Yamaha EF1000iS Service Manual Download Page 31

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ENG

3-1

CONTROL BOX

ENGINE

CONTROL BOX

Order

Job name

Q’ty

Remarks

Control box removal

Remove the parts in the order listed
below.

Front cover and rear cover

Refer to “COVERS” section in CHAPTER 2.

Tapping screw

Control box assembly

For installation, reverse the removal
procedure.

7VV10-03 02.10.4 10:38 AM Page 1

Summary of Contents for EF1000iS

Page 1: ...SERVICE MANUAL EF1000iS LIT 19616 01 02 7VV 28197 10 310137 ...

Page 2: ...you are interested Also I want to let you know that I am doing something special for Old Friends and Customers from the past and have started a Free Shop Manual of the month mailing list If you would like to join my Free Manuals Club Mailing List just use the contact us at my website above to send me an email and just say add me to the list in the subject line I promise not to flood you with junk ...

Page 3: ... 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 F...

Page 4: ...luid 9 Lubricant 0 Special tool q Tightening w Wear limit clearance e Engine speed r W V A Illustrated symbols t through d in the exploded diagram indicate the grades of lubri cant and the locations of the lubrication points t Apply engine oil y Apply gear oil u Apply molybdenum disulfide oil i Apply wheel bearing grease o Apply lightweight lithium soap base grease p Apply molybdenum disulfide gre...

Page 5: ...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 ...

Page 6: ...TRICAL 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 ...

Page 7: ...L 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 MAIN...

Page 8: ...he 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 ...

Page 9: ...d 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 P...

Page 10: ...eaned 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 1 and oil seal s 2 with 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 Oi...

Page 11: ...ston 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 ...

Page 12: ...t 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 ...

Page 13: ...GEN INFO ...

Page 14: ...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 eng...

Page 15: ...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 0 1 2 3 4 5 ...

Page 16: ...over 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 ...

Page 17: ...ning 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 9 Cover 3 9 Oil filler cap 3 Check 9 Check that the engine oil is at the spec ified level a Oil level checking steps 9 Place the engine on a level surface 9 Warm up the engine for several minutes 9 Stop the engine 9 Check that the e...

Page 18: ...p 6 Install 9 Drain 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 9 Drain joint 10 Install 9 Oil filler cap 9 Drain joint Clean the drain joint then install the drain joint t the mount base 9 Cover 3 INSP ADJ Recommended oil å YAMALUBE 4 10W 30 or SAE 10W 30 type SE SAE 30 ç SAE 20 SAE 10W E...

Page 19: ... 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 9 Fuel tank cap 9 Fuel tank filter 1 2 Inspect 9 Fuel tank filter Damage Replace 3 Clean 9 Fuel tank filter NOTE Clean the fuel tank filter with solvent and then dry it thoroughly 4 Install 9 Fuel tank filter 9 Fuel tank cap w Be sure the tank cap is tightened securely INS...

Page 20: ...nt cover 2 Drain the fuel from the fuel tank com pleatly 3 Remove 9 Fuel tank 1 9 Fuel hose 2 9 Fuel tank strainer 3 4 Inspect 9 Fuel tank strainer 1 Damage Replace 5 Clean 9 Fuel tank strainer Damage Replace NOTE Clean the fuel tank strainer with solvent and then dry it thoroughly 6 Install 9 Fuel tank strainer to the fuel tank 7 Install 9 Fuel hose 9 Fuel tank 9 Front cover 9 Rear cover 9 Side c...

Page 21: ...emove 9 Air filter element 2 3 inspect 9 Air filter element 1 Damage Replace Clogging Wash the element in a sol vent and then dry it thoroughly Oil the element and squeeze out the excess oil cC 8 Do not wring out the element this could cause it to tear 8 Do not wash the element in gasoline or in acidic alkalinic or organic solvents 4 Install 9 Air filter element 9 Air filter case cover 9 Cover 3 I...

Page 22: ... 2 Decarbonize 9 Muffler Tap on the muffler in the area shown in the illustration to loosen carbon buildup and then shake it out of the end of the muffler cC Don t use a wire to clean otherwise the noise damping material may come out and the damping effect may be reduced 3 Decarbonize 9 Muffler screen 9 Spark arrester cC When cleaning use the wire brush lightly to avoid damaging or scratching of t...

Page 23: ...g 2 9 Breather hose 3 9 Cylinder head cover 4 3 Gently operate the starter rope to bring the piston to the top dead center of its compression stroke when the screwdriv er inserted into the spark plug hole reach es the highest position 4 Measure 9 Valve clearance Out of specification Adjust NOTE Valve clearance must be measured when the engine is cool to the touch INSP ADJ Intake Valve cold 0 1 mm ...

Page 24: ... 3 use hexagonal wrench 6 Install 9 Cylinder head cover gasket 9 Cylinder head cover 9 Breather hose 9 Spark plug 9 Spark plug cap 9 Front cover 9 Rear cover 9 Side cover 9 Side cover 2 9 Side cover 3 INSP ADJ Adjuster Valve clearance Turn in Decrease Turn out Increase Locknut 4 Nm 0 4 m kg 2 9 ft lb Cylinder head cover bolt 6 Nm 6 m kg 4 3 ft lb Spark plug 13 Nm 1 3 m kg 9 4 ft lb ...

Page 25: ...g on the compression gauge w To prevent sparking when cranking the engine ground the high tension cord Testing steps below minimum level 9 Squirt a few drops of oil into the cylinder 9 Measure the compression again INSP ADJ Compression gauge YU 33223 90890 03081 Adapter YU 33223 3 90890 04082 Standard compression pressure 400 kPa 4 kg cm2 57 psi Reading Diagnosis If higher than without oil If the ...

Page 26: ... Inspect 9 Rated engine speed Specified engine speed OK Out of specification Refer to TROU BLESHOOTING in CHAPTER 3 Inspection steps 9 Operate the engine with no load 9 Turn economy switch 1 to OFF a 9 Measure the rated engine speed BREATHER HOSE 1 Remove 9 Cover 2 Inspect 9 Breather hose 1 Cracks damage Replace Poor connection Correct INSP ADJ Spark plug 13 Nm 1 3 m kg 9 4 ft lb Inductive tachome...

Page 27: ...g into the engine 1 Remove 9 Cover 2 Remove 9 Spark plug cap 9 Spark plug 3 Inspect 9 Electrode 1 Wear damage Replace 9 Insulator color 2 4 Measure 9 Spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap If necessary clean the spark plug with a spark plug cleaner Before installing the spark plug clean the gasket surface and plug surface INSP ADJ Spark plug gap 0 7 0 8 mm ...

Page 28: ...a 9 Start the engine 9 Check that the engine stops when the switch is set to STOP b ECONOMY SWITCH 1 Check 9 Economy switch 1 Checking steps 9 Set the economy switch 1 to ON a 9 Start the engine 9 Turn the switch of the electric device con nected to the AC outlet ON and OFF to check whether the engine speed increas es and decreases PILOT LIGHT 1 Check 9 Pilot light 1 Checking steps 9 Start the eng...

Page 29: ...set button 1 to the position of RESET a 9 Connect the pocket tester DC 20 V 9 Start the engine 9 Set the economy switch to OFF 9 Measure the DC voltage 9 Set the reset button to OFF b Voltage is zero OK NOTE If the restet bottn pup out OFF again refer to GENERATOR SYSTEM in CHAPTER 5 INSP ADJ Pocket tester YU 03112 90890 03112 Digital circuit tester 90890 03174 DC voltage More than 12 V at 5 000 r...

Page 30: ...INSP ADJ ______ l t t l ...

Page 31: ... Job name Q ty Remarks Control box removal Remove the parts in the order listed below Front cover and rear cover Refer to COVERS section in CHAPTER 2 1 Tapping screw 4 2 Control box assembly 1 For installation reverse the removal procedure 1 2 3 4 5 ...

Page 32: ...w 1 Tapping screw 4 2 Plate Assembly 1 3 Over load warning light 1 Disconnect 4 Pilot light 1 Disconnect 5 Oil warning light 1 Disconnect 6 AC receptacle 7 5A 2 1 Disconnect 7 Wire lead white 1 8 DC receptacle 12V 8A 1 Disconnect 9 Fuse 1 Disconnect 10 Engine switch 1 Disconnect 11 Economy switch 1 Disconnect 12 Earth terminal 1 Disconnect 13 Speed limiter 1 Disconnect ...

Page 33: ...ENG 3 3 CONTROL BOX 1 2 12 11 10 3 4 5 6 7 8 13 14 9 Order Job name Q ty Remarks 14 TCI unit Disconnect For assembly reverse the disassembly procedure ...

Page 34: ...3 4 CONTROL BOX 1 2 CONTROL BOX ASSEMBLY 1 Install 9 Control box 1 NOTE Insert the rid of control box to the front cover 2 ENG ...

Page 35: ...ts in the order listed below Front cover rear cover and fuel hose Refer to COVERS section in CHAPTER 2 Vacuum hose Refer to CARBURETOR section in CHAPTER 4 Fuel tank 1 Control unit 1 2 Generator lead wire coupler 1 Disconnect 3 Engine assembly 1 4 Engine bracket left right 1 1 5 Mount insulator 4 For installation reverse the removal procedure ...

Page 36: ... rotor removal Remove the parts in the order listed below Front cover and rear cover Refer to COVERS section in CHAPTER 2 Fuel tank Refer to CARBURETOR FUEL TANK Carburetor AND FUEL PUMP section in CHAPTER 4 1 Recoil starter assembly 1 2 Case cover 1 3 Element 1 4 Air filter case assembly 1 5 Ignition coil wire lead 1 6 Ignition coil 1 7 Rotor assembly 1 8 Woodruff key 1 For installation reverse t...

Page 37: ...1 2 3 4 5 6 7 Order Job name Q ty Remarks Recoil starter disassembly Remove the parts in the order listed below 1 Set screw 1 2 Collar 1 3 Friction spring 1 4 Reel 1 5 Spiral spring 1 6 Starter case 1 7 Swing arm 1 For disassembly reverse the assembly procedure ...

Page 38: ...e 9 Friction spring 1 9 Reel 2 cC Be sure to press down on the reel because the spring will pop out suddenly when it is removed from the reel 3 Remove 9 Spiral spring 1 4 Remove 9 Swing arm 1 RECOIL STARTER INSPECTION 1 Inspect 9 Starter rope 1 Damage Replace 9 Spiral spring 2 Deternation crack damage Replace ENG ...

Page 39: ...arm 1 9 Collar 2 install the swing arm to the collar 2 Install 9 Spiral spring 1 9 Reel 2 NOTE Hook the edge of spiral spring to the groove and then carefully wind the spring counter clockwise and place it on the reel 3 Wind the starter rope 1 clockwise two turns on the reel 4 Install 9 Reel 1 9 Starter case 2 NOTE Slowly install the hook a of the spiral spring into the groove ENG ...

Page 40: ...our turns 7 Pull the starter rope and check the recoil starter operation IGNITION COIL AND ROTOR REMOVAL 1 Remove 9 Ignition coil 1 9 Rotor nut 2 use the sheave holder 3 2 Remove 9 Rotor 1 use the rotor puller 2 bolt 3 washer 4 and nut 5 ENG Sheave holder YS 01880 90890 01701 Rotor puller YU 33270 90890 03162 Bolt 3 95817 06100 2 pcs Washer 4 95817 06380 2 pcs Nut 5 95817 06254 2 pcs ...

Page 41: ...Install 9 Woodruff key 1 9 Rotor 9 Rotor nut 2 NOTE When installing the rotor make sure the woodruff key is properly seated in the key way of the crankshaft 2 Install 9 Ignition coil 1 3 Inspection 9 Air gap inspect the clearance between the magneto on the rotor and ignition coil Out of specification Replace ENG Air gap 0 5 0 1 mm 0 02 0 004 in 6 Nm 0 6 m kg 4 3 ft lb 27 Nm 2 7 m kg 19 4 ft lb ...

Page 42: ...e parts in the order listed below Front cover and rear cover Refer to COVERS section in CHAPTER 2 Carburetor Refer to CARBURETOR FUEL TANK AND FUEL PUMP section in CHAPTER 4 1 Clip 2 2 Cylinder air shroud 2 1 3 Cylinder air shroud 1 1 4 Muffler assembly 1 5 Gasket 1 6 Silencer band 1 7 Cap 1 8 Wire net 1 9 Spark arrester 1 For installation reverse the removal procedure ...

Page 43: ...and rear cover Refer to COVERS section in CHAPTER 2 Fuel tank Refer to CARBURETOR FUEL TANK Carburetor AND FUEL PUMP section in CHAPTER 4 Cylinder air shroud Refer to MUFFLER section Engine assembly Refer to ENGINE REMOVAL section 1 Rear end cover 1 2 Magneto fan 1 3 Cover 1 4 Generator rotor 1 5 Stator assembly coupler 2 6 Stator coil assembly 1 For installation reverse the removal procedure ...

Page 44: ...the flywheel puller 2 and bolts 3 to remove the rotor 3 Remove 9 Stator coil 1 STATOR COIL INSTALLATION cC Be sure to remove any oil grease from the tapered portion of the magneto rotor using a cloth dampened with thinner 1 Install 9 Stator coil assembly 1 ENG Sheave holder YS 01880 90890 01701 Rotor puller YU 33270 90890 03162 Bolt 3 95817 06100 2 pcs 10 Nm 1 0 m kg 7 2 ft lb ...

Page 45: ...3 15 GENERATOR 3 2 1 2 Install 9 Rotor 1 9 Rotor nut 2 NOTE Attach the sheave holder 3 to hold the rotor ENG Sheave holder YS 01880 90890 01701 27 Nm 2 7 m kg 19 4 ft lb ...

Page 46: ... and Remove the parts in the order listed rocker arm removal below Front cover and rear cover Refer to COVERS section in CHAPTER 2 Fuel tank Refer to CARBURETOR FUEL TANK Carburetor AND FUEL PUMP section in CHAPTER 4 Cylinder air shroud Refer to MUFFLER section Engine assembly Refer to ENGINE REMOVAL section Generator Refer to GENERATOR REMOVAL section 1 Cylinder head cover 1 2 Cylinder head cover...

Page 47: ...3 ft lb 6 Nm 0 6 m kg 4 3 ft lb 13 Nm 1 3 m kg 9 4 ft lb 8 Nm 0 8 m kg 5 8 ft lb 3 Order Job name Q ty Remarks 6 Adjuster 2 Loosen 7 Dowel pin 1 below 8 Rocker arm 2 9 Push rod 2 10 Collar 1 11 Cam follower 2 12 Camshaft assembly 1 13 Dowel pin 2 For installation reverse the removal procedure ...

Page 48: ... 3 Inspection 9 Surface of camshaft gear teeth 9 Decompressor Crack damage wear Replace CAM FOLLOWER INSPECTION 1 Inspect 9 Cam follower Crack damage wear Replace PUSH ROD INSPECTION 1 Inspect 9 Push rod runout Out of specifications Replace ENG Cam lobes length a a 32 65 mm 1 29 in b b 28 25 mm 1 11 in Limit a a 31 65 mm 1 25 in b b 27 75 mm 1 09 in Runout limit 0 5 mm 0 02 in ...

Page 49: ... Crack damage wear Replace CAMSHAFT AND LOCKER ARM INSTALLA TION 1 Install 9 Camshaft 1 NOTE Make sure that the mark a on the crank shaft is aligned with the mark b on the camshaft 2 Install 9 Cam follower exhaust side 1 9 Cam follower intake side 2 9 Collar 3 NOTE Make sure that the piston place in Top Dead Center position then install the cam follower 3 Install 9 Push rod 1 NOTE Be sure install ...

Page 50: ...M 2 1 1 4 Install 9 Rocker arm 1 9 Dowel pin 2 NOTE Make sure align the push rod edge with the rocker arm groove then install the rocker arm 5 Install 9 Crankcase 1 NOTE Tighten the bolts to the specified torque in to steps and in order ENG ...

Page 51: ...and rear cover Refer to COVERS section in CHAPTER 2 Fuel tank Refer to CARBURETOR FUEL TANK Carburetor AND FUEL PUMP section in CHAPTER 4 Cylinder air shroud Refer to MUFFLER section Engine assembly Refer to ENGINE REMOVAL section Recoil starter Refer to RECOIL STARTER AND ROTOR section Generator Refer to GENERATOR REMOVAL section Rocker arm and camshaft Refer to ROCKER ARM AND CAMSHAFT section 1 ...

Page 52: ...AND PISTON RING E E E E 1 2 3 4 5 6 7 8 4 6 Nm 0 6 m kg 4 3 ft lb Order Job name Q ty Remarks 4 Piston pin circlip 2 5 Piston pin 1 6 Connecting rod 1 7 Piston ring set 1 8 Piston 1 For installation reverse the removal procedure ...

Page 53: ...ifications Rebore or replace cylinder and replace piston and piston rings 3 Measure 9 Piston pin hole inside diameter a Out of specifications Replace ENG Piston skirt diameter Standard 40 95 40 97 mm 1 612 1 613 in Piston pin hole inside diameter Standard 10 000 10 020 mm 0 3937 0 3945 in Limit 10 050 mm 0 3956 in Piston clearance 0 01 0 04 mm 0 0004 0 0016 in Piston clearance Cylinder inside diam...

Page 54: ...G INSPECTION 1 Measure 9 Piston ring end gap Out of specification Replace NOTE Insert the piston ring 1 into the cylinder and push it approximately a 5 mm 0 2 in into the cylinder Push the ring with the piston crown so that the ring is at angles to the cylinder bore Out of specifications Replace the piston and piston ring as a set ENG Piston pin diameter 9 99 10 00 mm 0 3933 0 3937 in Limit 9 95 m...

Page 55: ...ECTION 1 Measure 9 Crankshaft runout limit use a dial gauge Out of specification Replace 2 Inspect 9 Crankshaft sprocket 1 Crack damage wear Replace the crankshaft 3 Measure 9 Crank pin diameter a Out of specification Replace the crankshaft ENG Top ring Wear limit Piston ring side clearance 0 15 mm 0 006 in 0 06 0 11 mm 0 002 0 004 in 2nd ring 0 06 0 11 mm 0 002 0 004 in Runout limit 0 03 mm 0 001...

Page 56: ...onnecting rod 1 9 Connecting rod cap 1 NOTE Tighten the cap bolts so that the crankshaft does not move while the oil clearance is being measured 3 Remove 9 Connecting rod cap 9 Connecting rod 4 Measure 9 Connecting rod oil clearance Widest portion of the pressed Plastigauge Out of specification Replace crank shaft or connecting rod and then mea sure the clearance again ENG Connecting rod oil clear...

Page 57: ... smoothly 2 Apply 4 stroke engine oil to the inside of the connecting rod small end 3 Install 9 Piston 1 9 Piston pin 2 9 Piston pin circlip 3 NOTE Make sure that the YAMAHA mark a on the piston head and the 7VV mark b on the con necting rod toward as same faces then install CONNECTING ROD AND CRANKSHAFT INSTALLATION 1 Make sure that the end gap of each piston ring is positioned as shown in the il...

Page 58: ...t the mark a on the con necting rod is aligned the mark b on the rod cap 4 Install 9 Crankshaft 9 Connecting rod cap 9 Cam follower exhaust side 9 Cam follower intake side 9 Collar 9 Push rod 9 Rocker arm 9 Crankcase 2 Refer to CRANKCASE 2 AND CAMSHAFT section ENG 6 Nm 0 6 m kg 4 3 ft lb 8 Nm 0 8 m kg 5 8 ft lb ...

Page 59: ...S section in CHAPTER 2 Fuel tank Refer to CARBURETOR FUEL TANK Carburetor AND FUEL PUMP section in CHAPTER 4 Cylinder air shroud 1 2 Refer to MUFFLER section Engine assembly Refer to ENGINE REMOVAL section Generator Refer to GENERATOR REMOVAL section Rocker arm and camshaft Refer to ROCKER ARM AND CAMSHAFT section Crankshaft and piston Refer to CRANKSHAFT PISTON Piston ring AND PISTON RING section...

Page 60: ... 3 30 CYLINDER CRANKCASE 1 AND VALVE M M E B 1 2 3 4 5 1 2 6 7 Order Job name Q ty Remarks 4 Valve 2 1 5 Stem oil seal 1 6 Oil seal 1 7 Cylinder crankcase 1 1 For installation reverse the removal procedure ...

Page 61: ...t of specification Replace 2 Measure 9 Valve stem runout Out of specification Replace NOTE The value is half of that indication on the dial gauge 3 Measure 9 Valve spring free length a Out of specification Replace ENG Valve stem diameter 3 96 3 98 mm Intake 0 156 0 157 in 3 94 3 96 mm Exhaust 0 155 0 156 in Limit 3 92 mm Intake 0 154 in 3 90 mm Exhaust 0 153 in Valve stem runout limit 0 01 mm 0 00...

Page 62: ...R CRANKCASE 1 AND VALVE a 4 Measure 9 Valve spring tilt a Out of specification Replace 5 Inspect 9 Valve contact surface More than 2 3 of the contact surface does not contact Replace ENG Tilt limit 2 0 mm 0 079 in ...

Page 63: ...alve while the valve face is contacting the valve seat 4 Measure 9 Valve face contact width a Make sure that the contact width along the entire valve face is within specifica tions Out of specification rough eccentric wear Replace 5 Measure 9 Valve seat contact width b Make sure that the contact width along the entire valve seat is within specifica tions Out of specification rough eccentric wear R...

Page 64: ... margin thickness c Apply a small amount of coarse mechanic s blueing dye Dykem to the valve seat Press the valve through the valve guide and onto the valve seat to make a clear impression 9 Valve margin thickness Out of specification Replace 9 Valve face contact width Out of specification Replace ENG Valve seat width Intake Exhaust 0 8 mm 0 03 in ...

Page 65: ...LVE AND VALVE SPRING ASSEMBLY 1 Install 9 Valve 1 9 Valve spring 2 9 Valve spring retainer 3 NOTE 9 Apply a small amount of molybdenum disul fide oil to the valve stem and use the valve spring compressor 5 to install the parts 9 Press the spring retainer by your finger while installing the spring retainer ENG Maximum wear Maximum A B C Cylinder taper Maximum A Minimum C Cylinder inside diameter 41...

Page 66: ...ENG Iiii ...

Page 67: ...al Remove the parts in the order listed below Front cover and rear cover Refer to COVERS section in CHAPTER 2 Air cleaner case 1 Breather hose 1 2 Hose 3 1 3 Hose 4 1 4 Joint 1 5 Gasket 1 6 Throttle control motor coupler 1 Disconnect 7 Carburetor assembly 1 8 Gasket 1 9 Carburetor joint 1 10 Gasket 1 For installation reverse the removal procedure 1 2 3 4 5 ...

Page 68: ...name Q ty Remarks Carburetor disassembly Disassemble the parts in the order listed below 1 Throttle control motor cover 1 2 Throttle control motor 1 3 Motor bracket 1 4 Plate 1 5 Drain screw 1 6 Bolt 1 7 Gasket 1 8 Float chamber 1 9 Float chamber gasket 1 0 Float pin 1 q Float 1 w Needle assembly 1 e Main jet 1 ...

Page 69: ...3 CARBURETOR 7 Nm 0 7 m kg 5 1 ft lb 2 3 4 5 6 7 8 9 0 q w e r t u y 1 CARB Order Job name Q ty Remarks r Main nozzle 1 t Cap 1 y Pilot screw 1 u Pilot jet 1 For assemble reverse the disassembly procedure ...

Page 70: ... lightly contacts the float arm and then measure the float height a This mea surement should be made with the gasket removed 9 Do not adjustable the float height 2 Clean 9 Carburetor body Blow out all passages jets and carbu retor body with compressed air 3 Inspect 9 Valve seat Wear damage Replace Dirt Clean 1 Wear at groove 2 Dirt CARB Float height 1 5 mm 0 06 in ...

Page 71: ...ll 9 Inner cable 1 NOTE Place the carburetor choke valve in its fully open position a insert the tip of the inner cable into drum hole and then secure it in place with the screw THROTTLE CONTROL MOTOR 1 Install 9 Throttle control motor 1 NOTE 9 Install the shaft a of the throttle control motor by aligning it with the groove b of the throttle shaft 9 Install the throttle valve and then make sure th...

Page 72: ...ock fuel tank and Remove the parts in the order listed fuel change link removal below Front cover and rear cover Refer 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 ...

Page 73: ...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 ...

Page 74: ...FUEL PUMP INSPECTION 1 Inspect 9 Fuel 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 9 Fuel tank filter Wear Replace Dirt clog Clean CARB ...

Page 75: ...CARB1 _ I ...

Page 76: ...d warning light Red 4 Pilot light Green 5 Oil warning light Red 6 Generator assembly 7 Engine switch 8 Economy switch 9 DC circuit breaker 0 AC receptacle 7 5 A 2 q DC receptacle 12 V 8 A w Spark plug cap e High tension cable r Ignition coil t Throttle control motor y Rectifier 1 2 3 4 5 6 7 8 9 q 0 t 6 e r y 1 w ...

Page 77: ...coil 2 AC 3 DC charge coil 4 Generator assembly 5 Rectifier 6 Control unit assembly 7 Pilot light Green 8 AC receptacle 7 5A 2 9 Economy switch 0 Overload warning light Red q DC circuit breaker w DC receptacle 12V 8A e Speed limiter r TCI unit t Engine switch y Oil warning light Red u Ground terminal i Control box o Ground terminal p Oil level switch a Magneto rotor s Ignition coil d Spark plug f ...

Page 78: ...ity If the continuity is faulty at any point replace the switch NOTE 9 Set the pocket tester to 0 before starting a test 9 When testing the switch for continuity the pocket tester should be set to the 1 Ω range 9 When checking the switch turn it on and off a few times Pocket tester YU 03112 90890 03112 ...

Page 79: ...ooting Dynamic spark tester YU 34487 Ignition checker 90890 06754 1 Spark plug 9 Check the spark plug condition Refer to SPARK PLUG in CHAPTER 2 Repair or replace the spark plug SVU4055 SVU4060 2 Ignition spark gap 9 Disconnect the spark plug cap 1 from the spark plug 9 Connect the dynamic spark tester 2 or igni tion checker 3 as shown Spark plug cap 1 Dynamic spark tester or ignition checker Dyna...

Page 80: ...o not pull out the plug cap from the high tension cord 9 Remove Turn the plug cap counterclock wise 9 Install Turn the plug cap clockwise 9 Inspect the high tension cord for cracks or deterioration when install the pug cap 9 Cut 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 kΩ at 20 C 68 F Primary coil resistance 0 5 Ω 20 at...

Page 81: ... and ignition coil Air gap 0 5 0 1 mm 0 02 0 004 in 6 Engine switch 9 Disconnect the engine switch coupler in the control box 9 Connect 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 ...

Page 82: ...ster to the oil level switch for continuity Tester lead Blue lead 1 Tester lead Ground 2 1 2 1 2 å å å Continuity Correct No continuity Correct 8 Wire harness 9 Check the terminal of the connector for con tamination rust or disconnection Replace the speed limiter Replace the TCI unit Replace the oil level switch NO CONTINUITY CONTINUITY Correct or replace the connector NO GOOD GOOD GOOD ...

Page 83: ...ROTTLE CONTROL SYSTEM in CHAPTER 6 AC coil 1 AC voltage inspection 9 Connect Brown Green R S Green Brown S T and Brown Brown R T leads 9 Start the engine then measure the voltage Tester range AC300V GOOD TOO LOW DOES NOT GENERATE AC coil 1 W Or W W W W Br G Br Br Br Br R S T R S T AC coil 2 AC coil 1 AC voltage 130 260 V at 20 C 68 F Magnetic force is weak Replace the magneto rotor AC coil 1 resis...

Page 84: ...23 0 V at 20 C 68 F Magnetic force is weak Replace the magneto rotor AC coil 2 resistance inspection 9 Stop the engine 9 Measure the resistance between White Orange R S Orange White S T and White White R T leads Tester range Ω 1 SPECIFICATION OUT OF SPECIFICATION AC coil 2 W Or W Br G Br R S T R S T AC coil 1 AC coil 2 resistance 0 17 Ω 20 at 20 C 68 F Replace the AC coil 2 Replace the control uni...

Page 85: ...ISCONNECTED Replace the DC circuit breaker DC coil DC voltage inspection 9 Connect Blue leads 9 Start the engine then measure the voltage Tester range DC 20V GOOD TOO LOW DOES NOT GENERATE L L L L DC coil DC voltage 13 5 23 0 V at 20 C 68 F Replace the rectifier DC coil resistance inspection 9 Stop the engine 9 Measure the resistance between Blue leads Tester range Ω 1 SPECIFICATION OUT OF SPECIFI...

Page 86: ... warning unit or oil level switch Add Add Replace Set to ON Clean or replace fuel pump Clean or replace fuel cock Replace the fuel TCI unit Clean or replace Remove spark plug attach it to spark plug cap and then ground the spark plug to check for spark GOOD WEAK OR SPARK NO SPARK Check if fuel is deteriorated GOOD NO GOOD 9Check spark plug for dirt and check spark plug gap 9Check for voltage leaka...

Page 87: ...OF GOOD SPECIFICATION Check valve face and valve seat for wear GOOD WEAR Resurface or replace Check if the marks on the crankshaft and camshaft are aligned GOOD NO GOOD Correct or replace Check if there is seizure or wear on the piston piston ring or cylinder GOOD SEIZURE OR WEAR Rebore or replace Check the condition of the throttle control sys tem Refer to THROTTLE CONTROL SYS TEM 1 2 3 4 5 6 7 ...

Page 88: ... due to a dam aged carburetor joint or gasket GOOD NO GOOD 9 Tighten the carburetor bolts securely 9 R e p l a c e carburetor joint or gas ket with a new one Measure valve clear ance GOOD OUT OF SPECIFICATION Adjust Check compression using compression gauge GOOD OUT OF SPECIFICATION Check piston piston ring and cylinder GOOD NO GOOD Replace Check air gap GOOD NO GOOD Replace Check the condition of...

Page 89: ...GOOD NO GOOD Disassemble or clean Check for air suction due to a damaged throttle shaft seal carburetor joint or gasket GOOD NO GOOD Disassemble or replace Check compression using compression gauge GOOD TOO HIGH TOO LOW Decarbonize combustion chamber if there are carbon deposits Check valve face and valve seat for wear GOOD NO GOOD Resurface or replace Check if the marks on the crankshaft and cams...

Page 90: ...y out and then check the engine operating condition STABLE UNSTABLE Resurface or replace Check for air suction due to a damaged throttle shaft seal carburetor joint or gasket GOOD NO GOOD Disassemble or replace Check if slow or main passages such as the pilot jet and main jet in carburetor are clogged GOOD NO GOOD Disassemble or clean Check valve face and valve seat for wear GOOD NO GOOD Resurface...

Page 91: ...heck if it turns smoothly with slight resistance GOOD NO GOOD Replace the throttle control motor Replace the throttle control motor Replace the control motor Measure the coil resistance between 3 1 3 2 3 4 and 3 5 of the throttle control motor Tester range Ω 1 SPECIFICATION OUT OF SPECIFICATION Coil resistance 250 Ω 20 at 20 C 68 F Check the connections of the wire harness connectors and couplers ...

Page 92: ...ase when economy control switch is set to ON Check AC output GOOD NO GOOD Refer to GENERATOR SYSTEM in CHAPTER 5 Rotate the shaft of the throttle control motor GOOD NO GOOD Replace the throttle control motor Check economy switch GOOD NO GOOD Replace the economy switch Replace the control motor Check the connections of the wire harness connectors and couplers and the wires for an open circuit or sh...

Page 93: ...TRBLI I ...

Page 94: ...0 Hz kW PS 5 000 r min 1 21 1 65 Rated engine speed r min 5 000 Operating hours 60 Hz Hrs W no load 12 0 W rated load 4 3 Fuel Unleaded regular gasoline Fuel tank capacity L lmp gal US gal 2 5 0 55 0 66 Engine oil capacity L lmp qt US qt 0 32 0 28 0 34 Engine recomended oil 4 stroke engine oil API service classification SE or SF if not available SD Electrical Ignition system TCI Ignition timing BT...

Page 95: ...z 60 Rated output kVA 0 9 Rated current A 7 5 Safety device type AC Electronic no fuse breaker DC Circuit breaker No fuse breaker Rated engine speed r min 5 000 Voltage regulation Voltage feed back system Voltage stability Within 4 Frequency stability Hz Within 1 Rotating speed control Throttle motor control type Wave distortion ratio Less than 2 5 Number of phase Triple phase Insulation resistanc...

Page 96: ... 0 3 0 0039 0 0118 0 6 0 0236 Side clearance 0 06 0 11 0 002 0 004 0 15 0 006 OIl ring Type Solid Dimensions B T 1 5 1 9 0 059 0 075 End gap 0 2 0 7 0 0078 0 0275 0 9 0 0354 Cylinder mm in Inside diameter D 41 000 41 010 16 14 16 15 41 10 16 18 Taper limit 0 05 0 002 Warpage limit 0 05 0 002 Crankshaft mm in Big end side clearance A 0 2 0 65 0 008 0 026 0 7 0 028 Runout B 0 03 0 001 Crank pin diam...

Page 97: ...53 Valve face contact width D IN 0 8 0 03 1 8 0 07 EX 0 8 0 03 1 8 0 07 Valve stem runout limit 0 01 0 0004 θ 90 Valve guide Guide inside diameter IN 4 0 0 157 EX 4 0 0 157 Valve clearance cold IN 0 1 0 004 EX 0 1 0 004 Push rod mm in Runout limit 0 5 0 02 Valve spring mm in Free length IN 25 0 0 984 24 0 0 945 EX 25 0 0 984 24 0 0 945 Set length IN 15 1 0 594 EX 15 1 0 594 Tilt limit 2 0 0 079 7 ...

Page 98: ...KUNI I D mark 7VV 00 Bore size Ø 11 0 433 Main jet 62 5 Main air jet Ø 1 3 0 051 Pilot air jet Ø 0 9 0 004 Pilot outlet Ø 0 8 0 031 Valve seat size Ø 1 5 0 059 Main nozzle 2H Pilot jet 40 Throttle valve 110 Float height H 1 5 0 06 7 5 MAINTENANCE SPECIFICATIONS SPEC ...

Page 99: ...0 5 000 Coil resistance AC coil 1 Ω 20 0 47 Br G R S G Br S T Br Br R T With coupler disconnected AC coil 2 Ω 20 0 17 W Or R S Or W S T W W R T With coupler disconnected DC coil Ω 20 0 07 Blue Blue Electrical Ignition system TCI Ignition timing BTDC 33 Ignition coil Primary coil resistance Ω 20 0 5 Secondary coil resistance kΩ 20 11 5 Spark plug cap resistance kΩ 3 8 6 3 Spark plug minimum spark g...

Page 100: ...ir filter case M5 0 8 6 0 6 4 3 Muffler stay M6 1 0 10 1 0 7 2 Stud bolt IN M6 1 0 7 0 7 5 1 Stud bolt EX M6 1 0 7 0 7 5 1 Crankcase M5 0 8 8 0 8 5 8 Recoil starter M5 0 8 6 0 6 4 3 Mount insulator M6 1 0 12 1 2 8 7 Engine bracket M6 1 0 12 1 2 8 7 Ignition coil M5 0 8 6 0 6 4 3 Magneto rotor M10 1 25 27 2 7 19 4 TCI unit M4 1 1 0 1 0 7 Stator coil assembly M6 1 0 10 1 0 7 2 Generator rotor M10 1 ...

Page 101: ...ne speed GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fas teners with standard I S O pitch treads Torque specifications for special components or assemblies are included in the applicable sections of this book To avoid warpage tight en multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specifications call ...

Page 102: ...oil Connecting rod bolt Engine oil Piston pin Engine oil Piston Engine oil Camshaft 1 Engine oil Crankshaft bearing Engine oil Valve stem Molybdenum disulfide oil Valve stem end Molybdenum disulfide oil Valve rocker arm shaft Molybdenum disulfide oil Valve push rod Engine oil Valve cam follower Engine oil Camshaft gear Engine oil Camshaft lobe Engine oil Decompressor cam Engine oil Crankcase 2 bea...

Page 103: ...3 AC receptacle 7 5 A 2 4 Over load warning light Red 5 Pilot light Green 6 Oil warning light Red 7 Choke knob 8 Change link 9 Engine switch 0 Economy switch q DC circuit breaker w DC receptacle 12V 8A e DC receptacle lead r AC receptacle lead t Clamp å White tape side Clamp with each white tape 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 Y...

Page 104: ...2 lead 4 Ignition coil lead 5 Clamp 6 DC coil lead 7 Ground lead 8 Control motor lead 9 Rectifier stay å To control box From ignition coil ç Clamp the generator lead with clamp Insert the AC coil 1 2 lead DC coil lead and the clamp them To controller ƒ Certainly connect the each leads å ç ƒ 1 2 3 4 5 6 7 8 9 ...

Page 105: ...IRE ROUTING DIAGRAM SPEC 4 å 1 2 3 5 6 7 8 1 Control motor 2 AC coil 1 2 lead 3 DC coil lead 4 Control box 5 Control unit 6 Ignition coil lead 7 Control motor lead 8 Ground lead å From generator To rectifier ...

Page 106: ... 1 2 3 4 5 6 7 8 9 1 AC coil 1 2 lead 2 Ignition coil lead 3 DC coil lead 4 Control unit 5 Rectifier 6 Rectifier stay 7 Control motor lead 8 Ground lead 9 Control motor å To control box Pass the control motor lead under the fuel hose ...

Page 107: ...rd 3 Ignition coil lead 4 Ignition coil 5 Oil level switch 6 Oil level switch lead 7 Ground lead å Install the spark plug cap until stop the spark plug To TCI unit ç Tighten with the ground lead with oil level switch After tightened adjust the both air gaps to 0 5 0 1 mm 0 02 0 004 in ...

Page 108: ... 2 q Lotating damper w Filer net 1 e Fuel pipe r Air vent hose t Drain hose y Lever å Install the clip as shown Refer the angle A ç Install the hoses until it stops Less than 1 5 mm 0 059 in Mating the white both marks ƒ Do not contact to install the clip and lever Do not remove the rollett nut when install the fuel change link cable Fully pushed the choke knob as shown when install the choke cabl...

Page 109: ...PRINTED ON RECYCLED PAPER PRINTED IN USA YAMAHA MOTOR CO LTD E ...

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