Yamaha EF1000iS Service Manual

							ENG
3-2
CONTROL BOX
CONTROL BOX DISASSEMBLY
1
2
12
11 103
4
5
6
7 8 13
14
9
Order Job name Q’ty Remarks
Control box disassemblyRemove the parts in the order listed 
below.
1 Tapping screw 4
2 Plate Assembly 1
3 Over load warning light 1 Disconnect.
4 Pilot light 1 Disconnect.
5 Oil warning light 1 Disconnect.
6 AC receptacle (7.5A×2) 1 Disconnect.
7 Wire lead (white) 1
8 DC receptacle (12V-8A) 1 Disconnect.
9 Fuse 1 Disconnect.
10 Engine switch 1 Disconnect.
11 Economy switch 1 Disconnect.
12 Earth terminal 1 Disconnect.
13 Speed limiter 1 Disconnect.
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							ENG
3-3
CONTROL BOX
1
2
12
11 103
4
5
6
7 8 13
14
9
Order Job name Q’ty Remarks
14 TCI unit Disconnect.
For assembly, reverse the disassembly
procedure.
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							3-4
CONTROL BOX
12
CONTROL BOX ASSEMBLY
1 Install:
9Control box 1
NOTE:
Insert the rid of control box to the front cover
2.
ENG
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							ENG
3-5
ENGINE
ENGINE
1
23
4 5
12 Nm (12 m · kg, 8.6 ft · lb)
5
5
5
12 Nm (12 m · kg, 8.6 ft · lb)
Order Job name Q’ty Remarks
Engine removalRemove the parts in the order listed 
below.
Front cover, rear cover and fuel hoseRefer to “COVERS” section in CHAPTER 2.
Vacuum hose
Refer to “CARBURETOR” section in
CHAPTER 4.
Fuel tank
1 Control unit 1
2 Generator lead wire coupler 1 Disconnect.
3 Engine assembly 1
4 Engine bracket left/right 1/1
5 Mount insulator 4
For installation, reverse the removal 
procedure.
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							ENG
3-6
RECOIL STARTER AND ROTOR
RECOIL STARTER AND ROTOR
1 2
345
6
78
6 Nm (0.6 m· kg, 4.3 ft · lb)
27 Nm (2.7 m· kg, 19.4 ft · lb)
6 Nm (0.6 m · kg, 4.3 ft · lb)
6 Nm (0.6 m · kg, 4.3 ft · lb)
Order Job name Q’ty Remarks
Recoil starter and rotor removalRemove the parts in the order listed 
below.
Front cover and rear coverRefer to “COVERS” section in CHAPTER 2.
Fuel tankRefer to “CARBURETOR, FUEL TANK
CarburetorAND FUEL PUMP” section in CHAPTER 4.
1 Recoil starter assembly 1
2 Case cover 1
3 Element 1
4 Air filter case assembly 1
5 Ignition coil wire lead 1
6 Ignition coil 1
7 Rotor assembly 1
8 Woodruff key 1
For installation, reverse the removal
procedure.
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							ENG
3-7
RECOIL STARTER AND ROTOR
RECOIL STARTER DISASSEMBLY
1 2 3
45 6
7
Order Job name Q’ty Remarks
Recoil starter disassemblyRemove the parts in the order listed 
below.
1Set screw 1
2Collar 1
3Friction spring 1
4Reel 1
5Spiral spring 1
6Starter case 1
7Swing arm 1
For disassembly, reverse the assembly
procedure.
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							3-8
RECOIL STARTER AND ROTOR
1
2
1
2
1
1
1
2
RECOIL STARTER DISASSEMBLY
1. Remove:
9Set screw 1
9Collar 2
2. Remove:
9Friction spring 1
9Reel 2
cC
Be sure to press down on the reel, because
the spring will pop out suddenly when it is
removed from the reel.
3. Remove:
9Spiral spring 1
4. Remove:
9Swing arm 1
RECOIL STARTER INSPECTION
1. Inspect:
9Starter rope 1
Damage →Replace.
9Spiral spring 2
Deternation/crack/damage →Replace.
ENG
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							3-9
RECOIL STARTER AND ROTOR
1 23
1
2
1 2
1
1
2a
2. Inspect:
9Swing arm 1
9Friction spring 2
9Collar 3
Deternation/crack/damage →Replace.
RECOIL STARTER ASSEMBLY
1. Install:
9Swing arm 1
9Collar 2
install the swing arm to the collar.
2. Install:
9Spiral spring 1
9Reel 2
NOTE:
Hook the edge of spiral spring to the groove
and then carefully wind the spring counter
clockwise and place it on the reel.
3. Wind the starter rope 1clockwise two
turns on the reel.
4. Install:
9Reel 1
9Starter case 2
NOTE:
Slowly install the hook aof the spiral spring
into the groove.
ENG
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							3-10
RECOIL STARTER AND ROTOR
1 2
1
2
3
1
23
4
5
5. Install:
9Friction spring
9Collar 1
9Set screw 2
6. Hook the starter rope in the cutout in the
reel, and wind it counter clockwise four
turns.
7. Pull the starter rope and check the recoil
starter operation.
IGNITION COIL AND ROTOR REMOVAL
1. Remove:
9Ignition coil 1
9Rotor nut 2
use the sheave holder 3.
2. Remove:
9Rotor 1
use the rotor puller 2, bolt 3, washer
4and nut 5.
ENG
Sheave holder:
YS-01880, 90890-01701
Rotor puller:
YU-33270, 90890-03162
Bolt 3 ·········· 95817-06100·····2 pcs.
Washer 4 ···· 95817-06380···· 2 pcs.
Nut 5 ·········· 95817-06254···· 2 pcs.
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							3-11
RECOIL STARTER AND ROTOR
21
1
IGNITION COIL AND ROTOR INSTALLA-
TION
cC
Be sure to remove any oil grease from the
tapered portion of the magneto rotor using
a cloth dampened with thinner.
1. Install:
9Woodruff key 1
9Rotor
9Rotor nut 2
NOTE:
When installing the rotor, make sure the
woodruff key is properly seated in the key way
of the crankshaft.
2. Install:
9Ignition coil 1
3. Inspection:
9Air gap
inspect the clearance between the
magneto on the rotor and ignition coil.
Out of specification →Replace.
ENG
Air gap:
0.5 ± 0.1 mm
(0.02 ± 0.004 in)
6 Nm (0.6 m · kg, 4.3 ft · lb)
27 Nm (2.7 m · kg, 19.4 ft · lb)
7VV10-03  02.10.4 10:38 AM  Page 11