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Yamaha EF1000 Service Manual

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    							ENGINE ENG 
    JOB INSTRUCTION CHART 
    Order Job name/Parts  name Oty Remarks 
    Removal of Engine 
    Remove the parts in order. 
    Body cover/Fuel tank Refer to BODY COVER and 
    FUEL TANK section. 
    Muffler/Air filter Refer to MUFFLER and 
    AIR FILTER section. 
    1 Spark plug cap 1 
    2 Oil  level  lead/Engine stop lead 1 
    3 C.D.I. coupler 1 
    4 Condenser lead 2 
    5 DC rectifier coupler 1 
    6 Main coil coupler 1 
    7 Sub coil coupler 1 
    8 Nut 4 
    9 Earth lead 1 
    10 Fuel tank breather hose 1 
    11 Engine assembly 1 Reverse the removal procedure for 
    installation. 
    3-4  
    						
    							.11111111 
    CYLINDER HEAD COVER, CYLINDER HEAD, VALVE ENG B 
    CYLINDER HEAD COVER,  CYLINDER HEAD, VALVE 
    2 
    5 j11 Nm (1.1 m•kg, 8.0 ft•lb) I 
    10 Nm (1.0 m•kg, 7.2 ft•lb) 
    2 
    3-5  
    						
    							.11111111 
    CYLINDER HEAD COVER, CYLINDER HEAD, VALVE ENG [g 
    JOB INSTRUCTION  CHART 
    Order Job name/Parts name Qty Remarks 
    Removal 
    of cylinder  head cover, Remove the parts in order. 
    cylinder  head and 
    valve 
    Recoil 
    starter Refer to RECOIL  STARTER 
    section in chapter 3. 
    Air filter, Carburetor Refer to CARBURETOR 
    section in chapter 3. 
    1 Spark plug 1 
    2 Bolt 4 
    3 Cylinder head cover 1 
    4 Gasket  1 
    5 Air shround 1 
    1 
    6 Air shround 2  1 
    7 Bolt 4 NOTE: Follow proper tightening 
    sequence. 
    8 Cylinder head  1 NOTE: Set the piston at compression 
    top dead center before 
    removal. 
    9 Gasket  1 
    10 Dowel pin 2 
    11 Push rod 2 
    Reverse 
    the removal 
    procedure for installation. 
    Disassembly of Cylinder head Disassemble the parts  in the order. 
    CD Locknut 2 
    @ Adjuster 2 
    @ Rocker arm 2 
    @ Valve retainer 2 
    ® Valve spring 2 
    ® Push rod guide 1 
    (j) Exhaust valve 1 
    ® Intake valve 1 
    Reverse 
    the disasembly procedure 
    for assembly. 
    3-6  
    						
    							•llllull 
    CYLINDER HEAD COVER, CYLINDER HEAD, VALVE ENG 8 
    Intake Valve face: Exhaust Valve face: 
    @ 
    3-7 
    CYLINDER HEAD INSPECTION 
    1. Remove: 
    •Carbon deposits 
    Use rounded scraper. 
    2. Measure: 
    •Cylinder head warpage 
    Exceeds allowable limit ---?Resurface. 
    I~ 
    Warpage Limit: 
    0.1 mm (0.004 in) 
    VALVE 
    REMOVAL 
    1. Remove: 
    •Valve spring retainer CD 
    •Vale spring ~ 
    •Valve ® 
    VALVE INSPECTION 
    1. Inspect: 
    •Valve [email protected] 
    •Valve face [email protected] 
    Valve length: 
    Intake: 53.4 mm (2.10  in) 
    Exhaust: 53.6 mm (2.11  in) 
    Valve face diameter: 
    Intake: 19.0 mm (0.75 in) 
    Exhaust: 17.0 mm (0.67 in)  
    						
    							CYLINDER HEAD COVER, CYLINDER HEAD,  VALVE ENG 
    302-011 
    3-8 
    2. Inspect: 
    •Valve stem diameter® 
    Out of specification~Replace. 
    Valve stem diameter: 
    Standard: 
    Intake: 5.0 mm (0.2 in) 
    Exhaust: 5.0 mm (0.2 in) 
    Limit: 
    Intake: 4.89 mm (0.193 in) 
    Exhaust: 4.87 mm (0.192 in) 
    3. Measure: 
    •Valve stem bend 
    ~ Valve stem bend limit: 
    v A 0.01 mm (0.0004 in) 
    Out of specification~Replace. 
    VALVE SEAT INSPECTION 
    1 .Measure: 
    •Valve contact width ® 
    Poor seating ~Looping. 
    Out of specification~Replace. 
    Valve contact width: 
    Standard: 0.7 mm (0.03 in) 
    Limit: 1.2 mm (0.047 in) 
    2. Measure: 
    •Valve seat contact width® 
    Poor seating ~Looping. 
    Out of specification~Replace. 
    Valve seat contact width: 
    Standard: 0.7 mm (0.03 in) 
    Limit: 1.2 mm (0.047 in) 
    Valve/Valve Seat Assembly Lapping 
    1. Apply: 
    •Coarse lapping  compound (Small amount to 
    valve face) 
    2.  Position: 
    •Valve 
    (in cylinder head)  
    						
    							•llllull 
    CYLINDER HEAD COVER, CYLINDER HEAD, VALVE ENG 8 
    302-017 
    302-005 
    3-9 
    3. Rotate: 
    •Valve 
    Turn  until valve  and valve  seat are evenly 
    polished,  then clean 
    off compound. 
    4. Repeat  above steps with fine compound and 
    continue  lapping 
    until valve face shows  a 
    completely 
    smooth surface uniformly. 
    5. Eliminate: 
    •Compound 
    (from  valve face) 
    6. 
    Apply: 
    •Mechanics bluing  dye (Dykem) CD 
    (to valve  face and seat) 
    7.  Rotate: 
    •Valve 
    Valve must make full seat contact indicat­
    ed 
    by grey  surface all around  valve face 
    where  bluing 
    was removed. 
    8. 
    Apply: 
    •Solvent 
    (into  each  intake  and exhaust  port) 
    Leakage  past valve 
    seat-+ Repeat  valve lap­
    ping  until seal is complete. 
    NOTE: --------------------------
    Pour solvent into intake  and exhaust  ports only 
    after 
    completion of all valve work and  assembly 
    of head  parts. 
    Valve  Spring Measurement 
    1 . Measure: 
    • Valve  spring  free length CD 
    Out of specification--+ Replace. 
    Valve spring  free length: 
    27.4 mm (1.08 in) 
    Limit: 
    24.4 mm (0.96 in)  
    						
    							.11111111 
    CYLINDER HEAD COVER, CYLINDER HEAD,  VALVE ENG 8 
    -~-® 
    2 
    4 
    3-10 
    2. Measure: 
    •Valve spring [email protected] 
    Use a square 
    Out of specification~Replace. 
    I~ 
    lilt limit: 
    0.8 mm (0.031 in) 
    PUSH  ROD INSPECTION 
    1. Measure: 
    •Push rod bend 
    Roll on V-block 
    Exceeds bending limit~Replace. 
    I~ 
    Bend Limit: 
    0.5 mm (0.02 in) 
    CYLINDER HEAD INSTALLATION 
    1. Install: 
    •Cylinder head assembly 
    NOTE: ________________________ ___ 
    Follow proper tightening sequence. 
      Cylinder head bolt: 
    ~~ 11 Nm (1.1 m•kg, 8.0 ft•lb) 
    2. Adjust: 
    •Valve clearance 
    Refer to VALVE CLEARANCE ADJUST­
    MENT section  in CHAPTER 2.  
    						
    							•llllull 
    PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT ENG -
    PISTON, CAMSHAFT, CRANKCASE,  CRANKSHAFT 
    l 
    m 
    / 
    3-11 
    l 
    m 
    2  
    						
    							•llllull 
    PISTON, CAMSHAFT, CRANKCASE,  CRANKSHAFT ENG 8 
    JOB INSTRUCTION CHART 
    Order Job name/Parts name Oty Remarks 
    Removal of Piston,  Camshaft 
    Remove the parts in order. 
    Crankcase  and Crankshaft 
    Generator,  Rotor 
    Refer 
    to the GENERATOR section. 
    Engine Refer to the ENGINE section 
    Flywheel Refer to the FLYWHEEL section. 
    1 Bolt 7 NOTE: Follow proper tightening 
    sequence. 
    2 
    Crankcase cover 1 
    3  Gasket 1 
    4 
    Dowel pin 2 
    5 Camshaft 1 NOTE: Be sure to align the camshaft 
    gear mark with crankshaft 
    gear mark. 
    6 
    Valve lifter 2 
    7 Bolt 2 
    8 Connecting rod  cap 
    1 NOTE: Be sure the connecting rod 
    mark is aligned with the cap 
    mark. 
    9 Connecting rod 
    10 Piston pin circlip 2 
    11 Piston pin  1 
    12 Piston 1 NOTE: Be sure the  V   mark on the 
    piston head  faces to push 
    rod side. 
    13  Piston 
    ring 
    3 
    NOTE: Be sure to install rings so 
    that manufacturers marks 
    faces to piston head. 
    Be sure each piston ring end 
    is positioned as illustration. 
    14 Crankshaft 1 
    15 Bolt 2 
    16 
    Oil  level gauge 
    1 
    Reverse 
    the removal procedure 
    for installation. 
    3-12  
    						
    							PISTON, CAMSHAFT, CRANKCASE,  CRANKSHAFT ENG 
    3-13 
    CRANKSHAFT  REMOVAL 
    1. Remove: 
    •Camshaft 
    NOTE: ________________________ _ 
    Remove the camshaft, facing the camshaft 
    gear mark to the crankshaft gear mark. 
    2. Remove: 
    •Valve lifter 
    CAUTION: 
    Mark the valve lifters so that the exhaust 
    and intake valve sides are not confused. 
    CAMSHAFT AND VALVE LIFTER  INSPECTION 
    1. Measure: 
    •Cam lobes length® 
    Use a micrometer. 
    Out of specification---+Replace. 
    Cam lobe length @: 
    Standard: 20.5 mm (0.81 in) 
    Limit: 20.25 mm (0.80 in)  
    						
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