Yamaha EF1000 Generator Full Service & Repair 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 manual, 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 material 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 by the 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 procedures easier or clearer. MANUAL FORMAT The procedures in this manual are organized in a sequential, step-by-step format. The information 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 arrow symbol 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 .... ,. INFO @ •llllull ENG 1•1 @ I sPEc I g-1 ® ~ @ l @ ~ © [ij] @ 1 - m ® & a (2) l~5~l§ll @ IELEciUI (j) ~ ® 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 I EF1000 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.

Yamaha EF1000 Generator Full Service & Repair Manual

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