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Yamaha EF1000 Service Manual

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    							IGNITION SYSTEM I ELEC 11-==::J I 
    TROUBLESHOOTING CHART 
    NO SPARK OR WEAK SPARK 
    NOTE=------------------------------------------------------------
    •Remove the following parts before troubleshooting. 
    1) Spark plug 
    • Use the following special tool(s) in this troubleshooting. 
    Pocket tester: 
    YU-03112(90890-03112) 
    1. Spark plug 
    •Check the spark plug condition. 
    Refer to the SPARK  PLUG section in the 
    CHAPTER 2. 
    CORRECT 
    2. Ignition spark gap 
    •Disconnect the spark plug cap CD from 
    spark plug. 
    •Connect the ignition [email protected] as shown. 
    Spark plug cap (f)-+ 
    Ignition checker 
    Ignition checker lead-+ 
    Spark [email protected] 
    •Turn the crank and measure the ignition 
    spark [email protected] 
    Minimum spark gap: 
    6 
    mm (0.24 in) 
    * 
    OUT OF 
    SPECIFICATION 
    OR NO  SPARK 
    4-3 
    Dynamic  spark tester (Ignition 
    Checker): 
    YM-34487 
    (90890-06754) 
    INCORRECT 
    I Repair or replace spark plug. 
    MEET SPECIFICATION 
    I Ignition system is good.  
    						
    							* 
    l 
    3. Engine stop switch 
    •Disconnect the engine stop switch  leads. 
    •Connect the pocket  tester (Qx1) to the 
    engine stop switch. 
    •Do not push the engine stop switch; 
    Check the engine stop switch for continu-
    IGNITION  SYSTEM I ELEC I u I 
    CONTINUITY 
    ity. ·-----------
    NO 
    CONTINUITY 
    •Push the engine stop switch: 
    NO 
    CONTINUITY 
    Check the engine stop switch for continu-•••••••••• 
    ity. 
    CONTINUITY 
    4. Ignition coil  resistance (Primary) 
    •Remove the ignition coil. 
    •Connect the pocket  tester as shown. 
    aiM Ignition  coil resistance  (Primary): 
    0.23Q±10% 
    * 
    MEET 
    SPECIFICATION 
    I Replace engine stop switch. 
    OUT OF SPECIFICATION 
    I Replace ignition coil assembly. 
    4-4  
    						
    							* 
    l 
    5. Ignition coil resistance  (Secondary) 
    •Remove the ignition coil. 
    •Connect the pocket  tester as shown. 
    Ignition  coil resistance 
    (Secondary): 
    5.61 kQ±20% 
    MEET 
    SPECIFICATION 
    6. C.D.I. coil  resistance  (Pulser) 
    •Disconnect the C.D.I. coupler. 
    •Connect  the pocket  tester 
    as shown. 
    ts*J C.D.I. coil resistance (Pulser): 
    38Q±10% 
    MEET 
    SPECIFICATION 
    7. C.D.I. coil resistance  (Charge) 
    •Disconnect the C.D.I. coupler. 
    •Connect  the pocket  tester 
    as shown. 
    ~ C.D.I. coil resistance  (Charge): 
    350Q±10% 
    MEET 
    SPECIFICATION 
    IGNITION SYSTEM I ELEC I u I 
    (R X 1k) 
    OUT OF SPECIFICATION 
    I Replace ignition coil assembly. 
    (R x 1) 
    OUT OF SPECIFICATION 
    I Replace C.D.I. coil  assembly. 
    (R X 100) 
    OUT OF SPECIFICATION 
    I Replace C.D.I. coil assembly. 
    4-5  
    						
    							* 
    ! 
    8. Oil level gauge 
    • Drain the engine oil. 
    Refer to the ENGINE  OIL section in 
    CHAPTER 
    2. 
    • Remove  the oil level gauge. 
    • Connect  the pocket  tester as shown. 
    NO 
    CONTINUITY 
    •Overturn the oil  level gauge as shown. 
    CONTINUITY 
    •Tighten the oil level gauge bolts. 
    ~. 7 Nm (0.7 m • kg, 5.1 ft •lbl 
    9. Wiring connecting 
    • Check the entire ignition system for con-
    IGNITION  SYSTEM I ELEC I I~ I 
    CONTINUITY 
    I Replace oil level gauge. 
    NO  CONTINUITY 
    I Replace oil level gauge. 
    POOR  CONNECTION 
    nections. •••••••••• 
    CORRECT 
    I Replace  flywheel. 
    I Correct. 
    4-6  
    						
    							GENERATOR SYSTEM I ELEC I u I 
    TROUBLESHOOTING 
    1. AC generation is not normal Check output voltage at AC 
    Lr 
    Check AC receptacle with its ter-
    receptacle.  minals connected with a wire. 
    0-15V Conducting I Faulty  voltmeter or faulty load.  Specified 
    reading Not conducting Low reading 
    ~ Unusually 40-60V In-between 
    ~ 
    high reading 
    reading l Faulty AC receptacle 
    Reset  governor 
    arm/ shaft. 
    I Check engine  revolutions. 
    (i.e.  frequency) 
    Turn  adjust 
    bolt anticlockwise, r More  than 3,800 rpm. 
    observing  engine revolutions. L Too low Normal Stay unchanged I Return to normal 
    l Check wiring harness fo~ continuity: Check AC protector 
    Faulty  adjust plate or faulty 
    Conducting 
    Not conducting Conducting I Not conducting 
    governor. 
    • l Faulty AC protector 
    1--Check resistance  in main  coil. ~~ Faulty  wiring  harness I Check resistance in sub-coil. 
    Infinity or below standard Standard resistance fl ± 10% 
    Standard  resistance fl ± 10% 120V 11--r o;=oooc
    						
    							GENERATOR SYSTEM I ELEC I u I 
    2. DC generation is not normal. Check DC output voltage at DC 
    _r 
    Check  DC plug socket with its ter-
    receptacle. minals connected with a  wire. 
    I Approx. 5V I  I Not conducting Faulty pilot lamp.  Normal ov Conducting 
    Faulty 
    load. 
    I Faulty receptacle I 
    Make adjustment with adjust bolt, 1--Check engine  revolutions 
    observing  engine revolutions.  (i.e. 
    frequency). 
    Stay  unchanged 
    I Return to normal  (AC 
    voltage indicated  on meter) Check  DC protector More than I I I . 3,BOO rpm Too low Normal Erratic Conducting I Not conducting 
    I  I 
    ~~ R~..lgowmo• I I ~ arm/shaft. I Faulty  DC circuit breaker Faulty adjust plate or Check wiring harness for continuity: faulty governor. Conducting Not conducting Faulty wiring harness I 
    Check  resistance  in stator DC coil. 
    Standard  resistance !] ± 10% r--120V ----Check for internal grounding of coils 60Hz in stator DC  coil. ~ 0.433 
    I Not continuity -Continuity Broken wire or short-circuit in DC Infinity or below standard coil 
    I Faulty  coil I 
    Check output voltage at AC 
    Faulty  DC 
    rectifier receptacle. 
    I Normal direction I Continuity I 0-15V 
    I Reverse  direction I No continuity I Low reading 
    40-60V Not normal I Normal 
    In-between reading r---Follow same checking  procedure 
    subsequent to measurement for Specified  reading 
    main coil and sub-coil in TROUBLESHOOTING (B). (AC Generation) 
    I Faulty I DC rectifier 
    4-8  
    						
    							(R x 1) 
    2 
    (R X 1) 
    G 
    G 
    GENERATOR SYSTEM I ELEC I u I 
    4-9 
    INSPECTION 
    Main coil resistance 
    1. Disconnect the main coil coupler G). 
    2. Connect the pocket tester as shown. 
    Main coil resistance: 
    1.7640±10% 
    Out or specification~Replace stator assem­
    bly. 
    Sub  coil 
    resistance 
    1. Disconnect the sub coil coupler G). 
    2. Connect the pocket tester as shown. 
    Sub coil resistance: 
    2.990±10% 
    Out or specification~Replace stator assem­
    bly.  
    						
    							A 
    8 
    GENERATOR SYSTEM I ELEC I [~ I 
    4-10 
    Condenser functions 
    1. Disconnect the condenser leads. 
    2. Connect the pocket tester. 
    Turn 
    the pocket tester switch to Rx1 K 
    from OFF position. 
    Needle swings and returns back quickly-7 
    Correct. 
    Needle does not swing/return-7Replace. 
    F!•41 ;] ~II~ (CJ 
    Discharge the old condenser by shorting the 
    two terminals together. 
    Use  an 
    Insulated screw driver. 
    Do 
    not touch either of the terminals and 
    ground  before 
    the condenser  is discharged. 
    Rotor rectifier  continuitys 
    1. Desolder the rotor rectifiers. 
    2. Connect the pocket tester shown. 
    Continuity-7Correct. 
    No continuity-7Replace. 
    3. Connect the pocket tester as shown. 
    No continuity-7Correct. 
    Cantin u ity-7Replace. 
    ~: Nomal direction. 
    rn:J: Reverse direction. 
    Rotor resistance 
    1. Desolder the rotor rectifiers. 
    2. Connect the pocket tester as shown. 
    Rotor resistance: 
    4.110±10% 
    Out of specification-7Replace.  
    						
    							(R x 1) 
    A 
    B 
    GENERATOTR SYSTEM I ELEC I u I 
    4-11 
    DC coil resistance 
    1. Disconnect the DC coil coupler G). 
    2. Connect the pocket tester as shown. 
    DC coil resistance: 
    0.4330±10% 
    Out of specification~Replace stator assem­
    bly. 
    DC rectifier continuitys 
    1. Remove the DC rectifier. 
    2. Connect the pocket tester as shown. 
    Continuity~Correct. 
    No continuity~Replace DC rectifier. 
    3. Connect the pocket tester as shown. 
    No continuity~Correct. 
    Continuity~Replace DC rectifier. 
    ~: Normal direction. 
    [ID: Reverse direction. 
    Rotor remagnetized 
    1. Assembl the generator. 
    2. Start and turn the engine with no load. 
    3. Connect the battery (12V) to the con­
    denser terminal at the moment and the 
    rotor will be magnetized instantly. 
    CAUTION: 
    Do not connect the battery more than a few 
    seconds. This may cause deteriorate the bat­
    tery.  
    						
    							SPECIFICATIONS 
    GENERAL SPECIFICATIONS 
    MODEL CODE NUMBER 
    DIMENSIONS 
    Overall 
    Length 
    Overall Width 
    Overall Height 
    Dry Weight 
    ENGINE 
    Engine Type 
    Cylinder Arrangement 
    Displacement 
    Bore x Stroke 
    Compression Ratio 
    Operating 
    Hours 
    Fuel 
    Fuel  Tank  Capacity 
    Engine 
    Oil Capacity 
    Engine 
    Oil Grade 
    IGNITION  SYSTEM 
    Ignition Timing 
    Spark Plug Type 
    Gap 
    GENERATOR 
    AC Output 
    Rated  Voltage 
    Frequency 
    Rated 
    Output 
    Rated Current 
    Safety  Device Against 
    DC Output 
    Rated Voltage 
    Rated 
    Current 
    Safty  DevicemAoainst 
    Unit 
    mm(in) 
    mm (in) 
    mm(in) 
    kg (lb) 
    3 em 
    mm(in) 
    L (Imp gal, US gal) 
    L (Imp qt, US qt) 
    mm (in) 
    v 
    Hz 
    kVA 
    A 
    v 
    A 
    5-1 
    SPECIFICATIONS I SPEC I u • 
    EF1000 
    7FL 
    390 (15.4) 
    280(11.0) 
    388  (15.3) 
    24.8  (54.7) 
    4-stroke 
    OHV forced 
    air cooled 
    1 
    84.4 
    50 X 43  (1.97 X 1.69) 
    8.0: 1 
    5.0 
    Unleaded regular gasoline 
    3.8  (0.84, 1.0) 
    0.43 
    (0.38, 0.45) 
    4-stroke engine oil API Service  Classification 
    SE or SF if not available, SO 
    K [A] YAMALUBE 4 (10W-30) 
    ... 
    IQ] SAE 1~~ SAE #2~~ SAE #30 .,.. ... .,.. ....-
    C.D.I. 
    BTDC  23° 
    BPR6HS 
    0.6-0.7 (0.024-0.028) 
    120 60 
    0.85 
    7.1 
    Protector (Thermal type) 
    12 
    10 
    Protector  
    						
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