Subaru Robin Power Products EY15V Portable Generator User Manual
Contents
1. Low grade gasoline is used or engine is overloaded Cooling air circulation restricted Cooling air path misdirected causes loss of cooling efficiency Cylinder head cooling fins clogged up with dirt Engine operated in an enclosed space without fresh supply of cooling air Exhaust gas discharge restricted or carbon deposits in the combustion chamber Engine running on low octane gaoline detonates due to heavy load at low speed 39 11 5 ENGINE KNOCKS 1 Low quality gasoline 2 Engine operating under heavy load at low speed 3 Carbon or lead deposits in the cylinder head 4 Spark timing incorrect 5 Loose connecting rod bearing due to wear 6 Loose piston pin due to wear 7 Cuases of engine overheat 11 6 ENGINE BACKFIRES through CARBURETOR 1 Water or dirt in gasoline or low grade gasoline 2 Intake valve stuck 3 Valves overheated or red hot carbon particles in the combustion chamber 4 Engine cold 40 12 INSTALLATION Engine life ease of maintenance and inspection frequency of checks and repairs and operating cost all de pend on the way in which the engine is installed Carefully observe the following instructions for installing the engine 12 1 INSTALLING When mounting the engine carefully examine its position the method of connecting it to a load machine the foundation and the mehtod of supporting the engine When determining its mounting position in particular make2. 3 Procedures Remarks Remove the inner and outer tappet covers from the crankcase 66 x 12 mm bolt 2 pcs Pull out the intake and exhaust valves Remove the valve spring and the valve retainer Main bearing From the crankcase remove the bolt fastening the main bearing cover 6 x 30 mm bolt 8 pcs Remve the cover lightly tapping the cover evenly with a plastic hammer 16 Put the notch on the outer circumference of the spring retainer on this side Hook the medium size driver at the dent lower side of the spring retainer and pull out the valves while pulling the spring retainer toward you See Fi 18 Sems bolt Be careful not to dam age the oil seal See Fig 19 10 mm box spanner The front is this side driver 10 mm box spanner Procedures Remarks Camshaft 1 Remove the camshaft from the crankcase To prevent the tap pets from falling or damaging place the crankcase on the side See Fig 20 cal 1 Remove the tappets from the crankcase Before removing put a mark of intake or exhaust on each tappet Camshaft 18 Connecting rod 1 Scrape off carbon and other foreign de 10 mm box spanner and piston posits from the upper parts of the cylin or 10 mm spanner der and piston and then straighten out the bent tabs of the lock washers on the connecting rod and remove two pieces of the bolt 2 Rem
3. Cylinder gauge Cylinder gauge Micro meter Test bar and Dial gauge Re machine or Replace Re machine or Replace Replace Mag s 25 dia Drive s 15 dia Mag s 15 dia 45 Replace Micro meter ENGINE STANDARD CORRECTION USE CORRECTION REM L ITEM MODEL SIZE TOLERANCE LIMIT LIMIT ARRS ud METHOD EY15 Vernier F h DM adis MO Ge EY15 For total icd ple bii AER Intake 0 025 0 040 T EY15 Exhaust 65 a 0 056 0 078 Micro alve stem O D Replace EY20 Intake 6 5 dia 0 025 0 040 meter Exhaust 0 056 0 078 Exhaust 0 056 0 100 Cylinder I Evao Intake 0025 0002 9 93 Atmidale gauge tod Exhaust 0 056 0 100 EY15 Feeler Feeler gauge Replace Vernier Replace EY20 Intake 6 2 calipers SE Ma Exhaust GA Tota length Evie 0 06 0 chien Replace EY15 0 S 0 2 EY15 Feeler Adjust or Ek EY15 o o Timing Adjust i i Hm vet p xe pep po que d EY15 Contact Point openin 0 35 breaker 9 EY20 spanner Valve spring Clearance between stem and guide When cold 0 10 0 02 Tappet clearance Clearance between groove and retainer Intake amp Exhaust Valves intake EY15 Exhaust 5 9 Stem end length Tappet Ciearance between stem and guide Electric Device 46 ITE
4. LL 7 HH TIME 38 10 ROBIN SOLID STATE IGNITION ENGINE 10 1 FEATURES Model EY15V can employ as option a pointless igniton system called Solid State Ignition which is the cir cuit breaker type ignition device utilizing the power transistor as an element for controling electric current This system is outer coil type without pulser and is called T 1 C Transistor ignition circuit type To the EY20V this T I C is equipped as standard parts Being different from the breaker point type ignition system this brand new system is completely free from such troubles as starting up failure owing to dirty burnt or oxidized point surface lowering of igntion effi ciency being caused by moisture rough surface of breaker point and incorrect timing resultant from worn mechanical parts 10 2 BASIC THEORY of T I C See Fig 52 T I C Transistor igntion type consists of the fly wheel and ignition coil with built in transistor and its basic theory is as follows Resister Ignition Coil 1 Revolution of the flywheel generates electricity on the primary side of the ignition coil and the electric current A runs A makes the power tran sistor ON and the electric current B passes 2 The flywheel goes round further and at the time of ignition the electric current C runs then the electric current D runs to the signal transistor by which the electric current B passing through the power transistor is abruptly c
5. The fuel is metered by the main jet and fed to the main nozzle The air metered by the main air jet is mixed with the fuel through the bleed holes in the main nozzle and the mixture is atomized out of the main bore It is mixed again with the air taken through the air cleaner into an optimum fuel air mixture which is sup plied to the engine 8 1 4 CHOKE The choke is used for easy start in the cold season When the recoil starter is pulled with a closed choke the negative pressure applied to the main nozzle increases and draws much fuel accordingly thus easily start up the engine 8 2 DISASSEMBL Y and REASSEMBLY Apart from mechanical failusres most of carburetor troubles are caused by an incorrect mixing ratio which may arise mainly due to a clogged up air or fuel passage in jets or fuel level variations In order to assure pro per flow of air and fuel the carburetor must be kept clean at all times The carburetor disassembly and re assembly procedures are as follows See Fig 51 8 2 1 THROTTLE SYSTEM 1 Remove the Philips screw 33 and throttle valve 28 and pull out the throttle shaft 29 2 The spring 30 can be taken out by removing the throttle stop screw 31 Exercise care not to damage throttle valve ends 8 2 2 CHOKE SYSTEM 1 Remove the Philips screw 22 and choke valve 23 and pull out the choke shaft 24 2 When reassembling the choke shaft make sure that the cutout in the choke valve faces the mai
6. handle disassembed parts and clean them with washing oil 5 Use the correct tools in the correct way 5 2 SPECIAL TOOLS For yourreference the following shows special tools of Robin Engine for Disassembly Measuring and Inspec tion Instruments Tool Use Applicalbe Shape Model EY10 13 14 EY15 18 20 209 95004 07 ee SE off EY 25 27 33 EY35 40 44 ECO5 07 10 VN EC17 25 37 EY10 13 14 For mounting and Valve Spring dismounting Valve EY15 18 20 707 99093 97 Retainer Spring Retainer and Retainer Lock EY25 27 33 EY35 40 44 q Valve Guide For pulling off 205 95001 07 Puller Valve guide EY 13 14 woo e 206 95001 07 Tool 227 95001 07 207 95001 07 Valve Guide Puller For pulling off Valve guide Applicalbe Model Shape EY15 20 EY25 27 M 20248 Timing Tester For adjusting timing EY10 13 14 EY15 18 20 EY25 27 33 EY35 40 44 ECO3 04 05 ECO7 10 17 EC25 37 ZP 5 3 HOW TO DISASSEMBLE Length of the bolt indicates the length from the bolt head bottom surface to the threaded end Procedures Recoil starter Remove the recoil starter 10 mm box spanner 60 x 8 mm bolt 4 pcs Fuel tank Close the fuel cock 10 mm box spanner From the carburetor disconnect the fuel 10 mm box spanner pipe between the fuel strainer and carbu retor on the side of the carburetor Remove the tank band and fuel t
7. most favorable from the viewpoint of engine life and fuel consumption ratio with the governor in operation It is suggested therefore that when designing a driving system for any mech anism with this engine as prime mover the continous power requirement of that mechanism be kept below the continuous rated output specified 2 3 MAXIMUM TORQUE and FUEL CONSUMPTION RATIO at MAXIMUM OUTPUT These mean the maximum torque of the output shaft and fuel consumption ratio at the maximum output of an engine PERFORMANCE CURVE MODEL EY15V Kom 0 7 o 3 0 6 z Tos IF Horse Power Recommended Maximum Operating Horse Power i Recommended Operating Speed Rang EE S faa 2000 3000 3600 rpm Revolution c 3 1 PERFORMANCE CURVE MODEL EY20V Horse Power FAN Continuous Rated Horse Pow EE Recommended Maximum Operating Horse Power 2000 3000 3600 r p m Revolution FEATURES Compact lightweight durable powerful 4 cycle air cooled engine embodying ingenious design tech niques and skilful workmanship Simple construction smart appearance maximum easiness of start owing to automatic decompression device For EY15V engine Pointless Solid State igntion system is newly adopted for preventing poor igniting as option and EY20V engine is equipped with Pointless Solid State ignition system as st
8. on the output end See Fig 4 Crank Gear P Oil Scraper Press fit Press fit ATEN Fig 4 4 4 CONNECTING ROD and PISTON Top Ring The connecting rod is forged of aluminum alloy which itself serves as bearings at both the large and EE Second Ring small ends Oil Ring The piston is cast of aluminum alloy and has grooves for receiving two compression rings and one oil ring See Fig 5 Connecting Rod 4 5 CAMSHAFT The camshafts are integrally built with a cam gear of special cast iron and have intake and exhaust cams Also the camshafts have aluminum plain bearing attached to both ends No ball bearing is used See Fig 6 Fig 6 4 6 VALVE ARRANGEMENT Exhaust Valve The exhaust valve is located upstream of the cooling Intake Valve c air with the result that the exhaust valve is intensive de ly cooled for improved engine durability The inner side of the valve head is reinforced with hard alloy fused to it for added durability See Fig 7 4 7 CYLINDER HEAD The cylinder head is an aluminum die casting and forms a Ricardo type combustion chamber with am ple area for high combustion efficiency See Fig 8 4 8 GOVERNOR The governor is a centrifugal flyweight type which permits constant operation at the selected speed against load variations Governor gear is installed on the bearing cover without fail and it engages with the cam gear after reassembling
9. sure that gasoline and oil can easily be supplied and checked the spark plug can easily be checked the air cleaner can easily be serviced and that the oil can easily be discharges 12 2 VENTILATION Fresh air is necessary for cooling the engine and burning the fuel In case where the engine is operated under a hood or in a small room temperature rise in the engine room can cause vapor lock oil deterioration increased oil consumption loss of power piston seizure shorter engine life etc making it impossible to operate the engine properly It is necessary therefore to provide a duct or baffle to guide cooling air to the engine to prevent recirculation of he hot air used for engine cooling and temperature rise of the load machine Take steps as necessary to keep the engine room temperature below 50 C even in the hottest period of the year 12 3 EXHAUST GAS DISCHARGE Exhaust gas is noxious When operating the engine indoors be sure to discharge the exhaust gas outdoors 1f a long exhaust pipe is used in such a case the internal resistance increases causing loss of engine power Thus pipe inside diameter must increase in proportion to exhaust pipe length Exhaust pipe Less than 3 m long pipe inside diameter 25 mm Less than 5 m long pipe inside diameter 30 mm 12 4 POWER TRANSMISSION to DRIVEN MACHINES 12 4 1 BELT DRIVE Take the following notes into consideration V belts are preferable to flat belts The driving shaft of
10. the engine must be parallel to the driven shaft of the load The driving pulley of the engine must be in line with the driven pulley of the load Install the engine pulley as close to the engine as possible Tf possible span the belt horizontally Disengage the load when starting the engine If no clutch is used use a belt tension pulley or the like 12 4 2 FLEXIBLE COUPLING When using a flexible coupling runout and misalignment between the driven shaft and engine shaft must be minimized Runout and misalignment tolerance are specified by the coupling manufacturer 41 12 5 WIRING Wire as shown in the wiring diagram below BREAKER POINT IGNITION TYPE Condenser Ignition Coil Contact Breaker Connector Spark Plug Stop Switch Magneto Fig 53 SOLID STATE IGNITION TYPE T 1 C Standard Ignition Coil with Built in Transistor Connector Spark Plug Stop Switch Magneto Fig 54 42 13 CHECKS and CORRECTIONS After disassembling and cleaning the engine check and repair if necessary according to the correction table The correction table apolies whenever the engines are repaired It is important for the servicemen to be familier with the contents of this table Correct maintenance is recommended by observing the correction standards specified The meanings of the terms used in the correction table are as follows 1 Correction Repair adjustment or r
11. the groove of the gover nor shaft turn it clockwise fully until the gov ernor shaft no longer moves and then lock the governor lever to the governor shaft with the governor lever tightening bolt See Fig 48 Governor Shaft Fig 48 2439 8 CARBURETOR 8 1 OPERATION and CONSTRUCTION See Figs 49 and 50 8 1 1 FLOAT SYSTEM The float chamber is located just below the carburetor body and with a float and a needle valve maintains a constant fuel level during engine operation The fuel flows from the fuel tank into the float chamber through needle valve When the fuel rises to a speci fic level the float rises and when its buoyancy and fuel pressure are balanced the needle valve closes to shut off the fuel thereby keeping the fuel at the reference level By path Holes Choke Valve Pilot Jet Throttle Valve Main Nozzle Pilot Outlet Pilot Air Jet Fuel Bowl Main Jet Fig 49 Needle Valve Fuel Bowl 8 1 2 PILOT SYSTEM The pilot system feeds the fuel to the engine during idling and low speed operation The fuel is fed through the main jet to the pilot jet where it is metered and mixed with the air metered by the pilot air jet The fuel air mixture is fed to the engine through the pilot outlet and the by pass During engine idling the fuel is mainly fed from the pilot outlet 8 1 3 MAIN SYSTEM The main system feeds the fuel to the engine during medium and high speed operation
12. 0V For enabling to discriminate the intake mani fold of EY20V from that of EY 15V an em bossed mark 20 is given to the former while no embossed mark is given to the latter Fig 40 26 5 4 13 CARBURETOR and ITS RELATIVE PARTS 1 Connect the carburetor throttle lever with the connecting link and mount them onto the governor shaft 2 Connect the speed control lever to the governor lever with the governor spring and mount it onto the fuel tank bracket 3 Connect the choke lever to the carburetor with the choke rod and mount onto the fuel tank bracket 5 4 14 AIR CLEANER Mount the air cleaner to the intake manifold with two pieces of 6 mm nut and tighten the intake manifold mounting 6 mm nut Then fasten air cleaner mounting 6 mm bolt to the fuel tank bracket 5 4 15 FAN COVER and FUEL TANK Intall the fan cover and fuel tank 5 4 16 MUFFLER With one piece of bolt fasten the muffler cover to the muffler and with two pieces of bolt fasten the muffler to the crankcase 5 4 17 RECOIL STARTER With 4 pices of 66 x 8 mm bolt fasten the recoil starter Note It is feared that the bolt longer than 8 mm may damage the blades 27 6 MAGNETO 6 1 MAGNETO The spark for ignition is furnished by a magneto assembly The magneto consists of a flywheel ignition coil and contact breaker assembly including condenser of which flywheel is mounted on crankshaft and igni tion coil contact breaker are mounted in crankcas
13. 15 Tachometer EY20 ITEM MODEL ft lb TOOL REMARKS EY15 220 260 Torque wrench EY20 en Torque wrench EY20 170 200 EY15 Min accelerating revolution Cylinder head bolts Connecting rod bolts Magneto clamp 600 650 Torque wrench nuts EY20 Tightening Torque EY15 Main bearing cover boits 80 100 Torque wrench Torque wrench Spark plug 120 150 48 15 MAINTENANCE and STORING The following maintenance jobs apply when the engine is operated correctly under normal conditions The indicated maintenance intervals are by no means guarantees for maintenance free operations during these intervals For example if the engine is operated in extremely dusty conditions the air cleaner should be cleaned every day instead of every 50 hours 15 1 DAILY CHECKS and MAINTENANCE Checks and maintenance Reasons for requiring them Remove dust from whatever parts which The governor linkage is especially susceptible to accumulated dust dust Check external fuel leakage If any retighten Not only wasteful but also dangerous or replace Check screw tightening If any loose one is Loose screws and nuts will result in vibration found re tighten accidents Check oil level in crankcase and add up as If the engine is operated without sufficient oil necessary it will fail 15 2 EVERY 20 HOURS CHECKS and MAINTENANCE Reasons fo
14. 5 ng 39 11 4 Engine Overheat co baaa g i a uan EAS 39 11 5 Engine Knocks lu p oe TT a RUE Eer 40 11 6 Engine Backfires through Carburetor 40 INSTALLATION Cia ii ege PRU uh EU A it e 41 1251 zInstalling z dice ez Eon EDS ERN tet a wg g 41 12 2 Ventilation sud ieu eeu dp eu dA cee RM IS REI ES 41 12 3 Exhaust Gas Discharge lees AY 12 4 Power Transmission to Driven Machines ooooooooo oo 41 12 5 WIKINS a A e Seek a B E Ct shee 42 CHECKS and CORRECTIONS 43 TABLE of CORRECTION STANDARDS 44 MAINTENANCE and STORING eee 49 15 1 Daily Checks and Maintenance o o ooo ou 49 15 2 Every 20 Hours Checks and Maintenance o 49 15 3 Every 50 Hours 10 days Checks and Maintenance 49 15 4 Every 100 200 Hours Monthly Checks and Maintenance 49 15 5 Every 500 600 Hours Semiannual Checks and Maintenance 50 15 6 Every 1000 Hours Yearly Checks and Maintenance 50 15 7 Preparation for Long Abeyance lees 50 1 SPECIFICATIONS wm mw T Air Cooled 4 Cycle Verticle Shaft Single Cylinder Gasoline Engine 63 mm x 46 mm 2 48 x 1 81 6 3 2 7 3 600 3 5 3 600 Rotation Counter clockwise facing to P T O shaft 67 mm x 52 mm 2 64 x 2 05 Piston Displacement cu in 483
15. ANK DIA 0 037L 0 063L PIN 0 1L 0 3L CONNECTING ROD TO PISTON 0 010L 0 029L PISTON PIN TO PISTON 0 009T 0 010L L Loose T Tight Fig 22 19 5 4 2 PISTON and PISTON RING 1 If no ring expander is available install the rings by placing the open ring ends over the first land of the piston and spreading the rings only far enough to slip them over the correct ring grooves Note Pay attention not to break the rings by twisting Install the oil ring first followed by the second ring and then top ring Meantime the surfaces of the second ring and the top ring with carved marks are to be faced up Top Ring chrome plated Fe N Kg K KS Second Ring undercut Oil Ring chrome plated Open ends of Piston Ring Fig 23 Fig 24 2 Reassemble the piston and connecting rod by means of the piston pin Note Apply enough oil to the small top end of the connecting rod Be sure to place clips on both ends of the piston pin 3 When installing the connecting rod into place hold piston rings with the ring guide as shown in Fig 25 if no ring guide is available keep press ing the piston ring with finger tips and gently strike the top of the piston with a wooden piece or the like to push it in and check that the symbol 2 or mark MA on the connecting rod is in the direction of the flywheel magneto Note Apply enough oil to the piston rings con necting rod plain bearings and cyl
16. Er ioo de erg neto eae 6 4 10 L bricati n 22 da 09920588 b ec E Er as E n 6 4 11 Ianiti n zoe na ee xx Sk het BE Eque eder pau g c t 7 4 12 e TE TEE 7 4 13 Air Cleaner oi 22A Rar AEN St NEE e Med doe di dos 7 4 14 Sectional View of Engine e 8 DISASSEMBLY and REASSEMBLY e 12 5 1 Preparation and Suggestion e 12 5 2 Special Tools c xA ehe uhi he A S eb CR aS 12 5 3 How To Disassemble es 14 5 4 How To Reassemble 18 MAGNETO 0000 EC AGREGUE AO Ed Race E NU aued ips ay 28 6 1 Magneto A A A c c EES 28 6 2 Breaker Point Adjustment 28 6 3 Timing Adjustment 29 6 4 Magneto Trouble Shooting 30 6 5 Solid State lgnition o e 30 Section 10 11 12 13 14 15 Title Page GOVERNOR ADJUSTMENT 0 cee ee ee hn 31 CARBURETOR o ccna oie d a e Rs 2b A06 We a S468 h 33 8 1 Operation and Construction 33 8 2 Disassembly and Reassembly o eee ee eee tenes 34 BRAKE IN OPERATION of REASSEMBLED ENGINE 36 ROBIN SOLID STATE IGNITION ENGINE i ee ee 37 AEN OR AS O Rus vex ee a ee a Bd 37 10 2 Basic Theory of T 4 C oooo ee ee ee et eee et ees 37 TROUBLE SHOOTING 0 0 et ee eee 38 11 1 Starting Difficulties sse nen 38 1 32 Engine Mistires D ado a Ee do 1 s6 ee Bee 4445x465 39 1153 Engine StODS 2 ues du epum ae tA ER ERE Se 9p g
17. M MODEL CORRECTION LIMIT REMARKS 3 5 3600 Max Output Below 110 of rated output 4 6 3600 Continuous Rated 2 2 3000 Output 3 3000 135 of the standard value and up 3600 rpm at continuous rated output ITEM MODEL USE LIMIT cc hr REMARKS EA ITEM MODEL Doo npwane SERS DU RMAaRS e EY15 EY20 Y Use the SC or higher grade engine oil ITEM MODEL Comparison between oil viscosity and temparature REMARKS When the peripheral temparature is below 20 C use the oil of viscosity Lubricant Consumption Fixed quantity of Lubricant and quality fitted to the loca conditions Single lo grade Specified Lubricant 20 Quality i 30 i When the peripheral temparature is more EY20 than 40 C use the oil of viscosity and 40 quality fitted to the local conditions H Lt M Ke The oil consumption is apt to increase Multi 10W 30 wnen used under high peripheral tempa grade rature so t is necessary to check every LI Ld day 20 10 10 20 30 40 C 1f quatity and quantity of the engine oil become lower or less burning might be caused 4 Oil Change EY15 First time Change oil after 20 hours operation 9 EY20 Second Time and Thereafter Change oil every 50 hours operation MODEL CORRECTION LIMIT TOOL REMARKS EY15 5 400 Cylinder pressure 70 RT valug Pressure gauge ACEN EY20 6 400 ranksha V nM MODEL T0 2 EY
18. Robin Industrial Engines SERVICE MANUAL Models EY15V EY20V ROBIN AMERICA INC ROBIN TO WISCONSIN ROBIN ENGINE MODEL CROSS REFERENCE LIST ROBIN WISCONSIN ROBIN SIDE VALVE EYOS W1 080 EY15 WI 145 EY15V l WI 145V EY20 Wi 185 EY20V WI 185V EY23 W1 230 EY28 W1 280 EY35 W1 340 EY40 W1 390 EY45V W1 450V EY21 EY21W EY44 EY44W EY18 3 EY 18 3W EY25 EY25W EY27 EY27W OVERHEAD VALVE EHII WO1 115 EH12 WO1 120 EH15 WOI 150 EHI7 WO1 170 EH21 WOI 210 EH25 WO1 250 EH30 WO1 300 EH30V WO1 300V EH34 WOI 340 EH34V WOI 340V EH43V WO1 430V TWO CYCLE ECI3V WTI 125V DIESEL DY23 i WRD1 230 DY27 WRD1 270 DY30 WRD 1 300 DY35 WRD1 350 DY41 WRD1 410 Section CONTENTS Title Page SPECIFICATIONS 4 7 Loo t d eee we NR OS a ad X EA OR 1 PERFORMANCE ooo 2u 2 2 1 Maxim m O tp t e Ee emd A e actae S04 b 2 2 2 Continuous Rated Output 2 2 3 Maximum Torque and Fuel Consumption Ratio at Max Output 2 FEATURES curia a REC e Dee Ed 3 GENERAL DESCRIPTION of ENGINE CONSTRUCTION 4 4 1 Cylinder Crankcase e 4 4 2 Main Bearing Cover Q ee 4 4 3 Crankshaft at p Da cen BEE Se Re 3 2 c 4 4 4 Connecting Rod and Piston o ooo ees 5 4 5 Camshaft 2s A S epu A a Um c 5 4 6 Valve Arrangement noaua aaa 5 4 7 Cylinder Head ouo adu exe a wh a Aes 6 4 8 GOV OT zu ss 602262 DI RI PRESIDE amr Boe mis 6 4 9 COMA rhet di tt si neo cee Reelin ree
19. See Fig 9 4 9 COOLING The cooling fan serving also as a fly wheel cools the cylinder and cylinder head by forced air cooling Cylinder baffles is provided for guiding the cooling air 4 10 LUBRICATION The rotating and sliding parts are being lubricated by scooping and splashing the oil in the crankcase with the oil scraper attached to the crankshaft See Fig 10 Oil Scraper 4 11 IGNITION The ignition system is a flywheel magneto type with ignition timing set at 23 before TDC The magneto is composed of a fly wheel and ignition coil The flywheel serving also as a fan is mounted directly on the crank shaft and the ignition coil in the crankcase For further det ils refer to Section the Magneto See Fig 11 and Fig 12 Ignition Coil Ignition Coil Flywheel Flywheel 4 12 CARBURETOR A horizontal draft carburetor is employed It has been carefully set after thorough tests to assure satis factory start up acceleration fuel consumption out put performance etc For construction and other details refer to the Sec tion on Carburetor Construction Disassembly and Reassembly See Fig 13 4 13 AIR CLEANER The air cleaner of the standard type engine is an ob long type using a sponge element See Fig 14 Cleaner Element Cleaner Case Cleaner Cover Fig 14 4 14 SECTIONAL VIEW of ENGINE Recoi Starter Flywheel Cooling Fan Ignition Coil Blower Housing P
20. andard specifica tions Reliable prime mover for variety of purposes with smooth speed control by a governor under varying load conditions Economical because fuel consumption is very low Great versatility in installation by adopting recoil starter with eight different rope pull directions and oil drain available at bottom and carburetor side of engine as standaed specifications Lg 4 GENERAL DESCRIPTION of ENGINE CONSTRUCTION 4 1 CYLINDER CRANKCASE The cylinder and crankcase are single piece alumi num die casting The cylinder liner made of special cast iron is built into the alminum casting The in take and exhaust ports are located on one side of the cylinder and are also inserted into the casting The crankcase is separable on the output shaft side where the main bearing cover is attached to it See Fig 1 4 2 MAIN BEARING COVER Fig 1 The main bearing cover made of aluminum die casting is built onto the output shaft side of the crankcase so that the inside of the engine can readily be checked by simply removing the cover It is provided with a flange and boss for directly mounting on the machines Two oil drains are also available See Fig 2 and Fig 3 Oil drain Oil drain Governor Gear Fig 2 Fig 3 4 3 CRANKSHAFT Induction Hardening Portion of Crankpin The crankshaft is forged of carbon steel and the crankpin is induction hardened lt has a crank gear and a oil scraper press fitted
21. ank from the fuel tank bracket 60 x 12 mm bolt 2 pcs Muffler and Remove the muffler and muffler cover from Note that the EY20V 12 mm box spanner muffler cover the cylinder portion of the crankcase has 2 sheets of gasket or 12 mm spanner 89 x 100 mm bolt 2 pcs EY15V and 1 sheet of flange 89 x 106 mm bolt 2 pcs EY20V between the muffler and cylinder Air cleaner Remove the air cleaner cover and element Air cleaner is fastened 10 mm box spanner Loosen the intake manifold mounting nut together with the car 60 nut 2 pcs buretor Remove the air cleaner case from the car buretor and fuel tank bracket 66 nut 2 pcs 6 x 14 mm bolt 1 pce Disconnect the breather pipe Governor lever Remove the choke lever from the fuel tank Special bolt 14 mm box spanner and the relative bracket and remove the choke rod from or 14 mm spanner parts the carburetor Special bolt 1 pce Remove the governor lever from the Just loosen the bolt 10 mm box spanner governor lever shaft unnecessary to the 60 x 25 mm bolt 1 pce Remove the governor rod and rod spring from the carburetor Remove the governor spring from the speed control lever Carburetor Remove the carburetor from the intake manifold E Intake manifold Remove the intake manifold from the 10 mm box spanner cylinder portion of the crankcase 60 nut 2 pcs Fuel tank Remove the fuel tank bracket from the 10 mm box spanner bracket cra
22. appet clearance once again if it is correct Note Only for EY20V After the tappet clearance adjustment fit the oil seal to the intake valve stem Note INSTALLATION of SPRING RETAINERS Place the notch on the outer circumference of the retainer toward this side and insert the re tainer like pushing in using a special tool This special tool is used for EY18 and other models If a driver is used insertion may be easier Front should be this side 24 5 4 8 CYLINDER HEAD Remove carbon from the cylinder head particularly its combustion chamber and make clean the cooling fins Also check the head for distortion Note Note Note Note Replace the cylinder head gasket with a new one DISTINCTION between the GASKET of EY 15V and EY20V The pitch of the holes for the bolts fastening cylinder head and the outer circumference dimensions of the gasket for EY15V and EY20V are same However the inner dimensions are different each other The gasket for EY 15V has a red mark while the gasket for EY20V has a green mark Red Mark Green Mark EY15V EY20V Fig 36 k Cylinder head tightening torque 220 260 emppssed Mel kg cm DISCRIMINATION of CYLINDER HEAD As stated above the pitch of the holes of cyl o E inder head is common to both EY15V and EY20V For enabling to discrimate the cylin der head of EY 15V from that of EY20V an embossed mark 15 is given to the former while no e
23. cc 11 17 cu in Compression Ratio Continuous Rated Output HP rpm Cooling System Ful Automobile Gasoline Forced Air Cooling Splashing Type Automobile Oil Class SC Horizontal Draft Flat Type Fuel Tank Capacity Approx 1 5 liter 0 4 U S gal Reduction Ratio Speed Governor Ignition System Spark Plug NGK BM4A Recoil Starter Rope Type is available if required Dry weight Ibs 12 7 kg 28 lbs 14 5 kg 31 9 Ibs Centrifugal Flyweight Type Flywheel Magneto Type Solid State Ignition is avilable as option Flywheel Magneto Type Solid State Igntion is standard 371 mm 14 6 383 mm 15 08 Length in Dimensions Width in Height in 305 mm 12 0 311 mm 12 24 344 mm 13 5 356 mm 14 02 2 PERFORMANCE 2 1 MAXIMUM OUTPUT The maximum output of an engine is such standard power as developed by the engine after its initial break in period with all the moving parts properly worn in when operating with a fully open throttle valve There fore a new engine may not develop the maximum output in the beginning because the moving parts are not in a properly worn in condition 2 2 CONTINUOUS RATED OUTPUT The continuous rated output of an engine is such power as developed by that engine when running continu ously at an optimum speed and
24. ddle Portion Max cylin der dia and Piston dia at skert in thrust direc tion CORRECTION METHOD Surface plate Feeler Cylinder gauge Correct Cylinder 83086 Replace Replace Cylinder gauge Cylinder gauge Micro Replace meter gauge Cylinder gauge Micro meter Feeler gauge Vernier calipers Replace Replace Piston pin O D and crankpin Small end 1 D Clearance between small end 1 D and pinston pin Connecting Rod Large end side clearance Distance between large end and small end bores Crankpin O D Crankpin O D roundness E Crankpin O D cylindricity E c e O Crankpin O D parallelism Crankshaft journal O D Cam lobe height Journal O D ITEM ENGINE STANDARD MODEL SIZE TOLERANCE LIMIT EY15 Parallelism between large end and AS 0 05 small end bores EY15 EY15 EY20 EY15 EY20 EY15 EY20 EY15 2495 EY20 28 8 EY15 CORRECTION 0 013 CCC Large end 1 D o Clearance between rod large end I D E20 0 037 0 063 0 2 SE 0 010 0 021 0 08 0 08 mm s ate 83 Less than 0 005 Less than 0 005 Less than 0 008 Drive s 25 dia Mag s 25 dia Drive s 25 dia USE CORRECTION Micro Repi meter ep ace Cylinder gauge Replace Re machine or Replace
25. dling Overflow This trouble may be remedied depending on cases by lightly tapping the float chamber with the grip of a screwdriver or the like If the carburetor overflows excessive fuel runs into the cylinder when starting the engine making the fuel air mixture too rich to burn If this happens remove the spark plug and turn the starting pulley a few turns in order to let the rich fuel air mixture out of the spark pulg hole into the atmosphere Keep the carburetor choke open during this operation Dry the spark plug well screw it into place and try to start again When the engine is cold pull the craburetor knob to let the gasoline flow into the carburetor 1 2 COMPRESSION SYSTEM If starting difficultes and loss of power are not due to the fuel system or ignition system the followings must be checked for possible lack of compression 1 2 3 4 Engine inside is completely dried up because of a long period of non operation Loose or broken spark plug This causes a hissing noise made by mixture gas running out of cylinder in compression stroke during cranking Damaged head gasket or loose cylinder head A similar hissing noise is produced during compression stroke Incorrect Tappet Clearance If the correct compression is not obtained even after remedying the above disassemble the engine and check further as follows a Valve stuck open due to carbon or gum on the valve stem b If the piston rings are stuck on th
26. e directly The EY20V type engine normally incorporates a solid state ignition system T 1 C described in 6 5 SOLID STATE IGNITION 6 2 BREAKER POINT ADJUSTMENT Fig 41 The breaker points which are mounted in the crank case inside the flywheel should be checked twice a season or whenever the ignition spark becomes weak If there is an evidence of pitting or pyramidding the breaker points must be corrected and then it be comes necessary to readjust the gap to its proper clearance The normal breaker point opening point gap is 0 35 mm at full separation Since the spark timing of 23 is regulated by the point opening use a tim ing light to obtain an accurate spark advance Refer to 6 3 TIMING ADJUSTMENT Contact Breaker Fig 41 To adjust breaker point opening remove starting pulley blower housing and flywheel from the engine and proceed as follows See Fig 41 1 Remove the breaker cover from the contact breaker 2 Turn the crankshaft over until the breaker arm comes in contact with the high point of the breaker cam Maximum point opening 0 35 mm 3 Loosen the contact support plate lock screw just enough so that breaker can be moved 4 Insert a 0 35 mm feeler gauge between the points Caution Adjust the breaker point gap without opening it more than 2 mm otherwise rated heel pressing force may not be obtained due to the bending of contact breaker arm 5 Apply a screw driver to adjust tab and m
27. e piston remove the piston and connecting rod from the engine and clean remedy or replace the parts 38 11 1 3 ELECTRICAL SYSTEM Check the followings for lack of sparks 1 2 3 4 5 6 7 8 9 10 Leads of the ignition coil spark plug or contact breaker disconnected Ignition coil damaged and shorted Spark plug cable wet or soaked with oil Spark plug dirty or wet Spark plug electrode gap incorrect Spark plug electrodes in contact with each other Contact breaker point pitted or fused Breaker arm stuck Condernser leaking or grounded Incorrect spark timing 11 2 ENGINGE MIFIRES 1 2 3 4 5 6 7 Incorrect spark plug electrodge gap Adjust it to anywhere between 0 6 and 0 7 mm Ignition cable worn and leaking Sparks weak Ignition wire connections loose Pitted or worn breaker points Water in gasoline Insufficient compression 11 3 ENGINE STOPS 1 2 3 4 5 6 Fuel tank empty Water dirt gum etc in gasoline Vapor lock i e gasoline evaporating in the fuel lines due to overheat around the engine Vapor lock in the fuel lines or carburetor due to the use of too volatile winter gas in the hot season Air vent hole in the fuel tank cap plugged Bearing parts seized due to lack of oil Magneto or ignition coil faulty 11 4 ENGINE OVERHEATS 1 2 3 4 5 6 7 8 9 Crankcase oil level low Add oil immediately Spark timing incorrect
28. eplacement of any engine parts 2 Correction Limit The limit on wear damage or functional deterioration of engine parts beyond which normal engine per formance cannot be expected without repairing such parts 3 Use Limit The limit beyond which parts can no longer be used in respect of performance or strength 4 Standard Dimensions The design dimensions of new parts minus tolerance 5 Correction Tolerance Tolerance on the dimensions of engine parts refinished or adjusted 43 14 TABLE of CORRECTION STANDARDS Cylinder Piston Ring Flatness of cylinder head Cylindricity Valve seat contact width Valve guide 1 D O D at skirt in thrust direction incl over size B 0 25 C 0 5 Width of ring groove Piston pin hole Clearance between piston and cylinder Clearance between pisition ring and ring groove Fit between piston and piston pin Ring gap Ring width EY15 Less th E EY20 ss than 0 1 EY15 S T D 63 dia EY20 67 dia Dif between max amp min 0 019 EY15 EY20 EY15 EY20 B 67 23 dia 67 48 dia EY15 EY20 EY15 EY20 S T D 62 98 dia 8 63 23 dia Cc 63 48 dia S T D 66 98 dia 0 090 0 135 0 060 0 105 0 010 0 065 0 050 0 095 0 010 0 055 0 010 0 065 0 009 0 010 0 20 0 40 0 05 0 25 0 090 0 110 0 060 0 080 0 010 0 030 0 050 0 070 0 010 0 030 0 010 0 030 44 At mi
29. gine and the excitor coil primary excitation is available as an optional part The flywheel is for common use See Fig 52 30 7 GOVERNOR ADJUSTMENT Model EY15V and EY20V employ a centrifugal flyweight type governor The governor is mounted on the governor gear and the throttle valve of the carburetor is automatically regulated by a lever which is connect ed to the governor in order to maintain constant engine speed against load variations The adjustment procedure of the governor is as follows See Fig 45 1 Turn the speed control lever towards high speed and confirm that the carburetor throttle valve is fully opened Speed Control Lever T Choke Lever Governor Sorting A YY Hook Hole Low Speed High Speed H LUI Screw ME Ee Fig 45 e The point where the governor spring is to be Governor Spring hooked For EY15V the governor spring is to be hooked at the points 2 A while it is to be hooked at the points 2 B for EY20V See Fig 46 Note The governor lever for EY20V has an em bossed mark 20 while the lever of EY15V has no mark on it Governor Lever The Dimensions of the governor spring to be hooked are different each other according to the Hooking Points engine revolution Common to 3000 3600 3800 rpm eDiscrimination according to the dimensions Fig 46 EY 15V EY20V 3600 3800 rpm EY 15V EY20V 3000 rpm Fig 47 31 2 With a screwdriver in
30. he engine does not start or starts with difficulty or when its operation is unstable the following tests will 1 2 3 4 clarify if they are caused by a defect in the magneto Check igntion cable for possible corrosion broken worn insulator or loose connection Check the sparking as described later in this section Check if the breaker points require cleaning or adjusting or not If the points are badly corroded or pitted condenser may have to be replaced too Refer to BREAKER POINT ADJUSTMENT If no spark takes place replace ignition coil SPARK TESTING Remove spark plug from cylinder head and place it on blower housing with the ignition cable connected to it Crank the engine serveral times by starting pulley and observe the spark in the spark gap of spark plug If the spark is strong the ignition system can be eliminated as the source of trouble If the spark is weak or there is no spark at all repeat the checks according to the procedures 1 through 3 above The correct electrode gap is 0 6 0 7 mm Refer to section 13 CHECKS and CORRECTIONS 6 5 SOLID STATE IGNITION The following solid state ignition systems are available as optional part of EY15V and to EY20V engine these systems are equipped as standard parts T I On C TRANSISTOR IGNITION CIRCUIT the outside of the flywheel an ignition coil is installed which is so called outer coil type This is equipped to the standard type en
31. he main bearing cover to the crankcase the governor gear and cam gear Note As the governor gear is mounted on the main bearing cover side install the main bearing SC cover while checking that t meshes with the teeth of the cam gear See Fig 28 Mean time f the oil seal need be replaced press fit a new oil seal before installing the main bearing cover Note When installing main bearing cover apply oil to the bearing and oil seal lip Fit the oil seal Gan guide over the crankshaft to protect the oil seal lip from damage Then place the main GA bearing cover on D Check the crankshaft if its side clearance is 0 0 2 mm and if not adjust it with the ad usting shim See Fig 29 Main Bearing Cover th mm GEMET Fig 29 Note Main bearing cover tightening torque 80 100 kg cm Note Fig 30 shows one of the methods measuring p Dial Indicator the crankshaft side clearance between the ma A Ground Surface of Crankcase chined face of the crankcase and adjusting col The surface of the crankcase is lar As a paper packing is used on the machin to be put together with the sur ed face of the crankcase adjust the clearance face of the main bearing cover by taking this thickness of 0 22 mm into ac count See Fig 30 22 5 4 6 INTAKE and EXHAUST VALVES Remove carbon and gum deposite from the valves valve seats intake and exhaust ports and valve guides Note If the valve face i
32. inder wall before reassembling Note The open ends of the piston rings must be 90 apart from one another on the piston periphery Note The clearance between the piston and cyl Fig 25 inder must be measured at the piston skirt thrust surface ye Co SISCH Crankcase 8 aD Magneto Side Le Za ya 20 5 4 3 CONNECTING ROD 1 Turn the crankshaft to the bottom dead center lightly hammer the piston head until the con necting rod contacts the crankpin and assemble 2 When reassembling the connecting rod cap match the alignment projection mark on the rod See Fig 26 Note Use new lock washers and bend the tabs securely Note After reassembly confirm that the con necting rod moves lightly Note Connecting rod cap tightening torque EYIBV 90 115 kg cm EYZ20V 170 200 kg cm Note For the piston piston ring and rod clear ance see Fig 22 5 4 4 TAPPET and CAMSHAFT Insert the tappets back into their holes first and then mount the camshaft Note Align the timing mark at the rootof atooth of the cam gear with the one on the crank gear If the valve timing is wrong the engine can not operate properly or at all See Fig 27 Note If the intake valve and exhaust valve were as sembled contrarily each other the tappet clearance cannot be kept correctly Timing Mark 21 5 4 5 MAIN BEARING COVER Gegen Pay attention to the engagement of Install t
33. l primary wire 2 Remove the blower housing from the engine 3 Connect the timing tester lead with red rubber cap to the coil primary wire and ground the lead with black rubber cap to the crankcase See Fig 43 While the points are open the buzzer within tester remains ringing and when the points are closed the tester remains silent See Fig 43 4 Turn the flywheel slowly until alignment mark on the flywheel is in the line with alignment mark on the carankcase Coil Primary Wire 29 5 6 7 8 9 10 6 4 Remove the flywheel without turning crankshaft at all Loosen the lock screw of the breaker point support plate so that the breaker point can be rotated By rotating the support plate of the breaker point find the exact point when the buzzer within timing tester starts ringing from being silent See Figs 43 and 44 Put the flywheel back and check by rotating flywheel slowly If the buzzer in timing tester starts ring ing when line mark on the flywheel is in the line with line mark on the crankcase When the line marks are in alignment the timing is correct If the timing mark lines are not in alignment then readjust the point opening according to the BREAK ER POINT ADJUSTMENT by removing the flywheel and repeat the checking procedure 3 through 5 After completing the timing adjustment remount the blower housing and connect the coil primary lead to the stop switch MAGNETO TROUBLESHOOTING When t
34. lug Cap Spark Fuel Strainer Plug Crankcase Cylinder Head Governor Piston Ring Piston Pin Main Bearing Cover Oil Scraper Crankshaft MODEL EY15V Camshaft Air Cleaner Muffler Cover Tappet Intake and Fuel Tank Exhaust Valve Piston Connecting Rod Oil Filler MODEL EY15V Recoil Starter Flywheel Cooling Fan lgnition Coil Blower Housing ASAS TT ll 3209974399095 ft INN ee Fuel Strainer Crankcase Cylinder Head Governor Piston Ring Piston Pin Main Bearing Cover Oil Scraper Crankshaft MODEL EY20V 10 Camshaft Air Cleaner Muffler Cover Tappet Intake and Fuel Tank Exhaust Valve saro B ren Oil Seal Intake Valve FIL RES gt S med edi ee SH LEE TM x3 FT EA Sa H no mU d N O el N i IE Z Les r AE EE y Wm V E T AT NN Piston Connecting Rod Oil Filler MODEL EY20V 11 5 DISASSEMBLY and REASSEMBLY 5 1 PREPARATIONS and SUGGESTIONS ems 1 When disassembling the engine remember well the locations of individual parts so that they can be reas sembed correctly If you are uncertain of identifying some parts it is suggested that tags be attached to them 2 Have boxes ready to keep disassembed parts by group 3 To prevent missing and misplacing temporarily assemble each group of disassembed parts 4 Carefully
35. mbossed mark is given to the latter Fig 37 5 4 9 IGNITION PLUG Tightening torque of the ignition plug 120 150 kg cm 5 4 10 IGNITION COIL FLYWHEEL and STARTER PULLEY 1 Temporarily fasten the ignition coil to the crankcase and install the fly wheel to the crankshaft Starting pulley is fastened together with the fly wheel Note Before installing wipe out oil from the crankshaft and the tapered portion of the fly wheel Note Flywheel tightening torque 600 650 kg cm E95 2 After measuring the air gap between the ignition coil and flywheel retighten the ignition coil See Fig 38 Air gap 0 5 mm Thickness Gauge Fig 38 4 11 FUEL TANK BRACKET Distinction between the fuel tank bracket of EY20V and EY15V With four pieces of the bolt fasten the fuel tank Embossed Mark bracket to the crankcase Note DISTICTION between FUEL TANK BRACK ET of EY15V and THAT of EY20V For enabling to discriminate the fuel tank bracket of EY20V from that of EY 15V an em bossed mark 20 is given to the former while no embossed mark is given to the latter Fig 39 5 4 12 INTAKE MANIFOLD Distinction between the intake manifotd of EY20V and EY15V To the cylinder portion of the crankcase install the gasket and temporarily fasten the intake manifold Then install in the order of the gasket insulator gas Embossed Mark ket and carburetor Note DISTINCTION between INTAKE MANI 3 FOLD of EY15V and THAT of EY2
36. n air jet Meantime when reassembling set the rings 26 and 27 at the right position 8 2 3 PILOT SYSTEM 1 Remove the pilot jet 32 using correct tool to avoid damage to it 2 Reassembly Tighten the pilot jet securely Otherwise the fuel may leak causing engine malfunction Fig 51 8 2 4 MAIN SYSTEM 1 Remove the bolt 20 and take out float chamber body 18 2 Remove the main jet 21 from the body 14 3 Reassembly a Fasten the main jet securely to the body Otherwise the fuel may become too rich and cause engine malfunction b The bolt tightening torque is 70 kg cm 8 2 5 FLOAT SYSTEM 1 Pull out the float pin 17 and remove the float 16 and needle valve 25 If the needle valve need be re placed replace it with rubber needle Caution When cleaning the jets use neither a drill nor a wire because of possible damage of the orifice which will adversely affect fuel flow Be sure to use compressed air to blow them clean 2 When removing the needle valve and flots gently tap the reverse side using the rod more slender than the float pin and remove because the float pin is calked to the carburetor body 8B 9 BREAK IN OPERATION of REASSEMBLED ENGINE An overhauled engine must be operated at low speed break in the parts A thorough break in is indispensable particularly when the cylinder piston piston rings or valves are replaced with new ones The recommended break in schedule is shown below
37. nkcase 6 x 14 mm self tapping bolt 2 pcs 6 x 10 mm bolt 2 pcs Governor Rod Governor Spring Rod Spring Choke Rod Speed Control Lever SN Control Wire Fitting m Choke Lever Stop Switch Lock Bolt Carburetor Governor Shaft Fig 15 Governor Lever 14 1 Remove the starting pulley from the fly wheel 1449 nut 1 pce Fit a box or socket wrench over the fly wheel nut and strike it hard with a ham mer to remove the 14 mm nut and spring washer Be careful to damage the blades of the fly wheel with a driver and the like Strike counterclock wise with a hammer See Fig 16 19 mm box spanner or socket wrench Starting pulley i Flywheel 1 Remove the flywheel from the crankshaft Fit the flywheel pull er as per Fig 17 turn the center bolt clock wise and pull out the flywheel Flywheel Procedures Remarks Ignition coil 1 Remove the ignition plug cap from the Sems bolt 10 mm box spanner ignition plug and remove the ignition coil from the crankcase Ignition plug Remove the ignition plug from the cyl 19 mm box spanner inder head Cylinder head 1 Remove the 8 mm bolt and remove the 12 mm box spanner cylinder head from the crankcase 8 x 40 mm bolt 8 pcs 2 Remove the cylinder head gasket from the crnkcase 15 Intake and exhaust valve 1 2
38. ove the contact support plate just enough so that a slight drag is felt while sliding the feeler gauge from the gap between the points 6 Tighten the lock screw and recheck the breaker point gap 7 Pull a strip of 8 10 mm wide white paper through the closed points to remove oil and dust on the point surfaces Caution When inserting a sheet of paper never open the breaker po nt gap more than 2 mm 8 Mount the flywheel blower housing and starting pulley on the engine after adjustment 28 6 3 TIMING ADJUSTMENT See Figs 42 43 and 44 The spark is timed to occur at 23 before the piston reaches TDC on the compression stroke This spark ad vance of 23 is controlled by the breaker point opening and this advance is obtained when the breaker point opening is adjusted according to the BREAKER POINT ADJUSTMENT to its proper point opening How ever the advance timing is more accurately adjusted through the following procedures using a timing tester as shown in Fig 43 Note Refer to section 4 11 IGNITION and 4 13 CHECKS and CORRECTIONS 6 3 1 ALIGNMENT MARK for TIMING ADJUST MENT See Fig 42 For timing adjustment the following alignment marks are provided as shown in Fig 42 M mark and line on the crankcase P mark and line on the flywheel cooling fan lt E lt SM Alignment KY 6 3 2 TIMING ADJUSTMENT with TIMING TESTER 1 Disconnect the stop switch lead wires and the coi
39. ove the lock washers and connecting rod cap from the crankshaft 3 Turn the crankshaft until the piston is raised up to the hightest position push the connecting rod up and remove the piston out of the top of the cylinder St 19 Piston and 1 Remove the two clips pull out the piston Be careful not to piston pin pin and take the piston off from the damage the inside small end of the connecting rod of the small end the connecting rod 2 Spread the open ends of the piston rings Be careful not to and remove them from the piston break the rings by spreading too much 20 Crankshaft 1 Remove the woodruff key for the mag Be careful not to neto damage the rings by spreading too much 2 Lightly hammer the magneto end of the crankshaft and pull it out of the crank case AS 5 4 HOW TO REASSEMBLE ePrecaution in reassembling D 2 3 4 5 6 7 8 9 e Sequesnce and precautions in reassembling 5 4 1 CRANKSHAFT ERES GM 1 2 Every and each part should be cleaned thoroughly Especially pay utmost care and attention to the clean liness of the piston cylinder crankshaft connecting rod and bearings Scrape completely off carbons from the cylinder head and the upper part of the piston especially the carbon adhered in the groove of the piston ring should be carefully and completely taken out Carefully check the lip portion of ever
40. r float chamber 3 To prevent rust in the cylinder bore apply oil through the spark plug hole and turn the crankshaft several turns by hand Reinstall the plug 4 Turn the starting pulley by hand and leave it where the resistance is the heaviest 5 Clean the engine outside with oiled cloth 6 Put a vinyl or other cover over the engine and store the engine in dry place 50 Industrial Engines Robin America Inc 940 Lively Bivd Wood Dale IL 60191 Tel 708 350 8200 Fax 708 350 8212
41. r requiring them To remove run in wear particles 15 3 EVERY 50 HOURS 10 DAYS CHECKS and MAINTENANCE Checks and maintenance Change crankcase oil Checks and maintenance Reasons for requiring them Change crankcase oil Contaminated oil accelerates wear Clean air cleaner Clogged air cleaner harms engine operation Check spark plug If contaminated wash in Output power is reduced and starting is made gasoline or polish with emery paper difficult 15 4 EVERY 100 200 HOURS MONTHLY CHECKS and MAINTENANCE Checks and maintenance Reasons for requiring them Clean fuel filter and fuel tank The engine will be out of order Clean contact breaker points The engine output drops 49 15 5 EVERY 500 600 HOURS SEMIANNUAL CHECKS and MAINTENANCE Checks and maintenance Reasons for requiring them Remove cylinder head and remove carbon The engine will be out of order deposit Disassemble and clean carburetor 15 6 EVERY 1000 HOURS YEARLY CHECKS and MAINTENANCE Checks and maintenance Reasons for requiring them Perform overhauls clean correct or replace parts The engine output drops and become out of order Change piston rings Replace fuel pipe once a year To prevent from danger caused by the fuel leakage 15 7 PREPARATION for LONG ABEYANCE 1 Perform the above 15 1 and 15 2 maintenance jobs 2 Drain fuel from the fuel tank and carbureto
42. s dinted or warped replace the valves with new ones Note If there is an excessive clearance between the valve guide and valve stem replace the valve guide with a spare For replacing pull out the valve guide using the valve guide puller and bolts as shown in Fig 31 and press fit a new valve guide into place Valve Guide Puller Fig 31 A VALVE FACE ANGLE B SEAT ANGLE C GUIDE INSIDE DIA 6 5 een 0 025 INTAKE EUM 6 9 dia 0 040 0 056 EXHAUST LS 0992 0 078 INTAKE 0 025L 0 062L EXHAUST 0 056L 0 100L L LOOSE Fig 32 D VALVE STEM OUTSIDE DIA MAXIMUM ALLOWABLE CLEARANCE BETWEEN C amp D E 5 4 7 TAPPET ADJUSTMENT Lower the tappet all the way down push the valve and insert a feeler gauge between the valve and tappet stem to measure the clearance See Fig 33 Note The correct tappet clearance for both intake and exhaust valve is 0 1 mm 0 02 mm as ee when the engine is cold B Fit the oil seal to the valve stem Only for EY20 Fig 33 Fig 34 Note If the clearance is smaller than specified slightly grind the top of the valve stem and measure it again On the contrary if the clearance is too large replace the valve with new one and polish its contact surface with a compound to obtain a good fit Then adjust the clearance Note After the tappet clearance adjustment install the valve spring retainers and turn the crankshaft and measure the t
43. ut and as a result the high voltage electricity is generated on the secondary side of the ignition coi and it sparks at the plug Resister o Ki o o c E x E K 2 a Primary Coil Secondary Coil Spark Plug Resister Signal Transistor Fig 52 a 11 TROUBLE SHOOTING The following three conditions must be satisfied for satisfactory engine start 1 2 3 The cylinder filled with a proper fuel air mixture An appropriate compression in the cylinder Good sparks at the correct time to ignite the mixture The engine cannot be started unless these three conditions are met There are also other factors which make engine start difficult e g a heavy load on the engine when it is about to start at low speed and a high back pressure due to a long exhaust pipe just to say a few The most common causes of engine troubles are given below 11 11 1 2 3 4 5 6 7 11 1 STARTING DIFFICULTIES 1 1 FUEL SYSTEM No gasoline in the fuel tank or the fuel cock is closed The carburetor is not choked enough particularly when the engine is cold Water dust or gum in the gasoline block flow of the fuel to the carburetor Inferior grade gasoline or poor quality gasoline is not gasified enough to produce the correct fuel air mix ture The carburetor needle valve is held open by dirt or gum This trouble can be detected as the fuel flows out of the carburetor when the engone is i
44. y oil seal If faulty one is found replace it without any hesitation Apply enough oil to the lip portion of the oil seal when reassembling Replace all the gaskets with new ones Replace the key pin bolt nuts etc with new one if necessary Whenever tightening torque is specified conform to the specified figures Apply oi to the revolutionary parts and friction surfaces when reassembling Check and adjust the clearances of various portions and then reassemble When some main portions are assembled in the course of reassembling turn or move the gadgets by hand and pay attention to the frictional noise and resistance Fit the oil seal guide onto the end of the crank shaft and insert the crankshaft into the crank case as shown in Fig 21 Note In case of not using the oil seal guide be careful not to damage the oil seal lip Put woodruff key for magneto in place Oil Seal Guide Crankshaft Fig 21 18 o S 3 Dimensions of Crankshaft Pin Am 0 037 0 037 D Crankshaft pin Dia 24 dia 0050 26 dia o 050 W Crankshaft pin Width 23 Aj 24 Ge PISTON TO CYLINDER AT PISTON SKIRT THRUST FACE 0 020L 0 059L TOP SECOND 0 2L 0 4L 0 05L 0 25L OIL 0 2L 0 4L 0 05L 0 25L TOP RING 0 090L 0 135L 0 050L 0 095L PISTON RING GAP PISTON RING SIDE CLEARANCE IN GROOVES SECOND RING 0 060L 0 105L 0 010L 0 055L OIL RING 0 010L 0 065L 0 010L 0 065L CONNECTING ROD TO CR
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