Yamaha EF1000 Service Manual Download | Manualshive

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Summary of Contents for EF1000

Page 1: ...EF1000 Service Manual 7FL 28197 11...

Page 2: ......

Page 3: ...rized 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 by the...

Page 4: ...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 clearan...

Page 5: ...INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE ELECTRICAL SPECIFICATIONS 111 GEN INFO IIII nil ENG ELEC...

Page 6: ...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...

Page 7: ...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 RE...

Page 8: ...YSTEM 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...

Page 9: ...ial 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 S...

Page 10: ...g 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...

Page 11: ...he 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 compres...

Page 12: ...st 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 manufactur...

Page 13: ...r 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 compre...

Page 14: ...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...

Page 15: ...ket 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 nec...

Page 16: ...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...

Page 17: ...equently 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 10...

Page 18: ...e 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...

Page 19: ...d 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 m...

Page 20: ...aterial 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 coc...

Page 21: ...d Loosen the nut 1 2 turn counterclock wise and secure the locknut G e Set the control lever to the 1 1 position f Check whether the closed side of the lever contacts the stopper Contacts the stopper...

Page 22: ...and dry Oil the element and squeeze out excess oil Damage Replace Recommended Oil 3 Install Foam air filter oil or SAE 20 motor oil Air filter element Air filter cover NOTE Do not wring out the elemen...

Page 23: ...the loose carbon from car bon outlet CD of muffler VALVE CLEARANCE ADJUSTMENT 1 Remove Body panel Air shroud Gasket Cylinder head cover Spark plug 2 Measure Valve clearance Out of specification Adjus...

Page 24: ...n in Increase Decrease Turn out Decrease Increase 4 Tighten the locknut G Adjuster Locknut 10 Nm 1 0 m kg 7 2 ft lb COMPRESSION PRESSURE MEASUREMENT Insufficient compression pressure will result in pe...

Page 25: ...as without oil Defective piston ring s valve s and cylinder head gasket Improper valve timing and valve clearance Compression test steps above maximum levels Check cylinder head valve surfaces or pis...

Page 26: ...A 2 Start the engine and warm up for a few minutes 3 Adjust the engine speed by turning the adjust screw CD in or out Engine speed with no load 3 700 3 800 rpm GOVERNOR ADJUSTMENT 1 Remove Body panel...

Page 27: ...ion Regap Use a Wire Gauge or Feeler Gauge Spark Plug Gap 0 6 0 7 mm 0 024 0 028 in Clean the plug with a spark plug cleaner if necessary Standard Spark Plug BPR6HS NGK Before installing a spark plug...

Page 28: ...llllull AIR FITER CARBURATOR MUFFLER ENG 8 ENGINE AIR FILTER CARBURATOR MUFFLER 151 111 3 1...

Page 29: ...TER 2 Fuel tank Refer to FUEL TANK section in CHAPTER 2 1 Crankcase breather hose 1 2 Screw 2 3 Bolt 1 4 Air filter assmbly 1 5 Air filter gasket 1 6 Governor link rod 1 7 Carburetor assembly 1 8 Carb...

Page 30: ...ENGINE 3 3 re C b c tfJ reC b...

Page 31: ...FUEL TANK section Muffler Air filter Refer to MUFFLER and AIR FILTER section 1 Spark plug cap 1 2 Oil level lead Engine stop lead 1 3 C D I coupler 1 4 Condenser lead 2 5 DC rectifier coupler 1 6 Main...

Page 32: ...11111111 CYLINDER HEAD COVER CYLINDER HEAD VALVE ENG B CYLINDER HEAD COVER CYLINDER HEAD VALVE 2 5 j11 Nm 1 1 m kg 8 0 ft lb I 10 Nm 1 0 m kg 7 2 ft lb 2 3 5...

Page 33: ...1 2 Bolt 4 3 Cylinder head cover 1 4 Gasket 1 5 Air shround 1 1 6 Air shround 2 1 7 Bolt 4 NOTE Follow proper tightening sequence 8 Cylinder head 1 NOTE Set the piston at compression top dead center b...

Page 34: ...scraper 2 Measure Cylinder head warpage Exceeds allowable limit Resurface I Warpage Limit 0 1 mm 0 004 in VALVE REMOVAL 1 Remove Valve spring retainer CD Vale spring Valve VALVE INSPECTION 1 Inspect V...

Page 35: ...01 mm 0 0004 in Out of specification Replace VALVE SEAT INSPECTION 1 Measure Valve contact width Poor seating Looping Out of specification Replace Valve contact width Standard 0 7 mm 0 03 in Limit 1 2...

Page 36: ...g dye Dykem CD to valve face and seat 7 Rotate Valve Valve must make full seat contact indicat ed by grey surface all around valve face where bluing was removed 8 Apply Solvent into each intake and ex...

Page 37: ...ROD INSPECTION 1 Measure Push rod bend Roll on V block Exceeds bending limit Replace I Bend Limit 0 5 mm 0 02 in CYLINDER HEAD INSTALLATION 1 Install Cylinder head assembly NOTE _____________________...

Page 38: ...llllull PISTON CAMSHAFT CRANKCASE CRANKSHAFT ENG PISTON CAMSHAFT CRANKCASE CRANKSHAFT l m 3 11 l m 2...

Page 39: ...l pin 2 5 Camshaft 1 NOTE Be sure to align the camshaft gear mark with crankshaft gear mark 6 Valve lifter 2 7 Bolt 2 8 Connecting rod cap 1 NOTE Be sure the connecting rod mark is aligned with the ca...

Page 40: ...g the camshaft gear mark to the crankshaft gear mark 2 Remove Valve lifter CAUTION Mark the valve lifters so that the exhaust and intake valve sides are not confused CAMSHAFT AND VALVE LIFTER INSPECTI...

Page 41: ...NSPECTION 1 Inspect Cylinder walls Vertical scratches Rebore or replace cylinder 2 Measure Cylinder inside diameter D NOTE Obtain measurements at three depths by placing measuring instrument parallel...

Page 42: ...ge Piston size P Standard 50 0 mm 1 969 in Limit 49 93 mm 1 966 in 2 Measure Piston clearance Piston clearance Cylinder inside diameter D Piston skirt diameter P Out of specification Rebore cylinder a...

Page 43: ...01 in Piston ring end gap limit 0 9 mm 0 0354 in 5 Measure Piston ring side clearance Use a Thickness gauge Out of specification Replace NOTE ___________________________ Clean carbon from piston ring...

Page 44: ...eplace connec ting rod Oil clearance 0 016 0 034 mm 0 0006 0 0013 in Oil clearance limit 0 1 mm 0 004 in Oil clearance measuring steps 1 Clean all parts thoroughly 2 Place plastigauge onto crankpin 3...

Page 45: ...ON INSTALLATION 1 Install Piston rings CAUTION Be sure to install rings so that manufactur ers marks D faces to piston head Be sure each piston ring end is positioned as illustration Top ring 2nd ring...

Page 46: ...CAVrtoN Be sure the connecting rod mark D is aligned with the cap mark Connecting rod cap bolt 9 Nm 0 9 m kg 6 5 ft lb CAMSHAFT INSTALLATION 1 Install Camshaft eiv Jit i _________ Be sure to align the...

Page 47: ...ts in order Body cover Fuel tank Refer to the BODY COVER and FUEL TANK section in CHAPTER 2 1 Bolt 4 2 Recoil starter 1 3 Starter handle 1 4 Bolt 1 5 Drive plate 1 6 Drive spring 1 7 Drive pawl 1 8 Sp...

Page 48: ...ove Bolt D Drive plate Drive spring Drive pawl 4 Remove Drum sheave D Starter spring Spacer CAUTION Be sure to hold the starter spring in the drum sheave The spring will spread out sud denly when it i...

Page 49: ...hook with the drum slit then wind the spring counterclockwise into the drum from larger to smaller diame ter 2 Install Starter rope CAUTION Engage the spring hook D with the starter case hook 3 Insta...

Page 50: ...RT Order Job name Parts name Q ty Remarks Removal of Flywheel Remove the parts in order Recoil starter Refer to the RECOIL STARTER section 1 Nut 1 2 Washer 1 3 Starter 1 4 Flywheel 1 5 Key 1 6 Screw 1...

Page 51: ...llllull FLYWHEEL ENG 8 FLYWHEEL REMOVAL 1 Remove Flywheel CD Use a magneto puller Magneto puller YU 01351 90890 01351 3 24...

Page 52: ...1 Nm 2 1 m kg 15 2 ft lb l JOB INSTRUCTION CHART Order Job name Parts name Q ty Remarks Removal of Generator Remove the parts in order Engine Refer to ENGINE section 1 Bolt 3 2 Rear frame 1 3 Bolt 1 4...

Page 53: ...ROTOR INSTALLATION A Align the mark D on the flywheel magneto with the mark of crankcase ill Align the cut on the starter pulley with the mark on the fan case A ill Piston at TDC 2 Install Rotor assem...

Page 54: ...GOVERNOR Spring installation l6 Nm 0 6 m kg 4 3 ft lb I 1 m 3 27 IIIInil GOVERNOR ENG 8 Spring installation...

Page 55: ...overnor assmbly 9 Washer GOVERNOR ENG O ty Remarks 1 1 1 1 1 1 1 1 1 3 28 Remove the parts in order Refer to the GENERATOR section Refer to the CRANKSHAFT section Reverse the removal procedure for ins...

Page 56: ...11111111 CARBURETOR ENG 8 CARBURETOR EF1000 Type BV15 I D Mark 7FLOO Float height 17 mm 0 67 in 1 1110 9 4 B 3 3 29...

Page 57: ...k rod 1 2 Starter choke wire 1 3 Fuel hose 1 FMl l tCJ Always clean up spilled fuel immediatey 4 Screw 2 5 Air filter case 1 6 Gasket 1 7 Carburetor assembly 1 8 Carburetor cover 1 9 Joint 1 10 Gasket...

Page 58: ...ght This measurement should be made with the gasket removed I Float height 17 mm 0 67 in FUEL PASSAGE INSPECTION 1 Inspect Carburetor body Fuel passage Contamination Ciean as indicated Carburetor clea...

Page 59: ...ELECTRICAL COMPONENTS IELECII JI ELECTRICAL ELECTRICAL COMPONENTS CD Oil pilot light Engine stop switch Circuit protecter s Stator assembly Rotor assembly Spark plug j C D I unit 4 1...

Page 60: ...eter Oil level gauge AC protector Condenser AC receptacle DC protecter j DC receptacle Pilot lamp Stator assembly Rotor assembly Spark plug CIRCUIT DIAGRAM IELECIu I COLOR CODE B Black Br Brown G Gree...

Page 61: ...the SPARK PLUG section in the CHAPTER 2 CORRECT 2 Ignition spark gap Disconnect the spark plug cap CD from spark plug Connect the ignition checker as shown Spark plug cap f Ignition checker Ignition...

Page 62: ...GNITION SYSTEM IELECIu I CONTINUITY ity NO CONTINUITY Push the engine stop switch NO CONTINUITY Check the engine stop switch for continu ity CONTINUITY 4 Ignition coil resistance Primary Remove the ig...

Page 63: ...pocket tester as shown ts J C D I coil resistance Pulser 38Q 10 MEET SPECIFICATION 7 C D I coil resistance Charge Disconnect the C D I coupler Connect the pocket tester as shown C D I coil resistance...

Page 64: ...O CONTINUITY Overturn the oil level gauge as shown CONTINUITY Tighten the oil level gauge bolts 7 Nm 0 7 m kg 5 1 ft lbl 9 Wiring connecting Check the entire ignition system for con IGNITION SYSTEM IE...

Page 65: ...nser characteristics NOTE Check for internal grounding of win Characteristics If a digital meter is used the rise on dings in main coil and sub coil __ With tester set to R x 100 its nee readings may...

Page 66: ...t IFaulty DC circuit breaker Faulty adjust plate or Check wiring harness for continuity faulty governor Conducting Not conducting Faulty wiring harness I Check resistance in stator DC coil Standard re...

Page 67: ...ain coil coupler G 2 Connect the pocket tester as shown Main coil resistance 1 7640 10 Out or specification Replace stator assem bly Sub coil resistance 1 Disconnect the sub coil coupler G 2 Connect t...

Page 68: ...als together Use an Insulated screw driver Do not touch either of the terminals and ground before the condenser is discharged Rotor rectifier continuitys 1 Desolder the rotor rectifiers 2 Connect the...

Page 69: ...r as shown Continuity Correct No continuity Replace DC rectifier 3 Connect the pocket tester as shown No continuity Correct Continuity Replace DC rectifier Normal direction ID Reverse direction Rotor...

Page 70: ...Current Safety Device Against DC Output Rated Voltage Rated Current Safty DevicemAoainst Unit mm in mm in mm in kg lb 3 em mm in L Imp gal US gal L Imp qt US qt mm in v Hz kVA A v A 5 1 SPECIFICATION...

Page 71: ...CRANKSHAFT Unit mm in H D mm in mm in B mm in mm in 1 mm in Bill r A Big End Side Clearance A Runout Limit B Crank Pin Dia C Limit 5 2 SPECIFICATIONS ISPEC I u EF1000 0 020 0 035 0 0008 0 0014 50 0 1...

Page 72: ...th D Limit 11811 Valve Clearance Cold PUSH ROD Runout Limit Unit mm in mm in gJA 8 mm in L J c IN EX IN EX IN EX IN EX IN EX mm in SPECIFICATIONS ISPEC I rr 1 EF1000 12 0 22 0 0 016 0 034 0 0006 0 001...

Page 73: ...istance 20 AC excess current check DC excess current check Coil resistance 0 10 Main coil at 20 C Sub coil at 20 C DC coil at 20 C Rotor coil at 20 C Number of rectifier Rotor rectifier resistance Nor...

Page 74: ...ase cover M 6 X 1 0 10 1 0 7 2 Spark plug M14 X 1 25 20 2 0 14 5 Fan case M 6 X 1 0 7 0 7 5 1 Connecting rod M 6 X 1 0 9 0 9 6 5 Flywheel magneto M12 x 1 25 40 4 0 29 Governor arm M 6 X 1 0 6 0 6 4 3...

Page 75: ...e specified torque specifications call for clean dry threads Components should be at room tem perature Thread size M4 M5 M 6 M7 M8 M10 M12 DEFINITION OF UNITS Unit Read Definition mm Millimeter 10 3 m...

Page 76: ...HOSE ROUTING CD Carburetor air venthose Fuel tank breather hose HOSE ROUTING ISPEC I g I 5 7...

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