1. No category

ROBIN AMERICA, INC.
ROBIN TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST
ROBIN
EY08
EY15
EY 15V
EY20
EY20V
EY23
EY28
EY35
EY40
EY45V
EY2 1
EY44
EY 1 8-3
EY25
EY 27
EHll
EH12
EH15
EH17
EH21
EH25
EH30
EH3 OV
EH34
EH3 4V
EH43V
-
WISCONSIN ROBIN
Wf-080
W1-145
W1-145V
W1-185
W1-185V
W 1-230
W 1-280
W 1-340
W1-390
W 1-450V
EY21W
EY44W
EY 18-3 W
EY25W
EY27W
-
wo1-115
wo1-120
WO1-150
WO1-170
wo1-210
wo1-250
WO 1-300
WO 1-300v
WO 1 -340
WO 1-340V
WQ 1-430V
TWO CYCLE
EC13V
WT1-125V
DlESEL
DY23
DY27
DY30
DY3 5
DY4 1
WRD1-230
WRD 1-270
WRD 1-300
WRD1-350
WRD1-410
1
CONTENTS
.
Title
See tion
1.
SPECIFICATIONS
2.
PERFORMANCE
2-1
2-2
2-3
3.
4
.
Page
..........................................
...........................................
Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuous Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Torque and Fuel Consumption Ratio a t Max Output . . . . .
.
FEATURES
..............................................
GENERALDESCRIPTION of ENGINECONSTRUCTION
Cylinder. Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MainBearingCover
.....................................
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod andPiston
...............................
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decompression
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16 Diode Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17 Sectional View of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 . DISASSEMBLY and REASSEMBLY
5-3
5-4
2
..
2
2
2
4
............... 4
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4 -9
4-10
4-11
4-12
4-13
4-14
4.1.5
5-1
5-2
1
4
5
5
5
6
6
6
7
7
7
8
8
8
9
9
9
10
..............................
12
Preparations
and
Suggestion
...............................
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tappet Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Setting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
13
18
22
23
25
See rion
6.
CARBURETOR
6-1
6-2
7.
Page
Title
............................................
26
...............................
..............................
26
27
Operation
and Construction
Disassembly
and
Reassembly
.................
28
.................
29
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Circuit andOperatingTheory of S.S. I . System . . . . . . . . . . . . . . .
Checking S.S.I. Unitwith Tester . . . . . . . . . . . . : . . . . . . . . . . . . . . .
MeasuringResistances of Exciter Coil andPulser Coil . . . . . . . . . . . . . .
29
29
29
29
BREAK-INOPERATION of REASSEMBLEDENGINE
8. ROBINSOLIDSTATEIGNITIONENGINE(OPTION)
8-1
8-2
8-3
8-4
9. TROUBLESHOOTING.
9-1
9-2
9-3
9-4
9-5
9-6
.
10
......................................
30
Starting Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine
Misfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enginestops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine
Overheat
Engine
Knocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine
Backfires through Carburetor . . . . . . . . . . . . . . . . . . . . . . . . .
30
...........................................
33
.......................................
INSTALLATION
10-1 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3 Exhaust Gas Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4 Fuelsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5 PowerTransmission to Driven Machines . . . . . . . . . . . . . . . . . . . . . . .
10-6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
11
CHECKS and CORRECTIONS
..................................
12. TABLE of CORRECTIONSTANDARDS
.
13
MAINTENANCE and STORING
13-1
13-2
13-3
13-4
13-5
13-6
13-7
31
31
31
32
32
33
33
33
33
34
34
37
...........................
38
.................................
43
Daily and
Maintenance
..................................
Every 20 Hours Checks andMaintenance . . . . . . . . . . . . . . . . . . . . . .
Every 50 Hours (10 days)Checks andMaintenance . . . . . . . . . . . . . . . .
Every 100 200 Hours (Monthly) Checks andMaintenance . . . . . . . . . .
Everv 500- 600 Hours(Semiannual)ChecksandMaintenance . . . . . . . .
Every 1000 Hours (Yearly) ChecksandMaintenance
Preparation for Long Abeyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-
...............
43
43
43
43
44
44
44
1. SPECIFICATIONS
w
i
-1-
2. PERFORMANCE
2-1
MAXIMUM OUTPUT
The maximum ouput of an engine is such standard power as developed by the engine, after its initial break in period with all
the m,oving parts properly worn in,when operating with a fully open throttle valve. Therefore, a new engine may not develop
the maximum output in the beginning because the moving parts are not in a properly worn-in condition.
-
rpm
-2-
PERFORMANCE CURVE
MODEL EY40D
kg-m
2.2 (4.4)
2.1 (4.2)
10
9
8
7
HP
I
6
5
4
3
2
1
0
-3-
t
3. FEATURES
Small in size, light in weight
The cylinder and crankcase are of a one-piece aluminum diecast structure, which is light in weight. The dimensions are
reduced as much as possible for easy mounting.
Quiet operation with low level of vibration
Intake and exhaust noises are reduced by use of a newly designed muffler having glass wool and a cyclone cleaner. Machine noise is reduced by selectionof a suitable cam shaft profile and optimumclearances for inner parts. All t h s adds
up to a quiet engine. Vibration is also reduced to a low level by weight reduction of reciprocating parts, and selection
of a timing balancer and optimum balance factor.
Easy to start
These engines can easily be started because they employ an automatic decompression device and a newly designed recoil starter.
Wide range of adaptability
These models are available in various types of output shafts and also a type (Type B) with a built-in 1/2 reduction gear
for application to various kinds ofmachines. The engines have two oil drain ports, and theirrecoil starter can be pulled
in any desired direction. Various optional parts are also available. All these combine to increase adaptabilityto machines.
Durable, reliable and safe
A liner of special cast iron, hard-chrome-plate piston rings, forged rod, etc. are used to make these engines as reliable
and durable as the preceding models of the EY Series. Safety devices are also incorporated to assured added safety.
4. GENERAL DESCRIPTION of ENGINE CONSTRUCTION
4-1
CYLINDER, CRANKCASE
The cylinder and crankcase are
single piece aluminum die
casting. The cylinder liner, made of special cast iron, is built
into the aluminumcasting. The intake and exhaust portsare
located on one side of the cylinder, and arealso inserted in-
to the casing.
The crankcase is separable on the output shaft side, where
the main bearing cover is attached to it.(See Fig. 1 .)
Fig. 1
-4-
4-2
MAIN BEARINGCOVER
The main bearing cover made of aluminum die casting is built onto the output shaft side of the crankcase so that the inside
B
of the engine can readily be checked by simplyremoving the cover. It is provided with a flange and boss for directly mounting machines, such as generators and pumps.
Two oil gauges also serving as oil filler caps can be mounted. . (See Fig. 2 and Fig. 3 .)
R I N G for CENTERING
O I L GAUGE
Fig. 2
4-3
Fig. 3
CRANKSHAFT
The crankshaftis forged of carbon steel, and the crankpin is
-
induction-hardened. It has
INDUCTION HARDENING
(PORTION of C R A N K P I N )
a crank gear pressure-fitted on
the output end.
(See Fig. 4.)
CRANK GEAR (PRESSURE-FIT)
Fig. 4
4-4 CONNECTING ROD and PISTON
SECOND R I N G
The connecting rod is forged of aluminum alloy, which it-
self serves as bearings at both the large and small ends. The
large endhas a built-in oil scraper for splashng the lubricating oil.
The piston is cast of aluminum alloy, and has grooves for
receiving two compression rings and one oil ring.
(See Fig. 5.)
Fig. 5
-5-
4-5 CAMSHAFT
Models EY3S-B, 3S-BS, EY40-B and 40-BS have intake and
exhaust cams of forged carbon steel, which are fitted witha
cam gear under pressure. The assembly serves as output shaft
that is driven at one half the speed of the crankshaft. The
cam gear has a governor fitted to it.
Model EY35-D, 35-DS, EY40-D and 40-DS have a camshaft
of special cast iron, which is integrallyassembled with a cam
gear. The two ends of the shaft
serve as plain bearings so no
0
ball bearings are used.
(See Fig. 6 . )
4-6
Fig. 6
CYLINDERHEAD
The cylinder head is an aluminum die casting, and forms a
Ricardo type combustion chamber withample area for high
combustioneffeciency.Thesparkplug
is tiltedfor
easy
mounting of thefuel tank.
(See Fig. 7.)
Fig. 7
.
4-7 VALVEARRANGEMENT
The exhaust valve is located upstream of the coolingair with
the result thattheexhaust
valveis
intensivelycooled for
improved engine durability. The inner sideof the valve head
is reinforced with hard alloy fusedto it for added durability.
(See Fig. 8.)
Fig.
-6-
8
"
.
".
_.
.._
4-8
GOVERNOR
The governor is a centrifugal flyweight type which permits
constant operation a t the selected speed against load variations. (See Fig. 9.)
Fig. 9
4-9 BALANCER
The balancer is assembled with the main bearing cover. Unbalanced moments of inertia generated in vertical and horizontal directions by the crankshaft, piston and connecting
rod are balanced by the balancer whxh rotates at thesame
rate as the crankshaft in opposite direction thereto, thus reducing vibration due to unbalanced moments of inertia.
(See Fig. 10.)
Fig. 10
4-10
DECOMPRESSIONDEVICE
The intake cam has aspecial profile and the intakevalve is sligh.tly raised during the compression stroke to let a slight amou
of compressed air out tomake startingeasy. (See Fig. 11.)
IN TAPPET
TAPPET
EXHAUST
IN TAPPET
SHAFT
'.O.
SIDE
IN C A M
EXHAUST-CAM
DECOMP L I F T
Fig. I 1
-7-
4-11 COOLING DEVICE
The cooling fan serving also as flywheel cools the cylinder and cylinder head by forced air cooling. An air guide plate and
head cover are used to let the coolingair go through.
The cooling fan employs curved bladesso Types B and D have cooling fan parts special to their own.
" .
.
4-12 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 connecting rod.
(See Fig. 12.)
OIL SCRAPER
Fig. 72
4-13
IGNITION DEVICE
Models EY35 and EY40 have a flywheel magneto type ignition system (Fig. 13) with an ignition timing of 23" before TDC
(Top Dead Center). The flywheel (also serving as fan) is fitted onto the crankshaft; and the ignition coil, contact breaker,
and charging coil are directly assembled with the crankcase. An S.S.I. electronic system (Fig. 14) is also available in types,
including a 1SO-watt load type.
The S.S.I. system, except the 150-watt type, electrically advances the ignition timing. The ignition timing after this
advance
is 23" before TDC. (See Figs. 13 and 14.)
FLYWHEEL
POINT COVER
Fig. 13
IGNITI~NCOIL
Fig. 14
4-14 CARBURETOR
A horizontal draft carburetoris employed. It has been carefully set after thorough tests to assure satisfactory start up,
acceleration, fuel consumption,output performance etc.
For construction and other
details, refer to the Section 6 .
CARBURETOR (Construction, Disassembly and ReassemblY1.
(See Fig. 15.)
L
,
Fig. 15
4-15
AIR CLEANER
Cyclone type semi-wet double elementair cleaner is used.
(See Fig. 16.)
Fig. 16
4-16
DIODE RECTIFIER
The engines with an electric
starter have a diode rectifier
whichconvertsthealternatingcurrentgenerated
by the
charging coil into a direct current and charges the battery.
(See Fig. 17.)
Fig. 17
-9-
4-17 SECTIONALVIEW OF ENGINE
/
I
RECOIL STARTER (OPTION)
CRANKCASE
MODEL EY35D. 40D
- 10 -
BALANCER
FUEL TANK CAP
INTAKE & EXHAUST VALVE
F U E L COCK
BALANCER
MODEL EY35D, 40D
- 11 -
5. DISASSEMBLY and REASSEMBLY
5-1
1)
PREPARATIONS and SUGGESTIONS
Whendisassembling
theengine,remember
well thelocations of individualparts so thatthey can be reassembled
correctly. If you are uncertain of identifying some parts, itis suggested that tags be attached to them.
2) Have boxes ready to keep disassembled parts by group.
3) To prevent missing and misplacing, temporarily assemble each group of disassembled parts.
4) Carefully handle disassembled parts, and clean them with washing oil.
5) Use the correct tools in the correct way,
5-2
SPECIAL TOOLS
For your reference, the following shows special tools of Robin Engine for Disassembly, Measuring and Inspection Instruments.
~
Part No.
Tool
Wse
Applicable
Model
Shape
EY10,13,14
EY15,18,20
2099500407
Flywheel Puller
(with bolt)
For pulling off
Flywheel
EY25,27,33
EY35,40,44
EC05,07,10
ECf 7,25,37
EYIQ, 13.14
2079500307
Valve Spring
Retainer
For mounting and
dismounting Valve
Spring Retainer
and Retainer Lock
EY15,18,20
EY25,27,33
EY35,40,44
EYlO, 13,14
EY15,18,20
EY25,27,33
"20248
riming Tester
For adjusting
timing
EY35,40,44
EC03,04,05
EC07,10,17
,
"
-
EC25,37
- 12 -
5-3 HOW TO DISASSEMBLE
*Length of the bolt indicates the length from the bolt head bottom
surface t o the threaded end.
Order
Item
Procedures
Remarks
Be careful not tolose the
the gasket.
1
Engine
Drain engine oil.
Drain plugs on bothsides of the
case
2
Fuel tank
(1) Close the strainer cock.
(2) Move the fuel pipe clamp (on
strainer side) downward.
(3) Remove the tank from tank
bracket.
Tank bracket
Remove tank bracket.
4
Air cleaner
(1) Remove air cleaner cover and
element.
(2) Remove choke knob.
(3) Remove the bottom plate of
air cleaner.
Muffler cover
Flange bolt
8 mm (No.2) nut . . . 4 pcs.
SpI-ing washer . . . 4 pcs.
10 mm flange nut . . . 4 pcs.
(tightened together with
cylinder head)
3
5
Bolts, nuts, etc. used
Swivel
6 x 12 mm flange bolt
. . . 2 pcs.
Remove muffler cover.
6 x 8 (5T) Flange bolt
. . 4 pcs.
*
6
Muffler
8 mm brass nut . . . 2 pcs.
(1) Remove the flange portion
of the muffler.
(2) Remove the muffler bracket.
8 x 16 (ST) Bolt & washer
. . . 2 pcs., Washer . . . 1 pce
7
Carburetor
Remove the carburetor.
Be careful of the packing 6 mm nut . . . 2 pcs.
etc.
Joint sheet, insulator,and Spring washer . . . 2 pcs.
then paper packing, in t h s Washer . . . 2 pcs.
order from the engine side
8
Governor
lever
Remove the governor lever.
Be careful of the position
of the governor spring.
Fig. 18
- 13 -
6 mm special n u t . . , 1 pce.
Washer . . . 1 pce.
6 x 25 (7T) bolt . . . 1 pce.
I
I
Order
9
I
Item
Speed control
I
I
Procedures
Remarks
Bolts, nuts, etc. used
Remember the assembling Circle clip . . . 1 pce.
order of component parts. 8 mm butterfly n u t . . . 1 pce.
(See Fig. 19.)
Disassemble.
h
Fig. 19
Order
10
11
Remarks
Item
Operation
case
Electric
starter
(1) Disconnect the high voltage
wire connecting the electric
starter to the magnetic switch
on the side of the switch.
(2) Remove the bolts. (3 pcs.)
Bolts, nuts, etc. used
(See Fig. 20.)
Two of the three 6 x 8 (5T)
flange bolts tighten the
cylinder buffle and fan cover
together.
8 x 30 reamer bolt . . . 2 pcs.
Spring washer . . . 2 pcs.
Washer . . . 2 pcs.
Remove electric starter.
Fig. 20
- 14-
Order
-
Item
I
12 Fan cover
I
Procedures
Remarks
Removable by loosening
bolts
(1) Remove the fan cover.
(2) Remove the head cover.
(3) Remove the cylinder buffle.
13
Starting pulley Remove starting pulley.
14
Flywheel
I
I
Bolts, nuts, etc. used
6 x 8 flange bolt . . . 6 pcs.
6 x 8 flange bolt . . . 1 pce.
Remove
flywheel.
8 x 12 (ST)bolt
Be sure to use theflywheelpuller. Do not
18 mm nut . . . 1 pce.
Springwasher . . . 1 pce.
crankshaft.
-
Fig. 21
Fig. 22
b
--
. . . 3 pcs.
(See Fig. 21 .)
15 -
Order
15
Item
Electric
devices
Procedures
Remarks
(1) Remove point cover.
4 x 12 screw and washer
. . . 2 pcs.
4 x 8 screw and washer
. . . 1 pce.
(2) Remove contact breaker.
(3) Remove ignition coil and condenser.
16
17
Remove Tappet cover.
(1) Remove intake valve.
Intake and
exhaust valves (2) Remove exhaust valve.
I
Be careful of the primary
lead connecting direction.
Remove the lighting coil
6 x 25 screw and washer
before disassembly.
. . . 2 pcs.
Cylinder head (1) Remove spark plug.
(2) Remove cylinder head.
Tappet cover
(breather
plate)
Bolts, nuts, etc. used
Be mounting
Of the breather
valve
position
and the order of assembling packings.
(See Fig. 23.)
I
10 mm flange nut . . . 8 pcs.
6 x 14 flange bolt . . . 2 pcs.
I
I
Intake and exhaust valve
Use valve spring retainers.
springs, retainers and retainer locks are common;
but be sure to set up them
on the original valves.
(See Fig. 24.)
Fig. 23
Fig. 24
- 16-
1
Irder
I
~~~
19 Main bearing
cover
r
Procedures
Item
~
~
~~~~~
Remarks
I
(1) Set the piston to the TDC, remove blind plugin the lower
part of the front side of bearing cover, and insert the 4 mm
stick.
(2) Remove bolts.
(3) Strike the side of main bearing coverwith a plastic hammer or the like to remove the
cover from crankcase.
(See Fig. 25.)
Remove camshaft.
Camshaft can easily be
pulled by hand. Be careful not to let the tappets
drop. 1
Bolts, nuts,
used
etc.
6 x 8 flange bolt . . . 1 pce.
Gasket (aluminium) . . . 1 pce.
8 x 35 (7T)set bolt . . . 8 pcs.
In caseof TypeB, be careful not toremove camshaft
together.
*Crankshaft and camshaft
have adjustingshims.
(TYPe B)
~
20
Camshaft
I
Fig. 26
Fig. 25
Order
~
21
Intake/exhaust tappets
Bolts, nuts, etc. used
Remarks
Procedures
Item
~~
Remove intake/exhaust tappets.
1
Intake and exhaust tappets are the same, but be
sure to intall them in their
original positions because
of the valve clearance.
~~
22
23
(1) Return the lock washer.
Connecting
rod and piston (2) Remove bolts.
(3) Push the piston up out of
the topof cylinder.
Crankshaft
Hold crankshaftwithhand.and
gently
tap
the
flywheel
end.
the
8 x 46 reamer bolt
I
I
Be carefulof oil seal on
crankcase
magneto
side.
- 17 -
I
.
~
. 2 pcs.
HOW TO REASSEMBLE
5-4
5-4-1 PRECAUTION IN REASSEMBLY
Every and each part should be cleaned thoroughly. Especially, pay utmost care and attention to the cleanliness of the
piston, cylinder, crankshaft, connecting rod andbearings.
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 every 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 oil to the revolutionary parts and friction surfaces, whenreassembling.
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.
5 - 4 - 2 MEASURING CRANKCASE and CRANKSHAFT
Bore the cylinder or take other steps as necessary to meet
the following specifications before reassembling.
E Y40
EY35
I
I
W (Crankshaft Pin Width)
Bore
29 +0.1
0
78 dia. 40.019
I
84 dia.
- 0.108L
1
0.049L
,
+0.022
Piston Outside Diameter (In SkirtThrust Direction)
I
I Piston to Cylinder a t Piston Skirt Thrust Face
Piston Ring Gap (Top Ring
-
Second Ring)
0.049L
0.1 L
- 0.3L
0.05
-
I
-
Piston Ring Side Clearance in Grooves
(Top Ring Second Ring)
Clearance between Inside
Clearance between Connecting
and Outside Diameter
Rod Large End and Piston Pin
Side Clearance
0.070
0.020L
- 0.11 1 L
0.09
- 0.102L
-
0.042L
- 0.4L
0.1 1T - 0.01 1 L
Clearance between Connection
Rod Small End and Piston Pin
0.1 L
Clearance between Piston Pin and Pinston Pin Hole
L: LOOSE
Fig. 27
- 18 -
r'
5-4-3 ASSEMBLING ORDER and PRECAUTIONS
.
1) Place the tappets into the crankcase.
.
TIMING MARK ON CAMSHAFT SIDE
(Punch 2 pcskl
NOTE: The intake and exhaust tappets are the same,
but mark them differently whendisassembling because of different valve clearances; and
fit them into their origianl place. Apply oil t o
the tappets beforehand.
Assemble thecrankshaft
and camshaftatthesame
time.
NOTE: The same timing mark as on the crankshaft
side is punched on the crankshaft gear inward
of the
balancer
gear as shown in Fig. 28. So,
TIMING MARK ON CRANKSHA??
(Punch 1 pce.)
match these timing marks on the crankshaft
and
camshaft
Fig. 28
sides before installing these
shafts in the crankcase.
3)
Assemble the connecting rod with the piston.
NOTE: The piston is not offset so a new piston does not require to be installed in a specific direction, but a used piston
must be marked with a sign indicating its direction when disassembling so that it can be assembled again in the
direction indicated.
CAUTION: When inserting the piston pinand fitting the clip on, be careful not todamage the piston surface.
4) Fit thepiston.
pistontherings on
THRUST SIDE
NOTE: Each piston ring must be installed upside up,
that is, the puched mark a t the open ends up.
NOTE: The oil ring consists of three parts, that is, a
spacer, lower rail, and upper rail. Fit them
on
LOWER R A I L
UPPER R A I L
in this order. The openends of each ring must
be as shown in Fig. 29.
Fig. 29
ASSEMBLY TYPE
Fig. 3 1
Fig. 30
- 19-
OIL RING
5 ) Assemble thepiston
and connecting rod that were
readied in Steps 3) and 4).
NOTE: The symbol @FAN mark on the connecting
~
MATCH
rod must be on the magneto side.
NOTE: Be careful of the match mark on the cap. If
the match mark i s a t the correct position, the
oil scraper should be on the main bearing cover side.
. . . . . . . 8 x 46 (special)
Tightening torque . . . 250 300 kg-cm
NOTE: Tightening bolt
-
Use new lock washers,and bend their edges
securely.
u__
Fig. 32
Install the main bearing cover.
NOTE: If the oil seal is damagedwhen the governor
CRANKSHAFT SPACER
\
yoke is installed, replace it with a new one.
NOTE: Adjust the sideclearance
to anywherebe-
tween 0.05 and 0.2 mm.Thesideclearance
can be measured
by measuring sizes A and
B
as shown in Fig. 33, and assume that the thickness of packing C is 0.25 mm when tightened.
MAIN BEARING
* The side clearance can
also be measured as
BALANCER
shown in photos below. (Figs. 34 and 35)
Fig. 33
Fig. 35
Fig. 34
- 20 -
NOTE: Check the main bearing cover joint for flaw,
and correct if necessary.
Fit the governor sleeve into the camgear
with new packing.
* Move the piston upto TDC, insertthe 4 mm
stick into the main bearing cover, and fasten the balancer as shown in Fig. 36.
. . . . .. .
Tightening torque . . .170
Tightening bolt
8 x 35 (7T)
-
190 kg-cm
* Insert the blind plug (6 x 8 flange bolt) into
the balancer fixing hole with the aluminum
gasket, and check if the crankshaft srnooth-
Fig. 36
ly runs.
7) Install the intake and exhaust valves.
*
Intake and exhaust valve specifications are as follows:
4O
A.4
F
I
GUIDE
VALVE and VALVE GUIDE CLEARANCE
EY35
E Y40
A-VALVE FACE ANGLE
6-SEAT ANGLE
C-GUIDE INSIDE DIA.
~~~~
~
8dia.
+0.036
~
INTAKE
D-VALVE STEM OUTSIDE DIA.
dia. -0.070
-0.090
MAXIMUM ALLOWABLE
CLEARANCE 8ETWEEN C and D
INTAKE
0.030L
0.070L
Fig. 37
-21 -
-
0.091 L
0.126L
.TAPPET CLEARANCE ADJUSTMENT
Move the piston up to compression TDC, and adjust
the tappet clearance as follows, using a grinder or the
like.
Clearance (Models EY35,EY40 intake and exhaust):
0.13
- 0.17 mm when cold
Fig. 38
*
Intake and exhaust valve installation
Apply oil to the valve stems, and install the valves
securely by using the special tool, valve spring retainer and pliers. (See Fig. 39.)
After their installation, check the tappet clearance
again.
Fig. 39
8) Install the breather plate and tappet cover.
NOTE: Be careful of the gasket installing order (See
Fig. 40.) and breather valve position.
The breather valve must be on the intake valve
side.
6 x 14 flange bolt
..........
2 pcs.
Fig. 40
9) Install the cylinder head.
NOTE: Replace the head gasket with a new one, and tighten the nuts uniformly with the specified torque.
10 mm flange nut
Tightening torque
. . . . . . . . . . . 8 pa.
. . . 340 390 kg-cm
-
- 22 -
10) Electrical installation
*
Install the ignition coil and capacitor.
rKER
Screws: 6 x 25 screw and washer . . 2 pcs. each
*
Temporarily install the contact breaker.
Screw: 4 x 8 screw and washer
. . . 1 pce. each
CAUTION: Be careful of the location of the cord.
*IGNITION TIMING ADJUSTMENT
Ignition timing . . . . . . . . . . . .
23" before TDC
Fig. 4 1
Point gap . . . . . . . . . . . . . . . .0.35k0.05 mm
Adjusting method
If the point surfaces are rough, smoothen them. Hold
the top of the point cam on the crankshaft in contact
with the heel
of the contact breaker, and move the
contact breaker itself until the correct pointgap is obtained. The ignition timing of the engine depends on
the point gap. If the gap is correctly adjusted, the ignition timing will be 23" before TDC.
Fig. 42
.IGNITION TIMING CHECK
Use a timing tester, Part N0.M-20248
Checking method
As shown in Fig. 43, connect one of the leads of the timing tester to the primary wire of the ignition coil, and the
other lead to the crankcase, switch the timing tester on, and hold the earphone close to the ear. Slowly turn the flywheel in normal direction (clockwise for Type D, or counterclockwise for Type B), and if the mark on the flywheel
matches the M mark on the case when the buzzer sounds, it is the correct ignition timing. If the two marks do not
agree, repeat the above mentioned adjustment.
---"
FLYWHEEL
Fig. 44
Fig. 43
- 23 -
*SPARK CHECK
*
*
Clean the point surfaces of oil with paper or the like, and temporarilyinstall the flywheel.
Hold the high-voltage wire with hand so its end is about 5 mm away from the case, and turn the flywheel in normal
direction.
*
*
Check that a sparkis generated when the M mark on the flywheel passes the M mark on the case.
Install the point cover.
4 x 12 screw and washer
. . . . . . 2 PCS.
11)Installtheflywheel.
NOTE: Before installing the flywheef, clean the crankshaft andthe tapered part of the flywheel of oil.
16mmnut
. . . . . . . . . . . . . . . . 1pce.
. . . . . . . . . . . . . . 1 pce.
. . . . . . . . . . . . . . . . . . 1 pce.
Tightening torque . . .800 1000 kg-cm
Spring washer
Washer.
-
12) Install the starter pulley.
8 x 12 bolt (ST)
. . . . . . . . . . . . 3 pcs.
13) Install the fan cover and head cover cylinder buffle.
NOTE: Before installing the fan cover, first install the head cover on the cylinder head. Also install the muffler bracke t in place a t the same time.
6 x 8 flange bolt
............
7 pcs.'
14) Install the recoil starter
NOTE: Pulling directionmay vary with machine make.
6 x 8 flange bolt . . . . . . . . . . . . 4 pcs.
15)
Install thecarburetor.
NOTE: Install the carburetor with the joint sheet, insulator, and paper packing in this order.
6 mm nut . . . . . . . . . . . . . . . . . 2 pcs.
. . . . . . . . . . . . . . 2 pcs.
Washer. . . . . . . . . . . . . . . . . . . 2 pcs.
Spring washer
16) Install the
speed control and governor lever according
t o the arrangement of parts shown in Fig. 47. Hook
the governor spring at the proper hole.
8 mm wing nut
Clip..
. . . . . . . . . . . . . 1 pce.
. . . . . . . . . . . . . . . . . . . 1 pce.
0
Fig. 45
- 24 -
.GOVERNOR SETTING METHOD
*
Set the speed control lever to the high-speed position, and fasten it there with the
wing nut. (The
governor spring is in.)
*
Checkthatthecarburetorandthrottle
valve are
fully open.
*
Turnthe
governorshaftcounterclockwise,
and
fasten the governor lever. (See Fig. 46.)
Fig. 46
Install the starter motor.
8 x 30 reamer bolt
. . . . . . . . . . . 2 pcs.
. . . . . . . . . . . . . . 2 PcS.
Washer. . . . . . . . . . . . . . . . . . . 2 pes.
Spring washer
Install the operationcase. (with the electric starter)
6 x 8 flange bolt (5T) . . . . . . . . . 3 pcs.
*
*
Two of the three flange bolts tighten the case together with the cylinderbuffle and fan cover.
Properly wire as shown in the wiring diagrams (Pages 34 and 35).
Install the muffler.
NOTE: The muffler gasket must be placed in 'the correct direction. (Non-symmetric direction)
8m brass nut
. . . . . . . . . . . . . . . 2 pcs.
8 x 16 bolt (for bracket)
Washer.
.......
2 pcs.
. . . . . . . . . . . . . . . . . . 1 pce.
Install the mufflercover.
6 x 8 flange bolt (5T) . . . . . . . . . 4 pcs.
Install the air cleaner.
NOTE: Make sure that the tip ofthe breather pipe out of the tappet cover is clear off the element retainer.
6 x 12 flange bolt . . . . . . . . . . . 2 pcs.
After mounting the cleaner bottom plate, install the choke knob, element retainer, element
and cover in t h s order.
Install the tank bracket.
10 mm flange nut . . . . . . . . . . . 4 pcs.
(also for cylinder head)
Install the fuel tank.
8 mm No.2 nut
. . . . . . . . . . . . . 4 pcs.
Spring washer . . . . . . . . . . . . . . 4 pcs.
Connect the fuel pipe.
Clamp the pipe securely.
Supply 1.2 liter engine oil.
-25 -
6, CARBURETOR
SPECIFICATION
I
E Y40
Model
BV26-20
Part No.
2246230100
Main Jet
1
I
EY35
#107.5
BV26-19
#112.5
Main Air Jet
$1.2
$1.5
Pilot Jet
#57.5
#55
Throttle Valve
#135
#150
Pilot Screw
(Return)
I
2236230100
1 turn
6 -1 OPERATION and CONSTRUCTION
A
PI LOT
FUEL
NEEDLE VALVE
FLOAT
FLOAT CHAMBER
W
Fig. 48
- 26 -
6-1 -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 the
needle valve. When the fuel rises to a specific level, the
float rises; and when its buoyancy and fuel pressure are balanced, the needle valve close to the shut off the fuel, thereby
keeping the fuel at thereference level.
6-1 - 2 PI LOT SYSTEM
The pilot system feeds the fuelto the engine during idling and low-speed operation.
The fuel is fed through the main jet to thepilot jet, where it is metered, and mixed with the air metered by the pilotair jet.
The fuel-air mixtureis fed to the engine through the pilot outllet and the by-pass.
During engine idling, the fuel is mainly fed from the pilot outlet.
6-1-3 MAIN SYSTEM
The main system feeds the fuelto theengine during medium- and high-speed operation.
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 mixtureis atomized out of themain bore. It is mixed again with the air
taken through the air cleaner into an optimum fuel-air mixture, which
is supplied to the engine.
6-1 -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 themain nozzle increases and drawsmuch fuel accordingly; thuseasily start up theengine.
6-2 DISASSEMBLY and REASSEMBLY
Apart from mechanical failures, most of carburetor troubles arecaused by an incorrect mixing ratio, which mayarise mainly
due to a clogged up ah or fuel passage in jets, or fuel level variations. In order to assure proper flow of air and fuel, the car;
buretor must be kept clean at all times. The carburetor disassembly and reassembly procedures areas follows: (See Fig. 49.)
6-2-1 THROTTLE SYSTEM
1) Remove the Phdlips screw (I) and throttle valve ( 2 ) , and pull out the throttle shaft (3).
2) The spring (5) can be taken out by removing the throttle stop screw (4).
*Be careful of the direction of the throttle valve.
The circumference of the throttle valve is aslant. Install the valve so the punched mark on thevalve can be seen on the
left.
6-2-2 CHOKE SYSTEM
I)
Remove the Phillips screw ( 6 ) and choke valve (7), and pull out the choke shaft (8). Stop ring ( 9 ) can not be removed.
2) When reassembling the choke shaft, makesure that the cutout in the choke valve faces the main air jet.
'
6-2-3 PILOT SYSTEM
I)
Remove the pilot jet (1 0), using correct tool to avoid damage to it.
2)
Remove pilot screw (1 1) and spring (1 2).
3)
Reassembly
*Tighten the pilot jet securely. Otherwise, the fuel may leak,
causing engine malfunction.
*If the tapered part of the pilotscrew is out of shape, replace it with a new one.
- 27 -
6 - 2 - 4 MAIN SYSTEM
1) Remove thebolt
(1 3) andtakeoutfloat
chamber
body (15).
2)
Remove the main jet (17) and main nozzle (1 8), using
correct tool toavoid damage t o i t ,
3) Reassembly
Fasten the main jet securely to the body. Otherwise,
the fuel may become too rich and cause engine malfunction.
6 - 2 -5 FLOAT SYSTEM
When removing the needle valve (21) and float (20), gently
tap the
reverse side using therodmore
IA
slender thanthe
float pin (19) and remove because the float pin is calked to
‘17
-18
the carburetor body.
*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
19
air to blow them clean.
Fully tighten the pilot screw and then loosen it counterclockwise byoneturnfor
Model EY35, orone
turn and a half for Model EY40. When fully closing
the pilot screw, do not tighten it too hard. Otherwise,
the needle at the tipmight become damaged.
Turn the throttle stop
screwclockwise to a normal
idling speed of 1200 rpm.
Fig. 49
Make a final adjustment when the engineis in normal
operating condition at normal temperature with the correct
air cleaner mounted.
7. BREAK-IN OPERATION of REASSEMBLED ENGINE
An overhauled engine must be operated a t low speed break-in the parts. A thorough break-in is indispensable particularly
when the cylinder, piston, pistonrings or valves are replaced with new ones.
Thle recommended break-in schedule is shown below.
LOAD
SPEED
TIME
2,500 rprn
10 minutes
NO LOAD
3,000 rpm
10 minutes
NO LOAD
3,600 rprn
10 minutes
3,600 rpm
30 minutes
EY40
EY35
NO LOAD
~
4.0 HP
3.5 HP
7.0 HP
I
8.0 HP
- 28 -
~
1
3,600 rpm
I
60 minutes
1
8. ROBIN SOLID STATE IGNITION ENGINE (OPTION)
FEATURES
8-1
The S.S.I. system is free of the weak points of the conventional point type ignition system, that
is, ignition failure due to a
dirty or burnt contact point, oxidation during long storage,and
mechanical wear,and featuresmaintenance-free performance,
proper sparking, and freedom from the
ill effects of water, oil dust, and moisture.
8 - 2 BASIC CIRCUIT and OPERATING THEORY of
S.S. I. SYSTEM
1)
As the flywheelandmagneto
IGNITION UNIT
"-1
rotate, a voltage is in-
IGNITION COIL
duced in the exciter coil, and flows through the primary wire to the transistor base. A
2) At the same time, the transistor is energized to form a
circuit between the exciter coil and the transistor. B
3)
Attheignitiontime,electricpowerflowsfromthe
pulser coil to the SCR gate to energize the SCR. C
Thus the current flowing to the transistor is cut off,
and the exciter current suddenly rushes to the primary side of the ignition coil. D Thus, a high voltage is
L
generated on the secondary side of the ignition coil to
Fig.
produce a spark in the spark plug. E
8-3 CHECKING IGNITION UNIT
50
with TESTER
The ignition unit can be checked with an ordinary circuit
Connect (+) terminal of tester.
tester.
I
Checkit as shown in the table at right, and
if the test results
are as specified, the ignition unit is in normal condition. If
any of the test results is not satisfactory, replace the whole
ignition unit.
NOTE: Use a circuittester,nota
megger or other
tester t h a t requires high ovltage. ON in the
table indicates the forward characteristic of
the diode, and if the tester pointer moves to
a certain extent, it is good.
O F F in the table indicates
ma.
8-4 MEASURING RESISTANCES of EXCITER COIL and PULSER COIL
Exciter Coil
STD
150W
Fig. 51
*
Values in the
table
- 29 -
* 20%
4.5R * 20%
0.97Q
above
apply
where
Pulser Coil
A - t B
66Q
A + B
* 20%
t
ambient
temperature
is
20°C.
TROUBLE SHOOTING
9.
The following three conditions must besatisfied for satisfactory engine start.
1.
The cylinder filled with a proper fuel-air mixture.
2 . An appropriate compression in the cylinder.
3. 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., aheavy load on the engine when it is about to start at low speed, and high
a back pressure due to a long exhaust
pipe, just to say a few.
The most common causes of engine troubles
are given below:
9-1 STARTINGDIFFICULTIES
9-1 -1
FUEL SYSTEM
NO gasoline in th fuel tank; or the fuel cockis closed.
The carburetor is not choked enough,particularly when the engine is cold.
Water, dust or gum in the gasoline block flowof the fuel to the carburetor.
Inferior grade gasolineor poor quality gasolineis not gasfied enough to produce the correct fuel-air mixture.
The carburetor needle
valveis held open by dirt or gum. This trouble can be detected as the fuel flows out of the
carburetor when the engine is idling. (Overflow)
This trouble may be remedied, depending on cases, by lightly tapping the float chamber with thegrip of a screwdriver
of the like.
If the carburetor overflows, excessive fuel runs into thecylinder 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 plug hole into the atmosphere. Keep the carburetor choke open during this
operation. Dry the spark plug well, screw it into place, and tryto start again.
9-1-2
COMPRESSION SYSTEM
If starting difficulties and loss of power are not due to thefuel system or ignition system, the following mustbe checked for
possible lack of compression.
1) Engine inside is completely dried up because of a long period of non-operation.
2 ) Loose or broken spark plug. This causes a hissing noise made by mixture gas running out of cylinder in compression
stroke during cranking.
3)
Damaged head gasket or loose cylinder head.A similar hissing noise is produced during compression stroke.
4)
IncorrectTappetClearance
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 the piston, remove the piston and connecting rod from the engine, and clean, remedy
or replace the parts.
- 30 -
0
9-1-3
ELECTRICAL SYSTEM
Check the following for lack of sparks.
Leads of the ignition coil, spark plugor 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 points pitted or fused.
Breaker arm stuck.
Condenser leaking or grounded.
Incorrect spark timing.
ENGINE MISFIRES
Incorrect spark plug electrode 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.
9-3 ENGINE STOPS
1)
Fuel tank empty.Water, dirt, gum, etc. ingasoline.
Vapor lock, i. e.,gasoline evaporating in the fuel lines dueto overheat around the engine.
Vapor lock in the fuel lines or carburetor due to theuse of too volatile winter gas in the hotseason.
Air vent hole in the fuel tank capplugged.
Bearing p.arts seized due to lackof oil.
Magneto or ignition coil faulty.
9 - 4 ENGINE OVERHEAT
Crankcase oil level low. Add oil immediately.
Spark timing incorrect.
Low grade gasoline is used, o r engine is overloaded.
Cooling air circulation restricted.
Cooling air party misdirected causes loss of cooling efficiency.
Cylinder head cooling finsclogged up with dirt.
Engine operated in an enclosedspace without fresh supply of cooling air.
Exhaust gas discharge restricted, or carbon deposits in the combustion chamber.
Engine running on low-octane gasoline detonates due toheavy load at low speed.
- 31 -
ENGINE KNOCKS
Low-quality gasoline.
Engine operating under heavy load at low speed.
Carbon or lead deposits in the cylinder head.
Spark timing incorrect.
Loose connecting rod bearing due to wear.
Loose piston pin due to wear.
Causes of engine overheat.
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.
- 32 -
10. INSTALLATION
Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost all depend on the way
in whlch the engine is installed. Carefully observe the following instructions for
installing the engine.
10-1 INSTALLING
When mounting the engine, carefully examine its position, the methodof connecting it to a load (machine), the foundation,
and the methodof supporting the engine.
When determining its mounting position,in particular, make sure that gasoline and
oil can easily be supplied and checked,the
spark plug and breaker can easily be checked, the air cleaner can easily be serviced, and that the oilcan easily be discharged.
10-2 VENTILATION
Fresh air is necessary for cooling the engine and burning the fuel.
In cases 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, pistonseizure, 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 thehot air used for engine cooling, and temperaturerise of the load (machine).
Take steps as necessary to keep the engine room temperature below 50°Ceven in the hottest period of the year.
10-3 EXHAUST GAS DISCHARGE
Exhaust gas is noxious. When operating the engine indoors, be sureto discharge the exhaust gas outdoors. If 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, pipeinside diameter 30 mm,
Less than 5 m long, pipe inside diameter 33 mm.
*
Put safety covers over the exhaust pipe, muffler, etc.
10-4 FUEL STSTEM
If the fuel tank is removed from the engine in mounting the engine in a machine, install the fuel tank back so its bottom is
5 cm to 50 cm above the fuel joint of the carburetor. If the fuel tank is installed too low, the fuel will not be supplied. If
the fuel tankis too high,on the other hand, itcan cause the carburetor tooverflow.
Be careful of heat conduction,pipe size, bends, and leaks from the joints in
piping and makethe fuel pipe as shortas possible
to prevent air and vapor from being trapped. The standard fuelpipe diameter is 4 to 5 mm.
10-5 POWER TRANSMISSION to DRIVEN MACHINES
10-5-1 BELT D R I V E
Take the following notes into consideration.
*
V-belts are preferable to flat belts.
*
*
The driving shaft of 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.
*
If 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.
- 33 -
10-5-2 F L E X I B L E 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.
10-6 WIRING
Models EY35 and EY40 are available in types that have the ignition and starting systems shown in the wiring diagrams
below.
The parts indicated by dotted
lines in the diagram arenot normally supplied with the engine.
[RECOIL STARTER TYPE and LIGHTING COIL]
MAGNETO
Note: Standard type is not equipped
with the lighting coil.
STOP BUTTON
-
- - - - - - --1
E
Green/Yellow
SPARK PLUG
BUZZER
Fig. 52
[ELECTRIC STARTER TYPE]
MAGNETO
KEY SWITCH
ELECTRIC
STARTER
MAGNETIC
SWITCH
Fig. 53
[S.S.I. with RECOIL STARTER and LIGHTING COIL]
MAGNETO
1
SPARK PL.UG
STOP BUTTON
I
BUZZER
6V8W
@
*
J,
QLAMP
12V15W
Fig. 54
- 34 -
[S.S.I. with ELECTRIC STARTER]
KEY SWITCH
BATTERY
12W24AH
[S.S.I. 15OW with ELECTRIC STARTER]
RedIWhite
EXCITER COIL
CHARGING COIL
12V24AH
-
""_
[
""-I
Black/White
A
E L Z R I C STARTER
Red
Fig. 56
*
The symbols shown in the wiring diagrams above signify the following.
"""Not mounted on the engine
-
JIS CB104 jack
D
--
JIS CA104 plug
@ JIS LA104 or LA108 plate terminal
*
In the wiring diagram showing the circuit with a recoil, the ignition coil is optional, and therefore is not supplied on
the standard models.
- 35
-
10-7
VINYL-INSULATED WIRE
Recent engine sets become complex,and anincreasing number ofthem are remote-controlled.
When designing or repairing such machines, special care must be taken in selecting their wire. Select the correct wire from
the table below by considering the following.
FACTORS TO BE CONSIDERED
*
*
Amperage
*
Wire length
*
*
Mechanical strength of wire against vibration
Current flowing time (continuous, intermittent)
Wire size versus resistance
Size (mm2I
*
No. of conductors/
conductor diameter (mml
Resistor (Wml 2OoC
7r0.32
11r0.32
16r0.3 2
2610.32
41 10.32
6510.32
0.50
0.85
1.25
2.0
3 .O
5 .O
8.0
15.0
20.0
8410.45
4 110.80
30 .O
70f0.80
0.03250
0.02050
0.01410
0.00867
0.00550
0.00374
0.00228
0.00136
5010.45
0.00087
0.00051
(I
9
12
1.5
20
27
37
47
59
84
120
Electrical resistance increases with wire length, and decreases as conductor diameter increases. Resistance also varies
with material even if size and length are the same.
*
Albwable curre1
Nominal size means the nominal area of steel wire expressedby 00 square (SQ).
- 36
-
11. CHECKS and CORRECTIONS
After disassembling and cleaningthe engine, check and repair,
if necessary, according to the correction table. The correction
table applies whenever the engines are repaired. It is important for the servicemen to be familiar with the contents of tlus
table. Correct maintenance is recommended by observing the correction standardsspecified.
The meanings of the terms usedin the correction table are as follows:
Correction
1)
Repair, adjustment orreplacement of any engine parts.
2) CorrectionLimit
The limit on wear, damage or functional deterioration of engine parts beyond which normal engine performance 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) StandardDimensions
The design dimensionsof new parts minus tolerance.
5) CorrectionTolerance
Tolerance on thedimensions of engine parts refinished or adjusted.
- 37 -
12. TABLES OF CORRECTIONSTANDARDS
ITEM
Flatness of cylinder
head
ENGINE
MODEL
STANDARD
SIZE
T
TOLERANCE
LIMIT
0.05
0.1 5
EY35
EY40
EY35
S.T.D. 7 8 dia.
EY40
84 dia.
Bore
Roundness
EY35
EY40
Cylindricity
EY 35
EY40
Valve seat contact
width
EY35
EY40
Valve guide I.D.
EY 35
EY40
-
T
CORRECTION
Dif. between
max. & min.
+0.019
0.1 5
USE
LIMIT
REMARKS
TOOL
CORRECTION
METHOD
Surface
plate,
Feeler
Correct
0.65
0
0.01
Boring
0.01 5
-
O.D. at skirt, i n
thrust direction
(incl. oversize)
B 0.25
C 0.5
Width of ring
groove
Piston pin hole
EY35
EY40
EY35
EY40
EY35
EY40
1.2-1.5
2.5
8 dia.
+0.036
0.1 5
0.1 5
S.T.D. 77.951 dia.
B
78.201 dia.
C
73.451 dia.
S.T.D.83.951 dia.
B
84.201
dia.
C
84.451
dia.
0
-0.04
- 0.1
-0.1
Micrometer
Replace
0.1 5
0.1 5
Vernier
caliwrs
Replace
0.035
0.035
Cylinder
gauge,
Micrometer
Replace
Top, 2nd
Oil
0
2
Clearance between
pisition ring and
ring groove
F i t between piston
and piston pin
+0.04
Top
+0.055
-
EY35
0.048
0.108
EY40
0.048
0.1 11
Clearance between
piston and cylinder
-
Top
2nd
EY35
0.05
0.09
0.025
0.025
0.1 5
0.1 5
-
Max. cylinder dia. and
piston dia.
at skert in
thrust direction
Replace
EY40
Cylinder
gauge,
Micrometer
0.011 T
0.011 L
EY35
EY40
TOP
0.1
EY35
2nd
Ring gap
EY40
Oil 0.2
Ring width
Replace
-
+0.2
+0.002
-0.01 1
20 dia.
At middle
portion
+0.06
oil
4
Correct
EY35
Top.2nd
EY40
Oil
4
2
- 0.3
-
0.9
TOP -0.01
-0.03
2nd
1.5
Replace
-
- 0.1
-
- 38 -
1.5
-0.1
Mircrometer
ITEM
1 ENGINE1
MODEL
STANDARD
SIZE
1
CORRECTION
LIMIT
t
Large end I. D
EY35
EY40
1
-0
+0.016
dia.34
0.1
Oql
rod large end I.D.
and crankpin
33
Small end I.D.
EY35
EY40
EY15
a
:L."-EY15
EY20
V
Large end side
clearance
Parallelism between
large end and
I
0.2
20 dia.
I
I
1
+o.02
0.08
I
+
I
-0.03
Piston p i n 0.D.
1
1
USE
REMARKS
IM
TLO
L IETR A N C E
1
0.08
0.02
-
0.042
0.12
0.12
0.1
-
0.4
1.0
I
Micrometer
Replace
Cylinder
gauge
Replace
Cylinder
gauge,
Micrometer
Replace
Cylinder
gauge
Replace
Cylinder
gauge,
Micrometer
Replace
Feeler
gauge
Re-machine
or Replace
1
1
Test bar
0.1
gauge
Distance between
large end and
small end bores
Crankpin O.D.
Crankpin O.D.
roundness
Eb
1
cylindricity
Crankpin O.D.
Crankpin O . D .
parallelism
EY35
EY40
EY15
EY20
I
1
EY 20
EY15
-0.070
- -0.080
I
0.1 5
0.5
Less than 0.005
I
Re-machine
or Replace
Replace
Re-machine
or Replace
meter
Re-machine
or Replace
Micrometer
Re-machine
or Replace
or Replace
~
Drive 5. 25 dia.
Mag. s. 25 dia.
-0.003
Micrometer
Drive,s.
-0.014
dia.
25
EY40
I
Micrometer
Re-machine Dial
gauge
Less than 0.01
~~~~
I
Test bar
and Micrometer
Micro-
Less than 0.005
EY15
EY20
Crankshaft
journal O.D.
I
1
0'15
CORRECTION
METHOD
Mag. s. 25 dia.
Intake
36
to.1
Cam lobeheight
-0.25
Exhaust 35.5
Drive S. 35 dia.
EY35B
Mag.
S. 25 dia.
Drive S. 17 dia.
EY35D
-0.25
-0.003
-0.014
-0.003
-0.012
n.
-0.01
6
-0.027
,.
-
P
I."&,
Mag. S . 17
dia.
I
-0.01 6
-0.01 7
- 39 -
0.05
0.05
0.05
Replace
Micrometer
Replace
Micrometer
Replace
ITEM
LIMIT
1
Drive S. 35 dia.
EY4OB
4-
5
Journal
OD.
CORRECTIOP
METHOD
-0.003
S. 25 dia.
-0.01 2
-0.016
0.05
0.05
-1.5
-1.5
MicroMeter
Replace
Vernier
calipers
Replace
!Square
feeler
Qawe
Replace
Micro.
meter
Replace
-0.027
-0.027
1
46
1
- 0.030
-0.055
Valve stem O.D.
Clearance between
TOOL
-0.003
EY40D
EY35
EY40
1
-0.014
Drive S. 17 dia.
EY35
EY40
REMARKS
i
Mag.
.4-
1
-0.15
Exhaust 8 dia.
-0.070
EY35
Intake
0.030-0.091
EY40
Exhaust
0.070-0.126
0.3
I
0.3
Replace
mA
i dtd l e
Correct
w
4= II
I
Clearance between
grooveandretainer
Stem end length
- 1I
EY35
EY40
0.04-0.1 5
1
Replace
1
5.3
-0.5
Total length
-L
-0.5
E
Clearance between
stemandguide
EY35
EY40
1
0.025-0.062
I
0.2
Vernier
calipers
Replace
Vernier
calipers
Replace
Cylinder
gauge &
Micrometer
Replace
I
I
I
I
(
I
1
EY35
+1/4
Pilot screw
unscrew
EY40
I
1%
71
Spark plug
EY35
EY40
EY40
EY35
B-6HS
I
0.6
EY35
I
0.35 EY35
0.7
i 3O
23'before T.D.C.
EY40
-
I
f
5"
.
f 0.05
Adjust or
replace
1.0
Timing
tester
Adjust
f 0.1
Adjust
Point opening
EY40
-40
-
MODEL
ITEM
~~~
EY35
8.514000
EY40
10.0/3,600
EY35
7.013600
EY40
8.013600
Max. Output
Below 1 10% of rated output
Continuous Rated
output
I
ITEM
MODEL
literlhr
EY35
2.9
EY40
3.5
I
1
I
MODEL
ITEM
EY35
25
EY40
30
-
30
60
40
80
REMARKS
liter
MODEL
ITEM
USE L I M I T cc/hr
cc/hr
Lubricant
Consumption
-
At continuous rated output
Up 135% of standard consumption
Fuel Consumption
1
REMARKS
CORRECTIONPRECISENESS
REMARKS
EY35
Fixed quantity
of Lubricant
1.2
EY40
ITEM
liter
MODEL
REMARKS
Use the class SC or higher grade Engine Oil
0°C)
SAE 1 OW-30
Winter
(lower
than
Autumn
SAE
Spring
and
#20
Summer
SAE #30
I
1
I
I
OF OIL
ITEM FREQUENCY
EY35
EY40
MODEL
I
MODEL
First time: Change oil after 20 hours operation.
Second Time and Thereafter: Change oil every 50 hours operation.
Oil Change
ITEM
CHANGE
CORRECTION LIMIT
kg/cm'/rpm
I
I
I
TOOL
I
EY35
- 41
-
REMARKS
I
1
-
ITEM
MODEL
TOOL
rpm
REMARKS
,-
Min. accelerating
revolution
Crankshaft
-
r
ITEM
I
kgcm
T
ft-lb
TOOL
REMARKS
340- 390
24.6-28.3
Torque wrench
-
18-21.7
Torque wrench
57.9-72.3
Torque wrench
12.3-13.7
Torque wrench
18.8-21
Torque wrench
EY40
EY35
Connecting rod
bolts
Main bearing cover
bolts
I
EY35
Cylinder head
clamp nuts
Magneto
clamp
nuts
MODEL
250
EY40
1
EY35
EY40
1
300
800-1000
170-190
EY40
EY 35
Spark plug
260
EY40
-
290
-42
-
13. 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 theseintervals.
For example, if the engine is operated in extremely dusty conditions, the air cleaner should be cleaned every day instead of
every 50 hours.
13-1 D A I L Y CHECKS and MAINTENANCE
I
Checks and maintenance
Reasons for requiring them
The governor linkageis especially susceptible to dust.
Remove dust from whatever parts which
accumulated dust.
Not only wasteful butalso dangerous
Check external fuel leakage. If any, retighten or
replace.
I
Check screw tightening.If any loose one is found,
re-tighten.
Check oil level in crankcase and add up as necessary.
Loose screws and nuts will result in vibration
1
accidents.
I
If the engine is operated without sufficient oil, it will
fail.
13-2 EVERY 20 HOURS CHECKS and MAINTENANCE
maintenance
Reasons and Checks
I
1
I
for
them
requiring
1
Change crankcase oil.
TO
remove run-in wear particles
13-3 EVERY 50 HOURS (10 DAYS) CHECK and MAINTENANCE
Checks and maintenance Reasons
for requiring them
Contaminated oil accelerates wear.
Change crankcase oil.
1
I
1
Check spark plug. If contaminated, wash in
~ _ _ _ _
Clogged air cleaner harms engine operation.
Output power is reduced and starting
is made difficult.
gasoline or polish with emery paper.
13-4 EVERY 100- 200 HOURS (MONTHLY) CHECKS and MAINTENANCE
I
Reasons for requiring them
maintenance
and
Checks
Clean fuel filter and fuel tank.
The engine will be out of order.
Clean contact breaker points.
The engine output drops.
-43
-
1
13-5 EVER'.' 502
-
600 HOURS (SEMIANNUAL) CHECKS and MAINTENANCE
Reasons for requiring them
Checks and maintenance
The engine will be out of order.
Remove cylinder head and remove carbon
deposit.
Disassemble and clean carburetor.
13-6 EVERY 1000 HOURS (YEARLY) CHECKSand MAINTENANCE
I
I
Checks and maintenance
Reasons for requiring them
The engine output drops and become out of order.
Perform overhauls, clean, corrector replace
parts.
Change piston rings.
I
1
Replace fuel pipe
once
year.
a
To prevent
from
danger
caused
by
the fuel leakage.
13-7 PREPARATION for LONG ABEYANCE
1) Perform the above 13- 1 and 13-2 maintenance jobs.
2) Drain fuel from the fuel tank and carburetor 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.
- 44"
Industrial
Engines