Yamaha EF1000iS Service Manual

							4-6
FUEL PUMP, FUEL TANK AND FUEL CHANGE LINK
FUEL PUMP, FUEL TANK AND FUEL CHANGE LINK
3
2
1
4
7
6
5
9
8
11
10
4 Nm (0.4 m · kg, 2.9 ft · lb)
CARB
Order Job name Q’ty Remarks
Fuel cock, fuel tank andRemove the parts in the order listed 
fuel change link removalbelow.
Front cover and rear coverRefer to “COVERS” section in CHAPTER 2.
1 Pipe 3 1 Set the fuel cock to “OFF” position.
2 Pipe 4 1
3 Fuel change link assembly 1 Remove from the bracket.
4 Fuel tank assembly 1
5 Cap assembly 1
6 Strainer 1 1
7 Holder 1
8 Pipe 2 1
9 Fuel pump assembly 1
10 Fuel hose 1
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							4-7
FUEL PUMP, FUEL TANK AND FUEL CHANGE LINK
3
2
1
4
7
6
5
9
8
11
10
4 Nm (0.4 m · kg, 2.9 ft · lb)
CARB
Order Job name Q’ty Remarks
11 Fuel tank filter
Remove the parts in the order listed 
For installation, reverse the removal
procedure.
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							4-8
FUEL PUMP, FUEL TANK AND FUEL CHANGE LINK
A
FUEL PUMP INSPECTION
1. Inspect:
9Fuel pump
Inhale the hose form A→Open.
Blow the hose to A→Close.
cC
Excessive force will damage the fuel pump
must be replaced.
FUEL TANK FILTER INSPECTION
1. Inspect:
9Fuel tank filter
Wear →Replace.
Dirt/clog →Clean.
CARB
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							CARB
7VV10-04  02.10.7 6:54 PM  Page 9
1_, I  
						

							5-1
ELECTRICAL COMPONENTSELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1Control unit assembly
2Speed limiter
3Overload warning light (Red)
4Pilot light (Green)
5Oil warning light (Red)
6Generator assembly
7Engine switch
8Economy switch
9DC circuit breaker
0AC receptacle (7.5 A×2)
qDC receptacle (12 V-8 A)
wSpark plug cap
eHigh-tension cable
rIgnition coil
tThrottle control motor
yRectifier
1 2345
6
7
8 9 q
0
t
6
e
r y
1w
7VV10-05  02.10.9 8:36 AM  Page 1 
						

							5-2
CIRCUIT DIAGRAMELEC
CIRCUIT DIAGRAM
W
WWOr
W
WW
W
WW
Br
Br
BrBr
Br
Br Br W
W
WBr
Br Br
BrBr
BrBrG
Br
G
BrW
W
W W
Or
WR
R RBr
RBr
R
LLLL
L
L
L
Y
B B
B
B
B
BB
B
B
B
R
RR
R
L
L
L
L G G
Y
Y
O
R
L G
Y
O
OB/W
B/WB/W
B/W
B/W
B/W
B/WG/Y
G/Y
B/W B/W
Y Y
Y
Y O O R
S
T
R
S
T
1
2
3
4
f
s
a
d
gp
oy
u
it e
r w q0 98
7
6
5
1AC coil 1 (AC)
2AC coil 2 (AC)
3DC charge coil
4Generator assembly
5Rectifier
6Control unit assembly
7Pilot light (Green)
8AC receptacle (7.5A×2)
9Economy switch
0Overload warning light (Red)
qDC circuit breaker
wDC receptacle (12V-8A)
eSpeed limiter
rTCI unit
tEngine switch
yOil warning light (Red)
uGround terminal
iControl box
oGround terminal
pOil level switch
aMagneto rotor
sIgnition coil
dSpark plug
fThrottle control motor
gEngine assembly
COLOR CODE
B ........Black
Br .......brown
G ........Green
L.........Blue
Or.......Orange
R ........Red
W .......White
Y ........Yellow
B/W ....Black/White
G/Y ....Green/Yellow
1
2
3
4
5
6
7
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							5-3
SWITCHESELEC
SWITCHES
CHECKING SWITCH CONTINUITY
Use a tester to check the terminals for continu-
ity. If the continuity is faulty at any point,
replace the switch.
NOTE:
9Set the pocket tester to “0” before starting a
test.
9When testing the switch for continuity the
pocket tester should be set to the “×1” Ω
range.
9When checking the switch turn it on and off
a few times.
Pocket tester:
YU-03112, 90890-03112
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							5-4
IGNITION SYSTEMELEC
IGNITION SYSTEM
TROUBLESHOOTING CHART
NO SPARK OR WEAK SPARK
Inspection steps:
1. Spark plug
2. Ignition spark gap
3. Spark plug cap
4. Ignition coil resistance
5. Air gap6. Engine switch
7. Oil level switch
8. Wire harness
NOTE:
9Remove the following part(s) before troubleshooting.
1) Front cover and rear cover
2) Cylinder air shroud 1
3) Cylinder air shroud 2
9Use the following special tool(s) for troubleshooting.
Dynamic spark tester:
YU-34487
Ignition checker:
90890-06754
1. Spark plug
9Check the spark plug condition.
Refer to “SPARK PLUG” in CHAPTER 2.
Repair or replace the spark plug.
SVU4055
SVU4060
2. Ignition spark gap
9Disconnect the spark plug cap 1from the
spark plug.
9Connect the dynamic spark tester 2or igni-
tion checker 3as shown.
Spark plug cap 1→Dynamic spark
tester or ignition checker
Dynamic tester lead or ignition checker
lead →Spark plug 4
åFor USA
åExcept for USA
9Turn the crankshaft and measure the igni-
tion spark gap a.
å
∫
NO GOODGOOD
Pocket tester:
YU-03112, 90890-03112
Digital circuit tester:
90890-03174
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							5-5
IGNITION SYSTEMELEC
Minimum spark gap:
6 mm (0.24 in)
3. Spark plug cap
9Remove the spark plug cap.
9Connect the pocket tester (Ω×1k) to the
spark plug.
Tester (+) lead →Spark plug side 1
Tester (–) lead →
High-tension cord side 2
4. Ignition coil resistance
9Remove the ignition coil.
1) Primary coil resistance
9Connect the pocket tester (Ω×1k) to the pri-
mary terminal.
Tester (+) lead →Black/White terminal 1
Tester (–) lead →
Ground terminal 2
NOTE:
9Do not pull out the plug cap from the high-
tension cord.
9Remove →Turn the plug cap counterclock-
wise.
9Install →Turn the plug cap clockwise.
9Inspect the high-tension cord for cracks or
deterioration, when install the pug cap.
9Cut 5 mm off the end of the high-tension
cord, and then connect it to the plug cap.
2
1
1
2
Spark plug cap resistance:
3.8 ~ 6.3 k
Ωat 20 °C (68 °F)
Primary coil resistance:
0.5 Ω± 20% at 20 °C (68 °F)
The ignition system is good.
MEETS 
SPECIFICATION OUT OF
SPECIFICATION
OR NO SPARK
Repair or replace the spark plug.
OUT OF
SPECIFICATION MEETS 
SPECIFICATION
Replace the ignition coil.
OUT OF
SPECIFICATION
*
MEETS 
SPECIFICATION
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							5-6
IGNITION SYSTEMELEC
2) Secondary coil resistance
9Connect the pocket tester (Ω×1k) to the
secondary terminal.
Tester (+) lead →High-tension cord 1
Tester (–) lead →Ground terminal 2
Secondary coil resistance:
11.5 kΩ± 20% at 20 °C (68 °F)
1
2
5. Air gap
9Measure the thickness between the magnet
rotor and ignition coil.
Air gap:
0.5 ± 0.1 mm (0.02  ± 0.004 in)
6. Engine switch
9Disconnect the engine switch coupler in the
control box.
9Connect the pocket tester (Ω×1k) to the
engine switch terminal.
Tester (+) lead →Black/white terminal 1
Tester (–) lead →
Black terminal 2
Switch “ON” →Continuity
Switch “STOP” →No continuity
B B/W
1
2
Replace the ignition coil.
OUT OF
SPECIFICATION
*
MEETS 
SPECIFICATION
Adjust the air gap.
OUT OF
SPECIFICATIONMEETS 
SPECIFICATION
Replace the engine switch,
NO CONTINUITYCONTINUITY
*
7VV10-05  02.10.7 1:41 PM  Page 6