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- Robin Outdoor Power Equipment
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1. A L SAS UN HOSE CLAMP KNOB BOLT Disasserrbling Instructions 1 Remove the GUARDOIL 2 Remove the STARTER NO Part name 9 gt l ac gt O O O O O oc lt 22 O g 9 8 42 e U D ul 5 lt UO ac gt O O 0 42 0 ac e COVER ENGINE COVER PLUG GUARD OIL STARTER COVER PLUG COVER ENGINE GUARD OIL SCREW M5 20 3PCS TAPPING SCREW 5 16 5 STARTER TANK FUEL 2525808z23223322333 NOTICE The fuel will spout if the fuel tube is removed with the fuel tank filled with fuel 1 g DR NAS AN NST QRWN 20r 2 lt k g g www 42 ane Pree 29 N ib gt TANK FUEL 10 CONTROL CABLE AMRING For instructions on the lever disasserrbling see pages 14 and 15 7 CASE AIR CLEANER CASE VOLUTE Disassembling Instructions 1 Disconnect the wiring 2 Disconnect the CONTROL CABLE fromthe CARBURETOR 1 Remove the CASEAIR CLEANER 2 Disconnect the two tubes connected to the air cleaner ROCKER COVER AIR CLEANER SCREW M5 16 WSW 4PCS 1 Remove the PLATESEPARATOR 2 Remove the PLATE CHECK VALVE wth the CHECK VALVE 3 Remove the CHECK VALVE 1 NOTICE Be careful not to loose the parts Handle the CHECK VALVE wit
2. 2 O c D o O co C lt SOCKET HEAD BOLT M6 x 7O 3PCS PLUG SPARK Remove the ROCKER COVER and GASKET ROCKER COVER 1 Remove the PLUG SPARK 1 PLUG SPARK ROCKER COVER M5 x 30 WSW2PCS Disessenbiinginstruction Remove the COVER CAMGEAR PUSH ROD COVER CAMGEAR 2 Remove the PUSH ROD CAM LIFTER CAMGEAR 7 3 Remove the CAM LIFTER 4 Remove the CAMGEAR M5 x 16 WSWAPCS NETS mm m 8 CYLINDER HEAD 1 Remove the CYLINDER HEAD SOCKET HEAD BOLT M6 x 35 5PCS pay i gt 555 P m amp JS 1 Remove the ROCKER ARM and ROCKER SHAFT 8 1 ROCKER ARM 2 Remove the VALVE and SPRING VALVE and RETAINER SPRING 0 0 Remove the ROCKER SHAFT by hitting with SS 3 5 hammer metal bar held by the hand on the ees ROCKER SHAFT at the intake side Slide the RETAINER SPRINGS by pressing the SPRINGS wth the RETAINER SPRINGS and remove the VALVES ui gt Slide the Slide the RETAINER SPRING SPRING down 32 Dasentra rareo RETAINER PLATE 1 Rermove the LEAD VALVE and RETAINER PLATE CASE OIL 2 Remove the CASE OIL OTHERS SCREW 5 x 25 WSW5PCS BOLT M8 x 12 1PCS NOTICE Be careful not to loose the gasket SOCKET HEAD BOLT x 10 SWIPCS 33 Dises
3. i 477 N CEN 5 NI m s Uer en L NEN T Y lee b M IN DN E e k M M f t 995051 i rP ae RES gt 5 2 Nor QI n EX c d S 1 4 J Vi 2 bd Ren a f n y f p LJ E h EJ p 4 t VALVE CLEARANCE 1 Position the PISTON to the compression top dead center 1 Rotate the CRANKSHAFT clockwise holding the PULLEY by the hand until the position of the FLYWHEEL counter marks and CRANKCASE corre in a horizontal position Removing the PLUG SPARK will allow the smooth rotation Adjust VALVE clearance at After this the compression top dead 2 Make sure that by watching the INTAKE VALVE movement the VALVE is moved back to center the original position before the EXHAUST VALVE slightly moves the confirmation is completed 3 Even if the two counter marks and the CRANKCASE corre in a horizontal position where this happens before the EXHAUST VALVE moves to a large degree or the INTAKE VALVE moves when rotating the crankshaft clockwise slightly then rotate the CRANKSHAFT clockwse again holding the PULLEY by the hand the confirmation is completed 2 Loosen NUT and adjust VALVE CLEARANCE by rotating ADJ UST SCREW with a hexagon bar wrench VALVE CLEARANCE D 15rm Tighten NUT firmly after the adjustment
4. Be careful about the TORSION SPRING direction e LEVER LTHROTTLE CASE LLEVER 24 NO Part Assembling Instructions 13 3 CASE 1 LEVER 1 Join the CASE 2 LEVER fitted in according to no 13 1 and CASE LLEVER fitted in CASE 2 LEVER according to no 13 2 together CASE 2 LEVER TAPPING SCREW c2 4 16 5PCS Tightening torque 5 C M5 IPCS Used to tighten the lever on the SWIVEL PIPE see no 14 SCREW M5 25 1PCS Used to tighten the lever on the SWVEL PIPE see no 14 25 1 Fit the straight pipe wth the SWVEL in the FLEXIBLE PIPE and tighten the HOSE 76 CLAMP 2 Install the LEVER onto the straight pipe wth the SWVEL PIPE and tighten the clamp screw and nut 3 Fit the FLEXIBLE PIPE in the ELBOW on the blower and tighten the HOSE CLAMP 100 4 Insert the BLOWER PIPE into the SWVEL PIPE and turn the BLOWER PIPE clockwise to tighten it Insert the BLOWER NOZZLE into the BLOWER PIPE and turn the BLOWER NOZZLE clockwise to tighten it HOSE CLAMP 7 ARAA EIE ONLUS UNA i AM Vv ittm Pa PLE gt HOSE CLAMPo 100 DD __ a ee BLOWER PIPE BLOWER NOZZLE 26 15 BAND 1 Loop the end of the BAND through the lower part of the HANGER as shown in the figure at right The side of the BAND that has the folded tip should b
5. CASE 2 VOLUTE 2 Be careful not to leave the high tension code and wire between the CASE 2 VOLUTE and BASE 12 ENGINE 3 Install the GASKET MUFFLER on the CASE 2 VOLUTE rib wth the a as shown in the photograph Screwing sequence Screw the SOCKET HEAD BOLTS in numerical serial sequence CASE 2VOLUTE SOCKET HEAD BOLT 5 M6 30 W SW 6PCS 420 Tightening torque 80 o 0 IN IMPELLER After screwing the SOCKET HEAD BOLTS in numerical serial sequence SOCKET HEAD BOLT check if they are tightened with the M6 40 W SW APCS specified tigntening torque Tightening torque 80 20 IT 17 Asserrbling Instructions 3 CASE 1 VOLUTE 1 Fit the DAMPER 2s in the groove of the CASE 2 VOLUTE DAMPER 2 2 Install the ELBOW wth its outlet directed toward the CASE 1 VOLUTE ELBPW 3 Screw the TAPPING SCREWS clockwise beginning with the one at the ELBOW side O RING TAPPING SCREW 5 16 9PCS Tightening torque 202 H NUT M5 BLACK O RING Fit the O RING in the inner tor groove of the ELBOW Apply silicon or grease over the ring before fitting it if the ELBOW be srroothly with the hand After screwing the screws 7 DAMPER 2 SCREW M5 65 WSW 2PCS ELBOW Tightening torque 20 1 TT D 4 COVER INLET WASHERI kp 251 DAMPER 1 DAMPER 1 SCREW M5 40 1PCS Tightening torque 207 IT Tighten the S
6. Eo CYLINDER SCREW 0 ROCKER COVER 5 30 WSW 15 45 ex R iua SOCKET HEAD BOLT Tighten the BOLT again CYLINDER HEAD Mcr umm SE ef e CYLINDER HEAD ue ex ET P SSSR CYLINDER SCREW eee INSULATOR SCREW CARBURETOR PULLEY PULLEY M10 XU a ooo jf handclappino Patnam Assemblnginstructione 1 CRANKSHAFT 1 4 stroke engine oil over the PISTON RINGS and OIL RING after plac PISTON ing them PISTON RINGS OIL RING OTHRS SECOND RING White mark right shown in the figure Fit in the PISTON with P its mark directed as Nn t OM position OIL SEALS Apply grease over the inner part Position the open end of TOP RING and SEC OND RING in the opposite direction OIL RING asserrbly order SPACER 2 LOWER SIDE RAIL UPPER SIDE RAIL Position each open end of the parts in a respectively different 120 degree 38 m Part name Asserrbling Instructions MEN 3 CYLINDER HEAD install the VALVE and SPRING VALVE and RETAINER SPRING 2 Install the ROCKER ARM and ROCKER SHAFT 85 SE ES Apply the 4 stroke engine oil over the s 2 inner part of VALVE GUIDES 4 zi 5 5 7 i p Be careful that the INTAKE VALVE is large and EXHAUST VALVE is 5 Apply the 4 stroke engine oil over the VALVE GUIDE holes be ore inserting VALVE o insert VALVE in
7. 1 and CAP OIL 5 2 on the engine oil draining 2 Drain the ENGINE OIL see page 60 3 Screw the DRAIN BOLT and was CAP OIL e E DDrain the fuel CLEANER EE CLEANER ELEMENT COVERENGINE T P10 Ree the STARTER usc 1 SjRempvethe COVERENGINE _ 5 1 4 TANK FUEL 1 Remove the fuel tube The fuel wil spout if the fuel tube is P10 removed with the fuel tank filled with fuel the TANK FUEL mxm 2 SS S Er ums 1 Remove the WRE Fu 2RemwetheCONTOROLCABLE EU 6 1 LEVER DRemowethelEVERlani em j L _ P14 LEVER 2 ASSY Mx 2m LLLI LL 2 Remove the THROTTLE LEVER 1 ua CASEAIR CLEANER Remove the CASE AIR CLEANER M5x 16 ASI P11 PLATESEPA ___ jean nn __ PLATESEPARETOR by its body 2 Rerrove the PLATE CHECK VALVE wth CHECK VALVE the CHECK VALVE 1 Do not let the CHECK VALVE 1 missing fee er IL P12 the DAMPER 1 side eere lL DAMPER 2 side CASE LVOLUTE DRemovethe CASE LVOLUTE 5Xl6nm 9 P12 mo j C ZiRemwetheELBOW SRembvethe DAMPER2 C TjRemve the IMPELLER Momm H ZjRemove the ENGINE Mem 16 1 Deal Drawing of Equipment WIRE Tie wrap NUT SQUARE
8. 4 stroke engine oil grease 6 Liquid packing 7 File sand paper 8 Maste 3 4 5 2 NOTICE 1 Use the standard tools properly 2 While disassembling the engine blower memorize the locations of individual parts so that they be reassembled correctly Attach a tag to a part you are uncertain about its mounting position 3 Use boxes for keping disasserrbled parts in a group 4 To prevent any loss and wrong reassembly of screw bolts and nuts try to assemble each group of disasserrble parts terrporarily 5 Handle disassembled parts carefully and clean them with wash oll 6 After rerroving gaskets remove extraneous rraterial clearly fromthe gasket placed palaces 7 Use an impact driver for a screw bolt and screw etc that are difficult to be unfastened 8 Use new gaskets when reassembling 9 After reassembling each of the rotatable main parts rotate by hand to test it for bad movements and abnormal noises 10 After the completion of reassembly rotate the rotatable main parts by hand to test them for defects and looseness 3 SPECIAL TOOL FOR DISASSEMBLY Part L 00000000 Tool name 600060 Work Flywheel Puller DISASSEMBLY AND REASSEMBLY PROCEDURE LEQUIPMENT DISASSEMBLY For further disassembling instructions on each part see the pages ENGINE OIL 1 Unscrew the DRAIN BOLT M8x 12 S contarrination or dust off the BOLT and CAP OIL For further instructions 5
9. Gap between coil 03 Thickness gage Adjustment 00010 1 34 On wide open Fuel consumption l hr 163 throttle CAM GEAR Intake exhaust valve cc lt 4 LLI Q O a Electricity Fuel Fuel consumption Engine ia cc hr 7 Autorrotive Oil SAE10W 30 Class SF or higher Oil change Ist change 20h 2nd or later change 50h 71 5 Cleaning of air cleaner element Clean the element to avoid an extremely short life as well as poor start power and drive of the engine oil off the air cleaner cover and air cleaner plate breather Oil supply and change Remove dust and dirt around the oil filler and unscrew the oil gauge integrated oil cap Place the oil gauge integrated oil cap on a place where it can not get dirty with sand and or dust The dirty screwed back oil gauge integrated oil cap might cause poor oil circulation and or ablations of the engine parts resulting in an engine failure Be sure to wipe spilled oil off the space between the fuel tank and engine and start the engne Operation without wiping the spilled oil causes oil spots because the spilled oil is absorbed fromthe cooling air intakes and scattered Drained oil should be properly dealt with according to the law Do not discard squeeze the oil out of them it in a garbage b
10. SCREW ASSY CASE 2 COMPL SOCKET HEAD BOLT DAMPER 2 COMPL 1 SOCKET HEAD Md alc COVER PLUG PLUG senew ASSY 1 E E L 1 es p E COVERINLET CASE VOLUTE A GUARD MUFFLER COVERINLET TAPPING SCREW S TAPPING SCREW di COVER ENGINE TUBE ASSY BREATHER HOSE CLAMP SCREW ASSY RIVET LCK RIVET LOCK GUARD COMPL NET T CAP FUEL TANK ASSY FRAME CUSHION a SCREW ASSY FLANGE NUT Deal Drawing of Equipment AIR CLEANER CHECK VALVE PLATE CHECK VALVE TUBE L 130 TUBE L 190 TUBE L 25 PIPE JOINT ASSY 4 SCREW ASSY DUCT AIR CLEANER Deal Drawing of Equipment CONTROL LEVER CASE 1 LEVER COMPL SWITCH COM TORSHION SPRI LEVER 1 THROTT SELF LOCK CASE 2 LEVER COMP L WASHER WAVE WASHER SOCKET HEAD BOLT a TAPPING CONTROL CABLE NUT TUBE CABLE Lol ai NEL ss 3 COVERAIR CLEANER 1 Remove the COVERAIR CLEANER by looseninig KNOB BOLTS KNOB BOLT 2 Remove the DUCT by looseninig HODE CLAMPS ELEMENT DUCT HOSE CLAMP e COVER AIR CLEANER ELEMENT HOSE CLAMP DUCT T P ra s QR W ae X P ao XN J 55 is lt AM gt tS tA x Jj 5 S lt T sa CS P t ey NN b di gt all
11. STARTER is pulled Is the plug gap within 0 7 08 1 Is the PLUG dirty with carbon and or No Clean the PLUG with gasoline and dry it Remove carbon etc by a wire brush gasoline 0 0 After this clean the PLUG with gasoline again and dry it Is the gap between the COIL and es Adjust the gap within 0 3 0 1 FLYWHEEL within 0 3 0 1 0 0 See E es Any gasoline in the TANK FUEL Have you pushed the primer purrp to feed the gasoline to the CARBURETOR 0 PLUG and COIL L L L L L E Fill the TANK FUEL with gasoline Push the primer purrp to feed the gasoline to the CARBURETOR Have you pull the RECOIL STARTER with the choke closed at low terrperature The engine will not start with thick air fuel mixture at low temperature The engine does not start he engine has started Does the engine start by pulling the RECOIL STARTER with the throttle lever STE aues DOC SEE yes half open Are the fuel filter and or tube clogged Is No trouble in the fuel passage Correct the causes of bad fuel flow Replace faulty parts with new ones if the tube bent necessary Is the gasoline fresh es Gasoline stored in a bad way goes bad quickly Old gasoline should be replaced with new one Disasserrble the CARBURETOR to test it for the component parts being clogged up and or deteriorated he engine has started Engine does not start Clean the inside o
12. Tightening torque 50 4 Fasten the nuts and screws according to the corresponding specified tightening torque when reasserrbling Replace the old rocker cover gasket with the new one if needed 3 2 gt Thickness gauge 3 Adjust Screw VALVE clearanceO 15rmm 62 CLEANER CLEANING Pat eR Interval of Cleaning and Inspection Daily every 10 operating hours 1 Loosenthe KNOB BOLT 2 Remove the COVER AIR CLEANER 3 Take out the ELEMENT and remove any dirt with the brush NOTE The ELEMENT is a dry type and should not get wet Never wash with water 4 Replace the ELEMENT with a new one if it is damaged or very dirty Part No 6676500201 ELEMENT AIR CLEANER 5 Wo off any oil that has corre in to contact wth the breather with rag or cloth 6 Install the ELEMENT in the cleaner case 7 Attach the COVER AIR CLEANER and tighten the KNOB BOLT KNOB BOLT COVER AIR CLEANER 63
13. WSWAPCS SS i i 15 a Tightening torque 400 cm S85 ADJ UST SCREW Assembling Instructions ROCKER COVER 1 Attach the ROCKER COVER and GASKET ROCKER COVER NOTICE T he breather should be positioned at the plug side s SCREW M5 x 30 WSW2PCS m Tightening torque 400 25 Ix PLUG SPARK 1 Attach the PLUG SPARK 4 if BU me NOTICE The PLUGSPARK should be We 127 screwed into the threaded screw hole D 0 l straight 14 Ae NOTICE Be et not to bend the GAS m 2 or fail to place the WASHERS 1 M6 x 70 3 mU x Tightening torque 140 2 rm 2 SS T Z ue ighten the 3 zj A phi T after the test run Part rare Asserting retraction EE 15 INSULATOR 1 Attach the INSULATOR and GASKET INSULATOR OINT T 2 Fit the TUBES in the CYLINDER using the OINT T TUBE 3PCS use the correct tubes 3 Connect the TUBE to the INSULATOR at its joint NOTICE The GASKET should be placed with its smallest hole positioned SCREW at the upper right 5 x 25WSW2PCS Tightening torque 40 gt kgf m Connect the tube to the Air Cleaner breather see Yt a i i SI T Li page 20 um SCREW gt 5 x MWSWIPCS gS Connect the tube to the INSULATOR Li B rp Tightening torque 408 cm s a
14. high tension code in the groove of the CASE 2 The CONTROL CABLE should be under the high tension code 3 Connect the WRES from the LEVER and the ones of the COIL and hold the CONTROL CABLE and connected wre using the clamp of the CASE 2 10 TANK FUEL 3 S A Be sure to install the SCREW M6 12 WSW 2PCS Tightening torque 25279 21 NO Part AssentiingInstructions 10 GUARD MUFFLER 1 Fold the GUARD MUFFLER as shown in the photographs COVER ENGINE 2 Put the GUARD MUFFLER in the COVER ENGINE along its rail and fit the COVER ENGINE at its protruding portion into the groove of the GUARD MUFFLER 3 Fix the GUARD MUFFLER to the COVER ENGINE wth the TAPPING SCREW Folded part Details on being folded 1 TAPPING SCREW 4 6 NOTICE Be sure to install the Tightening torque 10 GUARD MUFFLER 11 COVER ENGINE 1 Fix the COVER PLUG in advance to the COVER ENGINE GUARD OIL 2 The GASKET CARBURETOR should be positioned on the part wth number b of the STARTER COVER ENGINE COVER PLUG COVER PLUG COVER ENGINE GUARD OIL SCREW M5 20 3PCS Tightening torque 258 GASKET CARBURETOR b TAPPING SCREW 5 16 4PCS Tightening torque 20 22 Part Assembling Instructions 12 1 KNOB BOLTS ney be screwed with the h
15. the level of the oil being drained decreases tilt the blower over on to the side with the drain so that the oil will corrpletely drain out After the oil has completely drained out tighten the oil drain bolt securely If the bolt is not tightly fastened this may result in an oil leak Adding oil during the oil change procedure is performed in the sarre manner as the separately explained procedure for adding oil whenever the level is insufficient Always add oil by filling fromthe opening under the oil cap Specified oil level Approximately 220 mL After filling with oil tighten the oil cap securely to prevent oil leaks Oil level gauge _ _ Upper limt Remain 100m Pac ing itm alurrinumweshef Oil drain bolt X CLEARANCE ADJ US T MENT Ld UL NN Lees l COVER ENGINE 1 Remove the GUARD OIL GUARD OIL 2 Remove the STARTER STARTER 3 Remove the COVER ENGINE COVER PLUG COYER ENGINE GUARD OIL SCREW M5 20 3PCS TAPPING SCREW 5 16 4PCS STARTER 2 TANK FUEL 1 Remove the fuel tube Notice The fuel will spout if the fuel tube is removed with the TANK F UEL filled with fuel 2 Remove the TANK FUEL SCREW M6 12 WSW 2PCS 61 NO Pat name Instructions 24 S E m 7 ROCKER COVER f m j gt f 4 y 4 k ur J N 7 Ah 1 p 7 pA X a N a 4 RN S UM rss Y Br S
16. ALVE side of the CYLINDER HEAD push 3 Remove the SPRING VALVE RETAINER and slide it RETARERPUATE nanas woo p Plastic or CASE OIL the recoil side of the OIL CASE hammer Remove the COIL 4 20 FLYWHEEL Pm Asserrble the FLYWHEEL puller as shown in the figure and remove the FLYWHEEL FLYWHEEL with the puller by turning puller it clockwise Rama flathead screwdriver into the four grooves in tum to remove Flat head CRANKCASE by prying it off with the screwdriver screwdriver 2 Remove the FLYWHEEL M6X30mm NE the CRANKCASE gem PISTON P36 3 Rerrpve the RING PISTON Do not darrage the OIL SEAL EE Privent dust from getting in the BEARING at the ROD CONNECTING small end Wcoening the open end of the ring might break it IIO MR 28 C parae NEN 1 PULLEY T Remove the PULLEY PULLEY M10 width across flats 15 2 CARBURETOR 1 the GASKET CARBURETOR and CARBURETOR and CASE INTAKE CASE INTAKE Fasten with the CARBURETOR SCREW 5 65WSW PCS 3 INSULATOR Remove the INSULATOR PIPE J OINT T 2 Remove the tube from the CYLINDER TUBE 3PCS NOTICE Detach the attached SCREW gasket thoroughly 5 25WSW2PCS SCREW 5 MWSWUPCS gF nr 29 Disasserrbling Instructions 1 eme Remove the MUFFLER and GASKET MUFFLER MUFFLER C
17. CREW temporarily here and then tighten it with the tightening torque above after the frame asserrbling Be careful about the DAMPER 1 direction Place the DAMPER 1 at the protruding portion on the vertical rib of the CASE LVOLUTE TAPPINNG SCREW 5 25 3PCS Tightening torque 202 COVER INLET VY v 18 FRAME Tighten the SCREW with the tightening torque as CUSHION e shown the preceding page after the FRAME Ns assembling FRAME RIVET 5 Y9 FRANGE NUT marzo M5 16 WSW MEC 2PCS Tightening torque 25 5 igntening torque 2522 Tightening torque 25 5 TT NN 1 1 19 E I 5 lt E t gt lt 5 5 8 8 5 8 gt O 3 i CASE AIR CLEANER inserting part of the tubes before installing them if necessary ROCKER COVERI AIR CLEANER Tubes layout AIR CYLINDER CASE AIR CLEANER SCREW MOLUTE CASE M5 16 WSW 4PCS O OU Tightening torque 2549 20 Asserrbling Instructions 4 Fix the cable to the ELBOW wth the tie wrap P NO LEVER 1 Insert the inner cable of the CONTROL CABLE into the CARBURETOR S adjusting bolt and CONTROL CABLE fit it in the SWVEL groove S MRING 2 Fit the outer cable of the CONTROL CABLE and
18. NG DIAPHRAGM ASSY SPRING RETAINING METERING BODY ASSY AIR PURGE PUMP PRIMER PRIMER PUMP D APHRAGM PUMP 48 3 Notice Clean the CARBURETOR using clean gasoline before disasserrbly 2 Disasserrble or reasserrble referring to the deal drawing Do not disasserrble the THROTTLE VALVE ASSY and PUMP BODY ASSY 4 Disasserrbly and reasserrbly procedure Remove the screw PUMP COVER and then the PRIMER PUMP COVER Remove dust clearly from the PRIMER PUMP if any Remove the PUMP BODY ASSY fromthe body do not let the SPRING missing Remove dust clearly fromthe INLET SCREEN if any Rerrove the J fromthe body Remove the SCREW THROTTLE COLLAR and then THROTTLE VALVE ASSY from the body Reasserrble the J ET and SPRING firmly when reassembling the CARBURETOR 5 Checking procedure amp Clean the body using gasoline and blow it clearly with compressed air 2 Test the J ET for dust and corrosion The dust needs cleaning and blowing with compressed air and corrosion replacing with new one Note The new J ET should have the same number with that of the old one Test the GASKETS for deformation and breakage Replace bad gaskets with new ones if any PUMP DIAPHRAGM should not be hardened or darraged amp The INLET VALVE and the OUTLET VALVE should be flat and not bent The DIAPHRAGM ASSY should be free of any hardening damage or bend After cleaning the PUMP BODY ASSY test
19. PCS PM WAVE WASHER SOCKET HEAD BOLT M6 14 1PCS 15 2 REASSEMBLY Equipment reasserrbly procedure l Notice Clean parts corrpletely Replace screws wth new ones if necessary Tighten up the tightening torque specified parts according to the specified tigntening torque 2 Tigntening torque of each part For further assembling instructions on each part see the corresponding pages e socker HeaDBowt 09 780 6 CASE 2 VOLUTE SOCKET HEAD BOLT 0 0 position socer meaner gt 78 gt 4 o FLYWHEEL SOCKET HEAD BOLT 0 0 cast mg 209 CASE 2 VOLUTE TAPPING SCREW 0 0 3 M5x 65 WSWS 15 41 0 Check if the ELBOW can be 20 2 0 2 smoothly rotated with the hand ELBOW SCREW 0 5 after screwing the screws elo o COVER INRET TAPPING SCREW 0 0 20 ss CASELVOLUTE SCREW 5 pam SCREW DAMPER1 SCREW 0 0 SCREW CASE 12 VOLUTE SCREW SCREW TANK FUEL SCREW 5 COVER ENGINE TAPPING SCREW TAPP 12 CASE 2 VOLUTE TAPPING SCREW MIENNE ENGINE SCREW 0 0 Check if the LEVER 2 CASE 2 LEVER 14 20 45 20 405 i moved wi after LEVER 2 THROTTLE SOCKET HEAD BOLT 0 0 fitting it in the CASE 2 LEVER by screwing the bolt CASE LLEVER 4x 16 5 13 05 10 3 CASE 2LEVER TAPPING SCREW 0 0 16 NO Part Assembling Instructions dg ERE EROR EE ERE e a
20. ROCKER COVER to check he valve clearance is within the whether the value clearance is 2 criterion 0 15 see 00000 est the CAMGEAR for any ablation of the den Any ablation of the CAM top needs replacing the CAMGEAR with a new one Valve train Due See 0 000U0 disassermbley 0 O00 0 reassemble Is the CAMGEAR timing right The timing mark of the CAMGEAR faces es Correct the bad CAMGEAR timing down vertically when the piston is 0 00 See 00000 at the top dead center Pull the RECOIL STARTER to check for proper while the engine stops Compression No Compressed insufficiently Return to work order get the proper in the corrbustion charrber Does the 0 00 compression in the combustion charrber Insufficient corrpressio compression seemto be insufficient Plug and Ignition on Does the PLUG ignite sufficiently The plug ignites insufficiently Return to work to get the sufficient spark Is the cooling air passage clogged up at its Cooling 0 00 wth dart Has the engine over heated Remove the dart to get the good cooling air flow consequently Unknown case Hxc Was it confirmed at the pre operation If the oil level is over 220cc drain the oil fromthe engine oil tank or if less 70 check that the engine oil tank was filled 1 0 fill the oil tank with engine oil to the level of 220cc Oil care with engine oil of 220cc See Poor acceleration and output
21. Robin Service manual Model FL H 500 FUJIROBIN INDUSTRIES LTD CONTENTS SEGIRHCOMNIOS III D D DB D DEB BLEELOB EL 7L ELE O EDI C 1 SPEO FI OS HL DEL DOLO D CO D FEE DEO DE UE OE 7E C U D EI L 2 PART NAMES I LB D UO D DU D EE DEO 7E OE OE 7E OE UE D DT UI U 1 PREPARATIONS UD HUU HII 1 PREPARATIONS D D D U D HEU DO HI OE D DI UE UU UT U D LU 2 Nancxgimnpuu uuiuutuitultututtLtubtLtut III SACSEMLY AND REAGSEMBLY PROCEDURE 1 EQU SASSEMBLY 2 EQU REASSEMBLY 0000000000000 ENG S A6SEMBLYL LT C D OU U UO D UU LI U ENG Ne REASSEMBLY DO LE UL U D CEU D LI UI L 5 CARBURETOR SASSEMBLY AND REASSEMBLYT 6 STARTER SASSEMBLY AND REASSEMBLY IV MALFUNCTION AND 0000001 V CHECK AND TION ING LLL C E E U D D D D EE DI n VI FOR TION IG 0000000000 00000 AND STORE LTD EL BEL BL BL BL BEL B EBD EE D E IX CHECK ERA AND ED CF BN CLEARANCE 00000000000 00000 XI GENER N5 00000001 SPECIFICATIONS LSPECIFICATIONS SPECIFICATIONS Type FL H7500 Dimensions LXWXH 350x 430x 495 13 7 169 19 5in only for Dry Weig
22. Test the fuel pipe for comng away 3 The coming away and or bent fuel pipe causes and or bend a fuel leak and or poor engine start Checking and cleaning of the PLUG 4 The bad PLUG SPARK causes poor power SPARK and or engine start Check the oil quantity If short supply 5 The engne might seize up in operation with supplementary oil X lack of the oil A pre operation check should be done Check and care after initial 20 hour use Check and care after every 50 hour use Oil change The dirty oil accelerates ablation of the parts Fuel filter cleaning The dirty fuel filter causes the fuel not to be supplied to the CARBURETOR resulting in a poor engine start Check and care after every 200 hour Check the valve clearance Adjust the 1 Increasing in the amount of clearance causes valve clearance if necessary the descent of the engine power output Decreasing in the engine revolution resulting in the engine malfunction needs the cleaning of the CYLINDER 2 The descent of the engine power output results HEAD after removing it the engine malfunction Fuel pipe replacement 3 A fuel leak is dangerous Long term nonuse of engine Perform procedure 1 and 2 2 Drain the fuel fromthe TANK FUEL and CARBURETOR B To prevent rust of the inside of the CYLINDER pour oil of about 2cc from the CARBURETOR attaching screw hole pull the RECOIL STARTER starting knob slowly 2
23. a new one Unknown causes Ask a serviceman without known cause of the engine trouble Work load E Is the engine overloaded ui Ask a serviceman for the correct workload es No gasoline in the TANK FUEL Have you pushed the primer pum to feed the Fill the TANK FUEL with gasoline Push the primer purrp to feed the gasoline to gasoline to the CARBURETOR mu Fuel Are the fuel filter and or tube clogged up No trouble in the fuel passage Correct the causes of bad fuel flow Replace faulty parts with new ones if Is the tube bent necessary Is the inside of the AIR CLEANER dirty No Dirty AIR CLEANER inside causes bad engine shaft revolution because air dust and or oil cannot be breathed well See O0 000 000 O 53 the CARBURETOR Poor acceleration and output shortage of engine Trouble Work order Point to be checked Action to be done Wthout problem Wth problem Does air fuel mixture leak fromthe mating faces of the CARBURETOR INSULATOR etc Investigate the leakage and correct it Replace the packing etc with a new one if necessary Fuel Clean the inside of the CARBURETOR Replace wear out parts such as the No trouble in the CARBURETOR diaphragm with new ones Replace the CARBURETOR with a new one if necessary See Adjust the valve clearance at 0 15 Disasserrble the CARBURETOR to test it for the component parts being clogged up and or deteriorated Remove the
24. ag to the ground and or drainage ditches Ask a store where you have bought the oil for unclear points about the disposal Check and or change the oil periodically change it once six months The oil deteriorates naturally Fuel Do not use rrixed gasoline gasoline mixed with the engine oil The mixed gasoline might cause carbon sedimentation resulting in an engine failure Use of old fuel causes a poor engine start Operation Open the throttle one thirds and start the warmed engine if it cannot easily start again Storage Store the equipment with the engine in an upright position in spite of its storage period Tell your users the correct storage way above 58 CARE AND STORAGE Care described below shows the standard procedure required at the correct engine use under usual conditions Therefore it will not give you any guarantee such that care is not necessary up to the indicated times An air cleaner cleaning for exarrple is necessary every several not ten hours a day during operation in a dust laden environment Daily check and care every 10 hours Parts cleaning 1 The dusty air cleaner element might cause poor engine drive Also the oil attached air cleaner element causes not only the inner but also outer parts to be dirty by the oil Test the parts for being not seated 2 The parts not seated causes vibration of the Tighten loose screws again if any engine and oil leaks
25. agnetic part on the downside this can be confirmed with the FLYWHEEL counter mark 2 oin CAMGEAR to CRANKGEAR with CAM top facing down vertically use the counter mark for reference 3 J oin the CAMLIFTER Be careful about the direc tion of the camlifters when installing them see the figure below ID counter nark Patnam Assembling Instructions 11 PUSH ROD 1 Insert the PUSH ROD into the PUSH ROD passage of the COVER CAMGEAR CYLINDER HEAD VALVE clearance 2 sure that the PUSH ROD is put into the spherical grooves of the CAM LIFTER and ROCKER ARM adjust bolt 3 Attach the COVER CAMGEAR 4 Loosen NUT and adjust VALVE CLEARANCE by rotating AD UST SCREW with a hexagon bar wrenchAdjust VALVE CLEAR ANCE at the corrpression top dead center the position of the CAM top and FLYWHEEL should rerrein in the same one at no 10 Be sure to close the COVER CAMGEAR before the clear ance adjustment 5 Tighten NUT firmy after the adjustment 5 VALVE CLEARANCE 0 15nm LLL 2 sure that the PUSH ROD is put into the spherical grooves Press the ROCKER ARM and fit in the PUSH ROD Aive d trok 3 lightening sequence 5 G of the SCREW the CAMGEAR CAMLIFTER and ROCKER ARM 4 f B F TO i sure that the PISTON is positioned to the top dead 3 center before installing the 4 COVERCAM GEAR SCREW DU M5 x 16
26. and COVER AIR CLEANER 2 The tightening torque of the HOSE CLAMP bolt should be 15kgf cm KNOB BOLT 3 Be careful that the DUCT fitted in is not covered with the COVER AIR CLEANER DUCT HOSE CLAMP COVERAIR CLEANER ELEMENT HOSE CLAMP Fit in the hose clamp with the bolt directed DUCT upward s 2 After fitting in the DUCT pull it in the direction of the arrow shown below until it stops so that the DUCT fitted in is not be covered with the COVERAIR CLEANER HOSE CLAMP 23 NO Pat name Assembling Instructions 13 1 LEVER 1 Fit the throttle lever in the CASE 2 _LEVER using the SOCKET HEAD BOLT WAVE WASHER CASE 21 WASHER SELF LOCK LEVER 2 THROTTLE LEVER 2 THROTTLE After screwing the bolt check if the LEVER 2 THROTTLE can be smoothly moved SELF LOCK NUT M6 1PCS lt lt 2 WAVE WASHER M6 14 1 5 Tightening torque 15 1 Let the SWTCH lead wrre and CONTROL CABLE into the TUBE CABLE in advance 2 Fit the SWTCH lead wre in the groove of the CASE 1 LEVER 3 Fit the end fitting of the control inner cable in the hole c of the LEVER 1 THROTTLE Fit the 13 2 CASE LLEVER LEVER LTHROTTLE CONTROL CABLE TORSION SPRING over the cylindrical hollow colum e and fit the LEVER 1 THROTTLE SWITCH hole d over the cylindrical colurm TORSION SPRING y SWTCH LEAD WRE CONTROL CABLE TUBE CABLE
27. e Check again that the equipment Unknown cause od I s has been in operation in an appropriate and work method Ask servicerran for further information Oil consumption Clouds of white smoke out of muffler during 54 V CHECK AND RECONDITIONING Check and recondition the engne according to the essential criteria for reconditioning after the disasserrbly and cleaning the terms used in the criteria for reconditioning are described below Reconditioning To repair adjust replace any wrong part of the engine so that it works like a new one Required reconditioning The point at which a part of the engine is thought that it does not function any more without being repaired because of its wear breakage and or decreased function Usage limit The point at which a part of the engine can not be used any rrore because of its poor performance and or strength Ll Gauge The design dimension of new parts exclusive of its permissible dimensional deviation Adjustment accuracy The accuracy of finished and or adjusted dimension of a repaired part of the engine 55 M CRITERIA FOR RECONDITIONING Criteria for reconditioning of EHO75 type engine losers im alm siii m Q Replacement Inside diameter of 0 10 0 10 Diameter of Inside micrometer valve guide central part O External diarreter p 50 99 Micrometer Replacement of skirt in thrust di
28. e facing outwards Then bring the end of the BAND back over the HANGER and thread the remaining length of the BAND through the BUCKLE Tighten the BUCKLE pushing it towards the HANGER in the direction of the arrow shown the drawing while pulling on the BAND in the opposite direction 2 After attaching the BAND tighten the BUCKLE to the HANGER Tug strongly at the BAND to make sure that the BAND is secure and will not come undone 3 Attach the HOOK at the bottom of the BAND to the ring on the frame Verify that the BAND is not twisted HANGER BUCKLE 27 3 ENGINE DISASSEMBLY For further disasserrbling instructions on each part see the corresponding paces Special tool VILU e C n e sy M5X25rm INSULATOR DRerove the INSULATOR the INSULATOR DRemvetheinsuLATOR ann unn pure CYLINDER side easy removal screwdriver pe m p PLUG SPARK mm plug 1 sma m pe emm d pene CAMGEAR P31 2 Remove the CAMLIFTER the SHAFT CAMGEAR 4 Remove the CAMGEAR EE 5 the PUSH ROD ene Rerrove the ROCKER SHAFT by hitting with hammer a metal bar ROCKER ARM 1 Remove the ROCKER SHAFT held by the hand on the ROCKER P32 SHAFT at the intake side 2 Remove the ROCKER ARM 5 Support the VALVE fromthe inner VALVE 1 Rerrpve the RETAINER SPRING P32 2 the V
29. enove completely all the carbon deposit fromthr COMBUSTION CHAMBER and the PISTON top Be careful not to damage the mating face between the CYLINDER HEAD and CYLINDER and the one between the CYLINDER and CRANKCASE and not to let any foreign material corre into them Test the lip of the OILSEALS for darmege Replace darreged OIL SEALS with new ones Apply oil over the lip before reasserrbly Replace all GASKETS with new ones Replace PINS and SCREWS with new ones if necessary Tighten up the tightening torque specified parts according to the specified tightening torque 4 stroke engine oil over the rotating portions and sliding surfaces Check and adjust the clearance After reasserrbling each of the rotatable main parts rotate by hand to test it for bad movements and abnorrral noises 2 lightening torque For further asserrbling instructions on each part see the corresponding pages Tightenin rt The kind of scre Tightening torque 5 Notice No Tigtenngpat Tne ndoscem ere D ir Pe CRANKCASE M6x 30 FLYWHEEL M1O 04 343 e FRANGE NUT COIL 4 20 WSW 925 20 0 CRANKCASE SOCKET HEAD BOLT RETANER PLATE 4 10 SW 20 5 Fasten wth the CRANKCASE SOCKET HEAD BOLT 00 0 CASE OIL and GASKET BOLT M8x 12 Be careful not to fail to DRAIN BOLT BOLT 50 10 49 h place the GASKET D CRM E n 39 25 C CRANKCASE SCREW 0 CYLINDER HEAD 6 30 120 420 11 8 g CYLINDER SOCKET HEAD BOLT 10 CUNO screw
30. erable over the rotating and friction parts at the end of the season and at disasserrbly OOLMhen the SWING ARM does not move smoothly When the SWING ARM does not move smoothly Apply grease over the SWING ARM end and in the vicinity of place along which the end slides Shell Albania No 3 52 V MALFUNCTION AND REPAIR Trouble Work order Point to be checked Action to be done Wthout problem Wth problem Does the CRANKSHAFT rotate by pulling Yes the RECOIL STARTER 0 0 Any breakage in the RECOIL STARTER 2 Is the clearance between the FLYWHEEL and COIL within the criterion Does the FLYWHEEL touch somewhere tolerance 0 0 Remove foreign material such as gravel if any Does the CRANKSHAFT rotate by rotating Yes Disasserrble the engine to investigate the FLYWHEEL by hand 0 0 0 0 Remove the rocker cover and COVER Repair the VALVE ROCK ER ARM PUSH ROD CAMLIFTER and CAMGEAR if CAMGEAR to test the CAMGEAR etc for any defects were found defects See 0 000i reasserble CRANKSHAFT does not rotate Any defect in the CRANKSHAFT bearing Disasserrble the whole engine Breakage of the bearings of the CRANKSHAFT and ROD CONNECTING and and or does the PISTON seize up problemsuch that the PISTON seizes up are likely Is the STOP SWITCH ON Switch the STOP SWTCH to ON Remove the PLUG SPARK and ground it Does it ignite if the RECOIL
31. f the CAP OIL stiff a A gasket used for long tire is likely to get stiff which causes an oil leak Is the gasket used with the oil drain bolt Be careful not to loose the GASKET HS fRncetegstewhaneoefenekenRDDUEEDUIND 00 e ue os and or work method place and or work method Ask a serviceman for the appropriate way Unknown cause Ask a serviceman without known cause of the oil leak Is the PLATE SEPARATOR in the AIR CLEANER loose Oil leak from engine Was it confirmed at the pre operation check that the engine oil tank was filled with engine oil of 220cc If the oil level is over 220cc drain the oil fromthe engine oil tank or if less 70cc fill the oil tank with engine oil to the level of 220cc See sure to clean the inside of the AIR CLEANER before operation The inside of the AIR CLEANER easily gets dirty with the engine oil See Is the inside of the AIR CLEANER cleaned before operation Drive the engine at about 7000rpmfor about 3 minutes Has the white smoke operation Performwork orders 7 4 or below until the problem of the excess oil Is the engjne oil consumed over 5cc an hour consumption is corrected Excess oil consumption may cause clouds of white smoke Clouds of white smoke do not corre out during operation with the oil consurrption at 5cc or less hour and in normal us
32. f the CARBURETOR and replace wear out parts with new ones if necessary See 00000 Properly compressed Compressed insufficiently roper compression in the combustion AR 0 0 0 0 charrber Pull the RECOIL STARTER swiftly 10 20 times with the choke open to start he engine has started the engine Rerrove the PLUG Pull the RECOILSTARTER swiftly 30 50 times he engine has started 0 0 Screw the PLUG and start the engine Remove the ROCKER COVER to check he valve clearance is within the whether the valve clearance is within 0 08 criterion 0 40 criterion 0 1 0 15 Still compressed insufficiently 0 0 Still compressed insufficiently Adjust the valve clearance at see 000000 Insufficient corrpressio Li est the CAMGEAR for any ablation of the No ablation Any ablation of the camtop needs replacing the CAMGEAR with a new one Is the CAMGEAR tirring right The timing mark of the CAMGEAR faces down es Correct the bad CAMGEAR tiring vertically when the PISTON is atthetop See dead center Disasserrble the whole engine to check whether any carbon remains attached to the valve face and or the inside of the combustion charrber No carbon attached 0 0 Remove any attached carbon if any est the CYLINDER bore and PISTON No ablation or damage Marked ablation and or damage needs replacing the CYLINDER RING for marked ablation and or darrage and or PISTON RING with
33. gure below Air gap 0 3mm Be careful not SOCKET HEAD BOLT to loose the gt M4 x 20 WSW2PCS WOODRUFF KEY Tightening torque 200 20 WRE female WRE male Li Fasten with the COIL THICKNESS GAUGE Air gap 0 3vm FLYWHEEL IGNITION COIL 41 patrare Asserbingintrution m CASE OIL 1 Fit the GASKET OILCASE LEAD VALVE and RETAINER PLATE CRANKCASE in the CRANKCASE OTHERS 2 Screw the DRAIN BOLT onto the CASE OIL with the GAS KET between them 3 oin the CRANKCASE and CASE OIL together SCREW 5 x 25 WSW5PCS Tightening torque 401 P cm BOLT M8 x 12 1 5 Tightening torque 50 10 NOTICE Be careful not to fail to place the GASKET SOCKET HEAD BOLT 4 10 SWIPCS Tightening torque 20 gt cm _ Attach LEAD VALVE with the cut out facing to OIL FILLER HOLE A e 4 careful about the oil tube Cut out danao Tightening sequence of the SCREW jPatmme Asserrbling Instructions 9 CYLINDER HEAD I Attach the CYLINDER HEAD Tightening sequence of the SOCKET HEAD BOLT SOCKETHEAD BOLT M6 x 35 5PCS Tightening torque 120 25 kgf cm GASKET CYLINDER HEAD pum Finally tighten again the BOLT that was ASS KE tightened first CAMGEAR 1 Position the piston to the top dead center CAMLIFTER Make sure that the FLYWHEEL is placed with its m
34. h care not to darrage it PLATE SEPARETOR 11 FRAME 1 Remove the FRAME m D D 25 wa i 1 A y a EN C 2 YY 7 y 7 4 J y n 2 Fr 7 1 4 D d 5 A A e 4 a H IN P 4 3 a 4 gt e S AN 4 2 Si M5 16 WSW MEC 2PCS CASE 1 VOLUTE 1 Remove the CASE LVOLUTE NOTICE Be careful not to loose the nuts DAMPER 2 ELBOW O RING NO Pat Disassembling Instructions TAPPING SCREW 5 16 5 NUT M5 BLACK DAMPER 2 SCREW M5 65 WSW 2PCS ELBOW 12 TEREST Nette IMPELLER A WAS SOCKET HEAD BOLT M6 40 W SW 4PCS h Z J 5 LIPS fg AMOR LLI 77 lt ea CASE 2 VOLUTE CASE 2 VOLUTE SOCKET HEAD BOLT M6 30 W SW 6PCS 13 NO Pat name _ Disassembling Instructions Disasserbling Instructions 6 1 LEVER 1 Remove the CASE 1 LEVER and CASE 2 LEVER ASSY CASE LLEVER CASE 2 LEVER ASSY TAPPING SCREW CASE 2 LEVER ASSY 4 16 5PCS Ne NUT M5 1PCS SCREW M5 25 1PCS CASE 1 LEVER 14 NO Pat name _ Disassembling Instructions ord EVER 2 Remove the LEVER 2 THROTTLE fromthe CASE 2 LEVER ASSY CASE 2 LEVER ASSY LEVER 2 THROTTLE LEVER 2 THROTTLE SELF ROCK NUT M6 I
35. ht kg 10 2 22 465 only for body EHO75F y Operating Part Perforrrance Engine RE AE RES 2 o 5 zi D e c Oo 9 D S a gt d o D 3 Air Cooled 4 Stroke Upright Single Cylinder OHV Gasoline Engine Piston Displacement mL J Ul Autorrotive Unleaded Gasoline Fuel Tank Capacity L 19 642 fl oz Autorrotive Oil SAE 10 30 Class SF or higher Autorrotive 4 Stroke Engine Oil 0 221 7 4 fl oz Engine Oil Capacity of Engine Oil L Diaphragm Type Ignition System Breakerless Magneto NGK CMR6A Recoil Starter with decompression Lubrication Forced Lubrication Max Air Volume min 2040 720 Air Volume with Nozzle 14111 498 J oystick Lever with rubber Engine Speed Control Lever Trigger Lever Cruise Control Lever n U UJ ne Flexible Pipe One Swivel Pipe One Blower Pipe One Blower Nozzle Standard Accessories Two Shoulder Strap Hose Bando 100 Hose Bando 76 Box Wrench Instruction Manual 2 E NS 222 f SAAN A WE h Ol A o coe arere Ooo DESIGNATION OF PARTS DESIGNATION OF PARTS DESIGNATION OF PARTS DESIGNATION OF PARTS 7 Knob Bolt 14 Air Inlet Net 21 Swivel Pipe ll PREPARATIONS PREPARATIONS 1 2 T ool for disassembly and reassembly Mash pan Mash oil light oil gasoline etc JAutorrotive
36. instructed Q If the RATCHET fails to function check whether the parts such as the spring have been rrissing L LPull the STARTER KNOB to pull out the STARTER ROPE to the end Unwind the STARTER ROPE 1 to 2 turns in the way as shown in Fig 6 16 the SPIRAL SPRING may be over stressed if the STARTER ROPE still remains in the rope groove Q If the STARTER ROPE is found weak to rrove back or the STARTER KNOB droops when you let it go apply grease over the rotating and friction parts If it does not recover pull the STARTER KNOB such that the STARTER ROPE is pulled by 1 to 2 turns In this instance make sure in the way described above that the SPIRAL SPRING is not stressed If the SPIRAL SPRING comes away with a sound and the STARTER ROPE will not be moved back reasserrble the RECOIL STARTER fromthe beginning LOther notice the SPIRAL SPRING fly out Make a ring having a smaller diameter than that of the SPIRAL SPRING housing by a thin wire Hook the SPIRAL SPRING at its outer end on the ring to wind it as shown in Fig 6 6 and fit it into the SPIRAL SPRING groove Press the SPIRAL SPRING with your finger to prevent it from coming away and remove the ring slowly The ring can easily be removed by prying it with the tip of a screwdriver See Fig 6 4 for how to fit the SPIRAL SPRING correctly into Fig 6 6 the groove off season and disassembly Apply grease heat resistant type is pref
37. it for deformation of the METERING LEVER and METERING LEVER SPRING height of the METERING LEVER dust stuck to the INLET SCREEN and VALVE leakage etc To check the MAIN CHECK VALVE for its correct operation place a vinyl or rubber hose at its end on the CHECK VALVE portion fromthe J ET side and breath it at the other end If you cannot breathe it and valve closes when you breathe it in it works correctly If not InTrerse it in gasoline for about 10 minutes and then repeat the procedure described above If the VALVE cannot be fixed even by doing this replace it with a new PUMP BODY ASSY Note Do not blow the MAIN CHECK VALVE with corrpressed air If you use an air gun keep it about 30cm away fromthe valve when the compressed air has a pressure of 6kg crv Test the PRIMER PUMP for any hole breakage and hardening Make sure that the COMBINATION VALVE works correctly 6 Marks on CARBURETOR EE LES Marks are stamped on the CARBURETOR as shown in the right figure TEL pi 7 Model mmi me 2 Date of manufacture Example WYK260 2 630 J uly 24 to J uly 30 2006 Week 30 what week number in the year Last digit of the year 49 6 RECOIL STARTER The RECOIL STARTER rarely malfunctions under norrral use When it fails however or needs greasing disasserrble and reasserrble it according to the following procedure Tools Screwdriver and pliers Disasserrbly HOC Renove the RECOIL STARTER fro
38. m the engine out the STARTER KNOB press the ROTARY REEL with your thurrb as shown in Fig 6 1 when the REEL cut out comes to the STARTER ROPE OUTLET and pull the STARTER ROPE to the inside of the RECOIL STARTER with a screwdriver Using the cut out rewind the REEL to the direction of the arrow until it stops by controlling the rotation of the REEL with your thumb the parts as shown in Fig 6 2 Remove the REEL slowly by turning it back and forth gently a way that SPIRAL SPRING will not come away fromthe REEL Be sure to wear a piece of protective glasses during disasserrbling to protect against a danger caused by possible spiral spring s coming away If the spiral ring flies out fit it correctly into the groove according to the procedures as shown in Fig 6 6 Untie the STARTER ROPE knot at the REEL end and take it away to corrplete the disasserrbly STARTER KNOB SPIRAL SPRING 50 JL Run the STARTER ROPE through the STARTER KNOB and make an overhand knot as shown in Fig 6 3 Run the STARTER KNOB at its opposite side fromthe STARTER CASE to the REEL make a knot in the same way and put the ROPE end corrpletely in the ROPE HOUSING of the REEL Then apply small amount of grease over the STARTER SHAFT and SPIRAL SPRING 1L Make sure that the SPIRAL SPRING is fit corrpletely in the spring groove of the REEL Formthe SPRING end to have 1
39. rection 6 1 14 1mm higher from bottom Width of ring Vernier calipers Replacement grooves 10 10 20 PIN hole en os5 Reaemt _ Gap between PISTON 01 01 At skirt Cylinder gauge Replacement and CYLINDER bottom in 6 1 14 1 mm higher piston thrust from bottom direction Gap between ring Gap gauge Replacement grooves and rings Top 0 12 2nd 0 12 Oil 0 20 Authorized tally of Microrreter PISTON and PISTON PIN Closed gauge Replacement 08 a When the whole 08 rng working face touches 9 mmm CYLINDER 08 2 Width Micrometer Replacement 2nd 10 Oil 2 0 External diarreter of 12 0 012 0 012 PISTON PIN 56 Height of cam top 28 nal Replacement Gap between Inside micrometer Replacement CAMSHAFT and Micrometer External diameter Micrometer Replacement of valve shaft 40 Intake 0 10 p 4 0 Exhaust Gap between valve At the center Inside micrometer Replacement shaft and valve of the VALVE Micrometer guide GUIDE Intake Exhaust Valve lift Vernier calipers CAMGEAR Lo oo _ Valve clearance in 08 04 gage see sles NENNEN EN External diameter p5 Micrometer Replacement Fee Diameter of rocker Three point Micrometer Replacement Gap between Micrometer Replacement rocker arm and Three point Micrometer rocker shaft EMEN NGK pws PLUG SPARK Thickness gage Adjustment o HE
40. sentiinginstruction 10 FLYWHEEL 1 Rerrpve the COIL COIL 2 Remove the FLYWHEEL SOCKET HEAD BOLT x 20 WSW2PCS FRANGE NUT 10 1 5 Part number 1000000000 Tool name 00000 Work Flywheel Puler utem 11 CYLINDER 1 Ram a flathead screwdriver into the four grooves in turn to CRANKSHAFT remove the CRANKCASE by prying it off with the screwdriver CRANKCASE see the figure below 2 Pull the CRANKSHAFT out of the CYLINDER Be careful not to darrage the OIL SEALS s m Ju RES L m 1 A m T og bo WORK wmm es bo eme ro cem i T ra ris i 25 i i LN m oc 22 x P T P i MET rue i ki T neu Pd 1 ma depen i t FC L ri 1 SOCKET HEAD BOLT gt M6 30 6PCS Grooves four Used to remove the CRANKCASE be care ful not to darrage the sealing surface 35 EE CRANKSHAFT 1 Rerrove the CLIP PISTON 2 Remove the 5 PISTON RINGS 3 Rerrove the PISTON RINGS and OIL RING OIL RING OTHERS NOTICE Wdening the open end of the ring might break it PIN PISTON CLIP Be careful not to damage the OIL SEAL 36 Engine reasserrbly procedure Notice Clean parts corrpletely specifically the PISTON CYLINDER CRANKCASE CRANKSHAFT and BEARINGS R
41. shortage of engine Is the engine oil consumed over 5cc an did hou Others Does the engine oil leak fromthe OIL CAP PN orders 0 00 0 and when a fairy large amount of etc leaked oil is found around the CAP OIL Disasserrble the whole engine Test the No ablation or darraged CYLINDER bore for marked ablation and 1 Marked ablation and or damege needs replacing the CYLINDER with new one darrage Asi ane dalrege 4 Tor ar ked abrasion po damaged Marked ablation and or darrage needs replacing the PISTON with a new one est the PISTON RING for marked Marked abrasion needs replacing the PISTON RING with a new one abrasion See disassemble reassemble Is the CAP OIL tightened Tighten the CAP OIL Was the engine oil spilled onto the Be careful not to spill the engine oil around the equipment at feeding and or Oil and engine care equipment at feeding and or changing oil changing If spilled wipe off the equipment Is the inside of the AIR CLEANER cleaned Be sure to clean the Inside of the AIR CLEANER before operation The inside of the AIR CLEANER easily gets dirty with the engine oil before operation see If loose Fasten the OIL SEPARATOR to the bottom or 9 Replace the OIL SEPARATOR with a new one 1701000000000 Is the gasket rubber packing Replace the gasket with a new Engine care ETT o
42. t its joint 16 CARBURETOR Attach the GASKET CARBURETOR CARBURETOR and CASE INTAKE NOTICE Be careful about the GASKET aspect when in stalling it NOTICE careful about the gasket damage after installing it SCREW 5 x 65WSWI1PCS 7 lightening torque 200 7 cm 17 PULLEY 1 Attach the PULLEY Tighten the STARTER together with the COVER ENGINE using the same SCREWS PULLEY 900 110 cm Pat rare Assemnirgirstmctee 18 1 Attach the CAP OIL NOTICE Be careful not to fail to place the PACK ING or fill the tank with oil 47 S CARBURETOR DISASSEMBLY AND REASSEMBLY This engine is equipped with a diaphragm type CARBURETOR 1 Function and structure of the diaphragm system Since the fuel level is kept constant in spite of any tilt angle of the engine it can be operated at any position The float chamber is provided with a diaphragm and covered by a cover Negative pressure in the air intake passage causes the diaphragm to swell upward and thereby pushing up the hinge to open the valve Upon the disappearance of the negative pressure the valve is closed by the spring pressure Then the fuel flow rate can be controlled by marking an appropriate determination of the diaphragm area and spring pressure 2 Disasserrbly and reassembly SWIVEL SCREW BODY ASSY PUMP THROTTLE COLLER NUT CABLE ADJ BRAGKE CABLE gt 2 WASHER GASKET METERI NG RI
43. to times and screw the PLUG SPARK W Pul the RECOIL STARTER starting knob slowy and stop pulling at the first heavy rroverrent just before the pressure top dead center Cover the equipment and store it in an upright position in a dustless place 29 IX CHECK DRAINAGE AND FEEDING OF ENGINE OIL Recommended Robin genuine oil or SAE10W 30 oil of API type SF grade or better 4 stroke motor oil for automobiles Oil capacity Approximately 0 22 L 220 1 Checking and Refilling Engine Oil 0 Follow the procedure below when the engine oil is cold i e the blower has not been running e nspection JSet the blower down on a level surface and remove the oil cap Verify that the oil level is within the upper and lower limit marks on the oil level gauge If the oil is not up to the 100mL level fill up with new oil e Adding the blower down on a level surface and remove the oil cap Fill the oil up to the upper limit of the oil level gauge 2 Oil Change Procedure Setthe blower down on a level surface 2 Place a weste oil container under the drainage hole 1 to catch the oil as it drains out The container should have a capacity of at least 220 rd to be able to catch all of the oil Loosen the oil drain bolt 2 to let the oil drain out careful not to allow oil to get on the fuel tank or other parts Remove the oil cap Removing the oil cap allows the oil to drain easily As
44. to 2 mmclearance between the SPIRAL SPRING inner end and REEL BUSH so that the STARTER SHAFT can hook on the HOOK securely as shown in Fig 6 4 The SPIRAL SPRING inner portion about 10cm long from the end can be charged in shape Before inserting the REEL in the STARTER CASE wind the STARTER ROPE around the REEL three turns in the direction of the arrow shown in Fig 6 5 draw out the third turn of the STARTER ROPE fromthe REEL ct out and fit the REEL corrpletely inside the STARTER CASE so that the SPIRAL SPRING inner end can hook on the hook Then hold the STARTER ROPE as shown in Fig 6 5 and twist the REEL 4 to 5 turns in the direction of the arrow using the REEL cut out After the corrpletion of winding of the STARTER ROPE hold the REEL tightly to prevent the STARTER ROPE from winding back pull the STARTER KNOB in order for the SPIRAL ROPE to tighten and then release the STARTER KNOB slowly Reasserrble the parts in reverse order of disasserrbly shown in Fig 6 2 Tighten the SETSCREW firmly gt x Be sure to perform the following procedure in order to make sure that the parts have been fit completely 51 Fig 6 3 SPIRAL SPRING END SPIRAL SPRING INNER END HOOK e STARTER SHAFT 1 2mm Fig 6 4 ICheck after reassembly LPull the STARTER KNOB a few times If the STARTER KNOB is too heavy to pull check the associated parts whether they have been reasserrbled as
45. to the RETAINER SPRING hole and slide RETAINER SPRING while pushing spring Slide the Joc RETAINER PRING 4 CYLINDER 1 Install the two CHECK VALVES on the CYLINDER S N Vy wv MA N 30 Asserrbling Instructions 5 CRANKCASE T Pipe position i Q gt gt Z 7 SS CYLINDER 1 Apply the 4 stroke engine oil over the inner wall of the cylinder and CRANKSHAFT sliding surface of the piston CRANKCASE 2 Insert the into the CYLINDER 3 Apply the silicon system liquid gasket equally over the shaded area of the crankcase as shown in the left figure ThreeBond 1216 recorrrended Be careful not to fill in the grooves and holes with the gasket fe VS CAES m J aw 24 ees Tightening sequence of the ee ie CS La SOCKET HEAD BOLTS 7 D E ew A Ai 7 L di P E M 2 The OIL SEAL should not stick out RUE fromthe CRANKCASE SOCKET HEAD BOLT J M6 x 30 6PCS Tightening torque 90 10kgf rm Patnam _ jAssnmbingismcios 00 7 FLYWHEEL 1 Degrease CRANKSHAFT and FLYWHEEL tapered portion com COIL pletely before joining them 2 Attach the SPRING PLUG CAP to the HIGH TENSION CODE 3 Insert the HIGH TENSION CODE with the SPRING PLUG CAP into PLUG CAP 4 Fit the and WRES in the CRANKASE See the fi
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