Yamaha EF1000 Service Manual

							IGNITION SYSTEM I ELEC 11-==::J I 
TROUBLESHOOTING CHART 
NO SPARK OR WEAK SPARK 
NOTE=------------------------------------------------------------
•Remove the following parts before troubleshooting. 
1) Spark plug 
• Use the following special tool(s) in this troubleshooting. 
Pocket tester: 
YU-03112(90890-03112) 
1. Spark plug 
•Check the spark plug condition. 
Refer to the SPARK  PLUG section in the 
CHAPTER 2. 
CORRECT 
2. Ignition spark gap 
•Disconnect the spark plug cap CD from 
spark plug. 
•Connect the ignition checker@ as shown. 
Spark plug cap (f)-+ 
Ignition checker 
Ignition checker lead-+ 
Spark plug@ 
•Turn the crank and measure the ignition 
spark gap@. 
Minimum spark gap: 
6 
mm (0.24 in) 
* 
OUT OF 
SPECIFICATION 
OR NO  SPARK 
4-3 
Dynamic  spark tester (Ignition 
Checker): 
YM-34487 
(90890-06754) 
INCORRECT 
I Repair or replace spark plug. 
MEET SPECIFICATION 
I Ignition system is good.  
						

							* 
l 
3. Engine stop switch 
•Disconnect the engine stop switch  leads. 
•Connect the pocket  tester (Qx1) to the 
engine stop switch. 
•Do not push the engine stop switch; 
Check the engine stop switch for continu-
IGNITION  SYSTEM I ELEC I u I 
CONTINUITY 
ity. ·-----------
NO 
CONTINUITY 
•Push the engine stop switch: 
NO 
CONTINUITY 
Check the engine stop switch for continu-•••••••••• 
ity. 
CONTINUITY 
4. Ignition coil  resistance (Primary) 
•Remove the ignition coil. 
•Connect the pocket  tester as shown. 
aiM Ignition  coil resistance  (Primary): 
0.23Q±10% 
* 
MEET 
SPECIFICATION 
I Replace engine stop switch. 
OUT OF SPECIFICATION 
I Replace ignition coil assembly. 
4-4  
						

							* 
l 
5. Ignition coil resistance  (Secondary) 
•Remove the ignition coil. 
•Connect the pocket  tester as shown. 
Ignition  coil resistance 
(Secondary): 
5.61 kQ±20% 
MEET 
SPECIFICATION 
6. C.D.I. coil  resistance  (Pulser) 
•Disconnect the C.D.I. coupler. 
•Connect  the pocket  tester 
as shown. 
ts*J C.D.I. coil resistance (Pulser): 
38Q±10% 
MEET 
SPECIFICATION 
7. C.D.I. coil resistance  (Charge) 
•Disconnect the C.D.I. coupler. 
•Connect  the pocket  tester 
as shown. 
~ C.D.I. coil resistance  (Charge): 
350Q±10% 
MEET 
SPECIFICATION 
IGNITION SYSTEM I ELEC I u I 
(R X 1k) 
OUT OF SPECIFICATION 
I Replace ignition coil assembly. 
(R x 1) 
OUT OF SPECIFICATION 
I Replace C.D.I. coil  assembly. 
(R X 100) 
OUT OF SPECIFICATION 
I Replace C.D.I. coil assembly. 
4-5  
						

							* 
! 
8. Oil level gauge 
• Drain the engine oil. 
Refer to the ENGINE  OIL section in 
CHAPTER 
2. 
• Remove  the oil level gauge. 
• Connect  the pocket  tester as shown. 
NO 
CONTINUITY 
•Overturn the oil  level gauge as shown. 
CONTINUITY 
•Tighten the oil level gauge bolts. 
~. 7 Nm (0.7 m • kg, 5.1 ft •lbl 
9. Wiring connecting 
• Check the entire ignition system for con-
IGNITION  SYSTEM I ELEC I I~ I 
CONTINUITY 
I Replace oil level gauge. 
NO  CONTINUITY 
I Replace oil level gauge. 
POOR  CONNECTION 
nections. •••••••••• 
CORRECT 
I Replace  flywheel. 
I Correct. 
4-6  
						

							GENERATOR SYSTEM I ELEC I u I 
TROUBLESHOOTING 
1. AC generation is not normal Check output voltage at AC 
Lr 
Check AC receptacle with its ter-
receptacle.  minals connected with a wire. 
0-15V Conducting I Faulty  voltmeter or faulty load.  Specified 
reading Not conducting Low reading 
~ Unusually 40-60V In-between 
~ 
high reading 
reading l Faulty AC receptacle 
Reset  governor 
arm/ shaft. 
I Check engine  revolutions. 
(i.e.  frequency) 
Turn  adjust 
bolt anticlockwise, r More  than 3,800 rpm. 
observing  engine revolutions. L Too low Normal Stay unchanged I Return to normal 
l Check wiring harness fo~ continuity: Check AC protector 
Faulty  adjust plate or faulty 
Conducting 
Not conducting Conducting I Not conducting 
governor. 
• l Faulty AC protector 
1--Check resistance  in main  coil. ~~ Faulty  wiring  harness I Check resistance in sub-coil. 
Infinity or below standard Standard resistance fl ± 10% 
Standard  resistance fl ± 10% 120V 11--r o;=oooc
						

							GENERATOR SYSTEM I ELEC I u I 
2. DC generation is not normal. Check DC output voltage at DC 
_r 
Check  DC plug socket with its ter-
receptacle. minals connected with a  wire. 
I Approx. 5V I  I Not conducting Faulty pilot lamp.  Normal ov Conducting 
Faulty 
load. 
I Faulty receptacle I 
Make adjustment with adjust bolt, 1--Check engine  revolutions 
observing  engine revolutions.  (i.e. 
frequency). 
Stay  unchanged 
I Return to normal  (AC 
voltage indicated  on meter) Check  DC protector More than I I I . 3,BOO rpm Too low Normal Erratic Conducting I Not conducting 
I  I 
~~ R~..lgowmo• I I ~ arm/shaft. I Faulty  DC circuit breaker Faulty adjust plate or Check wiring harness for continuity: faulty governor. Conducting Not conducting Faulty wiring harness I 
Check  resistance  in stator DC coil. 
Standard  resistance !] ± 10% r--120V ----Check for internal grounding of coils 60Hz in stator DC  coil. ~ 0.433 
I Not continuity -Continuity Broken wire or short-circuit in DC Infinity or below standard coil 
I Faulty  coil I 
Check output voltage at AC 
Faulty  DC 
rectifier receptacle. 
I Normal direction I Continuity I 0-15V 
I Reverse  direction I No continuity I Low reading 
40-60V Not normal I Normal 
In-between reading r---Follow same checking  procedure 
subsequent to measurement for Specified  reading 
main coil and sub-coil in TROUBLESHOOTING (B). (AC Generation) 
I Faulty I DC rectifier 
4-8  
						

							(R x 1) 
2 
(R X 1) 
G 
G 
GENERATOR SYSTEM I ELEC I u I 
4-9 
INSPECTION 
Main coil resistance 
1. Disconnect the main coil coupler G). 
2. Connect the pocket tester as shown. 
Main coil resistance: 
1.7640±10% 
Out or specification~Replace stator assem­
bly. 
Sub  coil 
resistance 
1. Disconnect the sub coil coupler G). 
2. Connect the pocket tester as shown. 
Sub coil resistance: 
2.990±10% 
Out or specification~Replace stator assem­
bly.  
						

							A 
8 
GENERATOR SYSTEM I ELEC I [~ I 
4-10 
Condenser functions 
1. Disconnect the condenser leads. 
2. Connect the pocket tester. 
Turn 
the pocket tester switch to Rx1 K 
from OFF position. 
Needle swings and returns back quickly-7 
Correct. 
Needle does not swing/return-7Replace. 
F!•41 ;] ~II~ (CJ 
Discharge the old condenser by shorting the 
two terminals together. 
Use  an 
Insulated screw driver. 
Do 
not touch either of the terminals and 
ground  before 
the condenser  is discharged. 
Rotor rectifier  continuitys 
1. Desolder the rotor rectifiers. 
2. Connect the pocket tester shown. 
Continuity-7Correct. 
No continuity-7Replace. 
3. Connect the pocket tester as shown. 
No continuity-7Correct. 
Cantin u ity-7Replace. 
~: Nomal direction. 
rn:J: Reverse direction. 
Rotor resistance 
1. Desolder the rotor rectifiers. 
2. Connect the pocket tester as shown. 
Rotor resistance: 
4.110±10% 
Out of specification-7Replace.  
						

							(R x 1) 
A 
B 
GENERATOTR SYSTEM I ELEC I u I 
4-11 
DC coil resistance 
1. Disconnect the DC coil coupler G). 
2. Connect the pocket tester as shown. 
DC coil resistance: 
0.4330±10% 
Out of specification~Replace stator assem­
bly. 
DC rectifier continuitys 
1. Remove the DC rectifier. 
2. Connect the pocket tester as shown. 
Continuity~Correct. 
No continuity~Replace DC rectifier. 
3. Connect the pocket tester as shown. 
No continuity~Correct. 
Continuity~Replace DC rectifier. 
~: Normal direction. 
[ID: Reverse direction. 
Rotor remagnetized 
1. Assembl the generator. 
2. Start and turn the engine with no load. 
3. Connect the battery (12V) to the con­
denser terminal at the moment and the 
rotor will be magnetized instantly. 
CAUTION: 
Do not connect the battery more than a few 
seconds. This may cause deteriorate the bat­
tery.  
						

							SPECIFICATIONS 
GENERAL SPECIFICATIONS 
MODEL CODE NUMBER 
DIMENSIONS 
Overall 
Length 
Overall Width 
Overall Height 
Dry Weight 
ENGINE 
Engine Type 
Cylinder Arrangement 
Displacement 
Bore x Stroke 
Compression Ratio 
Operating 
Hours 
Fuel 
Fuel  Tank  Capacity 
Engine 
Oil Capacity 
Engine 
Oil Grade 
IGNITION  SYSTEM 
Ignition Timing 
Spark Plug Type 
Gap 
GENERATOR 
AC Output 
Rated  Voltage 
Frequency 
Rated 
Output 
Rated Current 
Safety  Device Against 
DC Output 
Rated Voltage 
Rated 
Current 
Safty  DevicemAoainst 
Unit 
mm(in) 
mm (in) 
mm(in) 
kg (lb) 
3 em 
mm(in) 
L (Imp gal, US gal) 
L (Imp qt, US qt) 
mm (in) 
v 
Hz 
kVA 
A 
v 
A 
5-1 
SPECIFICATIONS I SPEC I u • 
EF1000 
7FL 
390 (15.4) 
280(11.0) 
388  (15.3) 
24.8  (54.7) 
4-stroke 
OHV forced 
air cooled 
1 
84.4 
50 X 43  (1.97 X 1.69) 
8.0: 1 
5.0 
Unleaded regular gasoline 
3.8  (0.84, 1.0) 
0.43 
(0.38, 0.45) 
4-stroke engine oil API Service  Classification 
SE or SF if not available, SO 
K [A] YAMALUBE 4 (10W-30) 
... 
IQ] SAE 1~~ SAE #2~~ SAE #30 .,.. ... .,.. ....-
C.D.I. 
BTDC  23° 
BPR6HS 
0.6-0.7 (0.024-0.028) 
120 60 
0.85 
7.1 
Protector (Thermal type) 
12 
10 
Protector