Yamaha EF1000iS, Service Manual

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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
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