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Yamaha EF1000A Service Manual

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    							YAMAHA 
    SERVICE MANUAL  
    						
    							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 
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    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.  
    						
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