Yamaha EF1000A Service Manual
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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 mechanics education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha generators 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 striving to further improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded 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 emission control system. Please read this material carefully EF1000A SERVICE MANUAL ©1997 Yamaha Motor Corporation, U.S.A. 1st Edition, February 1997 All right reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-19616-00-83 HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. & The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! &WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or person inspecting or repairing the machine. 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 cleaner. 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 reference that contains comprehensive explanations 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 the correct disassembly and assembly procedures.
CD GEN l!al INFO ® •II !lull ENG - @ I sPec I u-1 @ ~ ® -l ® ~ @ [ij] @ 1 - m ® l a @ ~~~~l§ll @ IELeciUI (J) ~ ® 1~1 @ § @ 1 9 ® ~ @ mil ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to@ are designed as thumb tabs to indicate the chapters number and content. CD General information @ Periodic inspection and adjustment @ Engine @ Electrical @ Specifications Illustrated symbols@ to@ are used to identi fy the specifications appearing. @ Special tool (J) Filling fluid @ Lubricant ® Tightening ® Wear limit, clearance @ 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®) @ Use New one
INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE ELECTRICAL SPECIFICATIONS •mlull - ENG ELEC SPEC
CONTENTS Chapter 1. GENERAL INFORMATION MACHINE IDENTIFICATION ................. 1-1 ENGINE SERIAL NUMBER ...................... 1-1 STARTING SERIAL NUMBER .................. 1-1 IMPORTANT INFORMATION ............... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ......................................... 1-2 NOTES ON SERVICE ................................ 1-2 ALL REPLACEMENT PARTS .................... 1-4 GASKETS, OIL SEALS AND 0-RINGS .... 1-4 BEARINGS AND OIL SEALS .................... 1-4 SPECIAL TOOLS ..................................... 1-5 Chapter 2. PERIODIC INSPECTIONS AND ADJUSTMENT INTRODUCTION ...................................... 2-1 MAINTENANCE INTERVALS CHART 2-1 PERIODIC MAINTENANCE/ LUBRICATION INTERVALS .................. 2-1 ENGINE ...................................................... 2-3 ENGINE OIL .............................................. 2-3 FUEL LINE INSPECTION.......................... 2-4 FUEL PETCOCK ........................................ 2-4 AIR FILTER ................................................ 2-4 MUFFLER .................................................. 2-5 VALVE CLEARANCE ADJUSTMENT....... 2-6 COMPRESSION PRESSURE MEASUREMENT ...................................... 2-7 CYLINDER HEAD DECARBONIZATION.. 2-8 GOVERNOR ADJUSTMENT .................... 2-8 ENGINE SPEED ADJUSTMENT .............. 2-9 BREATHER HOSE INSPECTION.............. 2-9 SPARK PLUG............................................ 2-9 A.C. PROTECTOR INSPECTION .............. 2-10 ENGINE SWITCH INSPECTION ............... 2-10 A. C. RECEPTACLE INSPECTION ............. 2-10 Chapter 3. ENGINE ENGINE OVERHAUL.............................. 3-1 MUFFLER PROTECTOR, FUEL TANK AND MUFFLER ..................................................... 3-1 JOB INSTRUCTION CHART .................... 3-1 AIR FILTER, CARBURETOR AND CONTROL BOX.................................. 3-2 JOB INSTRUCTION CHART.................... 3-2 CYLINDER HEAD COVER AND CYLINDER HEAD ................................ 3-3 JOB INSTRUCTION CHART.................... 3-3 INSPECTION........................................... 3-4 INSTALLATION ....................................... 3-4 ROCKER ARMS, VALVES AND VALVE SPRINGS................................ 3-5 JOB INSTRUCTION CHART.................... 3-5 REMOVAL............................................... 3-6 INSPECTION........................................... 3-6 RECOIL STARTER AND FLYWHEEL. .......... 3-10 JOB INSTRUCTION CHART .................... 3-10 RECOIL STARTER ........................................ 3-11 JOB INSTRUCTION CHART .................... 3-11 REMOVAL ............................................... 3-12 INSPECTION ........................................... 3-12 ASSEMBLY ............................................. 3-12 CRANKCASE COVER AND CAMSHAFT .... 3-14 JOB INSTRUCTION CHART .................... 3-14 REMOVAL ............................................... 3-15 INSPECTIOJ\! ........................................... 3-15 PISTON, CONNECTING ROD, CRANKSHAFT AND CRANKCASE ............. 3-17 JOB INSTRUCTION CHART .................... 3-17 INSPECTION ........................................... 3-18 GENERATOR ............................................... 3-23 JOB INSTRUCTION CHART .................... 3-23 REMOVAL ............................................... 3-24 INSTALLATION ....................................... 3-24 GOVERNOR ................................................. 3-25 JOB INSTRUCTION CHART .................... 3-25 INSPECTION ........................................... 3-26 CARBURETOR ............................................. 3-27 JOB INSTRUCTION CHART .................... 3-27
INSPECTION ........................................... 3-29 Chapter 4. ELECTRICAL ELECTRICAL COMPONENTS.............. 4-1 WIRING DIAGRAM............................. 4-1 SWITCH INSPECTION........................... 4-2 IGNITION SYSTEM ................................ 4-3 TROUBLE SHOOTING ............................. 4-3 GENERATOR SYSTEM.......................... 4-7 TROUBLE SHOOTING ............................. 4-7 Chapter 5. SPECIFICATIONS GENERAL SPECIFICATIONS................ 5-1 MAINTENANCE SPECIFICATIONS.... 5-2 ENGINE ..................................................... 5-2 ELECTRICAL ............................................. 5-4 TIGHTENING TORQUE ......................... 5-5 GENERAL TORQUE SPECIFICATIONS ... .. . ... . ... ...... ............. .... 5-5 DEFINITION OF UNITS.......................... 5-5 CABLE, HOSE ROUTING...................... 5-6
i: ------. -**•--- - . - MACHINE IDENTIFICATION ~~~~~ 1•1 1-1 GENERAL INFORMATION MACHINE IDENTIFICATION ENGINE SERIAL NUMBER The engine serial number CD is stamped into the right side of the body NOTE-· --------------------------The first three digits of these numbers are for model identification; the remaining digits are the unit production number. STARTING SERIAL NUMBER I EF1000A I 7TA-200101 ... NOTE-·-------------------------- Designs and specifications are subject to change without notice .
[ .~ 0 IMPORTANT INFORMATION GEN .-a INFO l!l) 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 engin.
Solvent IMPORTANT INFORMATION GEN ..-. INFO. 1-3 5. Tightening torque Be sure to follow torque specifications. When tightening bolts, nuts or screws, start with the 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 compressed air after disas sembly. b. Contact surfaces of moving parts should be oiled when reassembled. c. Make sure that parts move smoothly after each section ofthe machine is assembled.
IMPORTANT INFORMATION 300-002 300-003 1-4 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended b Yamaha for as sembly and adjustment. GASKETS, OIL SEALS, AND 0-RINGS 1. All gaskets, seals, and 0-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and 0- rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. BEARINGS AND OIL SEALS 1. Install the bearing(s) G) and oil seal(s) (g) with their manufactures marks or num bers facing outward. (In other words, the stamped letters must be on the side ex posed to view.) When installing oil seal(s), apply a light coating of light-weight lithi um base grease to the seal lip(s). Oil the bearings liberally when installing. Do not use compressd air to spin the bearings dry. This causes damage to the bearng surfaces.