Yamaha EF1000iS Service Manual

							SERVICE MANUAL
EF1000iS
LIT-19616-01-02 7VV-28197-10
310137
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							FOREWORD
This manual was written by the Yamaha Motor
Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible
to put an entire mechanic’s education into one
manual, so it is assumed that persons using
this book to perform maintenance and repairs
on Yamaha generators have a basic under-
standing of the mechanical precepts and pro-
cedures inherent to generator repair
technology. Without such knowledge,
attempted repairs or service to this model may
render it unfit for use and/or unsafe.
Yamaha Motor Company Ltd. is continually
striving to further improve all models manufac-
tured by Yamaha. Modifications and significant
changes in specifications or procedures will be
forwarded to all Authorized Yamaha dealers
and will, where applicable, appear in future
editions of this manual.
NOTE:
This Service Manual contains information
regarding periodic maintenance to the emis-
sion control system. Please read this material
carefully.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT
INFORMATION
This material is distinguished by the following
notation.
Q
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR  SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could
result in severe injury or deathto the
machine operator, a bystander, or a person
inspecting or repairing the machine.
cC
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
MANUAL FORMAT
The procedures in this manual are organized
in a sequential, step-by-step format. The infor-
mation has been compiled to provide the
mechanic with an easy to read, handy refer-
ence that contains comprehensive explana-
tions of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty
component will precede an arrow symbol and
the course of action required will follow the
symbol, e.g.,
9Bearings
Pitting/damage →Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams
before each disassembly section for ease in
identifying the correct disassembly and
assembly procedures. EF1000iS
SERVICE MANUAL
©2002 by Yamaha Motor
Corporation, U.S.A.
1st Edition, October 2002
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor
Corporation, U.S.A.
is expressly prohibited.
Printed in USA
LIT-19616-01-02
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							ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1through 7are designed
as thumb tabs to indicate the chapter’s number
and content.
1General information
2Periodic inspections and adjustments
3Engine
4Carburetor
5Electrical
6Trouble shooting
7Specifications
Illustrated symbols 8through rare used to
identify the specific tools and test equipment.
8Filling fluid
9Lubricant
0Special tool
qTightening
wWear limit, clearance
eEngine speed
rW,  V,  A
Illustrated symbols tthrough din the
exploded diagram indicate the grades of lubri-
cant and the locations of the lubrication points.
tApply engine oil
yApply gear oil
uApply molybdenum disulfide oil
iApply wheel bearing grease
oApply lightweight lithium-soap base grease
pApply molybdenum disulfide grease
aApply a locking agent (LOCTITE
®)
sApply Yamaha bond
dUse a new one
GEN
INFOINSP
ADJ
ENG
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EGM
BLSM
LT4New
12
34
5
6
CARB
SPEC
7
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8
9
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							INDEX
GENERAL INFORMATIONGEN
INFO
PERIODIC INSPECTIONS
AND ADJUSTMENTS
INSP
ADJ
ENGINEENG
CARBURETORCARB
ELECTRICALELEC
TROUBLESHOOTINGTRBL
SPECIFICATIONSSPEC
1
2
3
4
5
6
7
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							CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION....................1-1
SERIAL NUMBER................................1-1
STARTING SERIAL NUMBER.............1-1
IMPORTANT INFORMATION...................1-2
PREPARATION FOR REMOVAL AND
DISASSEMBLY
CAUTION ON SERVICE .....................1-2
NOTES ON SERVICE .........................1-2
ALL REPLACEMENT PARTS ..............1-3
GASKETS, OIL SEALS,
AND O-RINGS .....................................1-3
BEARINGS AND  OIL SEALS ..............1-3
SPECIAL TOOLS AND TESTERS.......1-4
CHAPTER 2.
PERIODIC INSPECTIONS AND
ADJUSTMENTS
INTRODUCTION ..................................... 2-1
MAINTENANCE INTERVALS CHART ... 2-1
PERIODIC MAINTENANCE/LUBRICATION
INTERVALS ............................................ 2-1
COVERS ................................................. 2-3
ENGINE .................................................. 2-4
ENGINE OIL LEAKAGE CHECKING  2-4
OIL LEVEL CHECKING ..................... 2-4
OIL REPLACEMENT ......................... 2-5
FUEL LEAKAGE ................................ 2-6
FUEL TANK FILTER  .......................... 2-6
FUEL TANK STRAINER  .................... 2-7
AIR FILTER ELEMENT ..................... 2-8
MUFFLER .......................................... 2-9
VALVE CLEARANCE ADJUSTMENT2-10
COMPRESSION PRESSURE  ......... 2-12
RATED ENGINE SPEED ................. 2-13
BREATHER HOSE  .......................... 2-13
ELECTRICAL........................................ 2-14
SPARK PLUG  .................................. 2-14
ENGINE SWITCH ............................ 2-15
ECONOMY SWITCH ....................... 2-15PILOT LIGHT ................................... 2-15
RECEPTACLE ................................. 2-16
DC CIRCUIT BREAKER .................. 2-16
CHAPTER 3.
ENGINE
CONTROL BOX ...................................... 3-1
CONTROL BOX DISASSEMBLY ...... 3-2
CONTROL BOX ASSEMBLY ............. 3-4
ENGINE .................................................. 3-5
RECOIL STARTER AND ROTOR .......... 3-6
RECOIL STARTER DISASSEMBLY .. 3-7
RECOIL STARTER INSPECTION  ..... 3-8
RECOIL STARTER ASSEMBLY ........ 3-9
IGNITION COIL AND ROTOR 
REMOVAL ....................................... 3-10
IGNITION COIL AND ROTOR
INSTALLATION ................................ 3-11
MUFFLER ............................................. 3-12
GENERATOR ........................................ 3-13
ROTOR AND  STATOR  COIL ASSEMBLY
REMOVAL ....................................... 3-14
STATOR COIL INSTALLATION  ....... 3-14
CRANKCASE2, CAMSHAFT AND
ROCKER ARM ...................................... 3-16
CAMSHAFT INSPECTION .............. 3-18
CAM FOLLOWER INSPECTION  .... 3-18
PUSH ROD INSPECTION ............... 3-18
ROCKER ARM  INSPECTION  ......... 3-19
CRANKCASE 2 INSPECTION  ........ 3-19
CAMSHAFT AND LOCKER ARM
INSTALLATION ................................ 3-19
CRANKSHAFT, PISTON AND
PISTON RING ....................................... 3-21
PISTON AND  PISTON  PIN
INSPECTION ................................... 3-23
PISTON RING INSPECTION  .......... 3-24
CRANKSHAFT INSPECTION ......... 3-25
CONNECTING ROD OIL CLEARANCE
INSPECTION ................................... 3-26
PISTON AND  PISTON  RING
INSTALLATION ................................ 3-27
CONNECTING ROD AND
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							CRANKSHAFT INSTALLATION ...... 3-27
CYLINDER (CRANKCASE 1) AND
VALVE ................................................... 3-29
VALVE AND  VALVE  SPRING
REMOVAL ....................................... 3-31
VALVE AND  VALVE  SPRING
INSPECTION ................................... 3-31
VALVE SEAT INSPECTION  ............ 3-33
CYLINDER (CRANKCASE 1)
INSPECTION ................................... 3-35
VALVE AND  VALVE  SPRING
ASSEMBLY ...................................... 3-35
CHAPTER 4.
CARBURETOR
CARBURETOR ....................................... 4-1
CARBURETOR DISASSEMBLY ....... 4-2
FLOAT HEIGHT INSPECTION .......... 4-4
CHOKE CABLE INSTALLATION  ....... 4-5
THROTTLE CONTROL MOTOR  ....... 4-5
FUEL PUMP, FUEL TANK AND
FUEL CHANGE LINK ............................. 4-6
FUEL PUMP INSPECTION ..................... 4-8
FUEL TANK FILTER INSPECTION ......... 4-8
CHAPTER 5.
ELECTRICAL
ELECTRICAL COMPONENTS ............... 5-1
CIRCUIT DIAGRAM .......................... 5-2
SWITCHES ............................................. 5-3
CHECKING SWITCH CONTINUITY . 5-3
IGNITION SYSTEM ................................ 5-4
TROUBLESHOOTING CHART ......... 5-4
GENERATOR SYSTEM .......................... 5-8
TROUBLESHOOTING CHART ......... 5-8
CHAPTER 6.
TROUBLESHOOTING
ENGINE .................................................. 6-1
THROTTLE CONTROL SYSTEM .......... 6-6
CHAPTER 7.
SPECIFICATIONS
GENERAL SPECIFICATIONS ................ 7-1
MAINTENANCE SPECIFICATIONS ....... 7-3
ENGINE ............................................. 7-3
GENERATOR AND  ELECTRICAL ..... 7-6
TIGHTENING TORQUE .......................... 7-7
GENERAL TORQUE SPECIFICATIONS7-8
DEFINITION OF UNITS .......................... 7-8
LUBRICATION POINT AND
TYPE OF LUBRICANTS ........................ 7-9
WIRE ROUTING DIAGRAM ................. 7-10
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							GEN
INFO
1-1
MACHINE IDENTIFICATION
1
7VV–
7VV-24163-00
GENERAL INFORMATION
MACHINE IDENTIFICATION
SERIAL NUMBER
The serial number is printed on a label 1
which is affixed to the generator as shown.
NOTE:
The first three characters of this number are
for model identification, the remaining digits
are the unit production number.
STARTING SERIAL NUMBER
7VV-200101~
NOTE:
Designs and specifications are subject to
change without notice.
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							GEN
INFO
1-2
SVU1030
SVU1040
SVU1050
SVU1060
SVU1070
SVU1080
SVU1090
SVU1100
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
CAUTION ON SERVICE
1. Fire prevention
When servicing the engine, always keep the engine and yourself
away from fire.
NOTES ON SERVICE
1. Correct tools
Be sure to use the correct special tool for the job to guard
against damage.
IMPORTANT INFORMATION
2. Oil, grease and seals
Be sure to use genuine Yamaha oils, grease and sealers, or the
equivalents.
3. Expendable parts
Always replace the gaskets, O-rings, cotter pins and circlips with
new parts when servicing engine.
4. Tightening torque
Be sure to follow torque specifications. When tightening bolts,
nuts or screws, start with the largest-diameter fastener and work
from an inner position to an outer position in a crisscross pat-
tern.
5. Notes on disassembly and assembly
a. Parts should be cleaned in solvent and blown dry with com-
pressed air after disassembly.
b. Contact surfaces of moving parts should be oiled when
reassembled.
c. Make sure that the parts, move smoothly after each section of
the machine is assembled.
1
2
3
4
5
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							GEN
INFO
1-3
SVU1110
SVU1120
ALL REPLACEMENT PARTS
We recommend the use of genuine Yamaha parts for all replace-
ments. Use oil and/or grease, recommended by Yamaha, for
assembly and adjustment.
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals, and O-rings should be replaced when an
engine is overhauled. All gaskets surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly.
Apply grease to the oil seal lips.
BEARINGS AND OIL SEALS
Install the bearing(s) 1and oil seal(s) 2with their manufacture’s
marks or numbers facing outward. (In other words, the stamped let-
ters must be on the side exposed to view.) When installing oil
seal(s), apply a light coating of lightweight lithium base grease to
the seal lip(s). Oil the bearings liberally when installing.
cC
Do not use compressed air to spin the bearings dry. This
causes damage to the bearing surfaces.
IMPORTANT INFORMATION
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							GEN
INFO
1-4
SVU1150
SVU1160
SVU1170
SVU1180
SVU1190
SVU1205
SPECIAL TOOLS AND TESTERS
The proper special tools are necessary for complete and accurate
tune-up and assembly. Using the correct special tool will help pre-
vent damage caused by the use of improper tools or improvised
techniques.
1. Thickness gauge
P/N. YU-26900-9, 90890-03079
This gauge is used to adjust valve clearance, piston clearance
and piston ring end gap.
2. Cylinder gauge
Commercially obtainable
This instrument is used for checking cylinder bore size and con-
dition.
3. Inductive tachometer
P/N. YU-8036-A
Engine tachometer
P/N. 90890-03113
This instrument is used for reading engine r/min.
4. Compression gauge 1
P/N. YU-33223, 90890-03081
Adapter 2
P/N. YU-33223-3, 90890-04082
This gauge is used for checking engine compression.
5. Dial gauge
P/N. YU-03097, 90890-03097
This instrument is used for checking crankshaft side clearance.
6. Sheave holder
P/N. YS-01880, 90890-01701
This tool is necessary for holding the magneto rotor.
SPECIAL TOOLS AND TESTERS
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