Yamaha EF1000iS Service Manual

							ENG
3-12
MUFFLER
MUFFLER
1
23
45
6 7 8 9
6 Nm (0.6 m · kg, 4.3 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
10 Nm (1.0 m · kg, 7.2 ft · lb)
Order Job name Q’ty Remarks
Muffler removalRemove the parts in the order listed 
below.
Front cover and rear coverRefer to “COVERS” section in CHAPTER 2.
CarburetorRefer to “CARBURETOR, FUEL TANK
AND FUEL PUMP” section in CHAPTER 4.
1 Clip 2
2 Cylinder air shroud 2 1
3 Cylinder air shroud 1 1
4 Muffler assembly 1
5 Gasket 1
6 Silencer band 1
7 Cap 1
8 Wire net 1
9 Spark arrester 1
For installation, reverse the removal
procedure.
7VV10-03  02.10.4 10:38 AM  Page 12 
						

							ENG
3-13
GENERATOR
GENERATOR
1 23 4 5
6
27 Nm (2.7 m · kg, 19.4 ft · lb) 
10 Nm (1.0 m · kg, 7.2 fr · lb) 
Order Job name Q’ty Remarks
Generator removalRemove the parts in the order listed 
below.
Front cover and rear coverRefer to “COVERS” section in CHAPTER 2.
Fuel tankRefer to “CARBURETOR, FUEL TANK
CarburetorAND FUEL PUMP” section in CHAPTER 4.
Cylinder air shroud Refer to “MUFFLER” section.
Engine assembly Refer to “ENGINE REMOVAL” section.
1 Rear end cover 1
2 Magneto fan 1
3 Cover 1
4 Generator rotor 1
5 Stator assembly coupler 2
6 Stator coil assembly 1
For installation, reverse the removal 
procedure.
7VV10-03  02.10.4 10:38 AM  Page 13 
						

							3-14
GENERATOR
21
231
1
1
ROTOR AND STATOR COIL ASSEMBLY
REMOVAL
1. Remove:
9Rotor nut 1
NOTE:
Attach the sheave holder 2to hold the rotor.
2. Remove:
9Magneto rotor 1
NOTE:
Use the flywheel puller 2and bolts 3to
remove the rotor.
3. Remove:
9Stator coil 1
STATOR COIL INSTALLATION
cC
Be sure to remove any oil grease from the
tapered portion of the magneto rotor using
a cloth dampened with thinner.
1. Install:
9Stator coil assembly 1
ENG
Sheave holder:
YS-01880, 90890-01701
Rotor puller:
YU-33270, 90890-03162
Bolt 3 ·········95817-06100 ····· 2 pcs.
10 Nm (1.0 m · kg, 7.2 ft · lb)
7VV10-03  02.10.4 10:38 AM  Page 14 
						

							3-15
GENERATOR
32
1
2. Install:
9Rotor 1
9Rotor nut 2
NOTE:
Attach the sheave holder 3to hold the rotor.
ENG
Sheave holder:
YS-01880, 90890-01701
27 Nm (2.7 m · kg, 19.4 ft · lb)
7VV10-03  02.10.4 10:38 AM  Page 15 
						

							ENG
3-16
CRANKSHAFT2, CAMSHAFT AND ROCKER ARM
CRANKCASE2, CAMSHAFT AND ROCKER ARM
2
1
5
6
78
9
11
12
4
13
M
10
6 Nm (0.6 m · kg, 4.3 ft · lb)
6 Nm (0.6 m · kg, 4.3 ft · lb)
13 Nm (1.3 m · kg, 9.4 ft · lb)
8 Nm (0.8 m · kg, 5.8 ft · lb)
3
Order Job name Q’ty Remarks
Crankcase 2, camshaft andRemove the parts in the order listed 
rocker arm removalbelow.
Front cover and rear coverRefer to “COVERS” section in CHAPTER 2.
Fuel tankRefer to “CARBURETOR, FUEL TANK
CarburetorAND FUEL PUMP” section in CHAPTER 4.
Cylinder air shroud Refer to “MUFFLER” section.
Engine assembly Refer to “ENGINE REMOVAL” section.
GeneratorRefer to “GENERATOR REMOVAL”
section.
1 Cylinder head cover 1
2 Cylinder head cover gasket 1
3 Crankcase 2 1
4 Dowel pin 2
5 Lock nut 2 Loosen.
7VV10-03  02.10.4 10:38 AM  Page 16 
						

							ENG
3-17
CRANKSHAFT2, CAMSHAFT AND ROCKER ARM
2
1
5
6
78
9
11
12
4
13
M
10
6 Nm (0.6 m · kg, 4.3 ft · lb)
6 Nm (0.6 m · kg, 4.3 ft · lb)
13 Nm (1.3 m · kg, 9.4 ft · lb)
8 Nm (0.8 m · kg, 5.8 ft · lb)
3
Order Job name Q’ty Remarks
6 Adjuster 2 Loosen.
7 Dowel pin 1 below.
8 Rocker arm 2
9 Push rod 2
10 Collar 1
11 Cam follower 2
12 Camshaft assembly 1
13 Dowel pin 2
For installation, reverse the removal
procedure.
7VV10-03  02.10.4 10:38 AM  Page 17 
						

							3-18
CRANKSHAFT2, CAMSHAFT AND ROCKER ARM
a b
CAMSHAFT INSPECTION
1. Inspect:
9Camshaft
Crack/damage/wear →Replace.
2. Inspect:
9Cam lobes length aand b
Out of specifications →Replace.
3. Inspection:
9Surface of camshaft gear teeth
9Decompressor
Crack/damage/wear →Replace.
CAM FOLLOWER INSPECTION
1. Inspect:
9Cam follower
Crack/damage/wear →Replace.
PUSH ROD INSPECTION
1. Inspect:
9Push rod runout
Out of specifications →Replace.
ENG
Cam lobes length:
 
: 
32.65 mm (1.29 in)
b b
: 
28.25 mm (1.11 in)
Limit:
a a
: 
31.65 mm (1.25 in)
b b
: 
27.75 mm (1.09 in)
Runout limit:
0.5 mm (0.02 in)
7VV10-03  02.10.4 10:38 AM  Page 18 
						

							3-19
CRANKSHAFT2, CAMSHAFT AND ROCKER ARM
2
1
1
a b
12 3
1
ROCKER ARM INSPECTION
1. Inspect:
9Rocker arm
Crack/damage/wear →Replace.
CRANKCASE 2 INSPECTION
1. Inspect:
9Crankcase 2 1
Crack/damage/wear →Replace.
9Bearing 2
Noise/wear/rotational failure →
Replace.
9Oil seal
Crack/damage/wear →Replace.
CAMSHAFT AND LOCKER ARM INSTALLA-
TION
1. Install:
9Camshaft 1
NOTE:
Make sure that the “
❍” mark aon the crank-
shaft is aligned with the “❍” mark bon the
camshaft.
2. Install:
9Cam follower (exhaust side) 1
9Cam follower (intake side) 2
9Collar 3
NOTE:
Make sure that the piston place in “Top Dead
Center” position, then install the cam follower.
3. Install:
9Push rod 1
NOTE:
Be sure install the push rod to the groove
through the cylinder head cover side.
ENG
7VV10-03  02.10.4 10:39 AM  Page 19 
						

							3-20
CRANKSHAFT2, CAMSHAFT AND ROCKER ARM
2
1
1
4. Install:
9Rocker arm 1
9Dowel pin 2
NOTE:
Make sure align the push rod edge with the
rocker arm groove, then install the rocker arm.
5. Install:
9Crankcase 1
NOTE:
Tighten the bolts to the specified torque in to
steps and in order.
ENG
7VV10-03  02.10.4 10:39 AM  Page 20 
						

							ENG
3-21
CRANKSHAFT, PISTON AND PISTON RING
CRANKSHAFT, PISTON AND PISTON RING
EE
E
E
1 2 34 5
67
8 46 Nm (0.6 m · kg, 4.3 ft · lb)
Order Job name Q’ty Remarks
Crankshaft, piston and piston ringRemove the parts in the order listed 
removalbelow.
Front cover and rear coverRefer to “COVERS” section in CHAPTER 2.
Fuel tankRefer to “CARBURETOR, FUEL TANK
CarburetorAND FUEL PUMP” section in CHAPTER 4.
Cylinder air shroud Refer to “MUFFLER” section.
Engine assembly Refer to “ENGINE REMOVAL” section.
Recoil starterRefer to “RECOIL STARTER AND
ROTOR” section.
GeneratorRefer to “GENERATOR REMOVAL”
section.
Rocker arm and camshaftRefer to “ROCKER ARM AND
CAMSHAFT” section.
1 Bolt 2
2 Connecting rod cap 1
3 Crankshaft assembly 1
7VV10-03  02.10.4 10:39 AM  Page 21