edition,  January  1995 
    All rights reserved.  Any reprinting  or 
    unauthorized  use 
    without the written 
    permission  of 
    Yamaha Motor Co., ltd. 
    is expressly prohibited. 
    Printed 
    in Japan 
    HOW TO USE THIS MANUAL 
    PARTICULARLY IMPORTANT 
    INFORMATION 
    This material is distinguished  by the following no­
    tation. 
    & 
    The Safety Alert Symbol means ATTENTION! 
    BECOME 
    ALERT! YOUR  SAFETY IS INVOLVED! 
    A WARNING 
    Failure to follow WARNING instructions could 
    result 
    in  severe  injury or death to the  machine 
    operator,  a bystander,  or a person  inspecting  or 
    repairing  the machine. 
    Illlli•lz•·•••·••·• 
    A CAUTION indicates special precautions that 
    must be taken to avoid  damage to the machine. 
    NOTE: 
    A NOTE provides  key information 
    
    to  make  proce­
    dures  easier  or 
    clearer. 
    MANUAL FORMAT 
    The procedures in this manual are organized 
    in a sequential, step-by-step format. The in­
    formation has  been compiled to provide the 
    mechanic with an easy to read, handy refer­
    ence 
    that contains comprehensive explana­
    tions of all  disassembly, repair, assembly, 
    and inspection operations. 
    In this  revised  format,  the condition of a faulty 
    component will precede an arrow symbol and  the 
    course 
    of action  required will follow the symbol, 
    e.g., 
    • Bearings 
    Pitting/ Damage~ Replace. 
    EXPLODED DIAGRAM 
    Each chapter  provides exploded diagrams  before 
    each 
    disassembly section for ease in  identifying 
    correct 
    disassembly and assembly procedures.  
    						
    							CD 
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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 
    GEN 
    INFO 
    •II II nil 
    -
    ENG 
    ELEC  
    						
    							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 .....................................................  2-4 
    ENGINE OIL......................................... 2-4 
    FUEL  COCK..........................................  2-5 
    START WIRE ADJUSTMENT..............  2-6 
    FUEL  LINE............................................  2-6 
    AIR FILTER........................................... 2-7 
    MUFFLER ............................................. 2-7 
    VALVE CLEARANCE ADJUSTMENT .. 2-8 
    COMPRESSION  PRESSURE 
    MEASUREMENT.................................  2-9 
    ENGINE SPEED ADJUSTMENT ......... 2-10 
    GOVERNOR 
    ADJUSTMENT ............... 2-10 
    SPARK  PLUG 
    ....................................... 2-11 
    CYLINDER HEAD .................................  2-12 
    BREATHER 
    HOSE  INSPECTION ......... 2-12 
    CHAPTER3 
    ENGINE 
    AIR CARBURETOR,  MUFFLER ................ 3-1 
    JOB INSTRUCTION CHART  ................ 3-2 
    ENGINE .....................................................  3-3 
    JOB INSTRUCTION CHART  ................  3-4 
    CYLINDER HEAD COVER, CYLINDER 
    HEAD,  VALVE  ...........................................  3-5 
    JOB INSTRUCTION CHART  ................  3-6 
    CYLINDER HAD INSPECTION ............ 3-7 
    VALVE REMOVAL ................................ 3-7  
    						
    							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 
    PISTON,PISTON  PIN AND 
    PISTON RING INSPECTION ...............  3-15 
    CRANKSHAFT  INSPECTION .............. 3-16 
    FLYWEIGHT  SHAFT (GOVERNOR) 
    GEAR INSPECTION .............................  3-17 
    CRANKCASE COVER INSPECTION ... 3-18 
    PISTON  RING AND PISTON 
    INSTALLATION 
    ....................................  3-18 
    CONNECTING ROD INSTALLATION .. 3-19 
    CAMSHAFT INSTALLATION ...............  3-19 
    CRANKCASE  COVER 
    INSTALLATION 
    ....................................  3-19 
    RECOIL STARTER ................................... 3-20 
    JOB INSTRUCTION CHART ................  3-20 
    RECOIL STARTER  REMOVAL ............. 3-21 
    RECOIL STARTER  INSPECTION ......... 3-21 
    RECOIL  STARTER  INSTALLATION ..... 3-22 
    FLYWHEEL  ...............................................  3-23 
    JOB INSTRUCTION CHART ................  3-23 
    FLYWHEEL 
    REMOVAL. ........................  3-24 
    GENERATOR ............................ .......... 3-25 
    JOB INSTRUCTION CHART .................  3-25 
    ROTOR REMOVAL. ..............................  3-26 
    STATOR INSTALLATION .....................  3-26 
    ROTOR INSTALLATION ......................  3-26 
    REAR  FRAME 
    INSTALLATION ............  3-26 
    GOVERNOR ............................................. 3-27 
    JOB INSTRUCTION  CHART ................ 3-28 
    CARBURETOR  ........................................ . 3-29 
    JOB INSTRUCTION CHART ................  3-30 
    FLOAT HEIGHT  INSPECTION ............. 3-31 
    FUEL PASSAGE  INSPECTION ............ 3-31 
    VALVE SEAT INSPECTION ..................  3-31  
    						
    							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  TORQUE ............................  5-5 
    GENERAL 
    TORQUE  SPECIFICATIONS ... 5-6 
    DEFINITION  OF UNITS ............................  5-6 
    HOSE ROUTING .......................................  5-7  
    						
    							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 when servicing 
    engine.  
    						
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