Yamaha EF1000iS User manual

SERVICE MANUAL
EF1000iS
LIT-19616-01-02 7VV-28197-10
310137
7VV-Cover 02.9.26 2:30 PM Page 1

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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 mechanic’s education into one
manual, so it is assumed that persons using
this book to perform maintenance and repairs
on Yamaha generators have a basic under-
standing of the mechanical precepts and pro-
cedures 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 manufac-
tured 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 emis-
sion control system. Please read this material
carefully.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT
INFORMATION
This material is distinguished by the following
notation.
Q
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could
result in severe injury or death to the
machine operator, a bystander, or a person
inspecting or repairing the machine.
cC
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 clearer.
MANUAL FORMAT
The procedures in this manual are organized
in a sequential, step-by-step format. The infor-
mation has been compiled to provide the
mechanic with an easy to read, handy refer-
ence that contains comprehensive explana-
tions 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.,
9Bearings
Pitting/damage →Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams
before each disassembly section for ease in
identifying the correct disassembly and
assembly procedures.
EF1000iS
SERVICE MANUAL
©2002 by Yamaha Motor
Corporation, U.S.A.
1st Edition, October 2002
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor
Corporation, U.S.A.
is expressly prohibited.
Printed in USA
LIT-19616-01-02
7VV10-00 02.10.4 10:35 AM Page 1

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1through 7are designed
as thumb tabs to indicate the chapter’s number
and content.
1General information
2Periodic inspections and adjustments
3Engine
4Carburetor
5Electrical
6Trouble shooting
7Specifications
Illustrated symbols 8through rare used to
identify the specific tools and test equipment.
8Filling fluid
9Lubricant
0Special tool
qTightening
wWear limit, clearance
eEngine speed
rW, V, A
Illustrated symbols tthrough din the
exploded diagram indicate the grades of lubri-
cant and the locations of the lubrication points.
tApply engine oil
yApply gear oil
uApply molybdenum disulfide oil
iApply wheel bearing grease
oApply lightweight lithium-soap base grease
pApply molybdenum disulfide grease
aApply a locking agent (LOCTITE®)
sApply Yamaha bond
dUse a new one
GEN
INFO
INSP
ADJ
ENG
ELEC
T
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.
.
EGM
BLS M
LT 4New
12
34
56
CARB
SPEC
7
TRBL
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tyu
iop
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7VV10-00 02.10.4 10:35 AM Page 2

INDEX
GENERAL INFORMATION GEN
INFO
PERIODIC INSPECTIONS
AND ADJUSTMENTS INSP
ADJ
ENGINE ENG
CARBURETOR
CARB
ELECTRICAL ELEC
TROUBLESHOOTING TRBL
SPECIFICATIONS SPEC
1
2
3
4
5
6
7
7VV10-00 02.10.4 10:35 AM Page 3

CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ....................1-1
SERIAL NUMBER................................1-1
STARTING SERIAL NUMBER.............1-1
IMPORTANT INFORMATION ...................1-2
PREPARATION FOR REMOVAL AND
DISASSEMBLY
CAUTION ON SERVICE .....................1-2
NOTES ON SERVICE .........................1-2
ALL REPLACEMENT PARTS..............1-3
GASKETS, OIL SEALS,
AND O-RINGS.....................................1-3
BEARINGS AND OIL SEALS ..............1-3
SPECIAL TOOLS AND TESTERS.......1-4
CHAPTER 2.
PERIODIC INSPECTIONS AND
ADJUSTMENTS
INTRODUCTION ..................................... 2-1
MAINTENANCE INTERVALS CHART ... 2-1
PERIODIC MAINTENANCE/LUBRICATION
INTERVALS ............................................ 2-1
COVERS ................................................. 2-3
ENGINE .................................................. 2-4
ENGINE OIL LEAKAGE CHECKING 2-4
OIL LEVEL CHECKING ..................... 2-4
OIL REPLACEMENT ......................... 2-5
FUEL LEAKAGE ................................ 2-6
FUEL TANK FILTER .......................... 2-6
FUEL TANK STRAINER .................... 2-7
AIR FILTER ELEMENT ..................... 2-8
MUFFLER .......................................... 2-9
VALVE CLEARANCE ADJUSTMENT 2-10
COMPRESSION PRESSURE ......... 2-12
RATED ENGINE SPEED ................. 2-13
BREATHER HOSE .......................... 2-13
ELECTRICAL ........................................ 2-14
SPARK PLUG .................................. 2-14
ENGINE SWITCH ............................ 2-15
ECONOMY SWITCH ....................... 2-15
PILOT LIGHT ................................... 2-15
RECEPTACLE ................................. 2-16
DC CIRCUIT BREAKER .................. 2-16
CHAPTER 3.
ENGINE
CONTROL BOX ...................................... 3-1
CONTROL BOX DISASSEMBLY ...... 3-2
CONTROL BOX ASSEMBLY ............. 3-4
ENGINE .................................................. 3-5
RECOIL STARTER AND ROTOR .......... 3-6
RECOIL STARTER DISASSEMBLY .. 3-7
RECOIL STARTER INSPECTION ..... 3-8
RECOIL STARTER ASSEMBLY ........ 3-9
IGNITION COIL AND ROTOR
REMOVAL ....................................... 3-10
IGNITION COIL AND ROTOR
INSTALLATION ................................ 3-11
MUFFLER ............................................. 3-12
GENERATOR ........................................ 3-13
ROTOR AND STATOR COIL ASSEMBLY
REMOVAL ....................................... 3-14
STATOR COIL INSTALLATION ....... 3-14
CRANKCASE2, CAMSHAFT AND
ROCKER ARM ...................................... 3-16
CAMSHAFT INSPECTION .............. 3-18
CAM FOLLOWER INSPECTION .... 3-18
PUSH ROD INSPECTION ............... 3-18
ROCKER ARM INSPECTION ......... 3-19
CRANKCASE 2 INSPECTION ........ 3-19
CAMSHAFT AND LOCKER ARM
INSTALLATION ................................ 3-19
CRANKSHAFT, PISTON AND
PISTON RING ....................................... 3-21
PISTON AND PISTON PIN
INSPECTION ................................... 3-23
PISTON RING INSPECTION .......... 3-24
CRANKSHAFT INSPECTION ......... 3-25
CONNECTING ROD OIL CLEARANCE
INSPECTION ................................... 3-26
PISTON AND PISTON RING
INSTALLATION ................................ 3-27
CONNECTING ROD AND
7VV10-00 02.10.4 10:35 AM Page 4

CRANKSHAFT INSTALLATION ...... 3-27
CYLINDER (CRANKCASE 1) AND
VALVE ................................................... 3-29
VALVE AND VALVE SPRING
REMOVAL ....................................... 3-31
VALVE AND VALVE SPRING
INSPECTION ................................... 3-31
VALVE SEAT INSPECTION ............ 3-33
CYLINDER (CRANKCASE 1)
INSPECTION ................................... 3-35
VALVE AND VALVE SPRING
ASSEMBLY ...................................... 3-35
CHAPTER 4.
CARBURETOR
CARBURETOR ....................................... 4-1
CARBURETOR DISASSEMBLY ....... 4-2
FLOAT HEIGHT INSPECTION .......... 4-4
CHOKE CABLE INSTALLATION ....... 4-5
THROTTLE CONTROL MOTOR ....... 4-5
FUEL PUMP, FUEL TANK AND
FUEL CHANGE LINK ............................. 4-6
FUEL PUMP INSPECTION ..................... 4-8
FUEL TANK FILTER INSPECTION ......... 4-8
CHAPTER 5.
ELECTRICAL
ELECTRICAL COMPONENTS ............... 5-1
CIRCUIT DIAGRAM .......................... 5-2
SWITCHES ............................................. 5-3
CHECKING SWITCH CONTINUITY . 5-3
IGNITION SYSTEM ................................ 5-4
TROUBLESHOOTING CHART ......... 5-4
GENERATOR SYSTEM .......................... 5-8
TROUBLESHOOTING CHART ......... 5-8
CHAPTER 6.
TROUBLESHOOTING
ENGINE .................................................. 6-1
THROTTLE CONTROL SYSTEM .......... 6-6
CHAPTER 7.
SPECIFICATIONS
GENERAL SPECIFICATIONS ................ 7-1
MAINTENANCE SPECIFICATIONS ....... 7-3
ENGINE ............................................. 7-3
GENERATOR AND ELECTRICAL ..... 7-6
TIGHTENING TORQUE .......................... 7-7
GENERAL TORQUE SPECIFICATIONS 7-8
DEFINITION OF UNITS .......................... 7-8
LUBRICATION POINT AND
TYPE OF LUBRICANTS ........................ 7-9
WIRE ROUTING DIAGRAM ................. 7-10
7VV10-00 02.10.4 10:35 AM Page 5

GEN
INFO
1-1
MACHINE IDENTIFICATION
1
7VV–
7VV-24163-00
GENERAL INFORMATION
MACHINE IDENTIFICATION
SERIAL NUMBER
The serial number is printed on a label 1
which is affixed to the generator as shown.
NOTE:
The first three characters of this number are
for model identification, the remaining digits
are the unit production number.
STARTING SERIAL NUMBER
7VV-200101~
NOTE:
Designs and specifications are subject to
change without notice.
7VV10-01 02.10.4 10:36 AM Page 1

GEN
INFO
1-2
SVU1030
SVU1040
SVU1050
SVU1060
SVU1070
SVU1080
SVU1090
SVU1100
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
CAUTION ON SERVICE
1. Fire prevention
When servicing the engine, always keep the engine and yourself
away from fire.
NOTES ON SERVICE
1. Correct tools
Be sure to use the correct special tool for the job to guard
against damage.
IMPORTANT INFORMATION
2. Oil, grease and seals
Be sure to use genuine Yamaha oils, grease and sealers, or the
equivalents.
3. Expendable parts
Always replace the gaskets, O-rings, cotter pins and circlips with
new parts when servicing engine.
4. Tightening torque
Be sure to follow torque specifications. When tightening bolts,
nuts or screws, start with the largest-diameter fastener and work
from an inner position to an outer position in a crisscross pat-
tern.
5. Notes on disassembly and assembly
a. Parts should be cleaned in solvent and blown dry with com-
pressed air after disassembly.
b. Contact surfaces of moving parts should be oiled when
reassembled.
c. Make sure that the parts, move smoothly after each section of
the machine is assembled.
1
2
3
4
5
7VV10-01 02.10.4 10:36 AM Page 2

GEN
INFO
1-3
SVU1110
SVU1120
ALL REPLACEMENT PARTS
We recommend the use of genuine Yamaha parts for all replace-
ments. Use oil and/or grease, recommended by Yamaha, for
assembly and adjustment.
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals, and O-rings should be replaced when an
engine is overhauled. All gaskets surfaces, oil seal lips, and O-
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
Install the bearing(s) 1and oil seal(s) 2with their manufacture’s
marks or numbers facing outward. (In other words, the stamped let-
ters must be on the side exposed to view.) When installing oil
seal(s), apply a light coating of lightweight lithium base grease to
the seal lip(s). Oil the bearings liberally when installing.
cC
Do not use compressed air to spin the bearings dry. This
causes damage to the bearing surfaces.
IMPORTANT INFORMATION
7VV10-01 02.10.4 10:36 AM Page 3

GEN
INFO
1-4
SVU1150
SVU1160
SVU1170
SVU1180
SVU1190
SVU1205
SPECIAL TOOLS AND TESTERS
The proper special tools are necessary for complete and accurate
tune-up and assembly. Using the correct special tool will help pre-
vent damage caused by the use of improper tools or improvised
techniques.
1. Thickness gauge
P/N. YU-26900-9, 90890-03079
This gauge is used to adjust valve clearance, piston clearance
and piston ring end gap.
2. Cylinder gauge
Commercially obtainable
This instrument is used for checking cylinder bore size and con-
dition.
3. Inductive tachometer
P/N. YU-8036-A
Engine tachometer
P/N. 90890-03113
This instrument is used for reading engine r/min.
4. Compression gauge 1
P/N. YU-33223, 90890-03081
Adapter 2
P/N. YU-33223-3, 90890-04082
This gauge is used for checking engine compression.
5. Dial gauge
P/N. YU-03097, 90890-03097
This instrument is used for checking crankshaft side clearance.
6. Sheave holder
P/N. YS-01880, 90890-01701
This tool is necessary for holding the magneto rotor.
SPECIAL TOOLS AND TESTERS
7VV10-01 02.10.4 10:36 AM Page 4

GEN
INFO
1-5
SVU1210
1
SVU1220
2
SVU1230
SVU1240
1
SVU1250
2
7. Rotor puller
1P/N. YU-33270
2P/N. 90890-01362
This tool is necessary for removing the magneto rotor.
8. Pocket tester
P/N. YU-03112, 90890-03112
This instrument is necessary for checking the electrical system.
9. Digital circuit tester
90890-03174
This instrument is necessary for checking the electrical system.
10.Dynamic spark tester 1
P/N. YM-34487
Ignition checker 2
P/N. 90890-06754
This instrument is necessary for checking the ignition system
components.
SPECIAL TOOLS AND TESTERS
7VV10-01 02.10.4 10:36 AM Page 5

GEN
INFO
7VV10-01 02.10.4 10:36 AM Page 6

INSP
ADJ
2-1
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 prepared
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 relat-
ed 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 indicated as “*” in the chart.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INTRODUCTION/MAINTENANCE INTERVALS CHART/
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
No. Item Remarks
Pre-Ope-
ration
check
(daily)
Initial Every
1
month
or 20 Hr
3
months
or 50 Hr
6
months
or 100 Hr
12
months
or 300 Hr
1. *Check condition.
Spark Plug Adjust gap and clean. Replace if necessary. 0
2. * Check and adjust Valve Clearance when engine is cold. 0
*
3. Crankcase Check breather hose for cracks or damage. 0
breather system Replace if necessary.
4. *Check and adjust engine idle speed. 0Idle speed
Check for leakage.
*Retighten or replace gasket if necessary. 0
5. Exhaust System Check muffler screen and spark arrester. Clean/ 0
replace if necessary.
Check oil level 0
6. Engine Oil Replace 00
*Clean.
7. Air Filter Replace ifnecessary. 0
Clean fuel tank filter.
8. Fuel Filter Replace if necessary. 0
Check fuel hose for crack or damage.
9. Fuel Line Replace if necessary. 0
10. *Check choke operation. 0Choke knob
11. Cooling System Check for fan damage. 0
12. Starting System Check recoil starter operation. 0
* : Related to emission control system.

INSP
ADJ
2-2
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
No. Item Remarks
Pre-Ope-
ration
check
(daily)
Initial Every
1
month
or 20 Hr
3
months
or 50 Hr
6
months
or 100 Hr
12
months
or 300 Hr
13. Generation Check the pilotlight comes on. 0
14. Fittings/ Check all fittingsand fasteners.
Fasteners Correct if necessary. 01
2
3
4
5

Order Job name Q’ty Remarks
Cover 2, cover 3, side cover 2, Remove the parts in the order listed
rear cover, front cover removal below.
1 Cover 2 1
2 Cover 3 1
3 Side cover 2 1
4 Rear cover 1
5 Remort control cable 1 Disconnect the fuel hose from the fuel
cock side.
6 Choke cable 1 Disconnect the fuel hose from the
carburetor side.
7 Front cover 1 Disconnect the couplers and lead wireds.
For installation, revers the removal
procedure.
2-3
COVERS
COVERS
1
2
3
4
5
6
7
6 Nm (0.6 m ·kg, 4.3 ft ·lb)
INSP
ADJ
7VV10-02 02.10.4 10:37 AM Page 3

2-4
ENGINE OIL LEAKAGE CHECKING/
OIL LEVEL CHECKING
1
700-087a
a
ENGINE
ENGINE OIL LEAKAGE CHECKING
1. Remove:
9Cover 3
9Side cover 2
9Side cover
2. Check the areas outside of the engine for
oil leakage.
Oil leakage →Replace the gasket, oil
seal, or O-ring.
OIL LEVEL CHECKING
1. Check:
9Oil level with oil warning light 1
Check whether the oil warning light
flashes by operating the recoil starter.
Oil warning light flashes →Add oil.
Oil warning light does not flash →OK
2. Remove:
9Cover 3
9Oil filler cap
3. Check:
9Check that the engine oil is at the spec-
ified level a.
Oil level checking steps:
9Place the engine on a level surface.
9Warm up the engine for several minutes.
9Stop the engine.
9Check that the engine oil is at the speci-
fied level a. Add oil if necessary.
4. Install:
9Oil filler cap
9Cover 3
INSP
ADJ
7VV10-02 02.10.4 10:37 AM Page 4

2-5
OIL REPLACEMENT
1
1
SVU2060
OIL REPLACEMENT
1. Warm up the engine for several minutes.
2. Stop the engine.
3. Remove:
9Drain joint 1
9Cover 3
Remove the drain joint from the mount
base.
4. Place a receptacle under the engine.
5. Remove:
9Oil filler cap
6. Install:
9Drain joint 1
7. Tilt the engine to drain the oil completely.
8. Fill:
NOTE:
Recommended engine oil classification:
API Service “SE”or “SF”, if not available, “SD”.
9. Remove:
9Drain joint
10.Install:
9Oil filler cap
9Drain joint
Clean the drain joint then install the
drain joint t the mount base.
9Cover 3
INSP
ADJ
Recommended oil:
åYAMALUBE 4 (10W-30) or SAE
10W-30 type SE
∫SAE #30
çSAE #20
∂SAE 10W
Engine oil quantity:
0.32 L (0.28 Imp qt, 0.34 US qt)
7VV10-02 02.10.4 10:37 AM Page 5

2-6
FUEL LEAKAGE/
FUEL TANK FILTER
1
FUEL LEAKAGE
1. Remove:
9Cover 3
2. Check:
9Leakage
Check at fuel tank, fuel pump, fuel
cock, fuel hose, and carburetor.
cC
Replace hose every four years.
FUEL TANK FILTER
w
Do not smoke, and keep away form open
flames, sparks, or any other source of fire
when handling or in the vicinity of fuel.
1. Remove:
9Fuel tank cap
9Fuel tank filter 1
2. Inspect:
9Fuel tank filter
Damage →Replace.
3. Clean:
9Fuel tank filter
NOTE:
Clean the fuel tank filter with solvent, and then
dry it thoroughly.
4. Install:
9Fuel tank filter
9Fuel tank cap
w
Be sure the tank cap is tightened securely.
INSP
ADJ
7VV10-02 02.10.4 10:37 AM Page 6

2-7
FUEL TANK STRAINER
2
3
1
1
FUEL TANK STRAINER
w
Do not smoke, and keep away form open
flames, sparks, or any other source of fire
when handling or in the vicinity of fuel.
1. Remove:
9Cover 3
9Side cover 2
9Rear cover
9Front cover
2. Drain the fuel from the fuel tank com-
pleatly.
3. Remove:
9Fuel tank 1
9Fuel hose 2
9Fuel tank strainer 3
4. Inspect:
9Fuel tank strainer 1
Damage →Replace.
5. Clean:
9Fuel tank strainer
Damage →Replace.
NOTE:
Clean the fuel tank strainer with solvent, and
then dry it thoroughly.
6. Install:
9Fuel tank strainer
to the fuel tank
7. Install:
9Fuel hose
9Fuel tank
9Front cover
9Rear cover
9Side cover 2
9Cover 3
INSP
ADJ
7VV10-02 02.10.4 10:37 AM Page 7