Yamaha EF1000A Service Manual

							ELECTRICAL COMPONENTS I ELEC I u I 
ELECTRICAL 
ELECTRICAL COMPONENTS 
WIRING  DIAGRAM 
(i) 
~: 
~I 
4-1 
@ 

						

							CD ® r---------1 
1  
1 
I  I 
: I I I I -Br Br-I L ________ j 
~--~----i 
I 0 0 I 
I  I 
I  I 
I B/W B 1 
i I I : 
L ______ _j 
@ ,---------------, 
I I 
:,r,s~ I 
I I I I ~w I L _______________ ~ 
SWITCH INSPECTION I ELEC I u I 
4-2 
SWITCH INSPECTION 
INSPECTION STEPS 
Using pocket  tester, check switches for conti­
nuity between their terminals to determine 
whether they are correctly connected. 
Replace the switch component if any of the 
combinations does not produce the correct 
reading. 
Pocket tester: 
VU-03112 (90890-03112) 
NOTE:--------------------------
•Turn the switch to the ON, OFF posi­
tions several times. 
•Adjust the pocket tester to correct 0 posi­
tion before  checking  switches. 
•Set the pocket tester selector to x1 Q. 
SWITCH  CONTINUITY  INSPECTION 
Refer to SWITCH INSPECTION and check 
for continuity between lead terminals. 
Poor connection, no continuity-+ Correct or 
replace. 
*The coupler locations are circled. 
G) A.C.protector 
@Engine switch 
@Oil level switch  
						

							IGNITION SYSTEM I ELEC I u I 
TROUBLE SHOOTING 
NO SPARK OR NO WEAK SPARK 
NOTE:----------------------------------------------------------
•Remove the following part(s) before trouble shooting. 
1) Drain the engine oil 3) Control box 
2) Spark plug 4) Oil level switch 
•Use this following special  tool(s) for troubleshooting. 
Pocket tester: 
VU-03112 (90890-03112) 
1. Spark plug 
• Check the spark plug condition. 
Refer to SPARK  PLUG in cha ter 2. 
Dynamic spark tester: 
YM-34487 
Ignition checker: 
90890-06754 
Repair or replace the spark plug. 
2. Ignition spark gap 
• Disconnect the spark plug cap from the 
spark plug. 
• 
Connect the ignition checker  as shown. 
Spark plug cap G)~ Ignition checker. 
Ignition checker lead ~Spark plug@. 
• Pull the crankshaft and measure the 
ignition spark plug@. 
Minimum spark gap: 
6 
mm (0,24 in) 
NO  GOOD 
* 
GOOD The ignition system  is good. 
4-3  
						

							* 
3. Spark plug cap 
• Remove the spark plug cap. 
• Connect the Pocket tester (Q x  1 k) to the 
spark plug cap. 
D 
D ll Spark plug cap  resistance: 
~ 3.7 ... 6.3 Kn at 20°C 
NO GOOD 
4. Ignition coil resistance 
• Remove the ignition coil. 
• 
Connect the Pocket tester (Q x  1 k) to the 
coil terminal (secondary). [AI 
Tester(+) lead ~ Hi-tension  cord G). 
Tester(-) lead~ Terminal@. 
ll_j Ignition coil resistance: 
3.4 
Kn±20o/o at 20°C 
• Connect the Pocket tester (Q x  1 k) to the 
coil terminal (primary). [ID 
Tester(+) lead ~Terminal G).(Bigger  hole) 
Tester (-) lead ~Terminal @.(Smaller  hole) 
CJ ll Ignition coil resistance: 
~ 0.06 n±20o/o at 20°C 
GOOD NO GOOD 
* 
IGNITION  SYSTEM I ELEC II~ I 
4-4 
NOTE:--------------------------
• Do not pull out the plug cap from the hi-
tension cord. 
• Remove~Turn the plug cap counter 
clockwise. 
• 
Install~ Turn  the plug cap clockwise. 
• 
Inspect the hi-tension cord, when install 
the plug cap. 
• Cut the hi-tension cord edge to 5 mm 
then install the plug cap. 
Replace the spark plug. 
Replace the ignition coil.  
						

							5. Engine switch 
• Remove engine switch connector from 
the control box. 
• Connect the Pocket tester (Q x 1 k) to the 
engine switch connector and turn the 
engine switch to ON. 
• Check the en ine switch for continuit . 
6. Coil  assembly resistance 
• Disconnect the coupler from the coil. 
• 
Connect the Pocket tester (Q x  1 k) to the 
connector (charge coil). 
Tester (+) lead ---7 Brown terminal @. 
Tester (-) lead ---7 White/Red terminal @. 
iQj Coil resistance  (charge coil): 
350 
Q±20o/o at 20°C 
• Connect the Pocket tester (n x  1 k) to the 
connector (pulsar  coil). 
Tester (+) lead ---7 Black terminal G). 
Tester (-) lead ---7 Black terminal@. 
D ll Coil resistance (pulsar  coil): 
~ 38 n±20o/o at 20°C 
NO GOOD 
7. Oil level switch 
• Remove the oil level switch. 
Refer 
to CRANKCASE in  chapter 3. 
• Connect the Pocket tester (n x  1 k) as 
shown. 
NO CONTINUITY 
* 
IGNITION SYSTEM I ELEC I u I 
OFF ON 
Replace 
the engine switch. 
Replace the coil assembly 
D 
CONTINUITY 
* 
Replace the oil level switch. 
4-5  
						

							8. C.D.I.unit 
•  Check 
the  connection  entire C. D. I. unit. 
NO GOOD 
I Replace the flywheel. 
4-6 
If do not check the C.D.I. spark test, replace 
the new C.D.I. unit. Because  the C.D.I. unit is 
difficulty check the specificated  circuit.  
						

							~ I -...J 
TROUBLE 
SHOOTING 
NOTE: 
¢ 
Indicates 
a value 
which 
meets 
the 
Service Date 
or 
state 
without 
any 
problems 
in inspection. 
• 
Indicates 
a state 
in 
which 
a problem 
has been 
found 
in the 
inspection  and remedy  is necessary. 
I 
GENERATOR 
DOES 
NOT 
GENERATE 
I 
Check 
stator 
main 
and 
sub 
coils 
for 
continuity. 
Check 
engine 
speed.  (No 
load) 
Main 
coil: 
R-Br 
Sub 
coil: 
G-G Br: Brown Step 
#1 
Adjust 
engine 
speed. 
Step 
#2 
F1l NG 
Check 
voltage 
generated 
by 
stator 
main 
coil 
under 
no 
load. 
R:Red G: Green Br: 
Brown 
OK 
ov 
LOW 
Operable 
with 
condenser 
connection 
removed. 
I Check  engine  side. 
I 
Remove 
sub 
coil 
connection 
and 
check 
each 
generated 
voltage 
while 
running. 
G) Primary 
coii:2-5V 
®Secondary 
coii:2-6V 
OK 
R: Red G: Green 
Br:  Brown 
C) m 2 m :a ~ 0 :a C/) < C/) -t m s: m r­m n D  
						

							 I 00 
~--Check 
A. 
C. 
receptacle. 
I • 
Check 
voltage 
generated 
by 
main 
coil 
after 
rotor 
is magnetized. 
Rotor  remagnetized 1. Start the engine  (no 
load) 
2. Connect  the battery  (D.C.12 
V) to the 
con­
denser 
terminal 
at the 
moment 
and 
the 
ro­
tor 
will 
be  magnetized 
instantly: 
tuma:; 
_________ 
_ 
Do 
not 
connect 
the 
battery  more than a 
few 
seconds.  This may cause  deteriorate 
the 
bat­
tery.  Check 
condenser 
characteristics. 

						

							___________________ G_E_NE_R_A_~_oR __ sv_s_T_E_M_IELECII~~ 
TROUBLE SHOOTING 
GENERATOR DOES NOT GENERATOR 
•Connect the pocket  tester 
(x1 kQ) to the  both  ter­
minal 
of the  condenser. 
•The needle  swings  and 
returns 
back quickly. 
• Remove  the rear  cover  and 
start  the engine. 
•Connect the  pocket  tester to 
the  Brown  and Red lead. 120V: 114~140V 
Main coil AC voltage 
• Disconnect  the sub coil 
coupler and  start  the engine. •Connect the  pocket  tester to 
the  Brown  and Red lead. 120V: 2~5 V 
Sub coil AC voltage 
• Disconnect  the sub coil 
coupler and  start  the engine. • Connect the  pocket  tester to 
the  Green  and Green lead. 120V: 2~6V 
Replace the condenser. 
Main 
coil resistance * 
4-9 
NOTE: ¢ Indicates a value which meets 
the Service  Date or state without any 
problems in inspection. 
• Indicates a state in which a problem 
has  been found in the inspection  and 
remedy is necessary. 
Replace the ACswitch. 
Replace 
the AC receptacle. 
Correct 
or replace the wireharness. 
Replace the stator assembly. 
Replace 
the stator assembly.  
						

							GENERAL SPECIFICATIONS I SPEC I g­
SPECIFICATIONS 
GENERAL SPECIFICATIONS 
Unit EF1000A 
MODEL CODE NUMBER 7TA 
DIMENSIONS: 
Overall  length 
mm(in) 399 (15.7) 
Overall width 305 (12.0) 
Overall 
height 410 (16.1) 
Dry 
weight kg (l•b)  23.0 (50.7) 
ENGINE: 
Type  4-Stroke OHV air cooled 
Cylinder 
arrangement 1 
Displacement ml (cm3 ) 84  (84) 
Bore  x stroke 
mm (in) 50.0 X 43.0 (1.97 X 1.69) 
Compression  ratio  8.4:1 
Rated out put 60Hz kW (PS) /3.600 r/min  1.5 (2.0) 
Operating 
hours 60Hz Hours 5.5 
Fuel 
Unleaded regular gasoline 
Fuel 
tank capacity  L (Imp 
gal, US gal) 3.8 (0.84,  1.00) 
Engine oil capacity  L (Imp qt, 
US  qt) 0.43  (0.38,  0.45) 
Engine oil grade  4-stroke engine oil API Service Classification 
SE or SF if not available, SD 
0°C 15°C 
Ao .I 
( iA! YAMALUBE  4 (10W-30) .... 
... 
IQISAE 10~ 
A to.. 
~ lCJSAE #20) 
A 
(!mSAE#30 ..  or 
32°F 59°F 
ELECTRICAL: 
Ignition system: C.D.I. 
Ignition timing B.T.D.C. 23° 
Spark plug type BPR6HS (NGK) 
Spark 
plug gap mm (in) 0.6-0.7  (0.024-0.028) 
Generator  system: 
A.C. output 
Rated voltage v 120 
Frequency Hz 60 
Rated output kVA 0.8 
Rated current A 6.7 
Safety  device 
type A.C. protector 
5-1