Yamaha EF1000iS Service Manual
Have a look at the manual Yamaha EF1000iS Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
GEN INFO 1-5 SVU1210 1 SVU1220 2 SVU1230 SVU1240 1 SVU1250 2 7. Rotor puller 1P/N. YU-33270 2P/N. 90890-01362 This tool is necessary for removing the magneto rotor. 8. Pocket tester P/N. YU-03112, 90890-03112 This instrument is necessary for checking the electrical system. 9. Digital circuit tester 90890-03174 This instrument is necessary for checking the electrical system. 10.Dynamic spark tester 1 P/N. YM-34487 Ignition checker 2 P/N. 90890-06754 This instrument is necessary for checking the ignition system components. SPECIAL TOOLS AND TESTERS 7VV10-01 02.10.4 10:36 AM Page 5
INSP ADJ 2-1 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter. MAINTENANCE INTERVALS CHART Proper periodic maintenance is important. Especially important are the maintenance services relat- ed to emissions control. These controls not only function to ensure cleaner air but are also vital to proper engine operation and maximum performance. In the following maintenance tables, the ser- vices related to emissions control are indicated as “*” in the chart. PERIODIC MAINTENANCE/LUBRICATION INTERVALSINTRODUCTION/MAINTENANCE INTERVALS CHART/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS No. Item RemarksPre-Ope- ration check (daily)Initial Every 1 month or 20 Hr3 months or 50 Hr6 months or 100 Hr12 months or 300 Hr 1.*Check condition.Spark Plug Adjust gap and clean. Replace if necessary.0 2.* Check and adjust Valve Clearance when engine is cold.0 * 3.CrankcaseCheck breather hose for cracks or damage. 0 breather systemReplace if necessary. 4.* Check and adjust engine idle speed.0 Idle speed Check for leakage. *Retighten or replace gasket if necessary.0 5. Exhaust System Check muffler screen and spark arrester. Clean/0 replace if necessary. Check oil level06. Engine Oil Replace00 *Clean. 7. Air Filter Replace ifnecessary.0 Clean fuel tank filter. 8. Fuel Filter Replace if necessary.0 Check fuel hose for crack or damage. 9. Fuel Line Replace if necessary.0 10.* Check choke operation.0 Choke knob 11. Cooling System Check for fan damage.0 12. Starting System Check recoil starter operation.0 * : Related to emission control system.
INSP ADJ 2-2 PERIODIC MAINTENANCE/LUBRICATION INTERVALS No. Item RemarksPre-Ope- ration check (daily)Initial Every 1 month or 20 Hr3 months or 50 Hr6 months or 100 Hr12 months or 300 Hr 13. Generation Check the pilotlight comes on.0 14.Fittings/ Check all fittingsand fasteners. Fasteners Correct if necessary.01 2 3 4 5
Order Job name Q’ty Remarks Cover 2, cover 3, side cover 2,Remove the parts in the order listed rear cover, front cover removalbelow. 1 Cover 2 1 2 Cover 3 1 3 Side cover 2 1 4 Rear cover 1 5 Remort control cable 1 Disconnect the fuel hose from the fuel cock side. 6 Choke cable 1 Disconnect the fuel hose from the carburetor side. 7 Front cover 1 Disconnect the couplers and lead wireds. For installation, revers the removal procedure. 2-3 COVERS COVERS 12 3 4 5 6 7 6 Nm (0.6 m · kg, 4.3 ft · lb) INSP ADJ 7VV10-02 02.10.4 10:37 AM Page 3
2-4 ENGINE OIL LEAKAGE CHECKING/ OIL LEVEL CHECKING 1 700-087a a ENGINE ENGINE OIL LEAKAGE CHECKING 1. Remove: 9Cover 3 9Side cover 2 9Side cover 2. Check the areas outside of the engine for oil leakage. Oil leakage →Replace the gasket, oil seal, or O-ring. OIL LEVEL CHECKING 1. Check: 9Oil level with oil warning light 1 Check whether the oil warning light flashes by operating the recoil starter. Oil warning light flashes →Add oil. Oil warning light does not flash →OK 2. Remove: 9Cover 3 9Oil filler cap 3. Check: 9Check that the engine oil is at the spec- ified level a. Oil level checking steps: 9Place the engine on a level surface. 9Warm up the engine for several minutes. 9Stop the engine. 9Check that the engine oil is at the speci- fied level a. Add oil if necessary. 4. Install: 9Oil filler cap 9Cover 3 INSP ADJ 7VV10-02 02.10.4 10:37 AM Page 4
2-5 OIL REPLACEMENT 1 1 SVU2060 OIL REPLACEMENT 1. Warm up the engine for several minutes. 2. Stop the engine. 3. Remove: 9Drain joint 1 9Cover 3 Remove the drain joint from the mount base. 4. Place a receptacle under the engine. 5. Remove: 9Oil filler cap 6. Install: 9Drain joint 1 7. Tilt the engine to drain the oil completely. 8. Fill: NOTE: Recommended engine oil classification: API Service “SE” or “SF”, if not available, “SD”. 9. Remove: 9Drain joint 10.Install: 9Oil filler cap 9Drain joint Clean the drain joint then install the drain joint t the mount base. 9Cover 3 INSP ADJ Recommended oil: åYAMALUBE 4 (10W-30) or SAE 10W-30 type SE ∫SAE #30 çSAE #20 ∂SAE 10W Engine oil quantity: 0.32 L (0.28 Imp qt, 0.34 US qt) 7VV10-02 02.10.4 10:37 AM Page 5
2-6 FUEL LEAKAGE/ FUEL TANK FILTER 1 FUEL LEAKAGE 1. Remove: 9Cover 3 2. Check: 9Leakage Check at fuel tank, fuel pump, fuel cock, fuel hose, and carburetor. cC Replace hose every four years. FUEL TANK FILTER w Do not smoke, and keep away form open flames, sparks, or any other source of fire when handling or in the vicinity of fuel. 1. Remove: 9Fuel tank cap 9Fuel tank filter 1 2. Inspect: 9Fuel tank filter Damage →Replace. 3. Clean: 9Fuel tank filter NOTE: Clean the fuel tank filter with solvent, and then dry it thoroughly. 4. Install: 9Fuel tank filter 9Fuel tank cap w Be sure the tank cap is tightened securely. INSP ADJ 7VV10-02 02.10.4 10:37 AM Page 6
2-7 FUEL TANK STRAINER 2 31 1 FUEL TANK STRAINER w Do not smoke, and keep away form open flames, sparks, or any other source of fire when handling or in the vicinity of fuel. 1. Remove: 9Cover 3 9Side cover 2 9Rear cover 9Front cover 2. Drain the fuel from the fuel tank com- pleatly. 3. Remove: 9Fuel tank 1 9Fuel hose 2 9Fuel tank strainer 3 4. Inspect: 9Fuel tank strainer 1 Damage →Replace. 5. Clean: 9Fuel tank strainer Damage →Replace. NOTE: Clean the fuel tank strainer with solvent, and then dry it thoroughly. 6. Install: 9Fuel tank strainer to the fuel tank 7. Install: 9Fuel hose 9Fuel tank 9Front cover 9Rear cover 9Side cover 2 9Cover 3 INSP ADJ 7VV10-02 02.10.4 10:37 AM Page 7
2-8 AIR FILTER ELEMENT 12 1 AIR FILTER ELEMENT cC The engine should never run without the element, otherwise excessive piston and/or cylinder wear may result. 1. Remove: 9Cover 3 9Air filter case cover 1 2. Remove: 9Air filter element 2 3. inspect: 9Air filter element 1 Damage →Replace. Clogging →Wash the element in a sol- vent, and then dry it thoroughly. Oil the element and squeeze out the excess oil. cC 8Do not wring out the element: this could cause it to tear. 8Do not wash the element in gasoline or in acidic, alkalinic, or organic solvents. 4. Install: 9Air filter element 9Air filter case cover 9Cover 3 INSP ADJ 7VV10-02 02.10.4 10:37 AM Page 8