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Yamaha EF1000iS Service Manual

Manual is about: GENERATOR

Summary of EF1000iS

  • Page 1

    Service manual ef1000is lit-19616-01-02 7vv-28197-10 310137 7vv-cover 02.9.26 2:30 pm page 1.

  • Page 2

    Www.Carburetor-manual.Com thank you for buying this manual from me! I appreciate your business and hope that you come back again. Please do not share this on the internet, as while we do not make a lot at this, it is what i do full time to support my family from here in the philippines. Check out ou...

  • Page 3: Foreword

    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 generat...

  • Page 4: Gen

    Illustrated symbols (refer to the illustration) illustrated symbols 1 through 7 are designed as thumb tabs to indicate the chapter’s number and content. 1 general information 2 periodic inspections and adjustments 3 engine 4 carburetor 5 electrical 6 trouble shooting 7 specifications illustrated sym...

  • Page 5: Index

    Index general information gen info periodic inspections and adjustments insp adj engine eng carburetor carb electrical elec troubleshooting trbl specifications spec 1 2 3 4 5 6 7 7vv10-00 02.10.4 10:35 am page 3.

  • Page 6

    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...

  • Page 7

    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 ....

  • Page 8: Gen

    Gen info 1-1 machine identification 1 7 v v – 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...

  • Page 9: Gen

    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...

  • Page 10: Gen

    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 o...

  • Page 11: Gen

    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. Thi...

  • Page 12: Gen

    Gen info 1-5 svu1210 1 svu1220 2 svu1230 svu1240 1 svu1250 2 7. Rotor puller 1 p/n. Yu-33270 2 p/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 teste...

  • Page 13: Gen

    Gen info 7vv10-01 02.10.4 10:36 am page 6.

  • Page 14: Insp

    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 f...

  • Page 15: Insp

    Insp adj 2-2 periodic maintenance/lubrication intervals no. Item remarks pre-ope- ration check (daily) initial every 1 month or 20 hr 3 months or 50 hr 6 months or 100 hr 12 months or 300 hr 13. Generation check the pilotlight comes on. 0 14. Fittings/ check all fittingsand fasteners. Fasteners corr...

  • Page 16: Insp

    Order job name q’ty remarks cover 2, cover 3, side cover 2, remove the parts in the order listed rear cover, front cover removal below. 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 fu...

  • Page 17: Insp

    2-4 engine oil leakage checking/ oil level checking 1 700-087a a engine engine oil leakage checking 1. Remove: 9 cover 3 9 side cover 2 9 side 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: 9 oil lev...

  • Page 18: Insp

    2-5 oil replacement 1 1 svu2060 oil replacement 1. Warm up the engine for several minutes. 2. Stop the engine. 3. Remove: 9 drain joint 1 9 cover 3 remove the drain joint from the mount base. 4. Place a receptacle under the engine. 5. Remove: 9 oil filler cap 6. Install: 9 drain joint 1 7. Tilt the ...

  • Page 19: Insp

    2-6 fuel leakage/ fuel tank filter 1 fuel leakage 1. Remove: 9 cover 3 2. Check: 9 leakage check at fuel tank, fuel pump, fuel cock, fuel hose, and carburetor. C c 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...

  • Page 20: Insp

    2-7 fuel tank strainer 2 3 1 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: 9 cover 3 9 side cover 2 9 rear cover 9 front cover 2. Drain the fuel from the fuel tank com- pleatly. 3. Remove:...

  • Page 21: Insp

    2-8 air filter element 1 2 1 air filter element c c the engine should never run without the element, otherwise excessive piston and/or cylinder wear may result. 1. Remove: 9 cover 3 9 air filter case cover 1 2. Remove: 9 air filter element 2 3. Inspect: 9 air filter element 1 damage → replace. Clogg...

  • Page 22: Insp

    2-9 muffler 1 2 3 4 svu2150 muffler w the engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair. 1. Remove: 9 muffler refer to “muffler” in chapter 3. 9 muff...

  • Page 23: Insp

    2-10 valve clearance adjustment 4 12 3 valve clearance adjustment 1. Remove: 9 cover 3 9 side cover 2 9 rear cover 9 front cover refer to “covers”. 9 carburetor refer to “carburetor” in chap- ter 3. 9 cylinder air shroud refer to “muffler” in chapter 3. 2. Remove: 9 spark plug cap 1 9 spark plug 2 9...

  • Page 24: Insp

    2-11 valve clearance adjustment 1 2 3 5. Adjust: 9 valve clearance adjustment steps: • loosen the locknut 1. • turn the adjuster 2 in or out to obtain the proper clearance. • tighten the locknut 3. Use hexagonal wrench. 6. Install: 9 cylinder head cover gasket 9 cylinder head cover 9 breather hose 9...

  • Page 25: Insp

    2-12 compression pressure 1 2 compression pressure note: measure the compression after checking and adjusting the valve clearance. 1. Warm up the engine for several minutes. 2. Remove: 9 spark plug 3. Remove: 9 cover 4. Connect: 9 compression gauge 1 9 adapter 2 5. Measure: 9 compression to measure ...

  • Page 26: Insp

    2-13 compression pressure/ rated engine speed/breather hose 1 1 a 1 testing steps (above maximum level): 9 check the cylinder head, valve surfaces, and piston crown for carbon deposits. 6. Install: • spark plug rated engine speed 1. Remove: 9 cover 2. Connect: 9 inductive tachometer 1 3. Inspect: 9 ...

  • Page 27: Insp

    2-14 spark plug 1 2 a electrical spark plug w inspect and adjust the areas around the cylinder head after the engine has cooled down completely. C c before removing the spark plug, use com- pressed air to clean the cylinder head cover to prevent dirt from falling into the engine. 1. Remove: 9 cover ...

  • Page 28: Insp

    2-15 spark plug/engine switch/ economy switch/pilot light a b b 1 a 1 a 1 5. Tighten: • spark plug note: to prevent thread damage, finger tighten a the spark plug before tightening it to the spec- ified torque b. Engine switch 1. Check: 9 engine switch 1 checking steps: 9 set the engine switch 1 to ...

  • Page 29: Insp

    2-16 receptacle/dc circuit breaker 2 1 1 a b receptacle 1. Check: 9 ac receptacles (7.5 a) 1 9 dc receptacle (12v, 8 a) 2 cracks/damage → replace. Poor connection → correct. Dc circuit breaker 1. Check: 9 dc circuit breaker checking steps: 9 press the reset button 1 to the position of “reset” a. 9 c...

  • Page 30: Insp

    Insp adj 7vv10-02 02.10.4 10:38 am page 17.

  • Page 31: Eng

    Eng 3-1 control box engine control box 1 2 order job name q’ty remarks control box removal remove the parts in the order listed below. Front cover and rear cover refer to “covers” section in chapter 2. 1 tapping screw 4 2 control box assembly 1 for installation, reverse the removal procedure. 1 2 3 ...

  • Page 32: Eng

    Eng 3-2 control box control box disassembly 1 2 12 11 10 3 4 5 6 7 8 13 14 9 order job name q’ty remarks control box disassembly remove the parts in the order listed below. 1 tapping screw 4 2 plate assembly 1 3 over load warning light 1 disconnect. 4 pilot light 1 disconnect. 5 oil warning light 1 ...

  • Page 33: Eng

    Eng 3-3 control box 1 2 12 11 10 3 4 5 6 7 8 13 14 9 order job name q’ty remarks 14 tci unit disconnect. For assembly, reverse the disassembly procedure. 7vv10-03 02.10.4 10:38 am page 3.

  • Page 34: Eng

    3-4 control box 1 2 control box assembly 1 install: 9 control box 1 note: insert the rid of control box to the front cover 2. Eng 7vv10-03 02.10.4 10:38 am page 4.

  • Page 35: Eng

    Eng 3-5 engine engine 1 2 3 4 5 12 nm (12 m · kg, 8.6 ft · lb) 5 5 5 12 nm (12 m · kg, 8.6 ft · lb) order job name q’ty remarks engine removal remove the parts in the order listed below. Front cover, rear cover and fuel hose refer to “covers” section in chapter 2. Vacuum hose refer to “carburetor” s...

  • Page 36: Eng

    Eng 3-6 recoil starter and rotor recoil starter and rotor 1 2 3 4 5 6 7 8 6 nm (0.6 m· kg, 4.3 ft · lb) 27 nm (2.7 m· kg, 19.4 ft · lb) 6 nm (0.6 m · kg, 4.3 ft · lb) 6 nm (0.6 m · kg, 4.3 ft · lb) order job name q’ty remarks recoil starter and rotor removal remove the parts in the order listed belo...

  • Page 37: Eng

    Eng 3-7 recoil starter and rotor recoil starter disassembly 1 2 3 4 5 6 7 order job name q’ty remarks recoil starter disassembly remove the parts in the order listed below. 1 set screw 1 2 collar 1 3 friction spring 1 4 reel 1 5 spiral spring 1 6 starter case 1 7 swing arm 1 for disassembly, reverse...

  • Page 38: Eng

    3-8 recoil starter and rotor 1 2 1 2 1 1 1 2 recoil starter disassembly 1. Remove: 9 set screw 1 9 collar 2 2. Remove: 9 friction spring 1 9 reel 2 c c be sure to press down on the reel, because the spring will pop out suddenly when it is removed from the reel. 3. Remove: 9 spiral spring 1 4. Remove...

  • Page 39: Eng

    3-9 recoil starter and rotor 1 2 3 1 2 1 2 1 1 2 a 2. Inspect: 9 swing arm 1 9 friction spring 2 9 collar 3 deternation/crack/damage → replace. Recoil starter assembly 1. Install: 9 swing arm 1 9 collar 2 install the swing arm to the collar. 2. Install: 9 spiral spring 1 9 reel 2 note: hook the edge...

  • Page 40: Eng

    3-10 recoil starter and rotor 1 2 1 2 3 1 2 3 4 5 5. Install: 9 friction spring 9 collar 1 9 set screw 2 6. Hook the starter rope in the cutout in the reel, and wind it counter clockwise four turns. 7. Pull the starter rope and check the recoil starter operation. Ignition coil and rotor removal 1. R...

  • Page 41: Eng

    3-11 recoil starter and rotor 2 1 1 ignition coil and rotor installa- tion c c be sure to remove any oil grease from the tapered portion of the magneto rotor using a cloth dampened with thinner. 1. Install: 9 woodruff key 1 9 rotor 9 rotor nut 2 note: when installing the rotor, make sure the woodruf...

  • Page 42: Eng

    Eng 3-12 muffler muffler 1 2 3 4 5 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 removal remove the parts in the order listed below. Front cover and rear cover refer to “covers” section in chapter 2. Carburet...

  • Page 43: Eng

    Eng 3-13 generator generator 1 2 3 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 removal remove the parts in the order listed below. Front cover and rear cover refer to “covers” section in chapter 2. Fuel tank refer to “carburetor, fuel ...

  • Page 44: Eng

    3-14 generator 2 1 2 3 1 1 1 rotor and stator coil assembly removal 1. Remove: 9 rotor nut 1 note: attach the sheave holder 2 to hold the rotor. 2. Remove: 9 magneto rotor 1 note: use the flywheel puller 2 and bolts 3 to remove the rotor. 3. Remove: 9 stator coil 1 stator coil installation c c be su...

  • Page 45: Eng

    3-15 generator 3 2 1 2. Install: 9 rotor 1 9 rotor nut 2 note: attach the sheave holder 3 to 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.

  • Page 46: Eng

    Eng 3-16 crankshaft2, camshaft and rocker arm crankcase2, camshaft and rocker arm 2 1 5 6 7 8 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 and remove ...

  • Page 47: Eng

    Eng 3-17 crankshaft2, camshaft and rocker arm 2 1 5 6 7 8 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...

  • Page 48: Eng

    3-18 crankshaft2, camshaft and rocker arm a b camshaft inspection 1. Inspect: 9 camshaft crack/damage/wear → replace. 2. Inspect: 9 cam lobes length a and b out of specifications → replace. 3. Inspection: 9 surface of camshaft gear teeth 9 decompressor crack/damage/wear → replace. Cam follower inspe...

  • Page 49: Eng

    3-19 crankshaft2, camshaft and rocker arm 2 1 1 a b 1 2 3 1 rocker arm inspection 1. Inspect: 9 rocker arm crack/damage/wear → replace. Crankcase 2 inspection 1. Inspect: 9 crankcase 2 1 crack/damage/wear → replace. 9 bearing 2 noise/wear/rotational failure → replace. 9 oil seal crack/damage/wear → ...

  • Page 50: Eng

    3-20 crankshaft2, camshaft and rocker arm 2 1 1 4. Install: 9 rocker arm 1 9 dowel pin 2 note: make sure align the push rod edge with the rocker arm groove, then install the rocker arm. 5. Install: 9 crankcase 1 note: tighten the bolts to the specified torque in to steps and in order. Eng 7vv10-03 0...

  • Page 51: Eng

    Eng 3-21 crankshaft, piston and piston ring crankshaft, piston and piston ring e e e e 1 2 3 4 5 6 7 8 4 6 nm (0.6 m · kg, 4.3 ft · lb) order job name q’ty remarks crankshaft, piston and piston ring remove the parts in the order listed removal below. Front cover and rear cover refer to “covers” sect...

  • Page 52: Eng

    Eng 3-22 crankshaft, piston and piston ring e e e e 1 2 3 4 5 6 7 8 4 6 nm (0.6 m · kg, 4.3 ft · lb) order job name q’ty remarks 4 piston pin circlip 2 5 piston pin 1 6 connecting rod 1 7 piston ring set 1 8 piston 1 for installation, reverse the removal procedure. 7vv10-03 02.10.4 10:39 am page 22.

  • Page 53: Eng

    3-23 crankshaft, piston and piston ring p a piston and piston pin inspection 1. Measure: 9 piston skirt diameter p a = 10 mm (0.4 in) from the piston bottom edge out of specification → replace. 2. Measure: 9 piston clearance out of specifications → rebore or replace cylinder and replace piston and p...

  • Page 54: Eng

    3-24 crankshaft, piston and piston ring a a 1 4. Measure: 9 piston pin diameter a out of specifications → replace. 5. Inspect: 9 check the piston pin enters smoothly into the piston pin hole. If the piston pin fits tightly into the pis- ton, check the piston pin hole. If there is any protrusion, use...

  • Page 55: Eng

    3-25 crankshaft, piston and piston ring 1 1 a 2. Measure: 9 piston side clearance out of specification → replace. Note: 9 clean carbon deposits from the piston ring grooves and ring s before measuring the side clearance. 9 measure the side clearance at several por- tions. Crankshaft inspection 1. Me...

  • Page 56: Eng

    3-26 crankshaft, piston and piston ring 1 1 2 connecting rod oil clearance inspection note: measure the oil clearance if replacing the crankshaft or connecting rod. 1. Place a piece of plastigauge 1 on the crank pin horizontally. Note: clean off oil from all parts thoroughly. 2. Install: 9 connectin...

  • Page 57: Eng

    3-27 crankshaft, piston and piston ring 1 2 3 1 2 3 rn a b 1 2 3 120° 120° 120° top ring second ring oil ring a 1 2 piston and piston ring installation 1. Install: 9 top ring 9 second ring 9 oil ring ring note: 9 be sure to install the top ring and second ring so that the “rn” mark a faces towerd th...

  • Page 58: Eng

    3-28 crankshaft, piston and piston ring a b 1 2 3. Install: 9 crankshaft 1 9 connecting rod cap 2 c c make sure that the “ ∇” mark a on the con- necting rod is aligned the “ ∆” mark b on the rod cap. 4. Install: 9 crankshaft 9 connecting rod cap 9 cam follower (exhaust side) 9 cam follower (intake s...

  • Page 59: Eng

    Eng 3-29 cylinder (crankcase 1) and valve cylinder (crankcase 1) and valve m m e b 1 2 3 4 5 1 2 6 7 order job name q’ty remarks cylinder (crankcase 1) and valve remove the parts in the order listed removal below. Front cover and rear cover refer to “covers” section in chapter 2. Fuel tank refer to ...

  • Page 60: Eng

    Eng 3-30 cylinder (crankcase 1) and valve m m e b 1 2 3 4 5 1 2 6 7 order job name q’ty remarks 4 valve 2 1 5 stem oil seal 1 6 oil seal 1 7 cylinder (crankcase 1) 1 for installation, reverse the removal procedure. 7vv10-03 02.10.4 10:39 am page 30

  • Page 61: Eng

    3-31 cylinder (crankcase 1) and valve 1 2 3 a a valve and valve spring removal 1. Remove: 9 spring retainer 1 9 valve spring 2 9 valve 3 note: press the spring retainer by your finger while removing the spring retainer. Valve and valve spring inspection 1. Measure: 9 valve stem diameter a out of spe...

  • Page 62: Eng

    3-32 cylinder (crankcase 1) and valve a 4. Measure: 9 valve spring tilt a out of specification → replace. 5. Inspect: 9 valve contact surface more than 2/3 of the contact surface does not contact → replace. Eng tilt limit: 2.0 mm (0.079 in) 7vv10-03 02.10.4 10:39 am page 32.

  • Page 63: Eng

    3-33 cylinder (crankcase 1) and valve a b c a valve seat inspection 1. Remove carbon deposits from the valve face and valve seat. 2. Apply a small amount of coarse mechan- ic's blueing dye (dykem) to the valve face. 3. Insert the vale into the valve guide and use a valve lapper to contact the valve ...

  • Page 64: Eng

    3-34 cylinder (crankcase 1) and valve b c a 6. Remove the carbon deposits on the valve face a and valve seat. 9 valve face contact seat width b 9 valve margin thickness c apply a small amount of coarse mechanic’s blueing dye (dykem) to the valve seat. Press the valve through the valve guide and onto...

  • Page 65: Eng

    3-35 cylinder (crankcase 1) and valve a b a b 3 2 1 cylinder (crankcase 1) inspection 1. Measure: 9 cylinder inside diameter note: take side to side a and front to back b mea- surements at each of the three locations a, b, c (total of six measurements), and then find the average of the measurements....

  • Page 66: Eng

    Eng 7vv10-03 02.10.4 10:39 am page 36.

  • Page 67: Carburetor

    4-1 carburetor carburetor carburetor 1 2 3 4 5 6 7 8 9 10 2 nm (0.2 m · kg, 1.4 ft · lb) 7 nm (0.7 m · kg, 5.1 ft · lb) 6 carb order job name q’ty remarks carburetor removal remove the parts in the order listed below. Front cover and rear cover refer to “covers” section in chapter 2. Air cleaner cas...

  • Page 68: Carb

    4-2 carburetor carburetor disassembly 7 nm (0.7 m · kg, 5.1 ft · lb) 2 3 4 5 6 7 8 9 0 q w e r t u y 1 carb order job name q’ty remarks carburetor disassembly disassemble the parts in the order listed below. 1 throttle control motor cover 1 2 throttle control motor 1 3 motor bracket 1 4 plate 1 5 dr...

  • Page 69: Carb

    4-3 carburetor 7 nm (0.7 m · kg, 5.1 ft · lb) 2 3 4 5 6 7 8 9 0 q w e r t u y 1 carb order job name q’ty remarks r main nozzle 1 t cap 1 y pilot screw 1 u pilot jet 1 for assemble, reverse the disassembly procedure. 7vv10-04 02.10.4 10:39 am page 3.

  • Page 70: Carb

    4-4 carburetor a 1 2 float height inspection 1. Measure: 9 float height out of specification → replace. Note: 9 lift up the float height so that the tip of the float valve lightly contacts the float arm, and then measure the float height a. (this mea- surement should be made with the gasket removed....

  • Page 71: Carb

    4-5 carburetor 1 1 a a 1 1 a b choke cable installation 1. Install: 9 choke cable note: push the choke knob 1 entirely in before installing it to the panel. 2. Install 9 choke cable 1 note: be sure install the choke cable end cap push out a 3mm (0.118 in) form the holder. 3. Install: 9 inner cable 1...

  • Page 72: Carb

    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 and remove the parts in the order listed fuel change link removal below. Front cover and rear cover ref...

  • Page 73: Carb

    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.

  • Page 74: Carb

    4-8 fuel pump, fuel tank and fuel change link a fuel pump inspection 1. Inspect: 9 fuel pump inhale the hose form a → open. Blow the hose to a → close. C c excessive force will damage the fuel pump must be replaced. Fuel tank filter inspection 1. Inspect: 9 fuel tank filter wear → replace. Dirt/clog...

  • Page 75: Carb

    Carb 7vv10-04 02.10.7 6:54 pm page 9.

  • Page 76: Elec

    5-1 electrical components elec electrical electrical components 1 control unit assembly 2 speed limiter 3 overload warning light (red) 4 pilot light (green) 5 oil warning light (red) 6 generator assembly 7 engine switch 8 economy switch 9 dc circuit breaker 0 ac receptacle (7.5 a × 2) q dc receptacl...

  • Page 77: Elec

    5-2 circuit diagram elec circuit diagram w w w or w w w w w w br br br br br br br w w w br br br br br br br g br g br w w w w or w r r r br r br r l ll l l l l y b b b b b b b b b b r r r r l l l l g g y y o r l g y o o b/w b/w b/w b/w b/w b/w b/w g/y g/y b/w b/w y y y y o o r s t r s t 1 2 3 4 f ...

  • Page 78: Elec

    5-3 switches elec 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: 9 set the pocket tester to “0” before starting a test. 9 when testing the switch for continuity the pocket tester should be ...

  • Page 79: Elec

    5-4 ignition system elec 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 gap 6. Engine switch 7. Oil level switch 8. Wire harness note: 9 remove the following part(s) before troubl...

  • Page 80: Elec

    5-5 ignition system elec minimum spark gap: 6 mm (0.24 in) 3. Spark plug cap 9 remove the spark plug cap. 9 connect 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 9 remove the ignition coil. 1)...

  • Page 81: Elec

    5-6 ignition system elec 2) secondary coil resistance 9 connect 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 k Ω ± 20% at 20 °c (68 °f) 1 2 5. Air gap 9 measure the thickness between t...

  • Page 82: Elec

    5-7 ignition system elec 7. Oil level switch 9 remove the oil level switch from the bottom of the crankcase. Refer to “crankshaft2, camshaft and rocker arm” in chapter 3. 9 connect the pocket tester to the oil level switch for continuity. Tester (+) lead → blue lead 1 tester (–) lead → ground 2 1 2 ...

  • Page 83: Elec

    5-8 generator system elec generator system troubleshooting chart weak or no ac current start the engine. Check the overload warning light. Does not turn on turns on start the engine. Check the pilot light. Does not turn on turns on rated engine speed inspection. 9 operate the engine with no load. 9 ...

  • Page 84: Elec

    5-9 generator system elec ac coil 2 ac voltage inspection 9 connect white-orange (r-s), orange-white (s-t), and white-white (r-t) leads. 9 start the engine, then measure the voltage. (tester range: ac120v) good too low does not generate ac coil 2 w or w w w w br g br br br br ac coil 1 r s t r s t a...

  • Page 85: Elec

    5-10 generator system elec troubleshooting chart weak or no dc current rated engine speed inspection. 9 operate the engine with no load. 9 set the economy switch to “off”. 5,000 r/min good out of specification check the throttle control system. Refer to “throttle control system” in chapter 6. Check ...

  • Page 86: Trbl

    6-1 engine trbl trouble shooting engine engine does not start check that the oil warn- ing light turns on by pulling the starter rope. Light on dose not turn on check engine oil level. Suffi- insuffi- cient cient check fuel level. Suffi- insuffi- cient cient check fuel cock lever position. “on” “off...

  • Page 87: Trbl

    6-2 engine trbl check carburetor for clogged passages or fuel overflow. Good not good * replace. Measure valve clear- ance. Good out of specification adjust. Check compression using compression gauge. Out of good specification check valve face and valve seat for wear. Good wear resurface or replace....

  • Page 88: Trbl

    6-3 engine trbl engine starts but stalls check fuel level. Suffi- insuffi- cient cient add. Clean. Check if fuel cock is clogged. Good no good clean. Check if fuel hose is clogged. Good no good 9 check if carburetor retaining nuts are loose. 9 check if there is air suction due to a dam- aged carbure...

  • Page 89: Trbl

    6-4 engine trbl engine speed does not increase check if the electric equipment consumes too much wattage for this generator. Good too much use a generator with a larger capacity. Check air filter element for dirt. Good no good clean. Check spark plug for dirt and check spark plug gap. Good no good c...

  • Page 90: Trbl

    6-5 engine trbl engine speed is uneven check fuel level. Sufficient insufficient add. Check if fuel is deteriorated. Good no good replace fuel. Check if fuel tank cap is clogged. Good no good replace. Check if fuel cock is clogged. Good no good clean. Check fuel pump operation. Good no good replace....

  • Page 91: Trbl

    6-6 throttle control system trbl throttle control system engine does not start, engine starts but stalls, engine speed does not increase, or engine speed is uneven. Check ac output. Good no good refer to “generator system” in chapter 5. Rotate the shaft of the throttle control motor to check if it t...

  • Page 92: Trbl

    6-7 throttle control system trbl 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”. Ch...

  • Page 93: Trbl

    Trbl 7vv10-06 02.10.8 8:12 pm page 8.

  • Page 94: Spec

    7-1 general specifications spec 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...

  • Page 95: Spec

    7-2 general specifications spec 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 rat...

  • Page 96: Spec

    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 diameter 10.000 ∼ 10.020 (0.3937 ∼ 0.3945) 10.050 (0.3956) piston pin: mm (in) p...

  • Page 97: Spec

    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 widt...

  • Page 98: Spec

    Unit standard limit carburetor: mm (in) type / manufacture bv15-11 / mikuni ••• i.D.Mark 7vv 00 ••• bore size Ø 11 (0.433) ••• main jet #62.5 ••• main air jet Ø 1.3 (0.051) ••• pilot air jet Ø 0.9 (0.004) ••• pilot outlet Ø 0.8 (0.031) ••• valve seat size Ø 1.5 (0.059) ••• main nozzle 2h ••• pilot j...

  • Page 99: Spec

    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 disco...

  • Page 100: Spec

    7-7 tightening torque spec tightening torque item thread size tightening torque nm (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....

  • Page 101: Spec

    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 2 pressure ...

  • Page 102: Spec

    7-9 lubrication point and type of lubricants spec lubrication point and type of lubricants part name type of lubricants oil seal lip (all) lithium-soap base grease connecting rod big end engine oil crank pin engine oil connecting rod bolt engine oil piston pin engine oil piston engine oil camshaft 1...

  • Page 103: Spec

    7-10 wire routing diagram spec wire routing diagram control box panel and behind control box å ∫ 1 2 3 4 5 6 7 8 9 0 q w e r t or b b w w r br br y b/w br r y b/w b b/w g/y b r b 1 speed limiter 2 tci unit 3 ac receptacle (7.5 a × 2) 4 over load warning light (red) 5 pilot light (green) 6 oil warnin...

  • Page 104: Spec

    7-11 wire routing diagram spec engine and generator 1 rectifier 2 ignition coil lead connector 3 ac coil 1, 2 lead 4 ignition coil lead 5 clamp 6 dc coil lead 7 ground lead 8 control motor lead 9 rectifier stay å to control box. ∫ from ignition coil. ç clamp the generator lead with clamp. ∂ insert t...

  • Page 105: Spec

    7-12 wire routing diagram spec 4 å ∫ 1 2 3 5 6 7 8 1 control motor 2 ac coil 1, 2 lead 3 dc coil lead 4 control box 5 control unit 6 ignition coil lead 7 control motor lead 8 ground lead å from generator. ∫ to rectifier. 7vv10-07 02.10.7 1:40 pm page 12.

  • Page 106: Spec

    7-13 wire routing diagram spec å ∫ 1 2 3 4 5 6 7 8 9 1 ac coil 1, 2 lead 2 ignition coil lead 3 dc coil lead 4 control unit 5 rectifier 6 rectifier stay 7 control motor lead 8 ground lead 9 control motor å to control box. ∫ pass the control motor lead under the fuel hose. 7vv10-07 02.10.7 1:40 pm pa...

  • Page 107: Spec

    7-14 wire routing diagram spec å ∫ ç 1 2 3 4 5 6 7 ∂ 1 spark plug cap 2 high-tension cord 3 ignition coil lead 4 ignition coil 5 oil level switch 6 oil level switch lead 7 ground lead å install the spark plug cap until stop the spark plug. ∫ to tci unit. ç tighten with the ground lead with oil level...

  • Page 108: Spec

    7-15 wire routing diagram spec å ∫ ç ∂ ∂ ´ ƒ 1 2 2 3 4 5 6 7 8 9 0 q w e e e r y t © ˙ c b a b c a 1 pipe 4 2 change link 3 choke cable 4 pipe 3 5 fuel tank cap assembly 6 strainer 7 holder 8 fuel pump assembly 9 fuel tank 0 pipe 2 q lotating damper w filer net 1 e fuel pipe r air vent hose t drain ...

  • Page 109

    Printed on recycled paper printed in usa yamaha motor co., ltd. (e) 7vv-cover 02.9.26 1:53 pm page 2.