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Yamaha EF1000 Service Manual

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    							STARTER WIRE ADJUSTMENT ~~~~j I C!it I 
    STARTER WIRE ADJUSTMENT 
    2-6 
    1. Remove: 
    •Rear cover 
    •Side cover 1 
    Adjustment  steps: 
    a. Set the control lever to ON. 
    b. Loosen the lock nut CD and [email protected] 
    c. Turn the nut @ clockwise ® until the 
    open side of the lever ® becomes free 
    from the [email protected] 
    d. Loosen the nut @ 1/2 turn counterclock­
    wise and secure the locknut G). 
    e. Set the control lever to the 1-..1 position. 
    f. Check whether the closed side of the 
    [email protected] contacts the [email protected] 
    Contacts the stopper--7Correct. 
    There  is a gap between the lever @ and 
    [email protected] --7* 
    *Loosen the [email protected] another 1/2 turn 
    counterclockwise and secure the lock 
    nut G). 
    g. Return to step T. 
    2. Install: 
    •Side cover 1 
    •Rear cover 
    FUEL LINE 
    1. Inspect: 
    •  Fuel 
    hose 
    Clacks/Damage--7Replace 
    Poor connection--7Correct  
    						
    							.// 
    + I I 1 
    710-035 741-035 
    r~g~l ~ 1 AIR FILTER/MUFFLER  _  _ ~ _ 
    2-7 
    AIR FILTER 
    1. Remove: 
    •Rear cover 
    •Air filter cover CD 
    •Air filter element~ 
    2. Inspect: 
    •Element 
    Clogging~Wash the element in solvent and 
    dry. 
    Oil the element and  squeeze out excess oil. 
    Damage~ Replace. 
    Recommended Oil: 
    3. Install: 
    Foam-air-filter oil 
    or 
    SAE # 20 motor oil 
    • Air filter  element 
    • 
    Air filter cover 
    NOTE: --------------------------
    Do not wring out the element. This could cause 
    it to tear. 
    The engine should never run without the ele­
    ment; excessive piston and/or cylinder wear 
    may result. 
    4. Install: 
    •Rear cover 
    MUFFLER 
    1. Remove: 
    •Rear cover 
    •Muffler  
    						
    							I
    IANDSJP I ~~ I VALVE CLEARANCE ADJUSTMENT ~ 
    -------------------------------------------------
    2-8 
    2. Decarbonize: 
    1) Tap on the muffler in the area shown in 
    the illustration. 
    CAUTION: 
    Dont use a wire to clean or the noise damp­
    ing material may come out, reducing the 
    damping effect. 
    2) Shake out the loose carbon from car­
    bon 
    outlet CD of muffler. 
    VALVE CLEARANCE ADJUSTMENT 
    1. Remove: 
    •Body panel 
    •Air shroud 
    •Gasket 
    •Cylinder head cover 
    •Spark plug 
    2.  Measure: 
    •Valve clearance 
    Out of specification---> Adjust. 
    Intake Valve 
    (Cold) 
    0.1 mm 
    (0.004 in) 
    Exhaust Valve 
    (Cold) 
    0.1 mm 
    (0.004 in) 
    NOTE: -------------------------
    •Be sure  piston is at Top  Dead  Center  (TDC) on 
    compression  stroke when measuring  clearance. 
    •Valve clearance must be measured  when the en­
    gine 
    is cool to the  touch.  
    						
    							I
    IANDSJP 1 ~o• 1 COMPRESSION PRESSURE MEASUREMENT _ ~ 
    -------------------------------------------------
    2-9 
    Valve clearance adjustment 
    1. Turn the crankshaft until the piston reach­
    es 
    top dead center (T.D.C.). 
    2. Loosen the locknut CD and insert the 0.1 
    mm (0.004 in) Thickness Gauge YU-
    26900-9  (90890-03079) between rocker 
    arm and valve stem. 
    3. Turn the adjuster @ in or out to obtain 
    the proper Thickness Gauge resistance 
    by pushing and pulling it. 
    Adjuster Resistance Valve Clearance 
    Turn in Increase Decrease 
    Turn out Decrease Increase 
    4. Tighten the locknut G). 
    Adjuster Locknut: 
    10 Nm (1.0 m•kg, 7.2 ft•lb) 
    COMPRESSION PRESSURE 
    MEASUREMENT 
    Insufficient compression  pressure will result in 
    performance 
    loss and  may  indicate leaking  valves 
    or worn or damaged  piston rings. 
    1. Measure: 
    •Valve clearance 
    2. Warm up engine for several minutes,  then 
    stop 
    the engine. 
    3. Remove: 
    •Spark plugs 
    4. Connect: 
    •Compression Gauge YU-33223 (90890-
    03081 
    l CD 
    •Adapter YU-33223-3 (90890-04082)@ 
    5. Measure: 
    •Compression 
    Standard compression pressure: 
    100 kPa  {1.0 kg/cm2
    , 14.2  psi) 
    A WARNING 
    When cranking engine, ground spark plug 
    wires to prevent sparking.  
    						
    							CYLINDER HEAD/ 
    BREATHER HOSE INSPECTION 
    2-10 
    Compression test steps (below minimum 
    levels): 
    •Squirt a few drops of oil into cylinder. 
    •Measure compression  again 
    Reading 
    Diagnosis 
    Higher than without •Worn cylinder, 
    oil piston and piston 
    rings 
    Same as without oil •Defective piston, 
    ring(s),  valve(s) and 
    cylinder head gasket 
    •Improper valve 
    timing and valve 
    clearance 
    Compression test steps (above maximum 
    levels): 
    •  Check  cylinder head, valve surfaces,  or piston 
    crown for carbon  deposits. 
    CYLINDER HEAD 
    1. Remove: 
    •Carbon deposits 
    Refer to the CYLINDER HEAD INSPEC­
    TION section in CHAPTER 3. 
    BREATHER HOSE INSPECTION 
    1. Inspect: 
    •Crankcase breather hose CD 
    Cracks/Damage-?Replace. 
    Loose connection---+Correct.  
    						
    							ENGINE SPEED ADJUSTMENT I 
    GOVERNOR ADJUSTMENT 
    --I~=--:! ==:=J ----, 
    __j__j 
    ~---.\..__,_,_ _ _j,o __j~ o 
    __j__jl 
    2-11 
    ENGINE SPEED ADJUSTMENT 
    1. Adjust: 
    •Engine speed (with no load) 
    Engine speed adjustment  steps: 
    1. Install the Tachometer (YU-8036-A). 
    2. Start the engine and warm up for a few 
    minutes. 
    3. Adjust the engine speed by turning the 
    adjust screw CD in or out. 
    {:} Engine speed (with no load): 
    3,700-3,800 rpm 
    GOVERNOR  ADJUSTMENT 
    1. Remove: 
    •Body panel 
    •Fuel tank 
    2. Adjust: 
    •Governor 
    Governor adjustment  steps: 
    1. Loosen the nut G). 
    2. Turn the governor [email protected] counterclock­
    wise until it stops. 
    3. Turn the governor shaft counterclock­
    wise until it stops. 
    4. Tighten the nut G).  
    						
    							____________ sP_A_R_K_P_Lu_G_I~IQI 
     , ,,~.._....._ __ 
    2-12 
    SPARK PLUG 
    1. Remove: 
    •Spark plug 
    2. Inspect: 
    •  Electrode 
    CD 
    Wear I Damage~ Replace. 
    •Insulator  color 
    ~ 
    3. Measure: 
    •Plug [email protected] 
    Out of specification~ Regap. 
    Use  a Wire  Gauge  or 
    Feeler Gauge. 
    Spark Plug Gap: 
    0.6-0.7 mm (0.024-0.028 in) 
    Clean the plug with a spark plug  cleaner if 
    necessary. 
    Standard  Spark Plug: 
    BPR6HS 
    (NGK) 
    Before installing a  spark plug,  clean the gasket 
    surface  and 
    plug surface. 
    4. Tighten: 
    •Spark plug 
    Spark Plug: 
    20 Nm (2.0 m•kg, 14.5 ft-lb) 
    NOTE=------------------
    Finger-tighten CD the spark plug before  torqu­
    ing 
    (2) to specification.  
    						
    							•llllull 
    AIR FITER, CARBURATOR, MUFFLER ENG 8 
    ENGINE 
    AIR FILTER, CARBURATOR,  MUFFLER 
    151.111 
    3-1  
    						
    							•I Ill nil 
    AIR FITER, CARBURATOR,  MUFFLER ENG B 
    JOB INSTRUCTION  CHART 
    Order Job name/Parts name Oty Remarks 
    Removal of Air filter, Carburator Remove the parts in order. 
    and 
    Muffler 
    Body cover Refer to BODY COVER section 
    in 
    CHAPTER 2. 
    Fuel tank Refer to FUEL TANK section 
    in 
    CHAPTER 2. 
    1 Crankcase breather hose  1 
    2 
    Screw 2 
    3 
    Bolt 1 
    4 
    Air filter assmbly 1 
    5 Air filter gasket 1 
    6 Governor link rod  1 
    7 
    Carburetor assembly 1 
    8 Carburetor cover 1 
    9 Joint 1 
    10 Intake manifold gasket  1 
    11 Bolt 6 
    12 Muffler cover 2  1 
    13 Nut/Bolt 2/1 
    14 Muffler assembly 1 
    15 Muffler gasket  1 
    16 Bolt 2 
    17 Muffler cover 1 1 
    Reverse 
    the removal procedure 
    for installation. 
    3-2  
    						
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