Yamaha EF1000 Service Manual

							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/Gasket@ 
Damage-7Replace. 
•Strainer@ 
Contamipation-7Ciean. 
NOTE: ________________________ _ 
Clean the body with solvent and wipe it off.