Yamaha EF1000iS Service Manual

							6-7
THROTTLE CONTROL SYSTEMTRBL
With no load, engine speed does not increase when economy control switch is
set to “OFF”.
With no load, engine speed does not decrease when economy control switch is
set to “ON”.
With load, engine speed does not increase when economy control switch is set to
“ON”.
Check AC  output.
GOOD NO GOODRefer to “GENERATOR SYSTEM” in
CHAPTER 5.
Rotate the shaft of the throttle control motor.
GOOD NO GOOD
Replace the throttle control motor.
Check economy switch.
GOOD NO GOOD
Replace the economy switch.
Replace the control motor.
Check the connections of the wire harness connectors
and couplers, and the wires for an open circuit or short
circuit.
GOOD NO GOOD
Correct or replace.
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							TRBL
7VV10-06  02.10.8 8:12 PM  Page 8
I?  I  
						

							7-1
GENERAL SPECIFICATIONSSPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Unit EF1000iS
Model code number 7VV2
Dimensions:
Overall length mm (in) 450 (17.7)
Overall width mm (in) 240 (9.5)
Overall height mm (in) 380 (15.0)
Dry weight kg (lb) 12.7 (27.9)
Engine:
Engine type 4-stroke OHV forced air cooled
Cylinder arrangement 1
Displacement L (cm
3) 0.050 (50)
Bore ×Stroke mm (in) 41.0 ×38.0 (1.61 ×1.50)
Compression ratio 8.2 : 1
Rated output  60 Hz · kW (PS) / 5,000 r / min 1.21 (1.65)
Rated engine speed r / min 5,000
Operating hours 60 Hz · Hrs
W / no load 12.0
W / rated load 4.3
Fuel Unleaded regular gasoline
Fuel tank capacity L (lmp gal, US gal) 2.5 (0.55, 0.66)
Engine oil capacity L (lmp qt, US qt) 0.32 (0.28, 0.34)
Engine recomended oil 4-stroke engine oil API service classification
SE or SF, if not available, SD
Electrical:
Ignition system TCI
Ignition timing BTDC 33°
Spark plug type CR6HSA (NGK)
Spark plug gap mm (in) 0.7 ∼ 0.8 (0.028 ∼ 0.031)
Generator:
Type Multi pole rotating field magnet
Initial excitation Permanent magnet
Driving method Direct connection
Rated power factor 1 
						

							7-2
GENERAL SPECIFICATIONSSPEC
Unit EF1000iS
Frequency variation
Instantaneous Less than 1 %
Settling Less than 0.1 %
Settling time Less than 7 sec
Voltage fluctuation
Instantaneous Less than 20 %
Settling Less than 3 %
Settling time Less than 5 sec
AC output
Rated voltage V 120
Frequency Hz 60
Rated output kVA 0.9
Rated current A 7.5
Safety device type AC Electronic no fuse breaker
DC Circuit breaker (No fuse breaker)
Rated engine speed r / min 5,000
Voltage regulation Voltage feed back system
Voltage stability Within ± 4 %
Frequency stability Hz Within ± 1
Rotating speed control Throttle motor control type
Wave distortion ratio Less than 2.5 %
Number of phase Triple phase
Insulation resistance MΩOver 10
Insulation type B type
Receptacle AC 15 A (Duples) ×2
DC 8 A×1
1
2
3
4
5
6
7 
						

							Unit Standard Limit
Piston: mm (in)
Piston clearance
0.01 ~ 0.04 (0.0004 ∼ 0.0016)0.1 (0.004)
Piston skirt “ D ”
40.95 ∼ 40.97 (1.612 ∼ 1.613)40.94 (1.6118)
Measuring point “ H ” 10 mm (0.4)•••
Piston pin hole inside diameter10.000 ∼ 10.020 (0.3937 ∼ 0.3945)10.050 (0.3956)
Piston pin: mm (in)
Piston pin diameter9.99 ∼ 10.00 (0.3933 ∼ 0.3937)9.95 (0.3917)
Piston ring: mm (in)
Top ring
Type Barrel face•••
Dimensions “ B ×T ” 0.8 ×1.6 (0.03 ∼ 0.06)•••
End gap 0.1 ~ 0.3 (0.0039 ∼ 0.0118) 0.6 (0.0236)
Side  clearance0.06 ~ 0.11 (0.002 ~ 0.004)0.15 (0.006)
2nd ring
Type Taper•••
Dimensions “ B ×T ” 0.8 ×1.7 (0.03∼ 0.07)•••
End gap0.10 ~ 0.3 (0.0039 ∼ 0.0118)0.6 (0.0236)
Side  clearance0.06 ~ 0.11 (0.002 ~ 0.004)0.15 (0.006)
OIl ring
Type Solid•••
Dimensions “ B ×T ” 1.5 ×1.9 (0.059 ∼ 0.075)•••
End gap 0.2 ~ 0.7 (0.0078 ∼ 0.0275) 0.9 (0.0354)
Cylinder: mm (in)
Inside diameter “ D ”
41.000 ∼ 41.010 (16.14 ∼ 16.15)41.10 (16.18)
Taper limit•••0.05 (0.002)
Warpage limit•••0.05 (0.002)
Crankshaft: mm (in)
Big end side clearance “ A ” 0.2 ~ 0.65 (0.008 ~ 0.026) 0.7 (0.028)
Runout “ B ” 0.03 (0.001)
Crank pin diameter “ C ”
15.970 ∼ 15.985 (0.629 ∼ 0.630)15.940 (0.627)
Connecting rod: mm (in)
Small end diameter “ A ”
10.006 ∼ 10.020 (0.3944 ∼ 0.3945)10.050 (0.396)
Oil clearance
0.015 ∼ 0.050 (0.0006 ∼ 0.0020)•••
Small end diameter “ B ”
16.000 ∼ 16.015 (0.6299 ∼ 0.6305)16.050 (0.632)
Oil clearance
0.015 ∼ 0.050 (0.0006 ∼ 0.0020)•••
7-3
MAINTENANCE SPECIFICATIONSSPEC
MAINTENANCE SPECIFICATIONS
ENGINE
TB 
						

							Unit Standard Limit
Camshaft: mm (in)
Camshaft outside diameter
Cam dimension IN EX
“ A”32.65 32.65
(1.29) (1.29)
“ B ”28.85 28.85
(1.14) (1.14)
Valve: mm (in)
Valve
Stem diameter “ B ”IN 3.96 ~ 3.98 (0.156 ~ 0.157) 3.92 (0.154)
EX 3.94 ~ 3.96 (0.155 ~ 0.156) 3.90 (0.153)
Valve face contact
width “ D ”IN 0.8 (0.03) 1.8 (0.07)
EX 0.8 (0.03) 1.8 (0.07)
Valve stem runout limit 0.01 (0.0004)
“ θ”•••90°
Valve guide
Guide inside diameter IN 4.0 (0.157)•••
EX 4.0 (0.157)•••
Valve clearance (cold) IN 0.1 (0.004)•••
EX 0.1 (0.004)•••
Push rod: mm (in)
Runout limit 0.5 (0.02)•••
Valve spring: mm (in)
Free length IN 25.0 (0.984) 24.0 (0.945)
EX 25.0 (0.984) 24.0 (0.945)
Set length IN 15.1 (0.594)•••
EX 15.1 (0.594)•••
Tilt limit•••2.0 (0.079)
7-4
MAINTENANCE SPECIFICATIONSSPEC 
						

							Unit Standard Limit
Carburetor: mm (in)
Type / manufacture BV15-11 / MIKUNI•••
I.D.mark 7VV 00•••
Bore sizeØ 11 (0.433)•••
Main jet #62.5•••
Main air jetØ 1.3 (0.051)•••
Pilot air jetØ 0.9 (0.004)•••
Pilot outletØ 0.8 (0.031)•••
Valve seat sizeØ 1.5 (0.059)•••
Main nozzle 2H•••
Pilot jet #40•••
Throttle valve #110•••
Float height “ H ”1.5 (0.06)•••
7-5
MAINTENANCE SPECIFICATIONSSPEC
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							Unit Standard Limit
Generator:
AC coil 1 AC voltage (3 phase) (V/r/min) 130 ~ 260 / 5,000•••
[
Br - G (R - S), G - Br (S - T), Br - Br (R - T)
With coupler disconnected]
AC coil 2 AC voltage (3 phase) (V/r/min) 13.5 ~ 23.0 / 5,000•••
[
W - Or (R - S), Or - W (S - T), W - W (R - T)
With coupler disconnected]
DC coil DC voltage (V/r/min) 13.5 ~ 23.0 / 5,000•••
Coil resistance
AC coil 1 (Ω± 20 %) 0.47•••
[
Br - G (R - S), G - Br (S - T), Br - Br (R - T)
With coupler disconnected]
AC coil 2 (Ω± 20 %) 0.17•••
[
W - Or (R - S), Or - W (S - T), W - W (R - T)
With coupler disconnected]
DC coil (Ω± 20 %) 0.07 (Blue-Blue)•••
Electrical:
Ignition system TCI•••
Ignition timing BTDC 33°•••
Ignition coil
Primary coil resistance (Ω± 20 %) 0.5•••
Secondary coil resistance
(kΩ± 20 %)11.5•••
Spark plug cap resistance (kΩ) 3.8 ~ 6.3 •••
Spark plug minimum spark gap mm(in) 6 (0.24)•••
7-6
MAINTENANCE SPECIFICATIONSSPEC
GENERATOR AND ELECTRICAL
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							7-7
TIGHTENING TORQUESPEC
TIGHTENING TORQUE
Item Thread sizeTightening torqueNm (m·kg, ft·lb)
Spark plug M10S ×1.0 13 (1.3, 9.4)
Cylinder head cover M5 ×0.8 6 (0.6, 4.3)
Connecting rod M5 ×0.8 6 (0.6, 4.3)
Valve adjuster locknut M5 ×0.8 6 (0.6, 4.3)
Air shroud cylinder 1,2 M5 ×0.8 6 (0.6, 4.3)
Air filter case M5 ×0.8 6 (0.6, 4.3)
Muffler stay M6 ×1.0 10 (1.0, 7.2)
Stud bolt (IN) M6 ×1.0 7 (0.7, 5.1)
Stud bolt (EX) M6 ×1.0 7 (0.7, 5.1)
Crankcase M5 ×0.8 8 (0.8, 5.8)
Recoil starter M5 ×0.8 6 (0.6, 4.3)
Mount insulator M6 ×1.0 12 (1.2, 8.7)
Engine bracket M6 ×1.0 12 (1.2, 8.7)
Ignition coil M5 ×0.8 6 (0.6, 4.3)
Magneto rotor M10 ×1.25 27 (2.7, 19.4)
TCI unit M4 1.1 (0.1, 0.7)
Stator coil assembly M6 ×1.0 10 (1.0, 7.2)
Generator rotor M10 ×1.25 27 (2.7, 19.4)
Front cover M5 ×0.8 6 (0.6, 4.3)
Oil level switch M6 ×1.0 7 (0.7, 5.1)
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							7-8
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS
SPEC
Unit Read Definition Measure
mm Millimeter 10
 3 meter Length
cm Centimeter 10
 2 meter Length
kg Kilogram 10
 3  gram Weight
N Newton 1 kg ×
 m/sec
 2 Force
Nm Newton meter N ×
 m Torque
m·kg Meter kilogram m ×
 kg Torque
Pa Pascal N/m
 2Pressure
N/mm Newton per millimeter N/mm Spring rate
LLiter
—Volume or capacity
cm
 3Cubic centimeter
r/min Rotation per minute—Engine speed
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fas-
teners with standard I.S.O. pitch treads.
Torque specifications for special components
or assemblies are included in the applicable
sections of this book. To avoid warpage, tight-
en multi fastener assemblies in a crisscross
fashion, in progressive stages, until full torque
is reached. Unless otherwise specifications
call for clean, dry treads. Components should
be at room temperature.
DEFINITION OF UNITS
Tread sizeTightening torque
Nm m·kg ft·lb
M4 2 0.2 1.4
M5 3 0.3 2.2
M6 7 0.7 5.1
M7 10 1.0 7.2
M8 15 1.5 11
M10 30 3.0 22
M12 60 6.0 43
7VV10-07  02.10.7 1:40 PM  Page 8