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Yamaha EF1000 Service Manual

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    							•llllull 
    PISTON, CAMSHAFT, CRANKCASE,  CRANKSHAFT ENG 8 
    a 
    A 
    B 
    c 
    3-14 
    2. Inspect: 
    •Camshaft CD 
    •Decompressor ell 
    •Valve [email protected] 
    Damage/Wear---+Replace. 
    3. Measure: 
    •Camshaft diameter 
    Out of specification--+Replace. 
    Camshaft diameter: 
    Standard: 12.0 mm (0.472 in) 
    Limit: 11.9 mm (0.468 in) 
    CRANKCASE  INSPECTION 
    1. Inspect: 
    •Cylinder walls 
    Vertical scratches---+Rebore or replace 
    cylinder. 
    2. Measure: 
    •Cylinder inside diameter D 
    NOTE: ---------------------------
    Obtain measurements at three depths by 
    placing measuring instrument parallel to and 
    at 
    right angles to crankshaft. 
    Out of specification---+Rebore cylinder, 
    and replace piston and piston rings. 
    ~ 
    Standard Wear limit 
    Cylinder inside 50.0 mm 50.15 mm diameter , Dl (1.969  in) 
    (1.974 in) 
    Cylinder Omm 0.5mm taper {0 in) (0.02 in) TI 
    D=Maximum A,B,C 
    T =Maximum A-Minimum C  
    						
    							.11111111 
    PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT ENG B 
    3-15 
    3. Inspect: 
    •Crankcase 
    Damage--+Replace. 
    •Bearing 
    Roughness--+Replace bearing. 
    PISTON, PISTON PIN AND PISTON  RING 
    INSPECTION 
    1. Measure: 
    •Piston skirt diameter P 
    @=10 mm (0.4  in) from the piston bottom edge. 
    Piston size P: 
    Standard: 50.0 mm (1.969  in) 
    Limit: 49.93 mm (1.966 in) 
    2. Measure: 
    •Piston clearance 
    Piston clearance= 
    Cylinder 
    inside diameter  D ­
    Piston skirt diameter  P  
    Out of specification--+Rebore cylinder 
    and replace piston and piston rings. 
    Piston clearance: 
    0.020-0.035 mm 
    (0.0008-0.0014 in) 
    3. Measure: 
    •Piston pin diameter® 
    Use  a micrometer. 
    Out of specification--+Replace. 
    Standard piston pin diameter: 
    12.0 mm (0.47 in) 
    Piston pin wear limit: 
    11.9 mm (0.468 in) 
    (  
    						
    							PISTON, CAMSHAFT, CRANKCASE,  CRANKSHAFT ENG B 
    3-16 
    4. Measure: 
    •Piston ring end gap 
    Use a Thickness  gauge. 
    Out of specification-+Replace. 
    NOTE: ________________________ __ 
    You cannot measure end gap on expander 
    spacer of oil control ring. If control ring rails 
    show excessive gap, replace all three rings. 
    Piston ring end gap: 
    0.1-0.25 mm (0.004-0.01 in) 
    Piston  ring end gap limit: 
    0.9 mm (0.0354 in) 
    5. Measure: 
    •Piston ring side clearance 
    Use  a Thickness  gauge. 
    Out of specification-+Replace. 
    NOTE: ________________________ ___ 
    Clean carbon from piston ring grooves and 
    rings before measuring side clearance. 
    Piston  ring side  clearance 
    Top  ring: 
    0.06 mm (0.0024 in) 
    2nd  ring  and 
    oil ring: 
    0.04 mm (0.0016 in) 
    Piston  ring side  clearance  limit: 
    0.15 mm (0.006 in) 
    CRANKSHAFT INSPECTION 
    1. Measure: 
    •Crankshaft runout 
    Use a Dial gauge. 
    Out of specification-+Replace. 
    Crankshaft  runout limit: 
    0.02 mm (0.0008 in)  
    						
    							•llllull 
    PISTON, CAMSHAFT, CRANKCASE,  CRANKSHAFT ENG B 
    3~ 
    3-17 
    2. Measure: 
    •Crankpin outside diameter 
    Use a micrometer. 
    Out of specification-+Replace. 
    Crankpin outside diameter: 
    22.0 mm (0.87 in) 
    Crankpin outside diameter limit: 
    21.9 mm (0.86 in) 
    3. Measure: 
    •Oil clearance 
    Use a plastigauge ®. 
    Out of specification-+Replace connec­
    ting rod. 
    Oil clearance: 
    0.016-0.034 mm 
    (0.0006-0.0013 in) 
    Oil clearance limit: 
    0.1 mm (0.004 in) 
    Oil clearance measuring  steps: 
    1. Clean all parts thoroughly. 
    2. Place plastigauge® onto crankpin. 
    3. Install the connecting rod and cap onto 
    crankcase. 
    4. Torque both cap bolts evenly. 
    ~ 
    Connecting rod cap bolt: 
    ~ 9 Nm (0.9 m•kg, 6.5 ft•lb) 
    5. Remove the connecting rod and mea-
    sure the plastigauge® width. 
    FLYWEIGHT  SHAFT (GOVERNOR) GEAR 
    INSPECTION 
    1. Inspect: 
    •Collar CD 
    •[email protected] 
    •Flyweight [email protected] 
    Damage/Wear-+ Replace.  
    						
    							•llllnll 
    PISTON, CAMSHAFT, CRANKCASE,  CRANKSHAFT ENG 8 
    3-18 
    CRANKCASE COVER INSPECTION 
    1. Inspect: 
    •Crankcase cover 
    •Bearing 
    Damage/Roughness---+Replace. 
    PISTON RING AND PISTON  INSTALLATION 
    1. Install: 
    •Piston rings 
    CAUTION: 
    • Be sure to install rings so that manufactur­
    ers marks 
    						
    							.11111111 
    PISTON, CAMSHAFT, CRANKCASE, CRANKSHAFT ENG B 
    3-19 
    Be sure the II V II mark on the piston head 
    faces to push rod side. 
    CONNECTING ROD INSTALLATION 
    1. Install: 
    •Connecting rod cap 
    CAVrtoN: --------------------Be sure the connecting rod mark 
    						
    							RECOIL STARTER ENG 
    RECOIL STARTER 
    I 40 Nm (4.0 m•kg, 29 ft•lb) I 
    13 
    JOB  INSTRUCTION CHART 
    Order Job name/Parts name Qty  Remarks 
    Removal of recoil starter Remove the parts in order. 
    Body cover/Fuel tank Refer to the BODY COVER and 
    FUEL TANK section  in CHAPTER 2. 
    1 Bolt 4 
    2 
    Recoil starter 1 
    3 Starter handle 1 
    4 
    Bolt 1 
    5 Drive plate 1 
    6 Drive spring 1 
    7 Drive pawl 1 
    8 Spring 1 
    9 Drum sheave  1 
    10 Starter spring 1 
    11 Spacer  1 
    12 Starter rope 1 
    13 Nut 1 
    14 
    Washer 1 
    15 Starter pulley 1  Reverse 
    the removal procedure for 
    installation. 
    3-20  
    						
    							-
    RECOIL STARTER ENG 
    RECOIL STARTER REMOVAL 
    CAUTION: 
    Release the spring pre-load before removing 
    the sheave drum bolt. Hook the rope into the 
    sheave drum slot G) and turn the sheave 
    drum assembly clockwise. 
    1. Untie: 
    •Knot 
    						
    							3-22 
    •nnull 
    RECOIL STARTER ENG B 
    RECOIL STARTER  INSTALLATION 
    1. Install: 
    •Starter spring CD 
    •Sheave drum~ 
    CAUTION: 
    Engage the spring hook @ with the drum 
    slit, then wind the spring counterclockwise 
    into the drum from larger to smaller diame­
    ter. 
    2. Install: 
    •Starter rope 
    CAUTION: 
    Engage the spring hook 
    						
    							FLYWHEEL ENG 
    FLYWHEEL 
    3 
    7 6~ 
    I 4 Nm {0.4 m•kg, 3 ft•lb) 
    JOB  INSTRUCTION CHART 
    Order Job name/Parts name Qty Remarks 
    Removal of 
    
    Flywheel 
    Remove the parts in  order. 
    Recoil starter  Refer to the RECOIL STARTER 
    section. 
    1 Nut 1 
    2 Washer 1 
    3 Starter 1 
    4 
    Flywheel 1 
    5 
    Key 1 
    6  Screw 1 
    7 
    Coil assembly 1 
    Reverse the removal procedure for 
    installation. 
    3-23  
    						
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