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 unfit for use and/or 
unsafe. 
Yamaha 
Motor Company Ltd.  is continually 
striving to further improve all models 
manufactured by Yamaha. Modifications and 
significant changes in specifications or 
procedures will be forwarded to all 
Authorized Yamaha dealers and will, where 
applicable, appear in future editions of this 
manual. 
NOTE~·-------------------------
This Service Manual contains information 
regarding periodic maintenance to the 
emission control system. Please  read this 
material  carefully 
EF1000A 
SERVICE 
MANUAL 
©1997  Yamaha Motor Corporation, U.S.A. 
1st Edition, February  1997 
All right reserved. Any reprinting or 
unauthorized use without the written 
permission of Yamaha Motor Corporation, 
U.S.A. is expressly prohibited. 
Printed in U.S.A. 
LIT-19616-00-83 
HOW  TO USE  THIS MANUAL 
PARTICULARLY IMPORTANT 
INFORMATION 
This material is distinguished by the 
following notation. 
& 
The Safety Alert Symbol means ATTENTION! 
BECOME 
ALERT! YOUR  SAFETY IS 
INVOLVED! 
&WARNING 
Failure to follow WARNING instructions could 
result in severe injury or death to the 
machine operator, a bystander, or person 
inspecting or repairing  the machine. 
A 
CAUTION indicates  special precautions that 
must be taken to avoid damage to the 
machine. 
NOTE: 
A 
NOTE provides key information to make 
procedures  easier 
or cleaner. 
MANUAL FORMAT 
The procedures in this manual are organized 
in a sequential, step-by-step format. The 
information has  been compiled to provide  the 
mechanic with an easy to read, handy 
reference that contains comprehensive 
explanations of all disassembly, repair, 
assembly,  and inspection  operations. 
In this revised format, the condition of a 
faulty component will precede an arrow 
symbol and the course of action required will 
follow the symbol, e.g., 
• Bearings 
Pitting/Damage-)>Replace. 
EXPLODED DIAGRAM 
Each chapter provides exploded diagrams 
before each disassembly section for ease in 
identifying the correct disassembly and 
assembly  procedures.  
						

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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  appearing. 
@ Special tool 
(J) Filling fluid 
@ Lubricant 
® Tightening 
® Wear limit, clearance 
@ Engine  speed 
@ Q,V,A 
Illustrated symbols@ to@ in the exploded 
diagram  indicate grade of lubricant and loca­
tion of lubrication point. 
@ Apply molybdenum disulfide  oil 
@ Apply engine oil 
® Apply lightweight lithium soap base grease 
@ Apply locking agent (LOCTITE®) 
@ 
Use New one  
						

							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 ....................  1-4 
SPECIAL TOOLS ..................................... 1-5 
Chapter 2. 
PERIODIC  INSPECTIONS 
AND ADJUSTMENT 
INTRODUCTION ...................................... 2-1 
MAINTENANCE INTERVALS CHART 2-1 
PERIODIC MAINTENANCE/ 
LUBRICATION  INTERVALS .................. 2-1 
ENGINE ...................................................... 2-3 
ENGINE OIL ..............................................  2-3 
FUEL 
LINE  INSPECTION.......................... 2-4 
FUEL 
PETCOCK ........................................  2-4 
AIR FILTER ................................................  2-4 
MUFFLER  ..................................................  2-5 
VALVE  CLEARANCE 
ADJUSTMENT....... 2-6 
COMPRESSION  PRESSURE 
MEASUREMENT ......................................  2-7 
CYLINDER HEAD DECARBONIZATION.. 2-8 
GOVERNOR ADJUSTMENT .................... 2-8 
ENGINE SPEED ADJUSTMENT ..............  2-9 
BREATHER 
HOSE  INSPECTION.............. 2-9 
SPARK PLUG............................................  2-9 
A.C. 
PROTECTOR  INSPECTION .............. 2-10 
ENGINE  SWITCH  INSPECTION 
............... 2-10 
A. C. RECEPTACLE INSPECTION ............. 2-10 
Chapter 3. 
ENGINE 
ENGINE OVERHAUL.............................. 3-1 
MUFFLER PROTECTOR, FUEL TANK AND 
MUFFLER  ..................................................... 3-1 
JOB INSTRUCTION CHART .................... 3-1 
AIR FILTER,  CARBURETOR 
AND CONTROL BOX..................................  3-2 
JOB INSTRUCTION CHART.................... 3-2 
CYLINDER HEAD COVER 
AND CYLINDER HEAD ................................ 3-3 
JOB INSTRUCTION CHART....................  3-3 
INSPECTION...........................................  3-4 
INSTALLATION ....................................... 3-4 
ROCKER ARMS, VALVES 
AND VALVE SPRINGS................................  3-5 
JOB INSTRUCTION CHART.................... 3-5 
REMOVAL...............................................  3-6 
INSPECTION...........................................  3-6 
RECOIL STARTER AND FLYWHEEL.  .......... 3-10 
JOB INSTRUCTION CHART .................... 3-10 
RECOIL  STARTER 
........................................  3-11 
JOB INSTRUCTION CHART ....................  3-11 
REMOVAL  ...............................................  3-12 
INSPECTION ........................................... 3-12 
ASSEMBLY .............................................  3-12 
CRANKCASE COVER AND CAMSHAFT .... 3-14 
JOB INSTRUCTION CHART  ....................  3-14 
REMOVAL  ...............................................  3-15 
INSPECTIOJ\! ........................................... 3-15 
PISTON, CONNECTING  ROD, 
CRANKSHAFT 
AND CRANKCASE .............  3-17 
JOB INSTRUCTION CHART ....................  3-17 
INSPECTION ...........................................  3-18 
GENERATOR  ...............................................  3-23 
JOB INSTRUCTION CHART ....................  3-23 
REMOVAL  ...............................................  3-24 
INSTALLATION ....................................... 3-24 
GOVERNOR .................................................  3-25 
JOB INSTRUCTION CHART ....................  3-25 
INSPECTION ...........................................  3-26 
CARBURETOR .............................................  3-27 
JOB INSTRUCTION CHART ....................  3-27  
						

							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 
MAINTENANCE SPECIFICATIONS.... 5-2 
ENGINE .....................................................  5-2 
ELECTRICAL ............................................. 5-4 
TIGHTENING TORQUE ......................... 5-5 
GENERAL TORQUE 
SPECIFICATIONS ... .. . ... . ... ...... ............. .... 5-5 
DEFINITION  OF UNITS.......................... 5-5 
CABLE, HOSE ROUTING...................... 5-6  
						

							i: 
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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 notice .  
						

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IMPORTANT INFORMATION 
GEN .-a 
INFO l!l) 
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 circlips 
with new parts when 
servicing  engin.  
						

							Solvent 
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 move smoothly after 
each  section 
ofthe machine  is assembled.  
						

							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  lips. 
BEARINGS AND OIL SEALS 
1. Install the bearing(s) G) and oil seal(s) (g) 
with their manufactures  marks or num­
bers facing outward. (In other words, the 
stamped 
letters must be on the side  ex­
posed 
to view.)  When installing  oil seal(s), 
apply a light coating of light-weight lithi­
um  base  grease to the seal lip(s).  Oil the 
bearings liberally when installing. 
Do not  use  compressd  air to spin the bearings 
dry.  This  causes  damage 
to the bearng  surfaces.