Yamaha EF1000A Service Manual

SPARK PLUG/ A.C. PROTECTOR INSPECTION/ 1~:gs 
1 
** 1 ENGINE SWITCH INSPECTION/ A. C. RECEPTACLE INSPECTION .  . ~ . 
ION) 
~ 
o(;) 
(OFF) 
If necessary, clean the spark plug with a spark 
plug  cleaner. 
Standard spark plug: 
Resistored spark plug : BPR6HS 
Before installing the spark plug, clean the 
gasket  surface  and plug surface. 
4. Tighten: 
•Spark plug CD 
ll'l!:"~.....,lr2~0-::-N:-m____,(2-.0-m-·-:-kg-,-,-4 ~ft-·lb--,) I 
NOTE:-------------------------
Finger tighten CD the spark plug...

ENGINE OVER HAUL ENG 
ENGINE 
ENGINE OVERHAUL 
MUFFLER PROTECTOR, FUEL TANK AND MUFFLER 
IELft ___ (Sia Nm (0:6 m•kg, 4.3 ft-lb)l 
~ [ 17 Nm (0. 7 m•kg, 5.1 ft-lb) I @ @ I 
0 
JOB INSTRUCTION CHART 
Order Job name/Parts name 
Muffler protector, fuel tank and 
muffler removal 
1 Muffler protector 
2 
Fuel hose 
3 Fuel tank 
4 Muffler assembly 
5  Gasket (muffler) 
2 
7 Nm (0.7 m•kg, 5.1 ft-lb) 
Oty Remarks 
Remove 
the parts in the order below. 
1 NOTE: Disconnect  the fuel  hose,  turn the fuel 
1...

ENG 
AIR ALTER, CARBURE ENGINE OVER HAUL 
TOR AND CONTROL BOX 
JOB INSTRUCTION CHART 
Order 
1 
2 
3 
4 
5 
6 
7 
8 
A Job name/Parts name 
•r filter, carburetor and 
c Fontlrol box removal 
ue tank 
B~eather hose 
Air filter assembl 
Gasket (air filter) y 
Governor link rod 
Carburetor assembl 
JGa_sket (carburetor) y 
omt 
Control box 
1 
1 
1 
1 
1 
1 
1 
1 
3-2  Remarks 
Remove the . parts m the order below 
Refer to MUF · FUEL TANK A~DLER PROTECTOR MUFFLER. I 
Refer to CARBURETOR 
NOTE: Disconnect...

CYLINDER HEAD COVER AND CYLINDER HEAD ENG 
CYLINDER HEAD COVER AND CYLINDER HEAD 
3 
JOB INSTRUCTION  CHART 
Order Job name/Parts name Oty 
Cylinder head cover  and 
cylinder head removal 
Muffler protector , muffler and 
fuel tank 
Recoil starter 
Air filter and carburetor 
1 Spark  plug/Plug  cap 1/1 
2 Air shroud upper 1 
3 
Air shroud under 1 
4 
Cylinder head cover 1/1 
5 Gasket (cylinder head  cover) 1 
6 
Cylinder head assembly 1 
7 
Gasket (cylinder head) 1 
8 Dowel pins 1 
9 Push  rods 1 
3-3...

IIANDSJP I d I CYLINDER HEAD COVER AND CYLINDER HEAD . ~ _ 
---------------------------------------------------
3-4 
INSPECTION 
Cylinder head 
1. Remove: 
•Carbon deposits 
Use  a rounded  scraper. 
NOTE=------------------------­
Be careful to the cylinder head inside when 
decarbonaizing. 
2. Inspect: 
•Cylinder head 
Ware/Damage~Replace. 
3. Measure: 
•Cylinder head wrappage 
Exceeds allowable limit~Replace. 
Wrappage limit: 
0.1 mm (0,004 in) 
INSTALLATION 
1. Install: 
•Dowel pins 
•Cylinder head...

ROCKER ARMS, VALVES AND VALVE SPRINGS ENG 
ROCKER ARMS, VALVES AND VALVE SPRINGS 
1 
m 
JOB INSTRUCTION CHART 
Order Job name/Parts name 
Rocker 
arms ,  valves  and 
valve 
springs removal 
Cylinder head assembly 
1 Locknuts/Adjusters 
2 Rocker  arms 
3 Valve spring seats 
4 Valve springs 
5 Push rod guide 
6 Valve (intake) 
7 Valve (exhaust) 
Qty Remarks 
Remove 
the parts  in the order below. 
Refer to CYLINDER HEAD. 
2/2 2  -J Refer to Valve and valve spring 2 
2  -installation. 
1 
1 
1 
For...

ROCKER ARMS, VALVES AND VALVE SPRINGS ENG 
@ 
3-6 
REMOVAL 
1. Remove: 
•Valve spring seat 

ROCKER ARMS, VALVES AND VALVE SPRINGS ENG 
302-005 
3-7 
3. Measure: 
•Valve stem bend 
Out of specification--+Replace. 
Valve stem bend limit: 
0.01 mm (0.0004 in) 
4. Measure: 
•Valve spring  free length® 
Out of specification--+Replace. 
Valve spring free length: 
27.4 mm (1.0787 in) 
limit: 
24.4 mm (0.9606 in) 
5. Measure: 
•Valve spring tilt® 
Use a square 
Out of specification--+Replace. 
Valve spring tilt limit: 
0.8 mm (0.03 in) 
6. Measure: 
•Valve spring  contact  surface 
Out of...

ROCKER ARMS, VALVES AND VALVE SPRINGS ENG 
302-011 
3-8 
Push rod 
1. Measure: 
• Push rod bend 
Roll on V-block 
Exceeds vending limit---+Replace. 
Push rod  vend limit: 
0.5 
mm (0.02 in) 
Valve seat 
1. Decarbinaized to the valve face  and valve 
seat. 
2. Measure: 
•Valve contact width® 
Poor seating---+Lap. 
Valve contact with: 
0. 7 mm (0.027 in) 
limit: 
1.2 mm (0.047 in) 
3. Measure: 
•Valve seat contact width® 
Poor seating---+Lap. 
Valve seat  contact  with: 
0. 7 mm (0.027 in) 
limit: 
1.2 mm...

ROCKER ARMS, VALVES AND VALVE SPRINGS ENG 
5. Remove: 
•Compound 
(from the valve face) 
6. Apply: 
•Mechanic]s bluing dye (Dykem) CD 
(to the valve face  and seat) 
7. Rotate: 
•Valve 
302-017 The valve must make full seat contact. 
L-------------------1 This is indicated by a gray surface all 
3-9 
around the valve face where the bluing 
was removed. 
8. Apply: 
•Solvent 
(into  each  intake  and exhaust  port) 
Leakage 
past valve seat---+Repeat valve 
lapping until the seal is complete....