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 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.  
						

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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 
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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.