Yamaha EF1000A Service Manual

							MAINTENANCE SPECIFICATIONS I SPEC I g­
MAINTENANCE SPECIFICATIONS 
ENGINE 
Item Standard Limit 
Piston: 
~~(in) Piston clearance 0.020-0.035 (0.00078-0.00137) 
Piston  size D 49.974-49.994  (1.967-1.968)  49.974 
(1.967) 
Measuring point H 10.0 (0.3937) D 
Piston pin: mm (in) 
Piston  pin 
diameter 11.996-12.000 (0.4723-0.4724)  11.95 (0.470) 
Piston 
ring: mm (in) 
Top 
ring Barrel 
~ 
End gap 0.1-0.25 (0.004-0.01)  0.9 
(0.035) 
Side clearance 0.06  (0.002) 0.15 (0.0059) 
2nd ring Plane 
~ 
End gap 0.1-0.25 (0.004-0.01)  0.9 
(0.035) 
Side clearance 0.04  (0.001) 0.15 (0.0059) 
Oil 
ring Solid +expander 
== Side clearance 0.2-0.4 (0.008-0.015)  0.15(0.0059) 
Cylinder head: mm (in) 
Warp limit 0.1 (0.004) 
Cylinder: mm (in) 
Bore size 
~ 
50.005-50.015 (1.9687-1.9690) 
Crankshaft: 
mm (in) 
Big 
end side clearance A 0.2-0.6 (0.008-0.024)  0.8(0.03) 
Runout limit B 9 0.02 
(0.0008)  0.04 
(0.0016) 
Crank  pin outside diameter "C~ t 22.0  (0.866)  21.9 (0.862) 
A 
Carburetor: 
Type/Quantity MIKUNI/1 
I.D.mark 7TA10 
Bore size mm (in) 10 (0.39) 
Float height mm (in)  17.0 (0.67) 
Main jet 56.3 
Main air jet mm (in) 
1.3 (0.051) 
Pilot air jet mm (in) 0.8 (0.03) 
Pi lot outlet mm (in) 0.8  (0.03) 
Valve  seat mm (in) 
1.8 (0.07) 
Main nozzle 11A 
Pilot jet #42.5 
Pilot screw 1-7/8 
Throttle valve 110 
Rated engine speed r/min 3,700-3,850 
5-2  
						

							MAINTENANCE SPECIFICATIONS I SPEC I g-
Item 
Connecting rod: 
Small end diameter A 
Oil clearance 
Big  end  diameter B 
Oil clearance 
Limit 
Camshaft: 
Camshaft  outside 
diameter 
Cam dimension 
A 
B 
Camshaft journal 
Limit 
Valve: 
Valve 
dimension 
mm (in) 
mm (in) 
QJ· 
B 
mm (in) 
c 
/~ 
Head  diameter A ~~'I : ~ 
Stem  diameter B 
Length C 
Seat width D 
Valve seat bend limit 
8 
Valve guide 
IN 
EX 
IN 
EX 
IN 
EX 
Guide  inside diameter IN 
EX 
Stem to guide clearance  IN 
EX 
Valve clearance  IN 
Push 
rod: 
Runout 
limit 
Valve spring: 
Free 
length 
Seat length 
Set 
force 
Tilt limit 
EX 
IN 
EX 
IN 
EX 
IN 
EX 
mm (in) 
mm (in)  Standard 
12.006-12.020 
(0.4727-0.4732) 
0.016-0.034 (0.00063-0.00134) 
21.977-21.995 (0.8652-0.8659) 
0.005  -0.023 
(0.00020-0.00090) 
IN EX 
20.5  (0.807)  20.5 (0.807) 
16.0  (0.63)  16.0 
(0.63) 
15.965 -15.990  (0.6285-0.6295) 
19 (0.748) 
17 (0.669) 
5 (0.196) 
5 (0.196) 
53.4 (2.10) 
53.6 (2.11) 
0.7 (0.027) 
0.7  (0.027) 
5.0  -5.012 
(0.1969-0.1973) 
5.0  -5.012 (0.1969-0.1973) 
0.037  -0.064 (0.00146-0.00252) 
0.045 -0.073 (0.00177-0.00283) 
0.1 (0.004) 
5-3 
0.1 (0.004) 
27.4  (1.0787) 
27.4  (1.0787) 
18.1  (0.7126) 
18.1  (0.7126) 
5.6 
kg (12.31b) 
5.6 kg (12.3 lb) 
Limit 
0.1(0.004) 
0.1  (0.004) 
15.95 (0.6280) 
1.2 (0.047) 
0.01  (0.0004) 
0.5  (0.02) 
0.8  (0.03)  
						

							MAINTENANCE SPECIFICATIONS I SPEC I g-
ELECTRICAL 
Item Standard Limit 
GENERATOR: 
Type  Brush-less, self-exciting, 
single-phase, 
A.C. generator 
Number of poles 2 
Excitation 
Self magnetization 
Initial excitation  Residual magnetization 
Driving 
method Direct  connection 
Rated 
power factor 1.0 
Frequency fluctuation Less than 5% 
Voltage v 120 
Frequency Hz 60 
Coil 
resistance 
Main coil  Q±10% 1.45 
Sub coil 
Q±10% 3.45 
Rotor 
coil  Q±10% 8.05 
ELECTRICAL: 
Ignition system: 
Type/I.D. mark/manufacture C.D.I. magneto/7TA/MORIYAMA 
Pulsar coil resistance Q±20% 38 
Charge 
coil resistance Q±20%  350 
Ignition coil: 
Ignition timing at 3.600 r/min B.T.D.C. 22.3~23.7° 
Primary coil resistance Q±20% 0.06 
Secondary  coil resistance kQ± 20% 3.4 
Plug  cap resistance 
kQ 3.7-6.3 
A.C. 
excess current check  Protector 
5-4  
						

							TIGHTENING TORQUE/ 
---------G-EN_E_R_A_L_T_o_R_a_u_E_s_~_c_IF_~_A_T-IO_N_S_/_ISPECI~ DEFINITION OF UNITS _ . W 
TIGHTENING TORQUE 
Thread size  Torque Nm (m•kg, 
ft•lb) Remarks 
Spark plug 
Cylinder  head cover 
Cylinder head 
Crankcase  cover 
Connecting  rod 
Rotor 
Governor arm 
Valve  clearance  adjusting 
nut 
Fly wheel 
Coil assembly 
Fuel  tank 
Muffler 
Carburetor 
Muffler protector 
Front flame 
Rear flame 
Recoil  starter 
GENERAL TORQUE 
SPECIFICATIONS 
M14x 1.25 
M 
6x 1.0 
M 6x 1.0 
M 6x 1.0 
M 6x 1.0 
M 8x 1.25 
M 
6x 1.0 
M 6x0.5 
M12x  1.25 
M 
6x 1.0 
M 6x 1.0 
M 6x 1.0 
M 6x 1.0 
M 6x 1.0 
M 8x 1.25 
M 
6x 1.0 
M 6x 1.0 
This chart specifies torque for standard 
fasteners with standard I.S.O. pitch threads. 
Torque specifications for special components 
or assemblies are included in the applicable 
sections of this book. To avoid warpage, 
tighten multi-fastener assemblies in a 
crisscross fashion, in progressive stages, 
until full torque is reached. Unless otherwise 
specified, torque specifications call for clean, 
dry threads. Components should be at room 
temperature. 
DEFINITION  OF UNITS 
Unit Read 
mm Millimeter 10·3 m 
em 
Centimeter 10·2 m 
20  (2.0, 14) 
9 (0.9, 6.5) 
11 (1.1, 8.0) 
10 (1.0, 7.2) 
9 
(0.9, 6.5) 
23  (2.3,  17) 
6 
(0.6, 4.3) 
10 (1.0, 7.2) 
40 (4.0, 29) 
7 
(0.7, 5.1) 
7 
(0.7, 5.1) 
7 
(0.7, 5.1) 
7(0.7,5.1) 
6 (0.6, 4.3) 
10(1.0, 7.2) 
10 (1.0, 7.2) 
7(0.7,5.1) 
Thread  size 
M4 
M5 
M6 
M7 
MB 
M10 
M12 
Definition 
kg Kilogram 1Q3 gram 
N Newton 1  kg  x m/sec2 
N•m Newton meter Nxm 
m•kg Meter-kilogram mxkg 
Pa Pascal N/m2 
N/mm Newton per millimeter N/mm 
L Litter -cm3 Cubic centimeter 
tr/mn Rotation per minute -
5-5 
Tightening torque 
Nm m•kg ftolb 
2 0.2 1,4 
3 
0.3 2,2 
7 
0.7 5,1 
10  1.0 7,2 
15  1.5 
10,8 
30  3.0 
21,7 
60 6.0 43,4 
Measure 
Length 
Length 
Weight 
Force 
Torque 
Torque  Pressure 
Spring  rate 
Volume or Capacity 
Engine  speed  
						

							CABLE, HOSE ROUTING 
CABLE,  HOSE ROUTING I SPEC I go-
CD 
5-6 
[A] control box panel 
[ID Behind control box 
[Q] Behind control box panel 
CD A.C.protector 
@A. C. receptacle 
®Ground (Earth terminal) 
@Engine switch 
J  
						

							___________________ c_A_BL_E_,_H_o_sE __ Ro_u_T_I_N_G_IsPECI ~ 
G) Carburetor 

						

							G) Fuel tank 
~ Fuelcock 
@Air filter 
@ Carburetor 
@Rear frame 
®Fuel hose 
[AJ Pass the fuel hose through on 
the crankcase to under the 
carburetor. 
CABLE, HOSE ROUTING I SPEC I rr-1 
5-8  
						

							CD Air shroud under 
@Crankcase 
@Plate 
@Flywheel 
® Coil assembly 
@ Oil level switch 
Q) Clamp 
@ Oil level switch lead 
®Coil assembly  lead 
CABLE, HOSE ROUTING I SPEC I g-1 
rn:J Pass the coil assembly  lead to 
the crankcase  and plate. 
[Q] Clamp with the oil level switch 
lead and  wireharness. 
[AJ Set in to the oil level switch lead 
to the slit of the crankcase. 
5-9