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

not

possible

put

entire mechanic's education into one manu-

al, so it

assumed

that

persons using this book

perform maintenance and repairs on Yamaha

generator have a basic understanding

the

mechanical precepts and procedures inherent

generator repair technology.

Without

such

knowledge, attempted repairs

service

this

model may render

unfit

for

use

and/or

unsafe.

Yamaha Motor Company Ltd.

continually striv-

ing

further improve all models manufactured

Yamaha.

Modifications

and

significant

changes

specifications or procedures will

for-

warded

all

Authorized Yamaha dealers and will,

where applicable, appear in future editions

this

manual.

NOTE:

--------------------------

This

Service

Manual

contains

information

regarding

periodic

maintenance

the

emis-

sion

control

system.

Please read

this

materi-

al carefully.

EF1000

SERVICE

MANUAL

Motor

Co., Ltd.

1st Edition, January 1995

unauthorized use

without

the

written

permission of Yamaha

Motor

Co.,

ltd.

expressly prohibited.

Printed

Japan

HOW

USE

THIS

MANUAL

PARTICULARLY

IMPORTANT

INFORMATION

This material

distinguished bythe following no-

tation.

The Safety

Alert

Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY

INVOLVED!

A WARNING

Failure

WARNING

instructions could

result in severe injury or death

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

avoid damage

the machine.

NOTE:

A NOTE provides key information to make proce-

dures easier or clearer.

MANUAL

FORMAT

The

procedures

this

manual

are

organized

in a

sequential,

step-by-step

format.

The

in-

formation

has been

compiled

provide

the

mechanic

with

an easy

read,

handy

refer-

ence

that

contains

comprehensive

explana-

tions

all disassembly, repair, assembly,

and

inspection

operations.

In this revised format, the condition

a faulty

component will precede

arrowsymbol and the

course

action required will

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.

GEN

....

INFO

•llllull

ENG

1•1

sPEc

g-1

[ij]

@ 1

® &

(2)

l~5~l§ll

IELEciUI

(j)

1~1

@ §

@ 1

ILLUSTRATED SYMBOLS

(Refer

the

illustration)

Illustrated

symbols

@ are designed

thumb

tabs

indicate

the

chapter's

number

and content.

General

information

Periodic

inspection

and

adjustment

®Engine

® Electrical

Specifications

Illustrated

symbols

@to

@ are used

iden-

tify

the

specifications

appearing.

® Special

tool

(])

Filling

fluid

Lubricant

Tightening

Wear

limit,

clearance

(j])

Engine

speed

@Q,V,A

Illustrated

symbols

@ in

the

exploded

diagram

indicate

grade

lubricant

and loca-

tion

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

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

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

is stamped into the

rear cover.

NOTE:

________________________

___

The

first

three

digits

these

numbers

are

for

model

identification;

the

remaining

digits

are

the

unit

production

number.

STARTING SERIAL

NUMBER

IEF1000

7FL

0400101-

NOTE:

--------------------------

Designs and specifications are subject

change

without

notice.

IMPORTANT INFORMATION

[

]

1-2

IMPORTANT INFORMATION

PREPARATION

FOR

REMOVAL

AND

DISASSEMBLY

NOTES ON SERVICE

Fire prevention

When

servicing the engine, always keep away

from

fire.

2. Right

tools

sure

use the

right

special

tool

for

the

job

guard against damage.

3. Oil, grease and sealers

Be sure

use genuine Yamaha oils, greases

and sealers,

the

equivalents.

4. Expendable parts

Always

replace gaskets,

0-rings,

cotter

pins,

and circlips

with

new

parts

when

servicing

engine.

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