SERVICE MANUAL - Subaru Industrial Power
Contents
1. NG U Stop switch p wap Y Choke lever IL x Il AUD IA Fuel switch Governor spring Nut M6 Governor arm Adjusting speed Don t adjust the speed because it is fixed If necessary please send it to the authorized dealer for adjusting If the user has a proper tools and repairing capacity only permit the following operation 1 Start the engine and allow it to warm up to normal operating temperature 2 Ifthe maximum speed is not conformed to specified value adjust throttle control and hole position of the support by adjusting governor spring EA190 engine maximum speed 3800 100rpm WARNING The engine has adjusted to specified speed when manufactured in the factory if the wrong adjusted from the user to cause the performance of the engine it is not covered the warranty of our company 15 IV DISASSEMBLING AND SERVICING 4 1 Troubleshooting 4 1 1 Starting difficult TROUBLE CAUSE REMEDY There 1 h fuel in fuel IGAS i SER EN SE Fill fuel open fuel cock tank and fuel cock is closed Air vent in the fuel filler cap is Dredge air vent Fuel supply clogged i Improper or clogged carbureto i Readjust or clean blow to get through main fuel channel Carburetor float needle valve 1s Dismantle needle valve and repair not closed properly or start hole clean blow to get through is clogged pco AS Repair float sticking Fuel is too filthy or deteri2. 23 4 3 3 Ignition coil flywheel En AU Description 2 Starting cup Ignition coil Ignition coil stop wire Ser 6 e Ignition coil NOTICE Check high tension line insulator for cracked replace 1f necessary Assembly 1 Disassemble engine housing fuel tank Ignition coi and recoil starter in order It 20 Bolt J 2 Measure the clearance between the Fhavhael ee MOE Las gap 0 35 0 45mm ignition coil and flywheel with the feeler a AA Se n Pa ON 8 Adjust the gap between the ignition coil ff SX and flywheel 4 Adjust method Loosen the bolt move ignition coil radial along with flywheel to adjust gap with feeler and screw down the bolt Primary terminal Check the ignition coil primary side Measure the resistance of the primary coil by attaching one ohmmeter lead to the ignition coil s primary terminal while touching the other tester lead to the iron core Primary side resistance value 1 0 1 5Q 24 Secondary side Measure the resistance of the secondary side of the coil with the spark plug cap removed touching one test lead to the high tension cord while touching the other tester lead to the coil s iron core Secondary side resistance value 5 7 RQ Flywheel Disassembly 1 Holding the flywheel with a commercially available flywheel brake remove the nut M14 2 Disassemble the starter cup and impeller Remove with a commercia
3. E ON Float l Small washer A class Philips screw Philips screw Needle valve Gasket NOTICE e Loosen the drain bolt and completely drain the fuel out before installing carburetor e No fire Reassembly 30 1 Check the float valve float seat and float spring for wear Float valve Y Float valve s at A A Worn Normal 2 Clean with compressed air before reassembling Main jet 3 Clean with compressed air before reassembling Main nozzle 31 4 3 7 Throttle control Returning spring hook the left end Governor lever insert the into the throttle shaft small hole left end into throttle valve Choke lever hook the shaft hole left end into the choke shaft hole Governor support Lever rubber sleeve Bolt M6x12 Throttle control upport fix bolt Engine stop switch Connect the engine stop switch line to crankcase while the other end connects to engine stop switch Bolt M6x12 I Governor i Fuel switch seat spring Fuel switch NOTICE Don t randomly replace throttle valve returning spring and governor spring hooking position or result in performance of the engine unstable Governor spring hook position shown as figure 32 4 3 8 Cylinder head valve train Spark plug Clean and adjust Cylinder head Before installation Exhaust valve Before Dowel A type spark plug before installation remove any carbon deposits from installation r
4. Exhaust side fig eIntake side Drive the intake valve guide to Valve guide Installation height IMM the specified height measured from the top of the valve guide to the cylinder cover as shown as fig d After installation inspect the valve guide for damage 1f damaged please replace Reamer For best results be sure the cylinder head is at room temperature before reaming valve guides Valve guide reamer Coat the reamer and valve guide with cutting oil Rotate the reamer clockwise through the valve guide for the full length of the reamer Continue to rotate the reamer clockwise while removing it from the valve guide Tools Valve guide reamer a Thoroughly clean the cylinder head to remove any cutting residue O b Check the valve guide bore 1t should be straight round and centered in the valve guide insert the valve and check operation If the valve does not operate smoothly the guide may have been bent XEZO during installation Replace the valve guide if it is bent or damaged Correct Incorrect c Check the valve stem to guide clearance d The valve stem to guide clearance The valve guide bore detract the valve stem outside diameter to get the clearance between the valve guide and valve stem 35 e If the clearance is over the service limit judge a new guide if it can make the clearance conforming to service limit 1f conforming to replace the guide and ream the guide refinis
5. an oil seal Driver handle Retainer assembler e Drive the oil seal in the cylinder barrel using following tool Oil seal Tools Driver handle Retainer assembler e Apply the lubrication oil on after reassembling f Piston e Apply oil to the piston and cylinder e Install the piston with the mark on the piston head opposite to the chain hole side Piston loader Chain hole 2 Piston check Check the piston and cylinder for contacting and check the groove for fault piston top for burn and cracks If damaged replace Clean the carbon deposit Clean the deposit round the piston top and cylinder neck before checking first soak the carbon deposit with kerosene and then clean with meter scraper or metal brush 41 Piston skirt O D Measure the piston skirt O D with outside micrometer 1 out of the service limit replace it 67 971 67 989mm 67 850mm b Piston pin bore to piston clearance Separately measure the piston pin bore I D and O D with inside micrometer and outside micrometer Then calculate clearance by measuring results 0 006 0 018mm 0 060mm c Piston cylinder clearance Difference between the diameter of cylinder maximum and piston skirt should be considered as piston cylinder clearance Check with piston converting in the cylinder and inserting feeler between piston skirt bearing face and wall then pull the feeler out if feeling resistance and smoothly out the thickness of the
6. as shown by the transferred marking compound should have good contact all the way around Valve lapping tool g Apply the abrasives to the valve seat face suitable for running in when rotating valve seat with valve seat cutter h After reassembling check the valve clearance 37 4 3 9 Crankcase cover governor gear No Gasket 8 Bolt M6x1 Dowel A type 9 Governor gear Assy Drain plug l Flyweight spindle Washer D10x 15 8x1 5 7 NOTICE Don t reuse the crankcase gasket Oil seal a Don t reuse b Apply the lubrication oil on the lip when using c Put the oil seal into the crankcase cover with special tool don t damage the edge of the oil seal d Apply the special lubrication oil onto oil seal after assembling Don t reuse the oil drain plug washer as can as possible use new one Bolt M6x30 Loosen and tighten the bolts in a crisscross pattern Especially when tightening all bolts should be tightened gradually and evenly up to specified torque Bolt torque 10 2N mo Governor gear First check governor gear for worn and damaged then assemble it Governor spindle clip Firmly insert governor spindle clip into the groove of the shaft when assembling Governor slider Insert the governor slider into the governor spindle and check the governor slider for turning freely 38 4 4 10 Crankshaft piston crankcase 6 Lowercover 16 Oilseal 6x 11x4 26 Connecting rod c
7. dropped out Replace ignition coil The other Repair or replace damaged parts 4 1 5 Engine overheat TROUBLE CAUSE REMEDY Abnormal oil volume or inferior oil Check the oil level and quality Exhaust pipe blocked up Clean exhaust pipe Shroud leaking Repair damaged part Cooling fins blocked by foreign matter Clear cooling fins Gasoline engine Cooling fan is loosen and misfunctioned Reinstall well overheat Connection rod deformation to make piston and cylinder bushing side wear Cylinder or piston or piston ring is worn Replace the worn parts Improper adjustment of engine governor to cause Readjust engine governor high speed Crankshaft main bearing burnt out Replace main bearing Replace connection rod 19 4 1 6 Abnormal sound TROUBLE CAUSE REMEDY Piston piston ring or cylinder is worn Replace the worn part Connection rod or piston pin and piston pin hole are worn Crankshaft main neck is worn Replace bearing Piston ring is broken Replace piston ring Too much carbon deposit in combusting chamber Replace the worn part Beating sound Clear away carbon deposit Metal beating sound when abnormal Too small electrode clearance of spark 3 Adjust electrode clearance properly combustion occurs plug Engine fuel is too much Check relative parts such as carburetor Improper fuel brand Replace fuel The other Improper valve clearance Readjust valve clearance properly Fly wheel is not connected with cranks
8. exceed service limit replace the connecting rod 16 005 16 021mm 16 090mm b Check big end diameter If out of the standard or exceed service limit replace the connecting rod Standard Service limit 30 000 30 018mm 30 066mm 43 c Connecting rod big end oil clearance e Wipe oil off the crank pin and connecting rod bearing mating surface Set the plastic gauge on the crank pin connecting rod and bolt to specified torque Torque 13 1N m NOTICE Place the plastic gauge axially Remove connecting rod and measure with plastic gauge If the clearance exceeds the service limit replace the connecting rod and recheck the clearance 0 019 0 049mm Plastic feeler with scale Bolt Plastic feeler 4 Camshaft check The camshaft is main driving part of the train valve mechanism which controls the intake and exhaust valves opening and closing Feature The shaft is equipped with cam and journal which can control intake and exhaust When operating camshaft operating face and lifter will be badly rubbed from periodically impacting and easily be damaged So the camshaft shall be wearable and lubrication well e Visually inspect cams surface and cams height for damaged and camshaft bore for loosening and wearing replace as required e Check camshaft for height dimension If out of the service limit replace the camshaft im EX lifter 27 88 mm 44 Check inner diameter of the camshaft bore if big
9. feeler shall be considered as piston cylinder clearance Standard Service limit 0 011 0 049mm 0 120mm NOTICE This clearance must be checked before and after repairing d Piston ring side clearance Check with placing each ring into each self groove The piston ring should be freely turned without loosening and sticking Then measure with inserting feeler into clearance of the ring between groove upper and lower face 42 Standard The first ring second ring Service limit 0 04 0 08 0 04 0 08mm 0 150mm e Piston ring end gap Flatly place the piston into the cylinder with pushing the piston head to working position Measure the opening clearance with feeler that clearance should not be too big or not too small being too big can result Mor in poor cylinder sealing performance while being too small can result in piston expansion from heating and cylinder block thus causing piston Feeler broken and sticking If opening clearance is too small file the opening Piston ring with fine flat file Check in the cylinder often when filing until the proper clearance 1s got Standard Service limit The first ring 0 13 0 28mm The second ring 0 20 0 40mm Check connecting rod If connecting rod bending twisting or big end shaft bush and small end outer ring movement or crack on one side should be rejected and replaced with new one a Check small end diameter If out of the standard or
10. 45 SUBARU Industrial Power Products EA190V SERVICE MANUAL This manual contains information on how to routine maintain and how to do troubleshooting Keep service manual handy so you can refer to it at any time This service manual describes correct methods of maintaining this engine As a result of person casualty and equipment damaged caused by the disregard for the rules our company does not assume any responsibility NOTICE Copyright reserved and no part of this publication may be reproduced without Fuji Heavy Industries Ltd s written permission Safety Messages Your safety and the safety of others are very important We have provided important safety messages in this manual and on the engine Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message 1s preceded by a safety alert symbol and one of three words DANGER WARNING or CAUTION These mean NMEA You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions ANN You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions WO Ull You CAN be HURT if you don t follow instructions Your engine or other property could be damaged if you don t follow instructions EPARTS DESCRIPTION sleale lalla l Lal Parr descrip iOi tot A Ea e et iii A died l 11 E A O l 5142 Model Se senal numer adidas Mone aa hill l I2 Specrlicaloni MAKSVA AAR
11. ETE Ai dd 2 Spero 3 LE DIMENSIONAND TORQUE rielaborata 4 DeL FAPINCdMmension gaelico bici N 4 ZAPPA CUNAS dalia iaia a ad 4 2 12 Installation holepositonis siai nto tai 5 SERIA MOZZI OUST CITI eaka akkas alaalia RE ORO A 5 DAM OL GUS VANE EE as 6 DES 521 01912480 COLQUC Vale estatut ici 7 DE AIP Olan DOI VOL GME valentini rit 7 UEMAINTENANG E alla 8 SN Maintenance sehe alos 8 A AA M t 9 DE AIR CREA NE Rato Be tele alii lilla i ce tali lrn 10 AE 10 Se trailer CC ei at lec citen acta ascens ten 10 A O enti O A TO ala 11 al o A A A t 12 320 Valve Clearance adjust MEA lalla 13 SN O allori 14 IV DISASSEMBLING AND SER VIC N Gia A A nee eae ea ila 16 AoW LOU o A A EE SERVE ED SEEDEDE 16 dE NE ESE duU MCU 21 48 enti enadeioa APR RARE PIONIERE AIAR IO E E soneuctenedeuot secs 16 Jele O PANNA lille li a lil 17 As NN a teC mentit tec E 18 ANE falena IA II A SER LERNER RER 19 Aste Enoc OLGA ti o neem 19 41 06 ADMOE MA SOUNG A A aa Aa 20 4 157 Exhaust sas color AI A iii 20 4 2 Preparation oL A A 21 DE NA A ietemici ERIE ES TERN 21 A Special ODS ae m a a a m a Gili 21 453 EN ai a dia 22 Aa Dal IRC COL SAC Hostal 22 RUS AO GRANA RR NBT RARE SR IA ARI RIA RARI RETTO COS OOO RI INCI III EP EP 23 4523 OO col biella lip LILLA Lele Ses 24 SAI II A A A A II E 26 AE 575 018 A at A a A Po mepcid Gata 21 A TEO aa a a SVOR RODES DE REED ERE TERESE EEDTE E 28 4 3 Ihnfowlecontroliscinspa libici iii 32 4 38 Cylinder head
12. Thread dia mm em Connecting rod bolt M6x1 0 C Valvelockingmi MS05 8 os III MAINTENANCE 3 1 Maintenance schedule Good maintenance 15 essential for safe economical and trouble free operation It will also help reduce air pollution Exhaust gas contains poisonous carbon monoxide Shut off the engine before performing any A WARNING maintenance If the engine must be run make sure the area is well ventilated Periodic maintenance and adjustment is necessary to keep the engine in good operating condition Perform the service and inspection at the intervals shown in the Maintenance schedule below Maintenance schedule Each Every 6 season Or months or 50 hrs First month or 20 hrs Each year or Engine oil Air cleaner Check clean Spark plug ESS om Val clearance Cylinder Clean head Cylinder Clean carbon Each 150 hours head piston deposit x This items should be serviced by company authorized dealer unless you have the proper tools and mechanically proficient NOTICE Service more frequently when used in dusty areas 3 2 Change oil change oil NOTICE Drain the engine oil rapidly and completely out when the engine 1s hot 1 Remove the drain plug and washer and tilt the engine to drain engine oil thoroughly 2 Reinstall the drain plug and washer into securely by hand 3 Tighten the oil drain plug EA190 torque value 20 24N m 4 Remove the dipstick and wipe up
13. Valve TEAT senta takka kolki a tut kk a 33 459 ChankCase Cover Over hor SCALA lilla 38 AA 0 Cranksha O PISO Chala Ca SC Arina kaisa aasad atlas laata 39 AS Becca sid rallo Alb el LA OLE LA In 46 I PARTS DESCRIPTION 1 1 Part description 1 1 1 Feature Spark plug Muffler M o B N 5 ta O Drain plug Fuel tank cap Fuel tank Starter handle lt 4 GT 2 ESA A VE all Fuel Valve Engine stop switch Air cleaner 1 1 2 Model amp serial number MXXXXX L x 06LV3 NUVANS x Serial number Engine model 1 2 Specification EA190 Specification Lx WxH not including crankshaft output i 425x360x290mm terminal Dry Weight 14kg iron flywheel or 13kg aluminum flywheel Engine Type Single cylinder vertical 4 stroke OHC Displacement 189m Bore x Stroke 68mmx52mm Theoretical Maximum Power 3 72kW 3 600r min Recommended Using Power 3 5 kW 3 400r min Maximum Torque 11 2N m 2 500r min 1 3 Service limit UNIT mm ti Maximum A E No load EB 3650 4000 ngine i FEE compression l gt pe at 1200rpm Cylinder head head Sleeve LD I D 68 00 68 02 00 68 02 ea 160 Cylinder head Flatness ooo O oos Skirt O D 67 971 67 989 Piston to cylinder clearance 0 011 0 049 Piston pin bore I D 16 006 16 012 Piston pin O D 15 994 16 00 Piston pin to piston pin bore clearance 0 006 0 018 Ring side clearance fir
14. amaged please replace with new one NOTICE Please replace the gear with a new set to ensure the engaging face completely engage in 45 4 5 Electric diagram Engine switch BI Engine switch BI pia Spark plug Ignition coil 46 47 48 ISSUE EMD ES7175 SUBARU FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS COMPANY December 2010 http www subaru robin jp 49
15. ash your hands with soap and water as soon as possible after handling used oil 3 3 AIR CLEANER NOTICE A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction clean the air cleaner each 50 hours or three months and service the air cleaner regularly Service more frequently when operating the engine in extremely dusty areas Using gasoline or flammable solvent to clean the filter element can cause a fire or explosion A WARNING Use only soapy water or nonflammable solvent Never run the engine without the air cleaner Rapid engine wear will result Connecting bolt E VES Pires Air cleaner element Screw off the connecting bolt and remove the air cleaner shell 2 Remove foam element or paper element Be careful to prevent dirt and debris from falling into the air cleaner base when opening Clean the element Foam element Clean the foam with detergent and then blow it dry with compressed air or squeeze it dry Dip the element in clean oil and then forcefully squeeze it dry and install it back Paper element Tap the element lightly several times on hard surface to remove excess dirt or blow compressed air lightly from the inside out If dirty replace in time CAUTION Foam element containing too much oil will jam the foam element holes 4 Check clean or replace damaged air cleaner parts Reassemble the air cleaner element into the shell install foam elemen
16. ch as main jet fuel path and float chamber surface The air enters into the carburetor through air filter Considering the intake can not be too much resistant and other factors the filter can not be too dense and therefore part of the air in the tiny impurities will enter into the carburetor through the air cleaner Thermal baffle Carburetor Gasket Gasket Disassembly reassembly First disassemble air cleaner and disassemble the carburetor as shown on the above figure 29 Before reassembling check the carburetor thermal gasket carburetor gasket and air cleaner gasket for damaged please replace it if necessary Please pay attention to assembling direction e Carburetor Wash the carburetor in the clean place first clean the outside surface and wash the inside the parts with special carburetor detergent or gasoline Except washing impurities please wash the gasoline colloid on the part surface Blow the washed parts clean with compression air and don t use cloth and paper against recontaminating Don t use the steel wire and other hard material to open the blocked hole to prevent carburetor performance from changing holes diameter Use the gasoline and compression air to clean it Ser no Description Ser no Description Ser no Description Throttle valve 1 Pilot jet 2 l l Throttle valve shaft Choke stopper spring Float chamber sealing ring Float pin Mainjet
17. cylinder head f Install the valve cover and tighten the four bolts to the specified torque bolt torque value 10 2N m Valve bolt Rocker Rocker shaft Lock nut Rocker Valve bolt screw in valve clearance becomes smaller Valve bolt screw out valve clearance becomes bigger CAUTION Clearance too big Intake and exhaust valve opening delay will shorten the intake and exhaust time lower the opening height of the valve and change normal distributing phase to result in power lowering from the intake lack and exhaust incomplete Furthermore it will also make valve train parts knock increasingly and wear quickly Clearance too small After running engine parts will be heated to expand and push the valve open making the engine closing not tight and result in leaking power lowering serious carbon deposit or burn on the valve surface even valve impacting the piston 3 7 Governor adjusting e Governor adjusting 1 Dismount the air cleaner 2 Loosen the nut M6 Be sure that the carburetor throttle valve 1s fully open 3 Rotate the governor arm shaft fully to the right governor fully open position to bottom by pressing governor support and retighten the nut torque value 7 IN m 4 Check to see that the governor support and throttle valve move freely 5 Check the maximum engine speed Throttle valve Throttle control assy Governor support D IL FX TI A
18. emove 10x14 the combustion chamber check carbon deposits and retainer contact P inspect the valve Valve Spring Spring retainer Valve rocker shaft Exhaust Bolt Lock nut Gasket AN a Stud M6 Crankshaft Cylinder head cover Camshaft spindle Bolt Assembly disassembly Turn and tighten the bolts in a crisscross pattern in 2 or 3 steps Torque 26N m Bolt M6x12 2 pcs Bolt M6x80 2 pcs Sealing ring Loosen and tighten the bolts in a crisscross o pattern Chain Especially when tightening all bolts should be tightened gradually and evenly up to specified torgue Torque 8 2N mo Intake valve Don t interchange with the exhaust valve in assembling Intake mark IN Exhaust mark EX Be careful not to damage the valve stem when installing 1 Disassembly reassembly 1 Disassemble recoil starter housing 2 Disassemble fuel tank 8 Disassemble ignition coil flywheel 4 Disassemble muffler Disassemble air cleaner 6 Disassemble carburetor Finally disassemble the cylinder head valve train as shown on the above figure NOTICE Valve spring retainer Push down the valve spring and move the retainer to the side so that valve stem slips through the side hole Do not remove the valve spring retainers while the cylinder head 1s attached to the cylinder or the valves will drop into the crankcase 2 Inspect Service Repair Valve ste
19. ger than the service limit replace the camshatt Standard Service limit 9 00 9 04mm 9 1090mm If the sprocket teeth damaged please replace the camshaft with new one Camshaft wearing cause analyses and to engine performance influence Poor lubrication will result in camshaft abnormal wearing such as oil viscosity low impurity too much and recycling oil little can t let the camshaft surface forming complete oil film to make the camshaft surface seriously worn in the high speed rubbing stat Second installing precision problem when the matching clearance of the camshaft journal and camshaft seat or bearing is out of the service limit camshaft rotation precision will lower and contacting with the relative part produce deviation face to make abnormal wearing 5 Crankshaft Push the bearing with care until it contacts the crankshaft in order not to damage the crankshaft output end and timing Driven gear gear Check timing gear for engagement clearance INS BER Des q gt of the chain The camshaft timing chain guide Camshaft Tensioner tensioner and crankshaft timing gear should Chain Timing gear be sufficiently matched with chain and contact governor driven gear of the governor gear Timing gear will be damaged in gear worn gear face peeling off and gear teeth broken Due to gear wearing the engagement clearance will become bigger and the noise will become bigger If the timing gear face is d
20. h the valve when replacing the valve guide Valve seat a Thoroughly clean the combustion chambers and valve seats to remove carbon deposits Apply a light coat of red lead powder or erasable valve face color painting to the valve faces b Insert the valves and then press the valve several times forcefully Be sure not to rotate valve on the seat Valve seat painted the color will show contacted with the valve If not the transferred marking compound will show any area of the seat that is not concentric c Using 45 cutter remove enough material to produce a smooth and concentric seat Turn cutter clockwise never counterclockwise Tool Valve seat cutter IN valve 32 Cutter holder LA EX valve 320 IN valve 452 EX valve 45 d Use the 32 45 cutters to narrow and adjust the valve seat so that it contacts the middle of the valve face The 32 cutter removes material from the top edge contact too high The 45 cutter removes material from the bottom edge contact too low Be sure that the width of the finished valve seat 1s within specification AN FA 36 e Use 45 cutter to remove any possible burrs at the edges of the seat f After resurfacing seat inspect for even valve seating width Apply colorant to the valve tapered face insert the valve and press it forcefully several times be sure the valve does not rotate on the seat 0 8mm The seating surface
21. haft tightly Connect tightly 4 1 7 Exhaust gas color abnormal TROUBLE CAUSE REMEDY Piston cylinder or piston ring is worn Replace the worn parts excessively Too much carbon deposit in combustion Black smoke or blue chamber Clear away thick smoke RE A KASONG Replace with qualified gasoline Air cleaner is clogged up Clean air cleaner filter element 20 4 2 Preparation of servicing 4 2 1 Safety precautions WARNING Indicate a possibility of invalid warranty and personal or equipment damage if instructions are not followed Please pay special attention to the following 1 Strictly set the engine according to the regulated power on the nameplate Do not overload overrun the engine or run it with low load and at low speed m a long time 2 Use regulated brand of fuel The fuel should be fully deposited and filtrated before use Keep clean the fuel filler change the oil periodically 3 Periodically check the installation connection and the degree of tightness of the fixed bolt Tighten it if necessary 4 Periodically clean the element of the air cleaner change it when necessary 5 The engine 15 air cooled so clean the cooling piece wind guide cover and fan in time in order to make the engine cool normally 6 The operator should be familiar with the working principle and structure of the gasoline engine knowing how to make an emergent stop and the operation of all controlling parts Any one without training
22. is forbidden to operate the engine Keep periodical maintenance Solve problems in time Do not run the engine in spite of malfunction 7 Running the engine in a well ventilated place keep it at least one meter away from building walls or other equipments keep away from inflammables such as gasoline matches and so on to avoid possibility of fire 8 Refuel in a well ventilated area with the engine stopped and in places refueling or storing gasoline no smoking and any flames or sparks 9 Refuel the fuel tank not too full so as to avoid fuel s spilling out If there is spilled fuel around be sure to clean it thoroughly before starting 10 Do not run the engine in airtight or ill ventilated places 11 The exhaust muffler is very hot during running the engine even after the engine stops Never touch it or you may get burns Transport or store the engine with it cooling down entirely 12 Safe warning label Please carefully read warning label before operating Our company will not assume any responsibility for person casualty or equipment damaged caused by disregarding this warning label 4 2 2 Special tools Application note Retainer assembler Assembling ball bearing Assembler handle Installing handle and bearing Inner retainer assembler Assembling ball bearing and time Diamond lap 45 Rectifying valve seat surface Diamond lap 32 Rectifying valve seat surface Flywheel driver Dismounting flywheel Bearing extractor Dismo
23. lly available flywheel puller FLYWHEEL BRAKE COMMERCIALLY AVAILABLE Ade er L R Er AL Be i q 4 RO L N IN WS Riz a RET I y Y da LIL AI WHEEL PULLER E gt D COMMERICIALLY AVAILABLE RR 4 Era E Ly KN KE A a AR sl A A FLYWHEEL NOTICE e Do not hit the flywheel with a hammer e Avoid the magnet section when attaching the puller Assembly a Clean the tapered part of dirt on crankshaft and flywheel oil grease and other foreign material before installation Be sure that there is no washer and other foreign material on the magnetic part b Set the key in the key groove on the crankshaft c Install the flywheel over the crankshaft NOTICE The flywheel may push the key out of its slot check after assembling Flywheel nut torque value 64 4N m aluminum flywheel 78 4N m iron flywheel Flywheel cast tron e Attach by aligning the four small holes in the flywheel e Attach by aligning the lug on the rear side of the starter cup with the small hole at the center of the flywheel 25 IMPELLER FLYWHEEL CAST IRON a O ss HOLE HOLE 5 E z E av xXx o O B E 4 3 4 Muffler Stud Hex flange nut M8 Muffler housing 26 Disassembly reassembly The muffler can produce carbon deposits in the long time operation and seriously trouble the exhaust system To get the best performance the muffler must be periodically removed the carbon de
24. longed contact with skin or breathing of fuel vapor 6 Keep out of reach of children RVC 190 fuel tank capacity 1 0L Only use unleaded gasoline and recommend gasoline grade 90 over Unleaded gasoline can reduce gasoline engine carbon deposit and prolong the exhaust system service life Never use contaminated gasoline or mixed gasoline with oil Don t allow the dust foreign matter or water entering into fuel tank CAUTION Fuel may damage the oil paint and plastic Be careful not to spill fuel when refueling Any damage due to fuel spilling is not within valid warranty If knocking or spark exploding sound occur at a steady speed under normal load change grade of gasoline if such phenomena still happen consult your dealer for help otherwise the engine may be damaged CAUTION When the engine is running continuously knocking or spark exploding sound occurring will damage engine Knocking or spark exploding sound from misusing will not be within the valid warranty 3 5 Spark Plug Service 1 Remove the spark plug cap Clear away dirt around the spark plug base 2 Use the plug wrench to remove the spark plug 3 Visually inspect the spark plug if the insulator is cracked replace with new the spark plug if deposit around the electrode remove carbon or other deposits with a stiff wire brush 4 Measure the spark plug clearance with a feeler The clearance should be 0 6 0 7mm If need adjusting ligh
25. lve will close untight to make the engine operating abnormal After operating one year or 300hrs check and adjust the valve 1 Dismount the spark plug cap spark plug cylinder head cover bolt cylinder head cover and gasket in order CAUTION After the cylinder head cover is removed engine oil may flow Be sure to wipe up any flowed oil Stud M6x109 Spark plug Cylinder head gasket Dowel D10x14 Bolt M6x12 Stud M6x102 gin 7 Cylinder head assy C ket Bolt M6x80 Head cover over gaske 2 Lightly pull the starting rope and set the piston at top dead center of the compression stroke insert screwdriver into the hole of the spark plug to check the height of piston 3 Measure the valve clearance Insert the feeler into the clearance to measure clearance IN 0 10 0 15mm Valve clearance EX 0 15 0 20mm e Adjust if the valve clearance is out of sa Peeler Gauss the service limit CAUTION Measure the valve clearance in the cold engine state 4 If adjustment is necessary proceed as follows a Hold valve adjusting bolt with tongs and loosen the valve lock nut b Turn valve adjusting bolt to obtain the specified clearance c Fix the valve adjusting bolt with tongs and then fix the valve lock nut with spanner 13 d Recheck valve clearance after tightening the valve lock nut torque value 8 1N m e Set the new gasket aligning the projection of the new gaskets with the projection of the
26. m outside diameter 33 Inspect the valve stem outside diameter with the micrometer if finding out of the standard or service limit or if visually inspecting the burn and damaged on the valve face please replace with new one o IN EX 5 440 5 455mm 5 430 5 445mm 5310mm 5 300mm Valve spring free length Measure the free length of the valve springs If out of the standard or service limit Please replace the spring Valve Guide Inspection Valve guide reamer a Inspect the valve guide for smooth scratch and damaged in the inner surface and matching between the valve guide and the valve seat for fastness b Using the valve guide reamer clean the valve guides to remove any carbon deposits before measuring If the valve guide inside diameter 1s below standard or out of the service limit replace the guide Standard Service limit 5 500 5 520mm 5 590mm Replacement a Chill the replacement valve guides in the freezer section of a refrigerator for about an hour b Drive the valve guide out of the combustion chamber side using valve guide driver Valve guide driver NOTICE Be careful to avoid damaging the cylinder head when driving out the valve guides 34 Intake side Clip c Install the new valve guides from the valve spring side of the cylinder head Nalve guide diver e Exhaust side Drive the exhaust valve guide until the clip is fully seated as shown as
27. nge or it will be damaged WARNING Don t start the engine without air cleaner or the engine will be quickly worn 4 3 6 Carburetor At high altitude the standard carburetor air fuel mixture will be excessively rich Output power will decrease and fuel consumption will increase Engine performance can be improved by installing a smaller diameter main jet in the carburetor and readjusting the pilot screw If you always operate the engine at altitudes higher than sea level 1000 meters over have RATO authorized dealer perform this carburetor modification If not should lower load power in operating gasoline engine Even equipped with suitable carburetor engine horsepower will decrease approximately 3 5 for each 300 meter increase in altitude The effect of altitude on horsepower will be lowered greater than this 1f no carburetor modification is made If a carburetor suitable to high altitude is equipped with engine suitable to a lower altitude the lean air fuel mixture will make engine output power lowering over heat and seriously damage The gasoline enters into the carburetor from the fuel tank and fuel filter The fuel filter can filter the foreign matters in the gasoline and oxide out of the fuel tank If having quality defectiveness partly foreign matters will enter into the carburetor Otherwise the gasoline contains some composition which can form the colloid after long sediment and attach in the carburetor parts 28 su
28. oil 5 Refill the recommended clean oil EA190 engine capacity 0 6L and check oil level Lay the engine and place it on the level ground when checking Check as following a Insert the dipstick into the filling hole without screwing down and check the oil level b If the oil level is too low add the recommended engine oil up to the oil upper limit c Reinstall the dipstick and screw down NOTICE Use 4 stroke engine oil API service classification SE class or equivalent Always check the API service label on the oil container to assure it includes the letters SE or equivalent SAE10W 30 is recommended for general use Other Demo Oil dipstick da ua Upper limit ENVIRONMENT TEMPERATURE viscosities shown in the chart may be used when the average temperature in your area 1s within the indicated range Recommend user to use SF class or equivalent WARNING Engine oil is a major factor affecting engine performance and service life Additive free and 2 stroke engine oil will damage the engine NOTICE For environment protecting please properly handle with the used oil Running with insufficient engine oil may damage the engine severely and it will not be covered the range of the warranty Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged A CAUTION periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly w
29. orated There is water in fuel Fuel i i Drai tra fuel d k pl supply is Too much fuel in cylinder a electrodes normal Select proper fuel brand corresponding Wrong fuel brand with the reguirements een Too much carbon deposit and CI ear away r o dirt around electrodes Li E Electrodes are burn damaged bad i i Replace spark plug ni seriously or insulators damaged conditions Improper electrodes gap Adjust to proper value High tension line is damaged Ignition coil is damaged Magneto loses magnetism Abnormal gap between the MEL i Adjust gap ignition coil and flywheel TROUBLE CAUSE REMEDY Piston ring is worn to or even over i i Replace its wear limit Piston ring is broken Piston ring is sticking Clear up carbon deposits Spark plug 1s not tightened or i TTT Tighten with a gasket in Normal without a gasket Normal ignition Check cylinder gasket and the flatness fuel supply system system of the surface by which cylinder block Air leakage between cylinder contacting with cylinder head block and cylinder head Tighten cylinder head bolts in stipulated order to stipulated torque i Check clearance and tightness Air leakage in the valves SE a repair 1f necessary 16 e Spark plug testing A WARNING Make sure there is no spilled fuel outside the engine and that ve a the spark plug isn t dipped with fuel To prevent fire keep sparks far awa
30. over Ball bearing Split pin Connecting rod bolt 8 Oilseal 25x 35x6 18 Firstring 28 Woodruffkey 9 Bolt M6x20 19 Secondring 29 Crankshaft _ 10 Breathercover 20 Oilringassy 30 39 Disassembly reassembly 120 Maker mark 1 Reassembly a Piston e Install with the maker mark facing upward as shown Second ring Do not interchange the top ring and the second ring top ring with chrome plated Oil ring assy e After assembly check for smooth movement of the piston ring Stagger the piston ring end gaps 120 apart Connecting rod Reassembly Make sure that the longer end marked 1s toward the piston head with the b Piston pin clip Install by setting front end of the clip in the piston groove holding the other end with long nosed pliers and rotating the clip in V Piston pin clip i Cut out Do not align the end gap of the clip with the cut out m the piston pin bore Alignment marks c Connecting rod cap Install by aligning the alignment marks on the connecting rod cap Connecting rod bolt Torque value 1341N m d Bearing e Apply oil to the circumference of a new ball bearing Driver handle le Retainer assembler e Drive the ball bearing in the cylinder barrel using special tool P Bearing 6205 Inner retainer 40 assembler Tools Driver handle Retainer assembler Inner assembler e Oil seal e Apply oil to the circumference of
31. posits Lightly tap the muffler and blow it with compressed air in cleaning carbon deposits Replace it if the muffler exist in water and is seriously rusted to make noise increasing NOTICE Don t clean with iron wire or the muffler material out to lower the muffler performance Don t reuse the muffler gasket WARNING The muffler can glow heat Please place the gasoline engine out touch of the passerby and children Don t place the flammable materials near the exhaust vent during operation Don t stand on the exhaust port direction when engine is operating because the exhausted gas will be poisonous for your health 4 3 5 Air cleaner Breather hose mee IN at L TEA Te w Air cleaner elbow Connecting bolt Hex Flange nut M6 Air cleaner element Housing Disassembly assembly Disassemble the air cleaner as shown on the above figure 21 NOTICE e Check for damage of the air cleaner gasket before reassembling If necessary please replace and pay attention to assembling direction viewing from the air cleaner side Breather hose e Before assembling check breather hose for deterioration or damage Replace if necessary Pay attention to connect the beveled end shorter big head end to the air cleaner housing while the other end connect to the engine NOTICE Don t wash the foam element with the gasoline acidity alkalic or organic solvent Don t pull and wrest the spo
32. st second 0 04 0 08 0 04 0 08 Piston rings Ring width first second 2 60 0 10 2 80 0 10 Ring end gap first second 0 13 0 28 0 20 0 40 Small end I D 16 005 16 021 Connecting Big end I D 30 000 30 018 rod Big oil clearance 0 019 0 049 nr end side clearance rea 3 0 7 on ouu clearance jee 10 0 15 0 15 0 20 Stem O D 5 440 5 455 5 430 5 445 Guide I D 5 500 5 520 Valve 5 500 5 520 Stem clearance 0 045 0 080 0 055 0 090 Seat width 0 85 Spring free length 30 50 Cam height 23 98 Camshaft 27 88 Journal I D 9 00 9 04 Camshaft LD 9 00 9 04 Spark plug 0 6 0 7 Resistance Primary coil 0 8 1 0 Q Ignition coil Secondary coil 5 9 7 2 KQ Cat flywheel 0 35 0 45mm II DIMENSION AND TORQUE 2 1 Engine dimension 2 1 1 Appearance dimension 360mm kid i i TIA S ai Es SE P Dn si CA i 1 4 S SQ 425mm algo E D LE lt a Ser FERI In mi Ep PI 290mm 2 1 2 Installation hole position 2 1 3 P T O dimension figure Engine Mounting Face 2 2 Torque value Governor gear Flywheel M14 aluminum 68 4 flywheel Valve cover 10 2 11 Brake 10 2 12 Ignition coil 10 2 Lower shell 3 e DT as 21 Fuel tank Notice For unspecified bolt screw and nut refer to the standard torque value 2 3 Standard torque value Thread dia mm Torque value N m 10mm bolt nut 29 34 Bolt and nut 7 11 2 4 Important bolt torque value
33. t or paper element back cover the shell on and screw in the connecting bolt 1 Drain the fuel into the container _ Bolt M6 X 25 3 4 Fuel parts oe o Don t smoke or use flame fires near rossa gt A WARNING KD the flammable solvent JD Tank cap 3 4 1 Strainer clean de 2 Loose the clip remove fuel tube and pull the strainer out 3 Check the strainer for damaged and clean the strainer in E Gauge the container 4 After cleaning reinsert the strainer in the fuel tank Clip Strainer_v gg P connect fuel tube and tighten the clips Cli lip NOTICE DA Tube Check all connecting position for leaking PER 10 3 4 2 Fuel check Upper limit 850CC 1 Remove the fuel tank cap and check fuel level 2 If the level is too low refuel the tank Please don t refuel over the fuel gauge Fuel Gauge WARNING 1 Gasoline 1s extremely flammable and 1s explosive under certain conditions 2 Refueling in a well ventilation area with the engine stopped Do not smoke or allow flames or sparks in the area where gasoline 1s stored or where the fuel tank is refueled 3 Do not overfill the fuel tank The fuel will not exceed the fuel gauge After refueling make sure the fuel tank cap is set back securely 4 Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine 5 Avoid repeated or pro
34. tly tap for gap too big or pry up with flat screwdriver for gap too small electrode 5 Check the spark plug washer if it is in good condition 6 Install the spark plug on and screw down it with plug wrench compress the plug washer Cover the spark plug cap on NOTICE To avoid cross threading first screw in spark plug by hand then tighten with a spark plug wrench to compress the gasket If a new spark plug is used more twist 1 2 turns after compressing the gasket If reinstall the used spark plug just more twist 1 8 1 4 turns Spark plug torque value 22 2N m The spark plug must be tightened securely or it may become very hot to damage the engine N Va N LO Plug wrench Spark plug cap 0 60 0 70mm Side electrode When replaced please pay attention to model of the spark plug to avoid damaging the engine or using recommended spark plug or the equivalent Incorrect heat range of the spark plug may damage the engine EA 190 recommended spark plug model NGK BPR7HS CHAMPION RL87YC TORCH E7RTC 12 3 6 Valve clearance adjustment Keep the clearance between engine valve rod end and driving parts for avoiding heat expanding and cold shrinking to effect engine performance If the valve clearance is too big it can result in exhausting unsmooth effecting engine performance and increasing engine noise valve abnormal if the valve clearance 1s too small the va
35. unting flywheel 21 4 3 Engine 4 3 1 Recoil starter housing Disassembly Description Ser Description Ser Description No No Hex Flange nut M6 Driving pawl 8 Starting rope grip Compression 15 Stud M6X83 spring Starter coil spring Philips screw assy M5x20 Rope guide assy Stud M6X68 Rope coil tray NOTICE Wear gloves during disassembly and take care not to allow the return spring to come out When assembling first check starter rope for damaged or broken then assemble it 22 4 3 2 Fuel tank e Disassembly reassembly The fuel tank does not require general maintenance but sometimes the dusts and vapor will trouble the fuel system so that periodically washing it with lubrication oil and gasoline is required WARNING Don t smoke or use fire near the flammable solvent e Clean installation Check the fuel tube for damage or leak Drain out the fuel into the proper container Remove screws M5x20 fuel tank cap and engine housing Remove the fuel tube fuel strainer and remove the fuel tank Clean the fuel tank and dry it thoroughly Install the strainer on fuel tank after cleaning and connect the fuel tube on Check the fuel tank for leak Install the engine housing fuel tank cap and screws M5x20 e Notice Check fuel tank cover vent for blocked Check the fuel strainer for clogged or broken Check the fuel hose for aging an cracks
36. y compression which cylinder block contacting Replace cylinder gasket with cylinder head Cylinder pressure check Drain the gasoline in the fuel tank into the container Drain the gasoline by loosening the fuel drain bolt of the carburetor Remove the spark plug cap and spark plug and install the cylinder pressure meter Forcibly pull the recoil starter several times and measure compression force Cylinder pressure 0 2Mpa at 500rpm Pressure meter ETA A z 4 1 3 Speed unstable TROUBLE CAUSE REMEDY Piston cylinder or piston ring is worn excessively Replace the worn parts I Piston pin and piston pin hole are worn excessively Replace piston or piston pin Knocking sound Connecting rod small head is worn excessively Replace tie rod Bearing for crankshaft main shaft is worn Replace roller bearing 18 4 1 4 Unable igniting TROUBLE CAUSE REMEDY Fuel is finished Refill fuel Carburetor is clogged Check fuel line and dredge N edle valveda seed Dismantle float chamber and clean or replace needle valve Spark plug is punctured or short circuited by carbon deposit Replace spark plug Los ide el de of k plug is d d igniting ie o electrode of spark plug is droppe Kilde pala Ignition system High tension wire is dropped out Ignition coil is punctured or short circuited Stop wire is located on engine body Find out meeting and insulate Cylinder is seriously scored and valve
37. y from the spark plug mounting hole When testing the spark plug never hold the high tension line Spark plug of the spark plug and spark plug cap with wet hand If having fuel cock turn the fuel cock to OFF position 1 no fuel cock first drain the gasoline of the fuel tank then drain the gasoline of the carburetor Spark plug cap Remove the spark plug and spark plug cap Install the spark plug cap Turn the engine stop switch to or STOP position Pass negative pole thread of the spark plug through cylinder cover to connect grounding and pull the starter handle to observe the spark High tension line 4 1 2 Power lack TROUBLE CAUSE REMEDY Air in fuel line or fuel line clogged Carburetor main fuel channel 1s not Readjust adjusted properly In carburetor needle valve hole Clean and blow to get through and main fuel channel clogged Fuel cock 1s clogged up Clean replace damaged part Too much carbon fouling in Clear away When increasing muffler and exhaust pipe Too much carbon deposit in throttle speed P Clear away Increase slow or combusting chamber even decrease and Air cleaner 1s clogged up Clean air cleaner filter element stop running Intake pipe is leaking Repair or replace Exhaust air or dredge fuel line Intake pipe is leaking Repair or replace Piston or cylinder or piston ring Replace the worn parts is worn Poor Air leakage from the surface b
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