Yamaha EF1000A Service Manual

							PISTON, CONNECTING  ROD, 
CRANKSHAFT AND CRANKCASE ENG 
Crankshaft 
3-20 
1. Measure: 
•Crankshaft 
runout 
Use  a dial  gauge. 
Out of specification--+Replace. 
Crankshaft runout: 
0.02 mm (0.0008 in) 
2. Inspect: 
•Crankshaft  sprocket teeth CD 
Wear/Damge--+Replace. 
3. Measure: 
•Crankpin  outside 
diameter® 
Use a micrometer. 
Out of specification--+Replace. 
Crankpin 
outside diameter: 
22.0 mm (0.866  in) 
Wear 
limit: 
21.9 mm (0.862  in) 
4. Measure: 
•Oil clearance 
Use Plastigauge®. 
Out of specification--+Replace the 
connecting  rod. 
Oil clearance: 
0.016 
.. 0.034 mm 
(0.00063 .. 000134 in) 
Oil  clearance limit: 
0.1 mm (0.00157 in) 
Oil clearance measurement steps: 
1. Thoroughly clean  all of the parts. 
2. Place plastigauge ®CD onto the crankpin. 
3. Install the connecting rod and cap @ 
onto the crankcase. 
4. Torque  both cap bolts  evenly. 
1~19 Nm (0.9 m•kg, 6.5 ft•lb) I  
						

							PISTON, CONNECTING  ROD, 
CRANKSHAFT AND CRANKCASE ENG 
3-21 
5. Remove the connecting rod and 
measure the plastigauge R with. 
NOTE:------------­
Do not move the crankshaft until the oil 
clearance measurement has been completed. 
Piston 
rings and piston installation 
1. Install: 
•Top ring® 
•2nd ring@ 
•Oil ring@ 
•Be sure to install the second ring so that 
the manufacturers mark 
						

							PISTON, CONNECTING  ROD, 
CRANKSHAFT AND CRANKCASE ENG 
3-22 
4. Install: 
•Connecting rod cap 
r..l~-,lr-9--:N~m;...._(0-.9-m-·-:-k-g,-6-.5-ft-.1---b--.,) I 
Make sure that the uV rod mark (i) is 
aligned with the uv cap mark ® . 
5. Install: 
•Camshaft 
•Dowel pins 
•Gasket (crankcase  cover) 
•Crankcase 
cover 
Refer to CRANKCASE  COVER AND 
CAMSHAFT section.  
						

							GENERATOR ENG 
GENERATOR 
JOB INSTRUCTION CHART 
Order Job name/parts  name Oty Remarks 
Generator removal Remove the parts in the order below. 
Muffler assembly -~Refer to FUEL TANK AND MUFFLER. Fuel tank -
Recoil starter assembly Refer to RECOIL STARTER AND FLYWHEEL. 
1 Rear flame 1 Refer to CRANKCASE COVER AND 
CAMSHAFT. 
2 Rotor bolt 1 NOTE: When  remove  rotor bolt, make sure add 
the stopper  to the flywheel. 
3  Rotor assembly 1 
4 Coupler 1 
5 Stator assembly 1 
For installation, reverse the removal 
procedure. 
3-23  
						

							3-24 
GENERATOR ENG 
REMOVAL 
1. Remove: 
•Rear flame CD 
NOTE:------------------------­
When remove the rear flame, use a soft 
hammer to rightly touch. 
Take  care 
the rotor assembly for removal. 
3. Remove: 
• Stator assembly CD 
Take  care the stator assembly for removal. 
INSTALLATION 
1. Install: 
•Stator assembly CD 
NOTE:--------------------------
Aiign the key CD on the stator assembly with 
the slot® on the crankcase  cover. 
2. Install: 
•Rear 
flame CD 
..... lx....;;;I.--1-0_N_m_(-1.-0-m--k-g-, -7.-2 -ft-·lb--.) I 
NOTE:--------------------------
Aiign the pin® on the rotor bearing with the 
slot® on the rear flame.  
						

							GOVERNOR ENG 
GOVERNOR 
!A] Spring installation: mJ Spring installation: 
~ 
1 
Gl 
JOB INSTRUCTION CHART 
Q-
Order Job name/parts  name Qty 
Governor removal 
Fuel tank 
Generator 
Crankshaft 
1 Spring 1 
2 Link  rod 1 
3 Governor arm 1 
4 
Clip 1 
5 Governor fork 1 
6 Pin 2 
7 Weight 2 
8 Collar 1 
9 Shaft 1 
10 Weight gear 1 
11 Adjusting plate  assembly 1 
3-25  Remarks 
Remove 
the parts  in the order below. 
Refer to FUEL TANK AND MUFFLER. 
Refer to GENERATOR. 
Refer to CRANKCASE COVER AND 
CAMSHAFT. 
For installation, reverse the removal 
procedure.  
						

							3-26 
GOVERNOR ENG 
INSPECTION 
1. Inspect: 
•Weight gear G) 
Cracks/Wear/Damge-+Replace. 
2. Inspect: 
•Weight@ 
Vend/Damge-+Replace.  
						

							CARBURETOR ENG 
CARBURETOR 
6 
3 
,---t3 
JOB INSTRUCTION  CHART 
Order Job name/parts name Qty Remarks 
Carburetor removal Remove the parts in the order below. 
Air filter assembly Refer to Fuel tank and air filter removal  
in chapter 3. 
1 Fuel hose NOTE: Before disconnect  the fuel hose, turn the 
2 Gasket (air filter) fuel petcock  position  to the C position. 
1 
3 Carburetor assembly 1 
4 Gasket (carburetor) 1 
5 Joint (carburetor) 1 
6 Gasket  (intake) 1 
For installation, reverse the removal 
procedure. 
3-27  
						

							----Type 
I.D. Mark 
Float height 
~ Float height: 17.0 mm (0.67 in) 
JOB INSTRUCTION 
EF1000A 
BV15 
7TA10 
17.0 
mm 
Order Job name/parts  name 
Carburetor  disassembly 
1 Bolt 
2 Gasket 
3 Float chamber 
4 Gasket {float chamber) 
5 
Float pin 
6 Float 
7 Needle/clip 
8 Main nozzle 
9 Main Jet 
10  Pilot screw 
11 Pilot jet 
CARBURETOR ENG 
ate Remarks 
Disassembly the parts  in the order below. 
1 
1 
1 
1 
1 
1 
1/1 
1 
1 
1 
1 
For 
assembly, reverse  the disassembly 
procedure. 
3-28  
						

							3-29 
CARBURETOR ENG 
INSPECTION 
1. Measure: 
•Float height 
NOTE:--------------------------
Piace the carburetor in an inverted position 
for measuring. 
Lift up the float so that the tip of the float 
valve lightly contacts the float arm, and 
measure 
the float height.  (This measurement 
should be made with the gasket  removed.) 
~ Float height 1M 
[61 17.0mm  (0.67 in) 
Out of specification--*Replace. 
2. Inspect: 
•Carburetor body 
•Fuel passage 
Contamination--*Ciean as indicated. 
Carburetor cleaning steps: 
• Wash the carburetor in a petroleum 
based solvent. (Do not use  a caustic 
carburetor cleaning  solution.) 
• Blow out all of the passages and jets 
with compressed  air. 
e passage 
or 
3. Inspect: 
•Valve seat 
Wear/Damage--*Replace. 
Contamination--*Ciean 
. 
CD Grooved wear 
(?) Dust