Yamaha EF800 EF1000 Motor Service Repair Manual
DESCRIPTION:
Yamaha EF800 EF1000 Motor Service Repair Manual
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 edumtion 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-V cedures inherent to generator repair technology. Vifithout 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.
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 cflsassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course.
- Bearings
- Pitting/damage —> Replace.
TABLE OF CONTENTS:
Yamaha EF800 EF1000 Motor Service Repair Manual
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 1-2
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
ENGINE 2-3
ENGINE OIL LEAKAGE CHECKING 2-3
OIL LEVEL CHECKING 2-3
OIL REPLACEMENT 2-3
FUEL LEAKAGE CHECKING 2-4
FUEL PETCOCK 2-4
AIR FILTER ELEMENT 2-5
MUFFLER 2-6
VALVE CLEARANCE ADJUSTMENT 2-6
COMPRESSION PRESSURE
CHECKING 2-8
RATED ENGINE SPEED CHECKING 2-9
ENGINE SPEED ADJUSTMENT 2-10
GOVERNOR ADJUSTMENT 2-10
BREATHER HOSE 2-11
RECOIL STARTER OPERATION
CHECKING 2-11
ELECTRICAL 2-12
SPARK PLUG 2-12
ENGINE SWITCH 2-13
RECEPTACLE 2-14
AC PROTECTOR 2-15
DC PROTECTOR 2-16
CHAPTER 3
ENGINE
ENGINE 3-1
AIR FILTER, CARBURETOR AND
CONTROL BOX 3-1
CONTROL BOX DISASSEMBLY
(EF800/EF1000) 3-2
CONTROL BOX DISASSEMBLY
(EF1000) 3-3
MUFFLER PROTECTOR, FUEL
TANK AND MUFFLER 3-4
CYLINDER HEAD COVER AND CYLINDER
HEAD 3-5
CYLINDER HEAD INSPECTION 3-6
CYLINDER HEAD INSTALLATION 3-6
ROCKER ARMS, VALVES AND VALVE
SPRINGS 3-7
VALVE, VALVE SPRING REMOVAL 3-8
VALVE AND VALVE SPRING
INSPECTION 3-8
ROCKER ARM INSPECTION 3-9
PUSH ROD INSPECTION 3-10
VALVE SEAT INSPECTION 3-10
VALVE SEAT ASSMBLY LAPPING 3-11
RECOIL STARTER, ROTOR 3-13
RECOIL STARTER 3-14
ROTOR REMOVAL 3-15
RECOIL STARTER INSPECTION 3-15
RECOIL STARTER ASSEMBLY 3-15
ROTOR ASSEMBLY 3-16
CRANKCASE COVER AND
CAMSHAFT 3-18
CRANKCASE COVER REMOVAL 3-19
CAMSHAFT INSPECTION 3-19
VALVE LIFTER INSPECTION 3-20
CRANKCASE COVER INSPECTION 3-20
CAMSHAFT INSTALLATION 3-20
CRANKCASE COVER INSTLLATION 3-20
PISTON, CONNECTING ROD, CRANKSHAFT
AND CRANKCASE 3-21
CRANKCASE (CYLINDER)
INSPECTION 3-22
PISTON AND PISTON PIN
INSPECTION 3-22
PISTON RING INSPECTION 3-23
CRANKSHAFT INSPECTION 3-24
CONNECTING ROD OIL
CLEARANCE INSPECTION 3-25
PISTON RINGS AND PISTON
INSTLLATION 3-26
GENERATOR 3-28
GENERATOR REMOVAL 3-29
GENERATOR INSTALLATION 3-29
GOVERNOR 3-31
GOVERNOR INSPECTION 3-32
CHAPTER 4
CARBURETOR
CARBURETOR 4-1
CARBURETOR DISASSEMBLY 4-2
FLOAT HEIGHT INSPECTION 4-3
CHAPTER 5
ELECTRICAL
ELECTRICAL COMPONENTS 5-1
CIRCUIT DIAGRAM 5-2
SWITCHES 5-5
CHECKING SWITCH CONTINUITY 5-5
SWITCH CONTINUITY INSPECTION 5-5
IGNITION SYSTEM 5-6
TROUBLESHOOTING CHART 5-6
GENERATOR SYSTEM 5-10
TROUBLESHOOTING CHART 5-10
CHAPTER 6
TROUBLE SHOOTING
ENGINE 6-1
ENGINE DOES NOT START 6-1
ENGINE SPEED DOES NOT
INCREASE 6-3
ENGINE SPEED IS UNEVEN 6-4
GOVERNOR OPERATION 6-5
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 SPECIFICATIONS 7-8
DEFINITION OF UNITS 7-8
LUBRICATION POINT AND TYPE OF LUBRICANTS
7-9
WIRE ROUTING DIAGRAM 7-10
CONTROL BOX PANEL AND
BEHIND CONTROL BOX 7-10
ENGINE AND GENERATOR 7-13
VIDEO PREVIEW OF THE MANUAL:
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]