Yamaha EF1000iS Service Manual

4-6
FUEL PUMP, FUEL TANK AND FUEL CHANGE LINK
FUEL PUMP, FUEL TANK AND FUEL CHANGE LINK
3
2
1
4
7
6
5
9
8
11
10
4 Nm (0.4 m · kg, 2.9 ft · lb)
CARB
Order Job name Q’ty Remarks
Fuel cock, fuel tank andRemove the parts in the order listed 
fuel change link removalbelow.
Front cover and rear coverRefer to “COVERS” section in CHAPTER 2.
1 Pipe 3 1 Set the fuel cock to “OFF” position.
2 Pipe 4 1
3 Fuel change link assembly 1 Remove from the bracket.
4 Fuel tank assembly 1
5 Cap assembly 1
6 Strainer 1 1
7...

4-7
FUEL PUMP, FUEL TANK AND FUEL CHANGE LINK
3
2
1
4
7
6
5
9
8
11
10
4 Nm (0.4 m · kg, 2.9 ft · lb)
CARB
Order Job name Q’ty Remarks
11 Fuel tank filter
Remove the parts in the order listed 
For installation, reverse the removal
procedure.
7VV10-04  02.10.4 10:39 AM  Page 7 

4-8
FUEL PUMP, FUEL TANK AND FUEL CHANGE LINK
A
FUEL PUMP INSPECTION
1. Inspect:
9Fuel pump
Inhale the hose form A→Open.
Blow the hose to A→Close.
cC
Excessive force will damage the fuel pump
must be replaced.
FUEL TANK FILTER INSPECTION
1. Inspect:
9Fuel tank filter
Wear →Replace.
Dirt/clog →Clean.
CARB
7VV10-04  02.10.4 10:39 AM  Page 8 

CARB
7VV10-04  02.10.7 6:54 PM  Page 9
1_, I  

5-1
ELECTRICAL COMPONENTSELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1Control unit assembly
2Speed limiter
3Overload warning light (Red)
4Pilot light (Green)
5Oil warning light (Red)
6Generator assembly
7Engine switch
8Economy switch
9DC circuit breaker
0AC receptacle (7.5 A×2)
qDC receptacle (12 V-8 A)
wSpark plug cap
eHigh-tension cable
rIgnition coil
tThrottle control motor
yRectifier
1 2345
6
7
8 9 q
0
t
6
e
r y
1w
7VV10-05  02.10.9 8:36 AM  Page 1 

5-2
CIRCUIT DIAGRAMELEC
CIRCUIT DIAGRAM
W
WWOr
W
WW
W
WW
Br
Br
BrBr
Br
Br Br W
W
WBr
Br Br
BrBr
BrBrG
Br
G
BrW
W
W W
Or
WR
R RBr
RBr
R
LLLL
L
L
L
Y
B B
B
B
B
BB
B
B
B
R
RR
R
L
L
L
L G G
Y
Y
O
R
L G
Y
O
OB/W
B/WB/W
B/W
B/W
B/W
B/WG/Y
G/Y
B/W B/W
Y Y
Y
Y O O R
S
T
R
S
T
1
2
3
4
f
s
a
d
gp
oy
u
it e
r w q0 98
7
6
5
1AC coil 1 (AC)
2AC coil 2 (AC)
3DC charge coil
4Generator assembly
5Rectifier
6Control unit assembly
7Pilot light (Green)
8AC receptacle (7.5A×2)
9Economy switch
0Overload warning light (Red)...

5-3
SWITCHESELEC
SWITCHES
CHECKING SWITCH CONTINUITY
Use a tester to check the terminals for continu-
ity. If the continuity is faulty at any point,
replace the switch.
NOTE:
9Set the pocket tester to “0” before starting a
test.
9When testing the switch for continuity the
pocket tester should be set to the “×1” Ω
range.
9When checking the switch turn it on and off
a few times.
Pocket tester:
YU-03112, 90890-03112
7VV10-05  02.10.7 1:41 PM  Page 3 

5-4
IGNITION SYSTEMELEC
IGNITION SYSTEM
TROUBLESHOOTING CHART
NO SPARK OR WEAK SPARK
Inspection steps:
1. Spark plug
2. Ignition spark gap
3. Spark plug cap
4. Ignition coil resistance
5. Air gap6. Engine switch
7. Oil level switch
8. Wire harness
NOTE:
9Remove the following part(s) before troubleshooting.
1) Front cover and rear cover
2) Cylinder air shroud 1
3) Cylinder air shroud 2
9Use the following special tool(s) for troubleshooting.
Dynamic spark tester:
YU-34487
Ignition checker:
90890-06754
1....

5-5
IGNITION SYSTEMELEC
Minimum spark gap:
6 mm (0.24 in)
3. Spark plug cap
9Remove the spark plug cap.
9Connect the pocket tester (Ω×1k) to the
spark plug.
Tester (+) lead →Spark plug side 1
Tester (–) lead →
High-tension cord side 2
4. Ignition coil resistance
9Remove the ignition coil.
1) Primary coil resistance
9Connect the pocket tester (Ω×1k) to the pri-
mary terminal.
Tester (+) lead →Black/White terminal 1
Tester (–) lead →
Ground terminal 2
NOTE:
9Do not pull out the plug cap from the high-...

5-6
IGNITION SYSTEMELEC
2) Secondary coil resistance
9Connect the pocket tester (Ω×1k) to the
secondary terminal.
Tester (+) lead →High-tension cord 1
Tester (–) lead →Ground terminal 2
Secondary coil resistance:
11.5 kΩ± 20% at 20 °C (68 °F)
1
2
5. Air gap
9Measure the thickness between the magnet
rotor and ignition coil.
Air gap:
0.5 ± 0.1 mm (0.02  ± 0.004 in)
6. Engine switch
9Disconnect the engine switch coupler in the
control box.
9Connect the pocket tester (Ω×1k) to the
engine switch terminal....