Yamaha EF1000A Service Manual

YAMAHA 
SERVICE MANUAL  

FOREWORD 
This manual was written by the Yamaha 
Motor Company primarily for use by Yamaha 
dealers and their qualified mechanics. It is 
not possible to put an entire mechanics 
education into one manual, so it is assumed 
that persons using this book to perform 
maintenance and repairs on Yamaha 
generators  have a basic 
understanding of the 
mechanical  precepts and procedures inherent 
to generator repair technology. Without such 
knowledge, attempted repairs or service to 
this model may render it...

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ILLUSTRATED SYMBOLS 
(Refer to the illustration) 
Illustrated symbols CD to@ are designed as 
thumb tabs to indicate  the chapters number 
and  content. 
CD General information 
@ Periodic  inspection  and adjustment 
@ Engine 
@ Electrical 
@ 
Specifications 
Illustrated symbols@ to@ are  used to identi­
fy the  specifications...

INDEX 
GENERAL INFORMATION 
PERIODIC INSPECTIONS 
AND ADJUSTMENTS 
ENGINE 
ELECTRICAL 
SPECIFICATIONS 
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CONTENTS 
Chapter 1. 
GENERAL INFORMATION 
MACHINE IDENTIFICATION ................. 1-1 
ENGINE SERIAL NUMBER ...................... 1-1 
STARTING  SERIAL NUMBER .................. 1-1 
IMPORTANT  INFORMATION ............... 1-2 
PREPARATION FOR REMOVAL AND 
DISASSEMBLY .........................................  1-2 
NOTES ON SERVICE ................................  1-2 
ALL REPLACEMENT PARTS .................... 1-4 
GASKETS, OIL SEALS AND 0-RINGS .... 1-4 
BEARINGS AND OIL  SEALS .......................

INSPECTION ........................................... 3-29 
Chapter 4. 
ELECTRICAL 
ELECTRICAL COMPONENTS.............. 4-1 
WIRING DIAGRAM............................. 4-1 
SWITCH INSPECTION........................... 4-2 
IGNITION SYSTEM ................................ 4-3 
TROUBLE 
SHOOTING .............................  4-3 
GENERATOR SYSTEM.......................... 4-7 
TROUBLE 
SHOOTING .............................  4-7 
Chapter 5. 
SPECIFICATIONS 
GENERAL SPECIFICATIONS................ 5-1...

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MACHINE IDENTIFICATION ~~~~~ 1•1 
1-1 
GENERAL INFORMATION 
MACHINE IDENTIFICATION 
ENGINE SERIAL NUMBER 
The engine serial number CD is stamped into 
the right side of the body 
NOTE-· --------------------------The first three digits of these numbers are for 
model identification; the remaining digits are 
the 
unit production number. 
STARTING  SERIAL NUMBER 
I EF1000A I 7TA-200101 ... 
NOTE-·--------------------------
Designs and specifications are subject to 
change without...

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IMPORTANT INFORMATION 
GEN .-a 
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1-2 
IMPORTANT  INFORMATION 
PREPARATION  FOR REMOVAL AND 
DISASSEMBLY 
NOTES 
ON SERVICE 
1. Fire prevention 
When  servicing  the engine,  always keep 
away from fire. 
2. Right tools 
Be sure to use the right special tool for the 
job to guard against  damage. 
3. Oil, grease  and sealers 
Be sure to use  genuine  Yamaha  oils, 
greases  and sealers, 
or the equivalents. 
4. Expendable  parts 
Always replace gaskets, 0-rings, cotter 
pins,  and...

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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 disas­
sembly. 
b. Contact  surfaces of moving parts should 
be oiled when reassembled. 
c. Make sure that parts...

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  b Yamaha for as­
sembly 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 
during reassembly. Apply grease to the oil 
seal...