Yamaha EF1000A Service Manual
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SPECIAL TOOLS SPECIAL TOOLS GEN INFO The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. YU-33294 (90890-05158) YU-1047 YU-03016 (90890-03016) YU-26900-9 (90890-03079) YU-33223 (90890-03081) YU-33223-3 (90890-04082) YU-03112 (90890-03112) YU-8036-A (90890-03113) (90890-06754) Tool name I Usage Piston ring compressor This tool is used to compress the piston rings when installing the piston. Rotor shock puller set These tools are used when removing the rotor. Cylinder gauge (35-60 mm) This gauge is used to measure the cylinder inside diameter. Service gauge (Thickness gauge) This gauge is used to measure the valve clearance. Compression gauge set CD Adaptor@ These tools are used to measure the engine compression. Pocket tester These instrument is invaluable for checking the electrical system. Indicative tachometer These instrument is invaluable for reading the engine rpm. Ignition checker This instrument is necessary for checking the ignition system components. 1-5 Illustration CD

INTRODUCTION/MAINTENANCE INTERVALS CHART/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being pre pared for sale. All service technicians should be familiar with this entire chapter. MAINTENANCE INTERVALS CHART Proper periodic maintenance is important. Especially important are the maintenance services re lated to emissions control. These controls not only function to ensure cleaner air but are also vital to proper engine operation and maximum performance. In the following maintenance tables, the ser vices related to emissions control are indicates as ** in the chart. PERIODIC MAINTENANCE/LUBRICATION INTERVALS Pre-O~era-Initial Every No. Item Remarks tion c eck 1 month 3 months 6 months 12months (daily) or 20 hr or 50 hr or 100 hr or 300 hr ** Check condition, adjust 1. Spark plug ~ap and clean. • eplace if necessary. ** Check and adjust 2.* Valve clearance when engine is cold. • ** Check breather hose Crankcase 3.* breather system for cracks or damage. • Replace if necessary. ** Check and adjust 4.* Idle speed engine idle speed. • Check for leakage. Retighten or replace • ** gasket if necessary. 5. Exhaust system Check spark arrester. Clean/replace if • necessary. ** Check oil level. • 6. Engine oil • Replace. • ** Clean. Replace if 7. Air filter • necessary. 8. Fuel filter Clean fuel ftetcock and fuel tank fi ter. • Replace if necessary. Check fuel hose for 9. Fuel line cracks or damage. • Replace if necessary. ** 10. Choke lever Check choke operation. • 11. Cooling system Check for fan damage. • 2-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS Pre-O~era-Initial Every No. Item Remarks tion c eck 1 month 3 months 6 months 12months (daily) or 20 hr or 50 hr or 100 hr or 300 hr ** Check recoil starter • 12. Starting system operation. ** More frequency if 13. Decarbonizatior • necessary. 14. Fittings/fasteners Check all fittings and fastners. Correct if • necessary. 2-2

ENGINE OIL 1•:gs 1 Q 1 ------------------------------------------------ 700..()65 -CD 2-3 ENGINE ENGINE OIL Recommended oil: lA] VAMALUBE 4 (10W-30) or SAE 10W-30 type SE [ID SAE #30 [QI SAE #20 [Q] SAE 10W Engine oil quantity: 0.43 L (0.38 Imp qt, 0.45 US qt) NOTE:------------------------ Recommended engine oil classification: API Service SE or SF, if not available, SD. Oil level inspection 1. Check: •Oil level Oil level adjustment steps: • Place the engine on a flat surface. • Warm up the engine for a few minutes. • Stop the engine. • Make sure that the engine oil is between the upper and lower levels. Add oil as necessary. G) Upper level (?) Lower level Oil replacement 1. Warm up the engine oil for several minutes. 2. Place a receptacle under the engine. 3. Remove: •Oil filler cap CD Tilting as shown the engine while the engine oil draining.

1•:gs1d1 FUEL LINE INSPECTION/FUEL PETCOCK/AIR FILTER _ . ~ _ + :-..· : ..... 2 2-4 4. Fill: •Engine oil Recommended engine oil: 0.43 L (0,38 Imp qt, 0.45 US qt) Do not allow foreign material to enter the· crankcase. 5. Install: •Oil filler cap FUEL LINE INSPECTION 1. Inspect: •Fuel hose G) •Fuel petcock ® Clacks/damage---+Replace. Poor connection---+Correct. FUEL PETCOCK Removal and inspection 1. Turn the fuel petcock lever the C position. 2. Inspect: •Fuel petcock cup G) Connection---+Ciean. •Gasket ® Da mage---+Replace. •Strainer ® Conta m i nation---+Ciea n. NOTE:-------------------------- Ciean the cup with solvent and dry it off. 3. Install: •Fuel petcock cup I X 11.5 Nm (0.15 m•kg, 1.1 ft•lb) I AIR FILTER 1. Remove: •Bolt G) •Air filter cover® •Air filter element® Refer to AIR FILTER.

IIANDSJP I ~ I AIR FILTER/MUFFLER ~ ------------------------------------------------------- • 2-5 2. Inspect: •Element Clogging~Wash the element in a solvent and dry it. Oil the element and squeeze out the excess oil. Damge~Rplace . • ~ Recommended oil: U Form-air-filter oil or SAE #20 motor oil 3. Inspect: •Air filter element •Air filter cover NOTE=-------------------------------------------------- Do not wiring out the element; this could cause it to tear. The engine should never be run without the air filter element; excessive piston and/or cylinder wear may result. MUFFLER 1. Remove: •Muffler protector •Muffler Refer to MUFFLER . 2. Remove: •Plate CD 3. Clean: •Exhaust pipe •Muffler body@ To loosen carbon buildup tap on the muffler, in the area shown in the illustration. Then, shake the carbon pieces out of the end of the muffler. Do not use a wire to the inside of the muffler or the nois damping material may come out, reducing the damping effect.

IIANDSJP I ~ I VALVE CLEARANCE ADJUSTMENT ~ ------------------------------------------------------- 2-6 VALVE CLEARANCE ADJUSTMENT NOTE=-------------------------- Valve clearance must be measured when the engine is cool to touch. 1. Remove: •Fuel tank •Breather hose CD •Air shroud (under)@ •Air shroud (upper)@ •Cylinder head cover@ •Spark plug @ 2. Pull the starter rope until the piston touches the screwdriver. the piston is then at TDC. 3. Inspect: •Valve clearance Out of specification---+Adjust. Standard valve clearance: Intake valve (cold) 0.1 mm (0.004 in) Exhaust valve (cold) 0.1 mm (0.004 in) Service gauge: VU-26900-9 (90890-03079) Valve clearance adjustment 1. Turn the crankshaft until the piston reaches top dead center (T.D.C.). 2. Loosen the locknut CD and insert the 0.1 mm (0.04 in) thickness gauge between the rocker arm and the valve top. 3. Turn the adjuster @ in or out to obtain the proper valve clearance. Move the thickness gauge up and down to check for the proper resistance. Adjuster Resistance Valve clearance Turn in Increase Decrease Turn out Decrease Increase 4. Tighten the locknut CD ll"l

VALVE CLEARANCE ADJUSTMENT/ l•:gs 1 ** 1 COMPRESSION PRESSURE MEASUREMENT _ . ~ _ 2-7 5. Install: •Cylinder head cover gasket •Cylinder head cover CD •Air shroud (upper) ® •Air shroud (under)@ •Breather hose@ •Spark plug@ 6. lighten: •Cylinder head cover 1~19 Nm (0.9 m•kg, 6.5 ft•lb) I COMPRESSION PRESSURE MEASUREMENT Insufficient compression pressure will result in performance loss and may indicate leaking valves or worm or damage piston rings. 1. Measure: •Valve clearance 2. Warm up the engine for several minutes, then stop the engine. 3. Remove: •Spark plug 4. Connect: •Adapter CD •Compression gauge® Compression gauge set: VU-33223 (90890-03081) Adapter: VU-33223-3 (90890-04082) 5. Measure: •Compression To measure the compression, pull the recoil starter until the needle stops rising on the compression gauge. Standard compression pressure: 100 kPa (10 kg/cm2 , 14.2 psi) To prevent the sparking when cranking the engine, ground the spark plug wire.

CYLINDER HEAD DECARBONIZATION/ l•:gs 1 d 1 GOVERNOR ADJUSTMENT _ . ~ _ 2-8 Compression test steps (below minimum levels): • Squirt a few drops of oil into the cylinder. • Measure the compression again Reading Diagnosis If higher than • Worn cylinder, without oil piston and piston ring. If the same as • Defective piston, without oil ring(s), valve(s) and cylinder head gasket. • Improper valve timing and valve clearance. Compression test steps (above maximum levels): • Check the cylinder head, valve surfaces, and piston crown for carbon deposits. CYLINDER HEAD DECARBONIZATION 1. Remove: •Carbon deposits Refer to CYLINDER HEAD INSPECTION GOVERNOR ADJUSTMENT 1. Remove: •Fuel tank 2. Adjust: •Governor Governor adjustment steps: 1. Loosen the nut (j). 2. Turn the governor arm @ counterclockwise until it stops. 3. Turn the governor shaft@ counterclockwise until it stops. 4. Tighten the nut.

ENGINE SPEED ADJUSTMENT/ l•:gr 1 ~ 1 BREATHER HOSE INSPECTION/SPARK PLUG _ . ~ _ 2-9 ENGINE SPEED ADJUSTMENT 1. Adjust: •Engine speed (with no load) Engine speed adjustment steps: 1. Install the Tachometer . 2. Start the engine and let it warmup for a few minutes. 3. Adjust the engine speed by turning the throttle stop screw CD in or out. Engine speed (with no load): 60Hz 3,700-3,850 rpm Inductive tachometer: VU-8036-A (90890-03113) BREATHER HOSE INSPECTION 1. Inspect: •Breather hose CD Clacks/damage-+Replace. Poor connection-+Correct. SPARK PLUG 1. Remove: •Spark plug Before removing the spark plug, use compressed air to clean the cylinder head cover to prevent dirt from falling the engine. 2. Inspect: •Electrode CD Wear/damage-+Replace. •Insulator color@ 3. Measure: •Plug gap@ Use a Wire gauge or thickness gauge. Out of specification-+Replace. Spark plug gap: 0,6-0,7 mm (0,024-0,028 in)