Yamaha EF1000 User manual

EF1000
Service
Manual
7FL-28197-11

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 manu-
al, so it
is assumed that persons using this book
to perform maintenance and repairs on Yamaha
generator 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 striv-
ing
to further improve all models manufactured
by Yamaha. Modifications and significant
changes in specifications or procedures will be for-
warded
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 materi-
al carefully.
EF1000
SERVICE
MANUAL
©1995 by Yamaha Motor Co., Ltd.
1st Edition, January 1995
All rights reserved. Any reprinting or
unauthorized use
without the written
permission of Yamaha
Motor Co., ltd.
is expressly prohibited.
Printed
in Japan
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT
INFORMATION
This material is distinguished bythe following no-
tation.
&
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY
IS INVOLVED!
A WARNING
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.
I"lllli•lz•·•••·••·•
A CAUTION indicates special precautions that
must be taken to avoid damage to the machine.
NOTE:
A NOTE provides key information to make proce-
dures easier or clearer.
MANUAL FORMAT
The procedures in this manual are organized
in a sequential, step-by-step format. The in-
formation 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 arrowsymbol 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
correct disassembly and assembly procedures.

CD
GEN
....
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INFO
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ENG
1•1
@
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@
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©
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@ 1
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(2)
l~5~l§ll
@
IELEciUI
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®
1~1
@ §
@ 1
9
®
~
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols CD to @ are designed as
thumb tabs to indicate the chapter's number
and content.
<D General information
~ Periodic inspection and adjustment
®Engine
® Electrical
® Specifications
Illustrated symbols @to @ are used to iden-
tify the specifications appearing.
® Special tool
(]) Filling fluid
@ Lubricant
® Tightening
@ Wear limit, clearance
(j]) 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®)

INDEX
GENERAL INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE
ELECTRICAL
SPECIFICATIONS
111
GEN
INFO
•II II nil
-
ENG
ELEC

CONTENTS
CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION..................... 1-1
IMPORTANT INFORMATION ...................1-2
SPECIAL TOOLS
AND TESTERS .............1-5
CHAPTER 2
PERIODIC INSPECTIONS
AND ADJUSTMENTS
INTRODUCTION....................................... 2-1
MAINTENANCE INTERVALS CHART...... 2-1
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS...................... 2-1
BODY COVER/FUEL TANK ......................2-3
JOB INSTRUCTION CHART................ 2-3
ENGINE.....................................................2-4
ENGINE OIL......................................... 2-4
FUEL COCK.......................................... 2-5
START WIRE ADJUSTMENT.............. 2-6
FUEL LINE............................................ 2-6
AIR FILTER...........................................
2-7
MUFFLER............................................. 2-7
VALVE CLEARANCE ADJUSTMENT .. 2-8
COMPRESSION PRESSURE
MEASUREMENT................................. 2-9
ENGINE SPEED
ADJUSTMENT ......... 2-10
GOVERNOR
ADJUSTMENT ............... 2-10
SPARK PLUG .......................................
2-11
CYLINDER HEAD................................. 2-12
BREATHER HOSE INSPECTION ......... 2-12
CHAPTER3
ENGINE
AIR CARBURETOR, MUFFLER ................ 3-1
JOB INSTRUCTION CHART................ 3-2
ENGINE.....................................................3-3
JOB INSTRUCTION CHART................ 3-4
CYLINDER HEAD COVER, CYLINDER
HEAD, VALVE ...........................................3-5
JOB INSTRUCTION CHART................ 3-6
CYLINDER HAD INSPECTION ............
3-7
VALVE REMOVAL ................................ 3-7

VALVE INSPECTION ............................ 3-7
VALVE SEAT INSPECTION.................. 3-8
PUSH ROD INSPECTION .................... 3-10
CYLINDER HEAD INSTALLATION ...... 3-10
PISTON,CAMSHAFT,CRANKCASE,
CRANKSHAFT.......................................
.. 3-11
JOB INSTRUCTION CHART................ 3-12
CRANKSHAFT REMOVAL................... 3-13
CAMSHAFT AND VALVE LIFTER
INSPECTION........................................ 3-13
CRANKCASE INSPECTION................. 3-14
PISTON,PISTON PIN
AND
PISTON RING INSPECTION ............... 3-15
CRANKSHAFT INSPECTION .............. 3-16
FLYWEIGHT SHAFT (GOVERNOR)
GEAR INSPECTION ............................. 3-17
CRANKCASE COVER INSPECTION ... 3-18
PISTON RING
AND PISTON
INSTALLATION.................................... 3-18
CONNECTING ROD INSTALLATION
.. 3-19
CAMSHAFT INSTALLATION............... 3-19
CRANKCASE COVER
INSTALLATION.................................... 3-19
RECOIL STARTER ................................... 3-20
JOB INSTRUCTION CHART................ 3-20
RECOIL STARTER REMOVAL ............. 3-21
RECOIL STARTER INSPECTION ......... 3-21
RECOIL STARTER INSTALLATION ..... 3-22
FLYWHEEL...............................................3-23
JOB INSTRUCTION CHART................ 3-23
FLYWHEEL REMOVAL......................... 3-24
GENERATOR...................................... 3-25
JOB INSTRUCTION CHART.................3-25
ROTOR REMOVAL............................... 3-26
STATOR INSTALLATION..................... 3-26
ROTOR INSTALLATION ...................... 3-26
REAR FRAME INSTALLATION............ 3-26
GOVERNOR .............................................3-27
JOB INSTRUCTION CHART................ 3-28
CARBURETOR......................................... 3-29
JOB INSTRUCTION CHART................ 3-30
FLOAT HEIGHT INSPECTION ............. 3-31
FUEL PASSAGE INSPECTION ............ 3-31
VALVE SEAT INSPECTION.................. 3-31

CHAPTER 4
ELECTRICAL
ELECTRICAL COMPONENTS ................. .4-1
CIRCUIT DIAGRAM ..................................4-2
IGNITION
SYSTEM ..................................4-3
TROUBLESHOOTING CHART ............ 4-3
GENERATOR SVSTEM.............................4-7
TROUBLESHOOTING CHART ............ 4-7
INSPECTION ........................................ 4-9
CHAPTER 5
SPECIFICATIONS
GENERAL SPECIFICATIONS.................... 5-1
MAINTENANCE SPECIFICATIONS..........5-2
TIGHTENING TORQUE ............................5-5
GENERAL TORQUE SPECIFICATIONS
... 5-6
DEFINITION OF
UNITS ............................5-6
HOSE ROUTING.......................................5-7

MACHINE IDENTIFICATION
~~~~.
790-027
1-1
GENERAL INFORMATION
MACHINE IDENTIFICATION
ENGINE SERIAL NUMBER
The engine serial number CD is stamped into the
rear cover.
NOTE: ________________________ ___
The first three digits of these numbers are
for model identification; the remaining digits
are the unit production number.
STARTING SERIAL NUMBER
IEF1000
7FL I 0400101-
NOTE: --------------------------
Designs and specifications are subject to change
without notice.

IMPORTANT INFORMATION
[ __ ]
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
engine.

Solvent
Dissolvant
Losungsmittel
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 disassembly.
b. Contact surfaces
of moving parts should be
oiled when reassembled.
c. Make sure
that parts move smoothly after
each section
of the 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
by
Yamaha
for
assembly 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 dur-
ing reassembly.
Apply
grease
to
the
oil seal
lips.
BEARINGS
AND
OIL
SEALS
1.
Install the bearing(s)
CD
and oil seal(s)
(l)
with
their manufacture's marks or numbers
facing outward. (In other words, the stamped
letters
must
be on the side exposed
to
view.)
When
installing oil seal(s), apply a light coat-
ing
of
light-weight
lithium base grease
to
the
seal lip(s). Oil the bearings liberally
when
in-
stalling.
1111111~····
--------
Do
not
use
compressed
air
to
spin
the
bear-
ings
dry.
This
causes
damage
to
the
bearing
surfaces.

SPECIAL TOOLS
AND
TESTERS
GEN
INFO
1-5
SPECIAL TOOLS
AND
TESTERS
The proper special tools are necessary
for
com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use
of
improper tools or improvised
techniques.
1.
Rotor shock
puller
P/N. YU-1047 (90890-01259)
Rotor
puller
attachment
(M10 x 1.25)
P/N. YU-1350 (90890-01349)
This tool
is
used
to
remove the rotor.
2.
Piston ring
compressor
P/N. YU-33294 (90890-05158)
This tool
is
used
to
compress the piston rings
when installing the piston.
3. Valve
spring
compressor
P/N. YM-01253 (90890-01253)
This
tool
is used
to
remove
the
valve spring.
4.
Service
gauge
(Thickness gauge)
P/N. YU-26900-9 (90890-03079)
This gauge
is
used
to
adjust valve clearance,
piston clearance and piston ring end gap.

SPECIAL TOOLS AND TESTERS
1-6
5. Cylinder gauge
P/N. YU-03017 (90890-03017)
This instrument
is used for checking cylinder bore
size and condition.
6. Inductive tachometer
P/N. YU-8036-A
This instrument
is used for reading engine rpm.
7. Compression gauge set
P/N. YU-33223 (90890-03081)
Adapter
P/N. YU-33223-3 (90890-04082)
This gauge
is for checking engine compression.
8. Dial gauge
P/N. YU-03097 (90890-03097)
This instrument
is used for checking crankshaft
side clearance.
9. Piston pin puller
P/N. YU-01304 (90890-01304)
This tool
is used to remove the piston pin.

SPECIAL TOOLS AND TESTERS
GEN ....
INFO l!IJ
1-7
10. Pocket tester
P/N. YU-03112 (90890-03112)
This instrument
is necessary for checking the elec-
trical system.
11. Dynamic spark tester [6]
P/N. YM-34487
Ignition checker rn:J
P/N. 90890-06754
This
instrument is necessary for checking the
ignition system components.

INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS INSP
ADJ
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and
adjustments. 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
related
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 services related to emissions control are indicatedas "**" in the chart.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
Pre-Opera- Initial
Every
No. Item Remarks
tion check 1
month 3 months 6 months
12 months
(daily)
or 20 Hr or 50 Hr or 100 Hr
or 300 Hr
**
Check condition adjust
1.
gap and clean. Replace •
Spark Plug
if necessary.
**
Check and adjust when
•
2.*
Valve Clearance
engine is cold.
**
Check breather hose
3.*
Crankcase breather
for cracks or damage.
•
system
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 muffler screen
and spark arrester. •
Clean/replace if neces-
sary.
Check
oil level •
6. Engine oil
Replace • •
**
Clean.
7. •
Air Filter Replace
if necessary.
Clean fuel
tank filter.
•
8 .. Fuel Filter Replace
if necessary.
*Check fuel cock filter.
•
Replace if necessary.
Check fuel hose
for
9.
Fuel Line crack
or damage.
•
*Replace if necessary.
**
Check control lever
10. •
Control lever
(choke) operation.
11.*
Control System Check
for fan damage.
•
12. Starting System Check recoil
starter
•
operation.
2-1

No.
13.*
14.
15.*
Item
**
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
Pre-Opera-
Initial
Remarks tion check 1
month 3 months
(daily)
or 20 Hr or 50 Hr
More frequently if
Decarbonization
necessary.
Check
the voltage
Generation
meter and pilot light
•
comes on.
Fittings/
Check all fittings and
fasteners.
Fasteners Correct
if necessary.
INSP
ADJ
Every
6 months
or 100 Hr
•
* :It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
**:Related to emission control system.
2-2
12 months
or 300 Hr
•

BODY COVER/FUEL TANK l'~g~ Itit I
BODY COVER/FUEL TANK
9
.. .,. ··.
. . . . . ., ·.
. . . .
. .
::. : .. ·
. .-. . . . .
. . .
4
3
2
JOB INSTRUCTION CHART
Order
Job name/Parts name
O'ty
Remarks
Removal of Body cover and Remove the parts in order.
Fuel tank
1 Rear
cover
1
2
Cover side 1 1
3
Front cover 1
4
Coupler/Engine stop lead 1
5
Coupler
1
6
Starter (Choke) wire 1
7 Fuel hose/Fuel
tank breather hose 1 NOTE:
Turn the fuel cock lever to "OFF".
F•1'N!1;l~!!~tc1Aiways clean up spilled fuel
immediatey.
8 Fuel
tank 1
9
Cover side 2 1 Reverse
the removal procedure
for installation.
2-3

_____________ E_N_G_IN_E_o_I_LI~IQI
ENGINE
(10W-30)
700-001 b
700-008
2-4
ENGINE OIL
Recommended oil:
[A] YAMALUBE 4-cycle oil or
SAE 1OW-30 type SE motor oil
rn:J SAE #30
[QJ SAE #20
[Q] SAE #10
Engine oil quantity:
0.43 L (0.38 Imp qt,
0.45 us qt)
NOTE: --------------------------
Recommended engine oil classifiaction:
API
Service "SE" or "SF" if not available,
"SD".
Oil Level Measurement
1. Check:
•Oil level
Oil level measurement steps:
•Place the engine on level ground.
•Warm up the engine for a few minutes.
•Stop the engine.
• Make
sure the engine oil is between upper and
lower levels. Add oil
as necessary.
CD Upper level
(2) Lower level
Oil Replacement
1. Warm up engine for several minutes.
2. Place a receptacle under the engine.
3. Remove:
•Oil filler cover

2-5
FUEL COCK
4. Remove:
•Oil filler cap CD
Drain the engine oil.
5. Fill:
•Crankcase
Use
oil filler cover CD
Recommended engine oil:
0.43 L (0.38
Imp qt, 0.45 US qt)
CAUTION:
Do not allow foreign material to enter the
crankcase.
6. Tighten:
•Oil filler cap
7. Install:
•Oil filler cover
FUEL COCK
Removal and Inspection
1. Remove:
•Body panel
2. Drain the fuel tank and remove the fuel
hose
from the fuel cock.
3. Inspect:
•Fuel cock body CD
Contamination-7Ciean.
•0-ring/Gasket@
Damage-7Replace.
•Strainer@
Contamipation-7Ciean.
NOTE: ________________________ _
Clean the body with solvent and wipe it off.