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Yamaha EF1000 Service Manual

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    							Solvent Dissolvant 
    Losungsmittel 
    IMPORTANT INFORMATION 
    GEN ~ 
    INFO~ 
    1-3 
    5. Tightening torque 
    Be sure to follow torque specifications.  When 
    tightening  bolts, nuts or screws,  start 
    with the 
    largest-diameter  one and 
    work from an inner 
    position 
    to an outer  position  in a crisscross 
    pattern. 
    6. Notes  on disassembly  and  assembly 
    a. Parts should  be cleaned  in solvent  and blown 
    dry with compressed  air after  disassembly. 
    b. 
    Contact surfaces of moving  parts should  be 
    oiled  when  reassembled. 
    c.  Make  sure 
    that parts move  smoothly  after 
    each  section 
    of the machine is assembled.  
    						
    							IMPORTANT INFORMATION 
    300~002 
    300~003 
    1-4 
    ALL REPLACEMENT PARTS 
    1. We recommend to use Yamaha  genuine parts 
    for all replacements.  Use oil and/or grease 
    recommended 
    by Yamaha for assembly and 
    adjustment. 
    GASKETS, OIL SEALS, AND 0-RINGS 
    1. All gaskets, seals, and 0-rings should be 
    replaced when an  engine  is overhauled. All 
    gasket  surfaces, oil seal lips, and 0-rings  must 
    be 
    cleaned. 
    2. Properly  oil all mating  parts and bearings  dur­
    ing  reassembly. 
    Apply grease to the oil seal 
    lips. 
    BEARINGS AND OIL SEALS 
    1. Install the  bearing(s) CD and oil seal(s) (l) 
    with their  manufactures  marks or numbers 
    facing  outward. 
    (In other words,  the stamped 
    letters must be on the  side  exposed to view.) 
    When installing  oil seal(s),  apply a light coat­
    ing 
    of light-weight lithium base  grease to the 
    seal lip(s).  Oil the bearings liberally when in­
    stalling. 
    1111111~···· --------
    Do not use compressed air to spin the bear­
    ings dry. This causes damage to the bearing 
    surfaces.  
    						
    							SPECIAL TOOLS AND TESTERS GEN 
    INFO 
    1-5 
    SPECIAL TOOLS AND TESTERS 
    The proper special  tools are necessary for com­
    plete and  accurate  tune-up and assembly. Using 
    the  correct 
    special  tool will help prevent  damage 
    caused  by the  use 
    of improper tools or improvised 
    techniques. 
    1. Rotor  shock puller 
    P/N. YU-1047  (90890-01259) 
    Rotor puller attachment (M10 x 1.25) 
    P/N. 
    YU-1350  (90890-01349) 
    This tool is used to remove the rotor. 
    2. Piston  ring compressor 
    P/N. YU-33294 (90890-05158) 
    This tool is used to compress  the piston  rings 
    when 
    installing the  piston. 
    3. 
    Valve spring compressor 
    P/N.  YM-01253 (90890-01253) 
    This tool is used to remove the valve spring. 
    4. Service gauge (Thickness  gauge) 
    P/N. 
    YU-26900-9  (90890-03079) 
    This gauge is used to adjust valve  clearance, 
    piston clearance and piston  ring end gap.  
    						
    							SPECIAL TOOLS AND TESTERS 
    1-6 
    5. Cylinder gauge 
    P/N. YU-03017  (90890-03017) 
    This instrument is used  for checking cylinder bore 
    size  and  condition. 
    6. Inductive tachometer 
    P/N.  YU-8036-A 
    This  instrument 
    is used for reading  engine rpm. 
    7. Compression gauge set 
    P/N.  YU-33223 
    (90890-03081) 
    Adapter 
    P/N. YU-33223-3 (90890-04082) 
    This  gauge is for checking  engine compression. 
    8. Dial gauge 
    P/N. YU-03097  (90890-03097) 
    This instrument is used for checking  crankshaft 
    side  clearance. 
    9. Piston pin puller 
    P/N. YU-01304  (90890-01304) 
    This tool is used to remove the piston  pin.  
    						
    							SPECIAL TOOLS AND TESTERS 
    GEN .... 
    INFO l!IJ 
    1-7 
    10. Pocket tester 
    P/N. YU-03112 (90890-03112) 
    This instrument is necessary  for checking  the elec­
    trical 
    system. 
    11. Dynamic spark tester [6] 
    P/N. YM-34487 
    Ignition checker rn:J 
    P/N. 90890-06754 
    This instrument is  necessary for checking the 
    ignition system components.  
    						
    							INTRODUCTION/PERIODIC MAINTENANCE/ 
    LUBRICATION  INTERVALS INSP 
    ADJ 
    PERIODIC INSPECTIONS AND ADJUSTMENTS 
    INTRODUCTION 
    This chapter includes all information necessary to perform recommended inspections and 
    adjustments. These preventive maintenance procedures, if followed, will ensure more reliable 
    machine operation and a longer service life. The  need for costly overhaul work will be greatly 
    reduced.  This information applies to machines already in service  as well as new machines that 
    are being prepared for sale. All service technicians should be familiar with this entire chapter. 
    MAINTENANCE  INTERVALS CHART 
    Proper periodic maintenance is important. Especially important are the maintenance services 
    related to emissions control. These controls not only function to ensure cleaner air but are also 
    vital to proper engine operation and maximum performance. In the following maintenance 
    tables, the services related to emissions control are indicatedas ** in the chart. 
    PERIODIC  MAINTENANCE/LUBRICATION  INTERVALS 
    Pre-Opera-Initial Every 
    No. Item Remarks tion check 
    1 month 3 months 6 months 12 months (daily) or 20 Hr or 50 Hr or 100 Hr or 300 Hr 
    ** Check condition adjust 
    1. gap and clean.  Replace • Spark Plug if necessary. 
    ** Check and adjust when 
    • 2.* Valve Clearance engine is cold. 
    ** Check breather hose 
    3.* Crankcase breather for cracks or damage. • system Replace if necessary. 
    ** Check and adjust 4.* • Idle speed engine idle speed. 
    Check for leakage. 
    *Retighten or replace • 
    ** gasket if necessary. 
    5. Exhaust System Check muffler screen 
    and  spark  arrester. 
    • Clean/replace if neces-
    sary. 
    Check oil level • 6. Engine oil Replace • • 
    ** Clean. 7. • Air Filter  Replace if necessary. 
    Clean 
    fuel tank filter. 
    • 8 .. Fuel Filter  Replace if necessary. 
    *Check fuel cock filter. 
    • Replace if necessary. 
    Check 
    fuel hose for 
    9. Fuel Line  crack or damage. • *Replace if necessary. 
    ** Check control lever 10. • Control lever (choke) operation. 
    11.* Control 
    System  Check for fan damage. • 
    12. Starting System Check 
    recoil starter 
    • operation. 
    2-1  
    						
    							No. 
    13.*  14. 
    15.* Item 
    ** 
    INTRODUCTION/PERIODIC MAINTENANCE/ 
    LUBRICATION  INTERVALS 
    Pre-Opera-Initial 
    Remarks tion check 
    1 month 3 months (daily) or 20 Hr or 50 Hr 
    More frequently if 
    Decarbonization necessary. 
    Check the voltage 
    Generation meter and pilot light • comes on. 
    Fittings/ Check all fittings and 
    fasteners. 
    Fasteners 
    Correct if necessary. 
    INSP 
    ADJ 
    Every 
    6 months 
    or 100 Hr 
    • 
    * :It is recommended that these items be  serviced by a Yamaha dealer or other qualified mechanic. 
    **:Related to emission control system. 
    2-2 
    12 months 
    or 300 Hr 
    •  
    						
    							BODY COVER/FUEL TANK l'~g~ I tit I 
    BODY COVER/FUEL TANK 
    9 
    .. .,. ··. .  .  .  . . ., ·. .  . .  . . . ::. : .. · . . -.  . . . . . . . 
    4 
    3 
    2 
    JOB INSTRUCTION CHART 
    Order Job name/Parts name Oty Remarks 
    Removal of Body cover and Remove the parts in order. 
    Fuel tank 
    1 Rear cover 1 
    2 Cover side 1 1 
    3 Front cover 1 
    4 Coupler/Engine stop lead 1 
    5 
    Coupler 1 
    6 Starter (Choke) wire 1 
    7 Fuel  hose/Fuel tank breather hose 1 NOTE: Turn the fuel cock lever to OFF. 
    F•1'N!1;l~!!~tc1Aiways clean up spilled fuel 
    immediatey. 
    8 Fuel tank 1 
    9 
    Cover side  2 1 
    Reverse the removal procedure 
    for installation. 
    2-3  
    						
    							_____________ E_N_G_IN_E_o_I_LI~IQI 
    ENGINE 
    (10W-30) 
    700-001 b 
    700-008 
    2-4 
    ENGINE OIL 
    Recommended oil: 
    [A] YAMALUBE 4-cycle oil or 
    SAE 1 OW-30 type SE motor oil 
    rn:J SAE #30 
    [QJ SAE #20 
    [Q] SAE #10 
    Engine oil quantity: 
    0.43  L (0.38 Imp qt, 
    0.45 us qt) 
    NOTE: --------------------------
    Recommended  engine  oil classifiaction: 
    API Service SE or SF if not available, 
    SD. 
    Oil Level Measurement 
    1. Check: 
    •Oil level 
    Oil level measurement steps: 
    •Place the engine  on level ground. 
    •Warm up the  engine  for a few minutes. 
    •Stop the  engine. 
    • Make sure the engine oil is between  upper and 
    lower  levels. Add oil as necessary. 
    CD Upper level 
    (2) Lower level 
    Oil Replacement 
    1. Warm  up engine  for several minutes. 
    2. Place a receptacle under the engine. 
    3. Remove: 
    •Oil filler cover  
    						
    							2-5 
    FUEL COCK 
    4. Remove: 
    •Oil filler cap CD 
    Drain the engine oil. 
    5. Fill: 
    •Crankcase Use 
    oil filler cover CD 
    Recommended engine oil: 
    0.43 L (0.38 Imp qt, 0.45 US qt) 
    CAUTION: 
    Do not allow foreign material to enter the 
    crankcase. 
    6. Tighten: 
    •Oil filler cap 
    7. Install: 
    •Oil filler cover 
    FUEL  COCK 
    Removal  and Inspection 
    1. Remove: 
    •Body panel 
    2. Drain the fuel tank and remove the fuel 
    hose from the fuel cock. 
    3. Inspect: 
    •Fuel cock body CD 
    Contamination-7Ciean. 
    •0-ring/[email protected] 
    Damage-7Replace. 
    •[email protected] 
    Contamipation-7Ciean. 
    NOTE: ________________________ _ 
    Clean the body with solvent and wipe it off.  
    						
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