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8. ignition system - Subaru Industrial Power

1. ITEM STD Limit CAMSHAFT Cam peak height intake and exhaust Intake 35 658 35 758 35 61 1 4039 1 4078 1 4020 F EXHAUST can peak INTAKE height Exhaust 39 408 39 508 39 36 1 5515 1 5554 1 5496 Cam inner diameter 10 0 10 036 10 05 IT D1 D2 0 3937 0 3951 0 3957 Cam sprocket inner diameter Pin cam sprocket outer diameter 5 Pin outer diameter 9 953 9 975 9 95 D3 D4 jp 03 04 0 3919 0 3927 0 3917 ER INTAKE EXHAUST VALVES Valve stem outer diameter T 5 970 5 985 5 85 0 2350 0 2356 0 2303 Exhaust 5 970 5 985 5 85 0 2350 0 2356 0 2303 Clearance between valve stem and valve guide Intake 0 050 0 083 0 3 0 0197 0 0033 0 0118 Exhaust 0 050 0 083 0 3 0 0197 0 0033 0 0118 Valve clearance in cold state Intake 0 12 0 15 0 25 0 0047 0 0059 0 0098 Exhaust 0 12 0 15 0 25 0 0047 0 0059 0 0098 76 Unit mm in ITEM Oil consumption has been measured under following condition Good break in operation has been finished Oil 10W 30 Grade SE Load Continuous load 3600 rpm Bo T STD Limit VALVE SPRING FREE LENGTH 36 5 1 4370 VALVE SEAT ANGLE INTAKE AND EXHAUST Valve cutter angle a Valve contact wi
2. CHAIN CAMSHAFT CHAIN M6 x 12 BOLT 1 pc S N Bolt used to prevent the CAMSHAFT pin camshaft from coming out lt TENSIONER PIN TENSIONER Fig 5 44 11 MOUNTING THE TENSIONER EE gt TENSIONER TENSIONER PIN TENSIONER Fig 5 45 12 BALANCER SHAFT Mount the balancer shaft on the crankcase align the timing marks on the balancer gear and the crankshaft gear NOTE Incorrect alignment of the timing marks can result in malfunction of the engine leading to damage due to interference of the parts Fig 5 46 TIMING MARK nu us 13 MAIN BEARING COVER Apply oil to the bearing and the oil seal lip when mounting the main bearing cover Also apply sealant Three Bond 1215 to the surface of the crankcase To avoid damaging the oil seal lip wrap the crankshaft key way portion with polyvinyl tape before mounting the main bearing cover NOTE Be careful that the lever portion of governor shaft does not face the main bearing cover Tightening torque 22 0 24 0 Nem 220 240 kgf cm 16 2 17 7 ft lb VIEW B GOVERNOR SHAFT M8 x 38 mm 8 pcs 12mm box wrench SEALANT Three bond 1215 MAIN BEARING COVER 34 14 Pass the pin rocker arm through the rocker arm and mount them on the cylinder head NOTE 1 Conduct this job at the compression top dead center The position of two
3. Fig 4 11 4 14 CARBURETOR The engine is equipped with a horizontal draft carburetor The carburetor setting is calibrated after careful testing for optimum all round performance including starting acceleration fuel consumption output power characteristics Special attention is also paid to the general purpose use of the engine For further information refer to page 54 section 13 CARBURETOR 4 15 AIR CLEANER The engine uses an air cleaner that is quieter than conventional ones A semi wet urethane foam element is used in the STD air cleaner Dual element air cleaner with a primary element of dry type sponge and secondary element of dry type paper and other types are also provided as special options 4 16 BALANCER Unbalanced inertia force is cancelled by the balancer which rotates at the same speed as the crankshaft to effectively reduce vibration 4 17 DECOMPRESSION SYSTEM The automatic decompression system is mounted on the camshaft It opens the exhaust valve before the compression top thereby alleviating the compression pressure and reducing the force required to pull the recoil starter During engine operation the decompression system is overpowered by centrifugal force and compression is fully utilized to produce power Urethane Element Type URETHANE FOAM AIR CLEANER COVER FP Dual Element Type URETHANE FOAM AIR Te CLEANER
4. Battery 12V 24AH or larger Key switch 066 00003 30 Electric starter Fig 9 2 48 9 3 MODEL WITH OIL SENSOR Orange z Orange Black Stop switch Black LED Oil sensor control unit LA106 Black LA104 To stop switch Oil sensor as option Fig 9 3 49 Oil sensor Body earth 10 3 COMPONENT PARTS Magnetic and shift type MAGNETIC SWITCH LEVER M kl PINION AY a ARMATURE AY gt A BRUSH HOLDER 5 REAR COVER FRONT METAL THROUGH BOLT 2 pcs PINION STOPPER SET Fig 10 3 51 10 ELECTRIC STARTER 10 1 SPECIFICATIONS Model EX35 40 mte 7 Model STARTING MOTOR AY Ee 2 M8x1 25 PINION GEAR Manufacturer DENSO Y D gt Volt V 12 oltage V is _ Big Power kW 0 6 A 5 pe Weight kg 3 4 i MOUNTING FACE 150 2 _53 8 204 d Fig 10 1 10 2 OPERATING PRINCIPLES The battery is connected to the 8 mm diameter terminal of the magnetic switch The figure below shows the state when the starter is ON M CONTACTOR gt BATTERY 12V 24AH or larger COIL ELE
5. Key Key Fig 15 2 Belt Pulley Installation Install the belt pulley in the no over hang condition as shown in the illustration Correct Incorrect Large over hang Pulley Crankshaft PTO Crankshaft PTO Fig 15 3 Pulley fitting onto PTO shoulder For proper pulley fitting onto PTO shoulder make round chamfer at pulley corner Sharp edge of pulley corner strikes PTO shoulder In this improper condition bolt will be loosened and PTO damaged finally Improper Pulley Pulley Crankshaft PTO Crankshaft PTO Round chamfer for proper fitting Sharp edge striking Fig 15 4 65 16 TROUBLESHOOTING If the engine shows any sign of malfunction the cause should be determined immediately and appropriate countermeasures should be taken to prevent the problem from worsening This section describes certain known problems their possible causes and appropriate countermeasures Note however that the list of problems presented here is not all Generally speaking since there is the possibility of multiple causes for a single problem please use your experience and common sense when deciding on what action to take 16 1 ENGINE The following three conditions must be fulfilled for satisfactory engine start 1 The cylin
6. BYPASS i B FLOATCHAMBER CHOKEBORE FLOAT CHAMBER CHOKE BORE E MAIN JET MAIN AIR BLEED SLOW JET SLOW AIR BLEED SLOW PORT BENTURE BYPASS HOLE nm IDLE HOLE THROTTLE BORE THROTTLE BORE SLOW AIR BLEED BLEED TO INTAKE PORT TO INTAKE PORT AIR INTAKE PORT Epos UC MAIN NOZZLE FUEL SLOW JET m Q A t d lt I Q 1 Ir 14 E NEEDLE VALVE if AER zu um FLOAT B B CHAMBER C C FUEL p AIR gt MIXTURE zz Fig 13 1 55 13 3 DISASSEMBLY AND REASSEMBLY Mechanical failures aside most carburetor malfunctions occur when the fuel air ratio of the mixture is not correct This is usually caused by clogged jets air passages and fuel passages or by variations in the fuel level To get the best possible performance from the carburetor ensure that the each passages are kept clean so that air and fuel can flow freely through them DETAIL A FUEL NIPPLE with locktight 2 0 RING SPACER O RING DRAIN SCREW TIGHTENING TORQUE 2 0 2 5 N m DETAIL B 8 PROJECTION dk 56 The procedures for overhauling the carburetor are described below Refer to Fig 13 2 13 3 1 THROTTLE SYSTEM 1 When the throttle stop screw is removed the spring can be taken out 2 Remove the phillips screw 92 and the throttle valve 63 then take o
7. Dual element type Urethane element type M6 flange nut 2 pcs M6 x 16 mm flange bolt 1 pc BREATHER PIPE Fig 5 60 25 SPEED CONTROL LEVER and BRACKET Tighten the bolt which is temporarily fit Fig 5 58 m Governor system adjustment method The governor unit is a centrifugal flyweight type and is installed on the governor gear Since it automatically adjusts the throttle valve of the carburetor by means of a link mechanism it is possible to maintain a constant engine speed even with load variations 1 Turn the speed control lever to the full speedposition makingsurethatthecarburetor throttle valve is fully open 2 Hold the top of the governor shaft with the plierand turning itcounterclockwise as far as itwill go Tighten the bolt on the governor lever GOVERN de SHAFT GOVERNOR LEVER GOVERNORSPRING GOVERNOR ROD and ROD SPRING 40 Fig 5 61 26 BAFFLE2 RECOIL BRACKET BLOWER HOUSING RECOIL STARTER and STOP SWITCH 1 Set the ignition coil cord to the notch of the insulator and then mount the baffle 2 to the crankcase M6x12 mm bolt 3 pcs 2 Mount the recoil bracket to the crankcase stud bolts M6 Nut 4 pcs 3 Mount the stop switch to the blower housing M4 x 12 mm screw and washer 2 pcs Tighten the wire 2 ground with the stop switch See Detail C 4 Mount the blower housing on the crankcase M6 x 16 mm bolt 5 pcs Tighten the w
8. E 2777 E PEPER ELEMENT Fig 4 13 ROCKER ARM EXHAUST VALVE SIDE EXHAUST VALVE CAMSHAFT Fig 4 15 4 18 SECTIONAL VIEW OF THE ENGINE Cross sectional view across the shaft FUEL TANK TANK CAP BLOWER HOUSING GOVERNOR LEVER COOLING BLOWER GOVERNOR GEAR RECOIL STARTER HANDLE CRANKSHAFT STARTING PULLEY RECOIL STARTER CONNECTING ROD FLYWHEEL Q RECOIL BRACKET BOLT CHARGE COIL SENSOR MAIN BEARING COVER RECOIL BRACKET OPTION OPTION Fig 4 16 10 Cross sectional view along the shaft GOVERNOR SHAFT CHAIN GUIDE MUFFLER COVER FUEL TANK GOVERNOR LEVER PISTON PIN EXHAUST MUFFLER TAIL SCREEN P ax m DEFLECTOR a REI OH 7 GOVERNOR Nu oy GEAR aee SPARK ARRESTER MAGNETIC OPTION SWITCH rj 96 0 6 5 ROCKER W D ARM We STOP 7 AE SWITCH SE CAMSHAFT 2 5 26 pd 2 2 INTAKE E 5686 DG VALVE eg ae STARTING Nu b PISTON MOTOR KH CA OPTION 5 26 OIL GAUGE PISTON RING BALANCER GE
9. or screwdriver Drain fuel from the carburetor drain OILGAUGE GASKET GASKET DRAIN PLUG Fig 5 2 L lio FUEL STRAINER Fig 5 3 13 DUAL ELEMENT TYPE M6 FLANGE NUT 2 pcs 55 AIR CLEANER COVER URETHAN FOAM PAPER ELEMENT AIR CLEANER BASE BREATHER PIPE M6 x 16 FLANGE BOLT 1 pc Fig 5 4 14 Step Parts to remove Remarks and procedures Fasteners Air cleaner cover Remove the air cleaner cover and element screwdriver 3 Air cleaner Remove the air cleaner while pulling the breather pipe 10 mm box spanner away from the rocker cover M6 nut 2 pcs 4 M6 x 16 1 pc URETHANE ELEMENT TYPE AIR CLEANER COVER URETHAN FOAM Step Parts to remove Remarks and procedures Fasteners Muffler and Muffler cover 1 Remove the muffler cover from the muffler 12 mm box spanner 2 Remove the muffler from the cylinder head Take 10 mm box spanner or care not to lose the gasket spanner Take care not to cut your hand with the muffler 5 M6 x 8 mm 4 pcs gasket M8 nut 2 pcs Seal the exhaust port with adhesive tape or plug M8 x 12 mm 1 pc it with cloth to prevent nuts and other objects from falling inside Fuel tank 1 Remove the fuel tank mounting nuts and bolts from 12 mm box spanner the crankcase 12 mm spanner M8 nut 2 pcs 6 2 Disconnect fuel hose from the strainer to carburetor M8 x 25 mm 2 pcs
10. 1 Low compression Check and repair 5 1 Ignition system problems 1 Loose ignition system wiring Inspect and tighten 2 Improper or faulty spark plug Clean or replace 2 Fuel system problems 1 Lean or rich fuel air mixture Clean adjust or replace carburetor 2 2 Carburetor contamination Overhaul or clean 3 Dirty or clogged fuel lines Clean or replace S 4 Air mixing from air intake system joints Tighten replace gasket E 3 Cylinder head 1 Carbon deposit in combustion chamber Clean 2 2 Leakage from cylinder head gasket Replace 4 Valve system problems 1 Improper valve clearance Adjust 2 Valve heat deterioration Replace 3 Worn or broken valve spring Replace 4 Improper valve timing Adjust 68 16 2 ELECTRIC STARTER Engine does not start e Charge or replace the battery corrosion of battery terminals Check battery charged Does the NG Does the NG state and battery terminal NG e Repair connection or crank run starter run gt connection or corrosion gt for any abnormality OK e Key switch e Connected state OK Operation sound of NG e Check repair wiring to the magnetic switch of starter starter magnetic switch e Repair or replace starter magnetic switch OK OK Check settlin
11. NOTE 1 Replace the valve with a new one if it shows signs of wear Refer to the STANDARD REPAIR TABLES on page 76 and 77 NOTE 2 Carefully scrape off any carbon deposits on the combustion chamber Apply oil to the valve stems before mounting the intake and exhaust valves Insert the valves in the cylinder head and place it on a level workbench Next mount the valve springs the spring retainers and collet valves Mount the stem seal on the intake valve guide ALIGNMENT MARKS Fig 5 37 Fig 5 38 COLLET VALVE SPRING RETAINER VALVE SPRING c PLATE ZA EXHAUST ONLY 2 ae i Y 051 STEM SEAL 0 INTAKE ONLY CYLINDER HEAD INTAKE VALVE VALVE SPRING SPRING RETAINER COLLET VALVE Fig 5 39 7 CHAIN GUIDE Mount the chain guide to the crankcase Models EX35 40 mounting positions 2 Fig 5 40 8 CYLINDER HEAD Inspect and repair any scratches on mounting surface and replace head gasket to new one before installing CHAIN GUIDE Fig 5 41 Tightening Torque flange bolt 4 pcs 14mm box wrench 17 0 19 0 170 190 kgf cm 12 3 13 7 ft lb M8 x 35 mm 6 flange bolt 2 pcs 12mm box wrench 274 step Cylinder head bolts Remarks 29 0 31 0 Nem 290 310 Re use M10 x 75 D 21 0 22 4 ft Ib 37 0 39 0 N
12. 0 090 0 15 n 0 0020 0 0035 0 0059 Oil ring 0 030 0 125 three piece 0 0012 0 0049 Piston pin hole ST 20 989 21 022 21 045 407 0 8263 0 8276 0 82854 Piston pin outer diameter 20 992 21 000 20 960 0 8265 0 8268 0 8252 Clearance between piston and cylinder at skirt 0 065 0 107 0 25 0 0026 0 0042 0 0098 0 10 0 25 1 5 Top 0 0039 0 0098 0 0591 Oil ring 0 15 0 55 1 5 three piece 0 0059 0 0217 0 0591 Unit mm in ITEM STD Limit CONNECTING ROD Large end inner diameter 38 000 38 016 38 1 1 4961 1 4967 1 5000 Clearance between large end and crank pin 0 030 0 060 0 2 0 0012 0 0024 0 0079 Small end inner diameter 21 010 21 023 21 08 0 8272 0 8277 0 8299 Clearance between small end and piston pin 0 010 0 032 0 12 0 0004 0 0013 0 0047 Large end side clearance ING 0 100 0 780 1 0 0 0039 0 0307 0 0394 CRANKSHAFT Crank pin outer diameter 37 956 37 970 37 85 1 49433 1 4949 1 4902 Journal outer diameter PA D1 34 986 34 997 1 3774 1 3778 D2 34 986 34 997 1 3774 1 3778 75 Unit mm in
13. 370 390 kgf c 26 7 28 2 1 33 o When replace to new cylinder head and flange bolts As for and only 1 step tightening Tighten the cylinder head bolts in diagonal order 1 Re use Oil the screw thread e Tighten all bolts 6pcs by 18 1 N m primary and then tighten longer ones M10 x 75mm flange bolt 4pcs by 30 1 m 2 When replace to new cylinder head and flange bolts Oil the screw thread e Tighten all bolts 6pcs by 18 1 m primary and then tighten longer ones M10 x 75mm flange bolt 4pcs by 38 1N m 31 M8 x 35 BOLT 2 pcs CYLINDER HEAD Fig 5 42 9 SETTING THE TIMING CHAIN a Align the timing mark on the crankshaft sprocket with the mark plate of the timing chain b Align the timing mark on the crankshaft sprocket with the mark plate of the opposite end of the timing chain Number of oval steel link 112 MARK PLATE The mark plate does not have a camshaft side or crankshaft sprocket side CHAIN GUIDE FITTING POSITION TIMING MARK CAMSHAFT SPROCKET CRANKSHAFT SPROCKET MARK PLATE Fig 5 43 10 MOUNTING THE CAMSHAFT ON THE CYLINDER HEAD Mount the camshaft on the cylinder head by inserting the pin camshaft through the head Fix the bolt to prevent the pin camshaft from coming out M6 x 12 BOLT 1 pc Bolt used to prevent the pin camshaft from coming out
14. Clean the air cleaner 2 A clogged air cleaner can cause engine malfunction 3 Inspect the spark plug Clean with gasoline or 3 A faulty spark plug can cause low power output polish with sandpaper if dirty and poor starting performance 18 4 INSPECTION AND MAINTENANCE EVERY 100 TO 200 HOURS EVERY MONTH MAINTENACE ITEMS REASON REMARKS 1 Clean the fuel strainer and fuel tank 1 Contaminated fuel can cause engine malfunction 2 Change the air cleaner element 2 A clogged air cleaner can cause engine malfunction 3 Clean and adjust the spark plug electrode 3 Cause low power output and poor starting performance 2 79 18 5 INSPECTION AND MAINTENANCE EVERY 300 HOURS MAINTENACE ITEMS REASON REMARKS 1 Inspect the intake and exhaust valve clearance 1 Incorrect clearance can cause low power output Adjust if necessary and engine malfunction 18 6 INSPECTION AND MAINTENANCE EVERY 500 TO 600 HOURS EVERY 6 MONTHS MAINTENACE ITEMS REASON REMARKS 1 Remove the cylinder head and remove any carbon 1 Carbon deposits can cause engine malfunction 2 Disassemble and clean the carburetor 2 A faulty carburetor can cause engine malfunction 3 Inspect and fitting the intake and exhaust valve 3 Unfitting can cause low power output and engine and the seats of them malfunction 18 7 MAINTENANCE EVERY 1 000 HOURS ANNUAL MAINTENANCE MAINTENACE ITEMS RE
15. take care when assemble Do not use drill or similar objects for cleaning the jets as these are likely to damage the orifices which in turn can impair fuel flow Use compressed air to clean the jets The float pin is pressed into the carburetor body When removing the needle valve and the float a rod or a similar tool slimmer than the float pin should be used Tap the reverse side gently and remove sure the direction of the O ring spacer 2 when reassembling Mount the O ring spacer 2 to set the projection on opposite side of the fuel nipple If it is mounted incorrect An engine improper running sure not any damage on the O ring and surely assemble it may cause of overflow 57 14 RECOIL STARTER 14 1 RECOIL STARTER Tools required Screwdriver pliers and protective glasses ACAUTION Put on the protective glasses prior to start disassembly 14 1 1 DISASSEMBLY PROCEDURE 1 Release the reel spring power 1 Hold the starter knob and pull out the starter rope 2 Pull out the rope fully and align the rope knot in the reel with the rope guide 3 Hold the reel down firmly with both thumbs taking care not to allow it to spring back Fig 14 1 4 Remove the knot from the reel untie the knot and pull the rope out toward the starter knob Note This procedure requires 2 people 5 While controlling the reel with the thumbs slowly wind it back as
16. 16 The position of compression top dead center ROCKER ARM EXHAUST VALVE SIDE ROCKER ARM INTAKE VALVE SIDE Fig 5 15 Fig 5 16 ROCKER ARM 5 EXHAUST VALVE SIDE ROCKER ARM ROCKER ARM INTAKE VALVE SIDE VIEW A GASKET ROCKER COVER Io ROCKER COVER Fig 5 14 M6 x 12 BOLT 4 pcs Step Parts to remove Remarks and procedures Fasteners Main bearing cover Remove the flange bolts of main bearing cover from 12 mm box spanner the crankcase M8 x 38mm 8 pcs Remove the main bearing cover while tapping gently 22 around the cover using a plastic hammer or similar tool See Fig 5 18 Be careful not to damage the oil gauge or oil seal or not to lose the pipe knocks Fig 5 18 MAIN BEARING COVER Fig 5 17 22 Step Parts to remove Remarks and procedures Fasteners Tensioner Camshaft 1 Remove the tensioner See Fig 5 20 M10 box spanner or Do not lose the pin tensioner spanner 2 Remove the retaining bolt of pin camshaft from M6 x 12mm 1 pc the cylinder head See Fig 5 21 23 3 Remove the pin camshaft taking care not to Pliers scratch the O ring 4 Remove the chain from the camshaft sprocket and then take out the camshaft See Fig 5 22 5 Remove the chain from the crankshaft RS M6 x 12 BOLT 1 pc Bolt used to prevent the pin camshaft from
17. B terminal for deformation looseness rusting or dust sticking Carefully check inserting method of the S terminal If not abnormal set the key Switch to START position while cranking no ignition of engine and check if voltage is applied to the S terminal and B terminal of starter motor KEY SWITCH 1 When no voltage is applied to the S terminal and B terminal check continuity of the terminals and key switch and repair or replace if necessary 2 If voltage is applied to the S terminal and B terminal go to 2 Battery checking 2 Battery checking Check battery voltage and specific gravity of battery fluid Voltage Normal value 12 4 to 12 8V Limit charging required 12 4V or lower Staring limit 12V at 20 C Specific gravity Normal value 1 22 to 1 29 Limit Charging required 1 22 or lower Service life Variance in specific gravity among cell 0 04 or more BATTERY 1 Charge or change the battery when voltage is lower than 12 4V or specific gravity is lower than 1 22 at 20 C 2 If the wiring and battery are normal remove the starter and go to 3 Checking of pinion operation Use battery rated 12V 24AH or larger 3 Checking of pinion operation Check if the pinion operates or sound of magnetic switch contactor is heard If the pinion does not operate or magnetic switch sound is not heard check continuity of each coil of magnetic switch 1 If
18. Fig 8 2 b At lower engine revolution when the flywheel reached the ignition point the low speed ignition timing control circuit operates to run the base current to turn the signal transistor ON allowing the current to bypass as current 14 At this moment the power transistor 2 turns OFF and the current I2 is abruptly shut resulting in the high voltage generated in the secondary coil which produces sparks at the spark plug c At higher engine revolution the advancing control circuit 6 operates at the ignition timing to run the base current 15 to turn the signal transistor D ON allowing the current to bypass as current le At this moment the power transistor turns OFF and the current I2 is abruptly shut resulting in the high voltage generated in the secondary coil which produces sparks at the spark plug The operating timing of the advancing control circuit advances in accordance with the increase of engine speed resulting in the advancing of ignition timing as shown in Fig 8 2 9 WIRING DIAGRAM 9 1 MODEL WITHOUT ELECTRIC STARTER Spark plug gt H Black 4 Ignition coil bs built in transistor Stop switch Flywheel 7777 Fig 9 1 9 2 MODEL WITH ELECTRIC STARTER Spark plug gt lt 1 Black qd FTT Magnet Ignition coil Key switch Charge coil Diod T
19. disassembly 80 18 9 ENGINE STORAGE 1 Carry out the maintenance jobs described in step 18 1 above 2 Drain fuel from the fuel tank and carburetor float chamber 3 To prevent rust in the cylinder bore inject oil through the spark plug hole pull the recoil starter knob gently 2 or 3 times and then put back the spark plug 4 Pull the recoil starter knob until the resistance is heavy Leave it in that position 5 Clean the exterior of the engine with an oiled cloth Place a plastic cover or similar over the engine and store the engine in a dry place 81 ISSUE EMD ES2461 Cx SUBARU FUJI HEAVY INDUSTRIES LTD INDUSTRIAL PRODUCTS COMPANY 4 410 ASAHI KITAMOTO SHI SAITAMA 364 8511 JAPAN TEL 81 48 593 7798 FAX 81 48 593 7946 Printed in Japan http www fhi co jp robin 2008 02
20. method after mounting air cleaner base ROD SPRING ROD SPRING None direction GOVERNOR SPRING Make sure a direction GOVERNOR ROD S Short length E GOVERNOR SPRING Long length M6 x 12 BOLT 1 pc Temporarily fit the bolt N GOVERNOR LEVER SPEED CONTROL LEVER and BRACKET KI E C Y md SHAFT E d f GASKET CHOKE LEVER GASKET y P di A A ei NY umet E M EN nae CARBURATOR INSULATOR Fig 5 58 38 23 SPEED CONTROL LEVER and BRACKET See Fig 5 58 59 Install the speed control lever and bracket to the top of the chock lever at the same time mount bracket to the intake side stud bolts on the cylinder head GOVERNOR ROD GOVERNOR ROD and ROD SPRING Long SPRING length ROD SPRING GOVERNOR LEVER GOVERNOR LEVER Short length SPEED CONTROL LEVER and BRACKET Variation of the governor spring The dimensions of the governor spring are different each other according to the Hz The governor spring for the standard engine is same as that for the engine to be connected to the 60 2 generator EX35 and 40 60Hz STD color silver EX35 and 40 50Hz color Different from silver 39 24 AIR CLEANER BASE Insert the breather pipe into the rocker cover and then mount the air cleaner base The following are positions to insert for each type of element
21. reel Fig 14 7 2 Tie a knot in the rope end Fig 14 8 3 Put the rope into the reel taking care that the rope end does not stick up Fig 14 9 4 Grasp the rope firmly with one hand at approximately 50 cm from the rope guide and keep the rope tense taking care that the rope EUER is not pulled into the reel 5 Release the reel carefully and allow the rope to be wound back slowly by the force of the spring until the knob reaches the rope guide Assembly is completed 3 CN Fig 14 9 The disassembly and the reassembly are completed however carry out the following to check if the necessary components have surely been assembled 61 14 1 3 CHECKING THE RECOIL STARTER AFTER REASSEMBLY 1 Pull the starter knob about 2 3 times a If the starter knob is too heavy to pull check that each parts have been assembled as specified b If the ratchet does not work check for missing parts such as the friction spring 2 Pull out the starter knob as far as it will go a If the starter rope remains in the rope slot in the reel the spring may be over stressed To fix this pull out the starter rope approximately 30 cm and controlling the rotation of the reel with your thumb allow the starter rope to rewind about 1 or 2 turns b If the starter rope rewinds slowly or only partially apply grease or oil to the rotary parts or the friction surfaces If this does not help try winding up the
22. side Remove the bolt for fuel strainer screwdriver 3 Remove the fuel tank from the crankcase 10 mm box spanner M6 x 12 mm 1 pc M6 x 12 BOLT 1 pc La FUEL STRAINER MUFFLER COVER M6 x 8 FLANGE BOLT 4 pcs Fig 5 6 FUEL TANK M8 NUT 2 m M8 x 12 P d Seal the exhaust port with adhesive MUFFLER BOLT 1 pe P d GASKET It has two faces ee ho od N tape or plug it with cloth H Fig 5 5 Step Parts to remove Remarks and procedures Fasteners Stop switch Disconnect the wire and remove the stop switch from screwdriver the blower housing M4 x 12 mm 2 pcs Recoil starter Remove the recoil starter from the blower housing 10 mm box spanner M6 x 14 mm 4 pcs Blower housing 1 Remove the blower housing synthetic resin from 10 mm box spanner the crankcase M6 x 16 mm 5 pcs Recoil bracket 2 Remove the recoil bracket from the crankcase M6 nut 4 pcs Baffle 2 Remove the baffle 2 synthetic resin from the 10 mm box spanner crankcase M6 x 12 mm 3 pcs M6 x 14 BOLT 4 pcs M4 x 12 SCREW and WASHER 2 pcs STEP 7 STOP SWITCH M6 x 16 BOLT 5 pcs M6 FLANGE NUT 4 pcs RECOIL STARTER BLOWER HOUSING RECOIL BRACKET Ze M6 x 12 BOLT 3 pcs BAFFLE 2 Fig 5 7 16 Step 11 Parts to remove Sp
23. the pinion operates or contactor sound is heard step to 4 Checking of magnetic switch 1 2 In case of no continuity Replace the magnetic switch 3 When continuity is OK Step to 4 Checking of magnetic switch 2 4 Checking of magnetic switch 1 Starter does not run or only click sound is heard 1 Operate the magnetic Switch and check B M terminals 2 Check the magnetic switch plunger and bobbin interior for dust sticking or rusting 1 In case of no continuity Contact continuity failure Replace the magnetic switch 2 When continuity is OK Step to 5 Motor checking 1 Clean the plunger If the bobbin interior is contaminated replace the magnetic switch 5 Motor checking Connect the side of the battery to the M terminal of magnetic switch and check if the motor runs 1 If the motor does not run check electric circuit inside the motor field coil armature and brush and replace faulty parts 70 Problem and check item Description Remedy Check engaged state of pinion and ring gear 2 Starter runs but engine not Motor idles and engine does not run 1 Remove and check the starter Check or replace the pinion clutch if necessary 2 Check battery charged state and battery terminal connection or corrosion for any abnormality If pinion and ring gear do not engage with each other and abnormal nois
24. 0 Ignition System Transistorized magneto Spark Plug NGK BR 6HS Charging Capacity Option 12 1A 3A 16 7A Option Starting System Recoil starter Electric starter Option Governor System Dry Weight kg Ob Centrifugal flyweight system 33 72 75 Dimensions L x W x H mm in 389 x 450 x 443 15 31 x 17 72 x 17 44 Specifications are subject to change without notice 2 PERFORMANCE 2 1 MAXIMUM OUTPUT The Maximum output is the output of an engine with its throttle valve fully opened and considering that all the moving parts are properly broken in A new engine may not produce full maximum output while its moving parts are still not broken in NOTE Power curves shown in the following charts are made in conformity with SAE internal combustion engine standard test code J1349 2 2 CONTINUOUS RATED OUTPUT The continuous rated output is the output of an engine at optimum governed speed which is most favorable from the view point of engin s life and fuel consumption When the engine is installed on a certain equipment it is recommended that the continuous output required from the equipment to be kept below this continuous rated output 2 3 MAXIMUM TORQUE The maximum torque is the torque at the output shaft when the engine is producing maximum output at a specific r p m 2 4 PERFORMANCE CURVES kgf 2 8 2 1 2 6 2 5 2 4 2 3 2 2 2 1 2 0 T
25. 42 SUBARU EX 20 Ca SUBARU FUJI DES LTD Gasoline Engine Air cooled 4 cycle SERVICE MANUAL CONTENTS Section Title Page 1 SPECIFICATIONS Dn ew Rate s Aw e oo eta D e eech 1 2 PERFORMANCE 55 Row pitas EE m n dh ne xn dn Rn Ct 2 3 FEATURES EX35 40 5 4 GENERAL DESCRIPTION OF ENGINE COMPONENTS 6 5 DISASSEMBLY AND REASSEMBLY 12 5 1 PREPARATIONS AND PRECAUTIONS 12 5 2 SPECIAL POOLS EE 12 5 3 DISASSEMBLY PROCEDURE ER SE Cet 13 5 4 REASSEMBEY PROCEDURES 27 6 ENGINE OIL e bon DR eee 45 eelere rp aha 46 8 IGNITION SYSTEM s xm Deer dor RR AC 47 9 WIRING BIAGRAM 5 bu RAE En rar MERE EXE EX RE E 48 10 ELECTRIC STARTER te er nce eral SENEC e E ER ch 50 ah el SENSOR EE 52 12 AUTOMATIC DECOMPRESSION 5 53 19 CARBURETOR 26 4 523433 xax bat imet AOL eU a ate Dra eid edd eed 54 T4 RECOIE STARTER eg enee e 58 15 INSTALLATION vc ia deese dee s 63 16 TROUBLESHOOTING 2 rs erae aca o rre d c ra en ee ios 66 17 STANDARD REPAIR 5 72 17 1 STANDA
26. AR 9 AIR CLEANER OIL DRAIN PLUG CRANKCASE CRANKSHAFT TENSIONER BAFFLE 2 TIMING CHAIN OIL SENSOR CONNECTING ROD OPTION For without starting motor Buffle 1 is mounted instead of starting motor Fig 4 17 11 5 DISASSEMBLY AND REASSEMBLY 5 1 PREPARATIONS AND PRECAUTIONS 1 When disassembling the engine memorize the location of each part so that you can reassemble the engine correctly If necessary attach identification tags with the required assembly information to the parts 2 Store groups of parts in separate boxes This will make reassembly easier 3 To prevent parts from being mislaid keep each group provisionally assembled after removing the parts from the engine 4 Handle the disassembled parts with the utmost care Clean them with cleaning oil if necessary 5 Use the correct tools in the correct way when disassembling and reassembling the engine 5 2 SPECIAL TOOLS Tool name Use Commercially available product Flywheel puller For pulling off the flywheel Commercially available product For locking the flywheel CHAIN WRENCH Fig 5 1 dues 5 3 DISASSEMBLY PROCEDURE Step Parts to remove Remarks and procedures Fasteners Drain the engine oill Remove a drain plug M14 x 12mm located on both sides of the case Take care not to lose the gaskets 14 mm spanner To discharge oil quickly remove the oil guage M22 Drain the fuel Shut OFF the fuel strainer
27. ASON REMARKS 1 Overhaul the engine Clean and correct the engine 1 Dirty misaligned or worn parts can cause low parts replacing if necessary power output and engine malfunction 2 Replace the piston rings 2 Faulty piston rings can cause low output power and engine malfunction 3 Replace the fuel hose 3 To prevent fuel leakage and attendant dangers 18 8 SPARK ARRESTER AND TAIL SCREEN OPTION Check and clean the spark arrester and the tail screen which are mounted on the tail of the exhaust muffler every 100 hours Clogged the spark arrester or the tail screen can cause prevents the flow of exhaust gas reduces engine output increases fuel consumption and makes starting difficult ACAUTION If the engine has been running the muffler the spark arrester and the tail screen will be very hot Allow the muffler to cool before checking or cleaning the spark arrester and the tail screen HOW TO REMOVE THE SPARK ARRESTER AND TAIL SCREEN 1 Remove the tapping screw the spark arrester screw 1pc and the tail screen screw 3ps CLEAN THE SPARK ARRESTER AND TAIL SCREEN 1 Use a brush to remove carbon deposits from the spark SPARK ARRESTER SCREEN arrester screen Be careful to avoid damaging the screen 2 The spark arrester must be free of breaks and holes Replace the spark arrester if it is damaged 3 Install the spark arrester and muffler protector in the reverse order of
28. CTRIC STARTER MAGNETIC SWITCH KEY SWITCH Fig 10 2 There are two energized circuits the magnetic switch M circuit and the starter motor S circuit When the key switch is ON the M circuit is closed the current flows in the direction of the arrows the coil of the magnetic switch is magnetically excited and the contactor is pulled As a result a low current flows through the M circuit and a high starter current flows through the S circuit This energizes the starter motor and cranks the engine lt Engagement of the pinion gear When the starter motor is started the weight built into the spiral splines located on the shaft moves in the direction of the axis driven by centrifugal force and pushes out the pinion gear and the pinion gear engages the ring gear 50 11 OIL SENSOR 11 1 SPECIFICATIONS Float type yP with lead switch incorporated Resistance at FULL oil level 100 M ohms or over Operating 30 to 180 degree Celsius Temperature 11 2 CONSTRUCTION AND OPERATION The oil sensor is composed of the float permanent magnet incorporated into the float and the oil sensor In accordance with the oil level the float moves FLOAT up and down oj When the oil level is upper level the float 1 P moves up PERMANENT MAGNET LEAD SWITCH Fig 11 2 When the oil lev
29. DARD DIMENSIONS AND LIMITS OF USE Unit mm in ITEM STD Limit CYLINDER HEAD Flatness 0 05 0 1 0 002 0 004 Intake exhaust valve seat contact width Intake 0 7 1 0 Exhaust 0 0276 0 0394 Intake 6 035 6 053 Exhaust 0 2376 0 2383 Di D2 i 7 Pin outer diameter 7 970 7 980 7 9 we i k D1 D2 0 3138 0 3142 0 3110 Rocker arm pin support inner diameter D3 D4 m ho Support inner diameter 8 00 8 018 8 05 D3 D4 0 3150 0 3157 0 3169 72 Unit mm in ITEM STD Limit CYLINDER Inner diameter Standard 89 000 89 022 3 5039 3 5040 To be rebored when the difference between max and min of diameter reached to 0 1 0 004 89 250 89 272 First reboring 8 5138 3 5147 Ditto Second reboring s Ditto Roundness after reboring Less than 0 01 0 0004 Cylindricity after reboring Less than 0 015 0 0006 PISTON Outer diameter at skirt in thrust direction 88 980 89 000 88 89 3 5032 3 5039 3 4996 n I Oversize 89 230 89 250 89 14 0 25 3 5130 3 5138 3 5095 Oversize 89 480 89 500 89 39 0 50 3 5228 3 5236 3 5193 8 Unit mm in ITEM STD Limit PISTON Ring groove side clearance To 0 050
30. E AND STORAGE The maintenance jobs described below apply to correct use of the engine under normal conditions The maintenance intervals mentioned in this section are not a guarantee that no maintenance is required during those intervals For example when the engine is used in dusty conditions the air cleaner should be cleaned every day rather than every 100 hours 18 1 DAILY MAINTENANCE EVERY 8 HOURS OF USE MAINTENACE ITEMS REASON REMARKS 1 Clean dust from engine 1 Dust can impair operation of various parts Governor linkage is especially sensitive to dust 2 Check for fuel leakage Tighten or replace parts 2 Uneconomical and dangerous if necessary 3 Check all parts are securely fastened Tighten 3 Looseness can result in vibration and accidents if necessary 4 Check oil level and add up to full mark 4 Running the engine with insufficient oil can result in serious problems including engine seizure 5 Check that the air cleaner element is clean 5 A clogged air cleaner can cause power loss and Clean or replace if necessary malfunction 18 2 INSPECTION AND MAINTENANCE AFTER THE FIRST 20 HOURS MAINTENACE ITEMS REASON REMARKS 1 Change the crankcase oil 1 Sludge is deposited during running in 18 3 INSPECTION AND MAINTENANCE EVERY 100 HOURS EVERY 10 DAYS MAINTENACE ITEMS REASON REMARKS 1 Change the crankcase oil 1 Contaminated oil quickens wear 2
31. ORQUE HP 14 0 13 0 12 0 11 0 10 0 9 0 8 0 a 7 0 OUTPUT NN e EN E i amp NI 6 0 5 0 4 0 3 0 2000 2400 2800 3200 3600 REVOLUTION r p m EX40D 1 Nem al 5 2 5 MAXIMUM 24 2 p 22 PS 14 0 W 10 0 REN HORSEPOWER unt 90 11 0 TF 10 0 7 0 9 0 8 0 6 0 5 Wi O 7 0 5 0 6 0 RECOMMENDED 4 0 HORSEPOWER 5 0 RANGE 4 0 3 0 3 0 2 0 2000 2400 2800 3200 3600 REVOLUTION gt r p m 3 FEATURES EX35 40 series 3 1 HIGH OUTPUT Thanks to the adoption of a cam profile exclusively for intake and exhaust and the optimization of the shape of the intake exhaust port and the shape of the combustion chamber the top of the class level maximum output is achieved 3 2 EXTREMELY SILENT SOFT TONE QUALITY EX engines are 2dBA quieter and softer in tone than other engines in the same class This quiet and soft tone is achieved by Resin blower housing reduce noise leakage of mechanical noise Employment of an optimized capacity Rigid Muffler 3 3 EXTREMELY EASY START Reliable Starting and Less Pulling Force are achieved by Sophisticated Mechanical Compression Release System as well as newly designed Combustion Chamber 3 4 EXTREMELY EASY MAINTENANCE Extreme ease of maintenance is realized by High Parts Commonality simpl
32. RD DIMENSIONS AND LIMITS OF USE 72 17 2 SERVICE DATA The following are only for your reference 77 17 3 TIGHTENING ee TEE 78 17 4 AIR GAP AND CLEARANCE wc a Rhe ee 78 18 MAINTENANCE AND STORAGE 1 SPECIFICATIONS Type Air Cooled 4 Cycle Slant Single Cylinder Horizontal P T O Shaft OHC Gasoline Engine Bore amp Stroke Piston Displacement ml cu in 89 x 65 3 50 x 2 56 404 24 65 Compression Ratio 8 3 Continuous Output kW HP r p m 5 5 7 5 3000 6 3 8 5 3600 6 3 8 5 3000 7 0 9 5 3600 Maximum Output kW HP r p m 7 4 10 0 3600 8 8 12 0 3600 N m r p m Kgf m r p m ft lb r p m Maximum Torque 26 2400 2 6 2400 19 18 2400 27 2400 2 7 2400 19 91 2400 Direction of Rotation Counterclockwise as viewed from the P T O shaft side Valve Arrangement Cooling System Overhead cam system Forced air cooling system Lubrication System Splash lubrication system Lubricant Automobile engine oil Grade SE or higher SG SH or SJ in recomended SAE 10W 30 Under ordinary atmospheric temperatures SAE 5W 30 In cold areas Capacity of Lubricant 1 2 Carburetor Horizontal draft Float type Fuel Automobile unleaded gasoline Fuel Consumption Rate g kW h g HP h 381 280 Fuel Supply System Gravity type Fuel Tank Capacity 7
33. air cooling system in which a synthetic resin cooling fan which is separate from the flywheel reduce noise and forces cooling air into the cylinder and cylinder head Baffles are provided to guide the flow of cooling air As for with starting motor baffle 1 is not mounted 4 11 LUBRICATION SYSTEM The rotating parts sliding parts and valves of the engine are lubricated with oil in the crankcase The oil is splashed onto the parts by the oil splasher on the connecting rod 4 12 TIMING CHAIN Timing chain system is adopted and designed for lubricating for the upper portion of cylinder head The timing chain is engaged between the sprocket portion of integrated camshaft in the cylinder head and the crankshaft gear sprocket The sprocket teeth in particular shape are adopted to enhance the durability and to realize low noise level TIMING CHAIN OIL SPLASHER MEN WC 5 y 4 13 IGNITION SYSTEM The ignition system is a transistor controlled magneto system with the ignition timing set at 24 degrees before the top dead center The magneto consists of a flywheel and ignition coil The flywheel cooling fan is separete from the flywheel is directly mounted on the crankshaft and the ignition coil is directly mounted on the crankcase Model EX35 and 40 has a smooth advanced ignition timing system to improve starting performance For further details refer to page 46 section 7 MAGNETO
34. aluminum alloy casting with grooves for mounting one compression ring and one oil ring Fig 4 4 4 5 PISTON RINGS The piston rings are made of special cast iron The profile of the top ring is a tapered face The oil ring is designed for better sealing and less oil consumption in combination with 3 pieces TAPER THREE PIECE CONSTRUCTION Fig 4 5 4 6 CAMSHAFT The camshaft and the sprocket are made of special sintered alloy They are constructed as a single piece The camshaft is provided with intake and exhaust cam and the decompression release lever is mounted on the sprocket shaft end side 4 7 VALVE ARRANGEMENT This engine has a chain driven overhead cam and EXHAUST VALVE INTAKE VALVE overhead valve construction with a single cam which has individual profile for intake and exhaust to perform high output 4 8 CYLINDER HEAD The cylinder head is on aluminum die casting with a dome shaped combustion chamber The intake and exhaust ports are arranged in a cross direction to improve combustion efficiency 4 9 GOVERNOR SYSTEM This engine is equipped with a centrifugal flyweight type governor that makes it possible to operate the engine at a constant speed even with load variations The governor flyweights are mounted on a governor gear GOVERNOR GEAR 4 10 COOLING SYSTEM Fig 4 9 The engine uses a forced
35. be easily replaced 5 4 GENERAL DESCRIPTION OF ENGINE COMPONENTS 4 1 CYLINDER AND CRANKCASE The cylinder and crankcase are aluminum die casting as a single piece A special cast iron cylinder liner is molded into the aluminum die casting The crankcase has a mounting surface on the output shaft side to which the main bearing cover is attached The cylinder is inclined to the right at an angle of 25 degrees from the horizontal as viewed from the output shaft side 4 2 MAIN BEARING COVER The main bearing cover is an aluminum die casting which is mounted on the output shaft side of the crankcase By removing the main bearing cover the inside of the engine can be inspected with ease Pilots and bosses are machined into the cover to facilitate the direct coupling of the engine with machines such as generators and pumps Oil gauges fillers are on both sides of the cover for easy maintenance 4 3 CRANKSHAFT The crankshaft is forged carbon steel and the crank pin is high frequency inductionhardened The crank sprocket used to drive the chain and the gear used to drive the governor gear are pressed into the output end of the shaft 4 4 CONNECTING ROD AND PISTON The connecting rod is a specially heat treated aluminum alloy die casting Its large and small ends function as bearings A splasher built into the connecting rod lubricates by splashing engine oil The piston is an
36. bled d pes GASKET M8 NUT 2 pcs MUFFLER Attention to the direction of bulge forming Bulge forming MUFFLER SIDE I 1 CYLINDER SIDE GASKET M8 x 12 BOLT Eege x irection of bulge Take utmost care not to cut your hand with the muffler gasket 1 forming M8 x 12 mm Bolt 1 pc M8 Nut 2 pcs Tightening torque 18 0 22 0 Nem 180 220 kgf cm 13 0 16 2 ft Ib 2 Mount the muffler cover on the muffler M6 x 8 mm Bolt 4 pcs 42 30 AIR CLEANER Mount the air cleaner element and cleaner cover URETHANE ELEMENT TYPE URETHANE AIR CLEANER COVER BOLT 15 M DUAL ELEMENT TYPE URETHANE FOAM AIR CLEANER COVER BOLT 4 o PAPER ELEMENT Fig 5 65 31 EXTERNAL INSPECTION Reassembly is completed Check that the wiring is correct and that there are no loose nuts and bolts or any other faults visible on the outside of the engine 32 FILLING WITH ENGINE OIL Use the automobile engine oil of API service class SE or higher grade The amount of oil refer to the table below Model Model EX35 EX40 Engine oil volume 1 2L maximum 43 33 BREAK IN OPERATION A new engine or an engine that has been completely overhauled by being fitted with a new piston rings valves and connecting rod should be thoroughly RUN IN before being put back into service Good bearing surfaces and running clearances between the
37. coming out Fig 5 20 Fig 5 21 CAMSHAFT CAMSHAFT CTENSIONER STEP 23 CHAIN M6 x 12 BOLT 1 pc Bolt used to prevent the CAMSHAFT pin camshaft from coming out K TENSIONER PIN STEP 23 TENSIONER Fig 5 19 2 98 Step Parts to remove Remarks and procedures Fasteners Cylinder head 1 Remove the cylinder head from the crankcase 12 mm box spanner Chain guide 2 Remove the cylinder head gasket from the cylinder head M10 x 75mm 4 pcs Take care not to lose the dowel pin M8 x 35mm 2 pcs 24 3 Remove the chain guide from the top side of the crankcase If the chain guide is removed from the inner side of the crankcase it might be damaged Intake and exhaust 1 Remove the collet valve from the spring retainer 25 valves See Fig 5 24 2 Remove the intake valve and the exhaust valve CHAIN GUIDE COLLET VALVE SPRING RETAINER VALVE SPRING a GASKET UNE De PLATE EXHAUST ONLY DOWEL PIN LQ KG MEY NW 9 50 E EXHAUST VALVE COLLET VALVE STEM SEAL DOWEL PIN INTAKE ONLY CYLINDER HEAD SPRING RETAINER M8 x 35 BOLT 2 pcs Fig 5 23 24 Step 26 Parts to remove Connecting rod and piston Remarks and procedures 1 Scrape off any carbon from the cylinder and the piston head then remove the connecting rod bolt 2 Remove the connecting rod cap 3 Rotate the cra
38. der filled with a proper fuel air mixture 2 Good compression in the cylinder 3 Good spark properly timed 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 Problem and possible cause Remedy 1 Ignition system problems 1 Spark plug Improper spark plug gap Adjust the gap Insulation defect Replace Carbon deposits Clean 2 Ignition coil Insulation defect or discontinuity Replace 2 Fuel system problems Poor contact or broken wire Repair or replace 3 Improper air gap between ignition coil and flywheel 1 No fuel in fuel tank Adjust Refill 2 Fuel hose clogged or pinched Clean or replace Throttle valve malfunction does not close fully Check and adjust 3 Air in fuel lines Check and retighten joints 4 Poor quality gasoline or water in gasoline Replace 5 Carburetor Overflow Adjust T Clogged or damaged Overhaul o 3 Engine core components problems 1 Insufficient tightening of cylinder head bolts Check and retighten 2 Wearing of piston piston rings and or cylinder Repair or replace 3 Improper contact of valve and seat Repair 4 Valve sticking Repair 5 Improper valve clearance Adjus
39. ditions Care must be taken when using multi grade engine oil because the oil consumption rate tends to increase when the air temperature is high 6 3 ADDING AND CHANGING ENGINE OIL O Engine oil inspection and filling up Every time you use the engine add engine oil up to the designated maximum level Engine oil change Firsttime After 20 hours use Thereafter Every 100 hours use 45 7 MAGNETO 7 1 MAGNETO The Robin Engine uses a T I C type breakerless magneto ignition system 1 T C TRANSISTOR IGNITER CIRCUIT has the ignition coil outside the flywheel which is the standard specification A charge coil system is available as an option The flywheel is a specialized piece of equipment As for the lighting coil the ignition coil is outside the flywheel and a lighting coil is inside 7 2 INSPECTING THE MAGNETO If the engine does not start has difficulty starting or does not run smoothly check the magneto for defects according to the following procedure 1 Carefully check the high tension cable for any damage or short circuiting 2 Check the sparking D Take the spark plug out of the cylinder head connect the spark plug with the plug cap and ground it on the cylinder head or any other metallic part of the engine The gap between the electrodes of the spark plug should be between 0 6 mm and 0 7 mm 2 Rotate the engine by pulling the recoil starter and c
40. dth b a 90 bod b 0 7 1 0 2 0 E 0 0276 0 0394 0 0787 b b a CHAIN LENGTH 160N 16kgf gt E 346 20 349 0 13 6299 13 7402 L D V 17 2 SERVICE DATA The following are only for your reference 5 EX40 Compression pressure Kg cm 500 rpm 4 5 Fuel consumption Continuous load 3600 rpm L Hr 33 3 8 Capacity L 1 2 Lubricant Efficacy mL 600 Consumption mL Hr 7 11 17 3 TIGHTENING TORQUE Tightening Torque ITEM N m cm ft Ib Re use 29 0 31 0 290 310 21 0 22 4 M10x75 flange bolt When replace to new Cylinder head bolts cylinder head and 37 0 39 0 370 390 26 7 28 2 flange bolts M8x35 flange bolt 17 0 19 0 170 190 12 3 13 7 Connecting rod cap bolts 22 5 27 5 225 275 16 3 19 9 Flywheel nut 100 0 120 0 1000 1200 72 3 86 8 Main bearing cover bolts 22 0 24 0 220 240 16 2 17 7 New 12 0 15 0 120 150 8 7 10 8 Spark plug Re tightening 23 0 27 0 230 270 16 6 19 5 Muffler nut 18 0 22 0 180 220 13 0 16 2 Ignition coil 7 0 9 0 70 90 5 1 6 5 Oil sensor Option 8 0 10 0 80 100 5 8 7 2 17 4 AIR GAP AND CLEARANCE Clearance ITEM mm in Valve clearance Intake Exhaust 0 12 0 15 0 0047 0 0059 Air gap Ignition and flywheel 0 3 0 5 0 012 0 020 Electrode gap Spark plug 0 6 0 7 0 024 0 028 78 18 MAINTENANC
41. e is heard between end faces of pinion and ring gear check the starter pinion and ring gear RING GEAR PINION GEAR 1 Remove the starter and check pinion and ring gear end faces If worn replace the pinion and ring gear 2 In case of sliding fault of the pinion correct it 3 If shift lever or spring is deformed replace it 3 Both starter and engine run but the engine does not start Check if the rotation speed is normal or slow If slow check the battery and engine oil viscosity 1 When the rotation speed is normal Check the ignition system and fuel system 2 When the rotation speed is slow a Check the battery b Check the viscosity of engine oil If not normal change the oil c If both a and b are normal Remove and check the starter 16 3 IGNITION COIL 20 degree C 68F HIGH TENSION WIRE 5 7 kQ 16 4 CHARGE COIL 20 degree C 68F NORMAL RESISTANCE Green White Yellow Black White Yellow Green White Black White 0 1 0 2 Q X B Kl ss 4 17 STANDARD REPAIR TABLES STD in the following table is the parts dimension from the brand new engine or the spare parts Whereas Limit shows the maximum allowance for the parts to be used on the engine If the measurement exceeds beyond the Limit the part needs to be replaced and or repaired 17 1 STAN
42. e length 3 5m Pipe inner diameter 33 mm The ideal solution is forced exhaustion outdoors by installing a blower on the exhaust pipe Install a safety cover on the exhaust pipe muffler and other related parts 15 4 FUEL SYSTEM If the fuel tank is detached from the engine the height from the bottom of the fuel tank to the fuel joint of the carburetor should be between 5 cm and 50 cm When using a fuel pump the bottom of the fuel tank can be up to 20 cm below the carburetor Position the fuel tank carefully because when it is low fuel is not fed to the carburetor and when it is high it can cause an overflow in the carburetor When piping the fuel the hose should be as short as possible and attention should be paid to heat transmission size bending leakage at hose joints and so on Care should also be taken to prevent air lock and vapor lock 63 15 5 POWER TRANSMISSION TO DRIVE MACHINES 15 5 1 BELT DRIVE Note the following Use V belt rather than a flat belt eThe drive shaft of the engine must be parallel to the drive shaft of the driven machine eThe drive pulley of the engine must be in line with the driven pulley of the machine e nstall the engine pulley as close to the engine as possible e f possible span the belt horizontally eDisengage the load when starting the engine A belt tensioner or similar should be installed if no clutch is used 15 5 2 FLEXIBLE COUPLING When using a flexible coupling run o
43. eed control lever and Bracket Remarks and procedures Remove the speed control lever and bracket from the cylinder head Release the bolt temporarily Slide to dismount the speed control lever and bracket from the cylinder head and the choke lever of the carburetor Fasteners 10 mm box spanner M6 x 12 mm 1 pc 12 Governor system 1 Loosen the bolt and remove the governor lever from the governor shaft There is no need to remove the bolt 2 Remove the governor spring 3 Remove the governor rod and the rod spring from the carburetor 10 mm box spanner or spanner M6 x 25 mm 1 pc 13 Carburetor Insulator Remove the carburetor from the cylinder head Remove the insulator Tus H GEZA 12 es e GOVERNOR LEVER ROD SPRING GOVERNOR ROD B eon SPRING 2 gt GASKET GOVERNOR dem SHAFT 7 oe 7 L qu INSULATOR i d ek De GASKET 7 Fig 5 8 17 SPEED CONTROL LEVER and BRACKET idi nm CHOKE LEVER mw CARBURETOR Step Parts to remove Remarks and procedures Fasteners 14 Ignition coil Remove the spark plug cap from the spark plug and remove the ignition coil from the crankcase 10 mm box spanner M6 x 25 mm 2 pcs 15 Starting pulley Cooling Blower Remove the starting pulley and cooling Blower from the flywheel Fit a box wrench or a socket wrench on the f
44. el is lower level the float moves down The permanent magnet is close to the lead Switch and the lead switch is activated by the magnetic force MAGNETIC FORCE NOTE With regards to the wiring diagram Fig 11 3 please refer to the section 9 3 page49 52 12 AUTOMATIC DECOMPRESSION SYSTEM 12 1 FUNCTIONS AND CONSTRUCTION EX series engines employ an automatic decompression system as a standard feature This enables easy starting of the engine with lighter recoil pull The automatic decompression system releases the compression of the engine by lifting up the exhaust valve at cranking speed The following is the explanation of the function At the end of the compression process the release lever lifts up the rocker arm exhaust which in turn opens up the exhaust valve slightly to release the compression The release lever has a flyweight on its end and another end of the lever is a crescent cam When the engine is cranked the crescent cam projects above the cam profile and lifts up the rocker arm exhaust because the force of the return spring on the weight is larger than the centrifugal force on the weight ROCKER ARM EXHAUST ROCKER ARM INTAKE ROCKER ARM EXHAUST RELEASE LEVER CAM CRESCENT CAM 7 RELEASE LEVER CAMSHAFT Fig 12 1 DETAIL When the cranking speed reaches a specified r p m the crescent cam is retracted under
45. far as it will go ACAUTION When the rope is pulled out to its full length the force stored in the spring reaches its maximum Be careful not to drop it or release your grip on it suddenly 58 2 Remove the components Fig 14 2 SET SCREW 1 Grip the case and loosen the set screw RATCHET 2 Take out the set screw the ratchet guide the Cay GUIDE im i IS FRICTION friction spring and the ratchet in that order SPRING 3 Remove the reel Fig 14 2 RATCHET 1 Hold down the reel gently to keep it from RETURN escaping from its case and rotate it slowly SPRING back and forth by quarter turns until it moves smoothly 2 Lift the reel up little by little and take it out of SS the case 3 If the spring is about to pop out of the reel repeat steps 3 1 and 3 2 STARTER p ps 3 3 CASE ACAUTION Since the spring is stored in the reel make sure not to drop or shake the reel after removing it Place it on a level surface such as a table Disassembly is completed Put on the protective glasses prior to start reassembly 14 1 2 REASSEMBLY PROCEDURE 1 Put the reel back into the case GREASE 1 Apply grease to the surface of the case Fig 14 3 2 Adjust the position of the inner end of the spring in the reel Fig 14 4 3 Hold the reel in such a way that the inner end SHAFT HOOK Fig 14 3 of the spring hooks ont
46. g of spring and sliding of pinion Check 2 gt NS gt e Replace if pinion ring gear ang gear end face is worn Correction of pinion gap OK With starter alone connect Check pinion roller clutch ge NG Replace motor for damage or replace EOS HOLDS brush holder or armature starter and check if motor runs OK Check battery charged state and battery terminal 2 4 ti connection or corrosion ife p Es for any abnormality SE Y NG battery charged e Charge or replace the battery Too slow state and battery terminal NG e Repair connection or Normal rotation connection or corrosion corrosion of battery terminals for any abnormality OK T OK Check ignition system and fuel system Check viscosity of engine NG EE oil for any abnormality Change the engine oil OK Replace the starter with NG new one and check if it Check the engine interior runs p Repair or replace the starter X When the starter continuously runs Immediately remove the terminal of the battery Motor does not stop even when the key switch is turned off gt or starter magnetic switch Repair or replace the key switch 69 Problem and check item Description Remedy 1 Checking of continuity of wiring Check S terminal and
47. h locking pliers adopted as shown in the illustration Tightening torque 100 0 120 0 Nem 1000 1200 kgf cm 72 3 86 8 ft lb M18 Nut 1 pc 24mm box wrench 20 IGNITION COIL When mounting the ignition coil insert a thickness gauge between the ignition coil and the flywheel to check the air gap 0 3 0 5 mm AirgaP 9 012 0 020 in Tightening torque 7 0 9 0 Nem 70 90 kgf cm 5 1 6 5 ft Ib M6 x 25 mm bolt and washer 2 pcs Make sure to put in the wire 1 to the notch on the crankcase and tighten it with the clamp M6x8 mm bolt 1 pc COOLING BLOWER Align the 2 bosses of starting pulley with the depression of flywheel Fig 5 54 e IGNITION COIL Fig 5 56 21 CARBURATOR a Replace the gasket of insulator with a new one and mount the insulator on the cylinder head intake side b Mount the carburetor 22 GOVERNOR LEVER See Fig 5 58 59 a Pass the governor rod through the rod spring then connect to the throttle lever of the carburetor b Attach the governor rod and rod spring to the governor lever then mount the governor lever on the governor shaft Do not adjust the bolt on the governor lever yet c Connect the governor lever and the speed control lever with the governor spring NOTE See page 40 for details on the adjustment
48. harge coil only M6 x 16 BOLT and WASHER 2 pcs 5 4 REASSEMBLY PROCEDURE 5 4 1 NOTES ON REASSEMBLY 1 Clean the each parts carefully taking special care with the piston cylinder crankshaft connecting rod and bearings 2 Scrape off any carbon deposits on the cylinder head and the piston head Be particularly careful when removing carbon from the piston ring grooves 3 Inspect the oil seals for any damage to the lip Replace them if damaged Apply oil to the lip before reassembly 4 Replace all the gaskets with new ones 5 Replace the keys pins bolts and nuts with new ones if necessary 4 5 6 Tighten nuts and bolts to the specified torque settings 7 When reassembling the engine apply oil to all moving parts 8 Check clearances and end plays and adjust if necessary 9 When mounting any major part during reassembly of the engine rotate it with your hand to check for any jamming or abnormal noise 5 4 2 ASSEMBLY STEPS AND PRECAUTIONS 1 OIL SENSOR a Mount the oil sensor and fix the wire with the clamp Tightening torque M6 x 16 BOLT and WASHER 8 0 10 0 N m 80 100 kat om 5 8 7 2 ft lb NOTE SHIELD PLATE M6 x 10 TAPPING BOLT 1 pc For charge coil only Make sure to not damaged cut off the oil Fig 5 29 sensor wire after assembly procedure 2 CRANKSHAFT a Wrap the key way portion of the crankshaft with poly
49. he battery to the magnetic switch 4 Remove the electric starter Remove the Baffle 1 from the crankcase Fasteners 12 mm box spanner M8 nuts 12 mm box spanner M8 x 12 mm 1 pc MODEL WITH ELECTRIC MODEL WITHOUT STARTER TYPE OPTION ELECTRIC STARTER ELECTRIC STARTER TYPE M8 x 28 BAFFLE 1 M8 x 12 BOLT 2 pcs CASE BOLT 1 pc y a Fig 5 12 19 Step Parts to remove Remarks and procedures Fasteners MODEL WITH CHARGE COIL TYPE Wire clamp Disconnect the wire clamp 10 mm box spanner M6 x 10 mm 1 pc NOTE 18 Disconnect the wire clamp in this step also an engine which has both of the charge coil and the oil sensor However please make sure to not damaged cut off the oil sensor wire after disassembly procedure Charge coil Remove the charge coil screwdriver 49 Spark plug Remove the spark plug from the cylinder head 21 mm plug wrench WIRE CLAMP _ M6 x 10 TAPPING BOLT 1 pc p CHARGE COIL Q ty 2 M6x25L 2 M6x20L 4 CHARGE COIL CHARGE COIL baue H Fig 5 13 20 Step Parts to remove Remarks and procedures Fasteners Rocker cover 1 Remove the rocker cover from the cylinder head 10 mm box spanner 20 2 Remove the gasket rocker cover M6 x 12mm 4 pcs Rocker arm Remove the pin rocker arm and the rocker arm from 21 the cylinder head at the compression top dead center See Fig 5
50. heck the spark plug gap for sparking If the spark plug is sparking check the intensity of the spark Before checking the spark plug disconnect the primary wire from the connector 3 Next disconnect the spark plug from the plug cap and check the end of the high tension cable for sparking 46 8 IGNITION SYSTEM The ignition system is a pointless flywheel magneto with automatic advancing characteristic Being different from the breaker point type ignition system this system is completely free from such troubles as starting up failure due to dirty burnt or corroded point surface 8 1 IGNITION COIL INTERNAL CIRCUIT o 2 5 Ka S 5 5 o E 2 SEET 5 5 5 2 amp Ignition 2 x Timing o g Control Circuit 5 15 Automatic E S Advancing S I2 c Control B 5 Circuit I4 o Ie Fig 8 1 8 2 BASIC THEORY ELECTRONIC ADVANCING FLYWHEEL B T D C MAGNETO SYSTEM Revolution of the flywheel generates electricity on 30 Low speed High speed the primary side of the ignition coil and the 254 base current D flows to the power transistor M Current l1 turns the power transistor ON and the 2 i T tuati electric current 12 flows This is the same situation 0 500 1000 2000 3000 4000 when the contact breaker is closed in a case of ENGINE REVOLUTION r p m breaker point type ignition system
51. ifies maintenance amp lowers repair cost due to fewer parts for service Only with ordinary tools routine maintenance assembly and disassembly can be performed 3 5 EXTREMELY ADVANCED TECHNOLOGY Extreme reliability and durability are achieved by Heavy Duty Chain Driven OHC System Oval type case hardened steel links enhance performance and resist stretching which result in extended maintenance free operation Completely New Main Bearing Cover s Design Flush mounted main bearing cover with lower moment of deformation significantly increases reliability and engine life Superior Cooling and Lubrication System Heat reduction is achieved by more efficient larger and more numerous cooling fins on crankcase cylinder and mounting base as well as by outstanding oil delivery system Large Ball Bearings on both ends of crankshaft for maximum stability under demanding loads Cast Iron Cylinder Liner resists wear 3 6 EXTREME POWER AND PERFORMANCE Extremely Higher Power and Lower Fuel Consumption are realized by High speed and homogeneous combustion achieved by sophisticated Pentroof Combustion Chamber which includes Intake and Exhaust Valves located at optimum angle Straight Intake Port with minimal air flow resistance Environmentally friendly EX engines comply with EPA Phase 2 and CARB Tier Emission Regulations in the USA Extreme application compatibility With four versatile models existing slant cylinder engines can
52. ire 2 ground with the blower housing See View D 5 Mount the recoil starter on the recoil bracket M6 x 14 mm bolt 4 pcs DETAIL C BAFFLE 1 The baffle 1 is mounted as for without electric starter WASHER 2 pes and M6 x 14 BOLT 4 pcs M6 x 15 BOLT 5 pcs STOP SWITCH M6 FLANGE Tighten the wire 2 NUT 4 pcs ground with the stop switch RECOIL STARTER Tighten the wire 2 ground with the blower housing LV d BAFFLE 2 27 WIRING Fig 5 62 Refer to the wiring diagram See page 48 and 49 for wiring details 41 28 FUEL TANK and FUEL STRAINER 1 Mount the fuel tank to the crankcase and connect the fuel pipe to the fuel tank and the fuel strainer Hold the fuel pipe with the clamp on the brower housing and then tighten the bolts and nuts for the fuel tank M8 nut 2 pcs 8 x 25 mm bolt 2 pcs 2 Connect the fuel pipe to the fuel strainer and the carburetor Mount the fuel strainer to the speed control bracket M6 x 12 mm Bolt 1 pc 29 MUFFLER 1 Mount the muffler and the gasket on the cylinder head NOTE Be sure to remove any tape or cloth FUEL TANK rd M6 x 12 BOLT 1 pc Clamp on the brower housing Oy Sie TR ee FUEL STRAINER Fig 5 63 MUFFLER COVER used to cover the exhaust port M6 x 8 BOLT when the engine was disassem
53. lywheel nut and loosen the nut by knocking the wrench sharply with a hammer See Fig 5 10 NOTE 1 Do not insert a screwdriver or other object between the flywheel blades which is a synthetic resin otherwise the risk of damaging the blades might be occurred 2 Knock the wrench with a hammer in a counter clockwise direction 24 mm box spanner or Socket wrench M18 nut 16 Flywheel Remove the flywheel from the crankshaft Leave the nut temporarily to prevent the flywheel from dropping out Fit the flywheel puller as shown in Figure 5 11 and remove the flywheel from the crankshaft by rotating the bolt at the center in a clockwise direction Knock the center bolt with a hammer sometimes Flywheel puller ATTACH NUT TEMPORARILY FLYWHEEL PULLER M6 x 8 BOLT 1 pc Fig 5 10 FLYWHEEL Fig 5 11 COOLING BLOWER STARTING PULLEY Fig 5 9 418 IGNITION COIL CH M18 NUT 1 pc M6 x 25 BOLT and WASHER 2 pcs Step 17 Parts to remove MODEL WITH ELECTRIC STARTER TYPE Control box Diode rectifier Magnetic switch Electric starter option MODEL WITHOUT ELECTRIC STARTER TYPE Baffle 1 Case Remarks and procedures 1 Disconnect the grounding cable from battery 2 Disconnect the wire leading from the key switch ST terminal to the magnetic switch 3 Disconnect the wire that connects the positive terminal of t
54. lywheel side If you with the ring guide with the do not have a ring guide hold the piston rings with the fingers and tap the upper part of the piston with a piece of wood NOTE 1 Apply oil to the piston rings the large end of the connecting rod and cylinder before installing the connecting rod into the cylinder NOTE 2 The piston ring gaps should be positioned around the piston at 180 degree intervals See Fig 5 36 When assembling the piston and connecting rod make sure to align the mark on the piston head with the MAG mark on the connecting rod Fig 5 34 PISTON RING GUIDE CONNECTING ROD 07 7 FLYWHEEL SIDE Fig 5 35 P T O SHAFT SIDE RING K 180 MAG MARK SIDE FLYWHEEL SIDE gt TOP RING Fig 5 36 29 b Rotate the crankshaft down to the bottom dead center and lightly tap the piston head until the large end of the connecting rod touches the crank pin c To mount the connecting rod line up the matching marks and fit the clinch portions firmly together 8 bolt 12mm box wrench Tightening torque 22 5 27 5 Nem 225 275 kgf cm 16 3 19 9 ft Ib d Check for free movement of the connecting rod by turning the crankshaft slowly 6 INTAKE AND EXHAUST VALVES Take the following points into account when mounting the intake and exhaust valves on the cylinder head
55. nkshaft until the piston comes to its top position Push the connecting rod and remove the piston from the upper part of the cylinder Fasteners 12 mm box spanner M8 x 40mm 2 pcs 27 Piston and piston rings 1 Remove the piston clips 2 pcs Take out the piston pin and then remove the piston from the connecting rod small end taking care not to damage the connecting rod small end 2 Remove the piston rings from the piston by spreading them at the gap Take special care not to damage the rings when doing this M8 x 40 CONNECTING ROD BOLT 2 pcs CONNECTING ROD CAP CONNECTING ROD PISTON PIN Fig 5 25 9B PISTON RING CLIP 5 NS Step Parts to remove Remarks and procedures Fasteners 28 Crankshaft 1 Remove the woodruff key for the flywheel magneto 2 Remove the crankshaft from the crankcase by tapping its magneto side end with a plastic hammer taking care not to damage the oil seal See Fig 5 27 Plastic hammer 29 MODEL WITH OIL SENSOR TYPE Oil sensor 1 Remove the clamp Model without charge coil type See Fig 5 28 2 Remove the oil sensor from the crankcase M6 x 10mm 1 pc M6 x 16mm 2 pcs OIL SENSOR Fig 5 27 CRANKSHAFT iy amp Lote 0 4 WIRE CLAMP Fig 5 28 M6 x 10 TAPPING BOLT 1 pc Fig 5 26 WIRE CLAMP SHIELD PLATE For c
56. o the shaft hook and Position where the inner end of the then place the reel carefully back into the 5 2 spring touches to the rib of the bearing case Elo 14 4 4 Turn the reel gently counterclockwise to confirm that the spring is hooked 59 2 Mount the components 1 Mount the ratchet into the reel Fig 14 5 2 Mount the ratchet guide assembly taking care not to move the ratchet Fig 14 6 3 Tighten the set screw 1 Hold the ratchet guide gently by your hand to prevent it from rotating then tighten the set Screw Tightening torque M6 5 5 Nem 55 4 0 ft lb 4 Tension the reel spring 1 Grip the case and turn the reel 6 times counterclockwise 2 Fix the reel so that the rope hole in the reel is aligned with the rope guide Fig 14 7 THE RATCHET SHOULD BE IN THE CLOSED POSITION Fig 14 5 Set screw Ratchet E guide Friction spring Ratchet guide sub assembly Fig 14 6 ROPE HOLE IN REEL ROPE GUIDE Fig 14 7 The spring force reaches its maximum value when the reel is wound up Be careful not to drop it or release your grip on it suddenly 5 Install the rope NOTE This procedure requires 2 people 1 Pass the rope end through the rope guide and the rope hole of the reel and pull through Approx 20mm approximately 20 cm out of the
57. punch marks on cam sprocket is in parallel with the cylinder head surface at a time NOTE 2 Make sure that the piston is at the compression top dead center by checking mutual position between the flywheel and the ignition coil or by checking that the key way is at the top See each Fig 5 50 15 VALVE CLEARANCE ADJUSTMENT Temporarily fit the flywheel Rotate the crankshaft up to the compression top dead center and insert the thickness gauge between the valve and the adjusting screw of rocker arm to measure the clearance Adjustment method Loosen the nut on the adjustment screw and turn the screw to adjust the valve clearance When the valve clearance is correct tighten the nut Valve clearance when the engine is cold Intake valve side 0 12799 mm 0 0047 42972 in Exhaust valve side Tightening torque 5 0 7 0 Nem 50 70 kof om 3 6 5 1 ft lb NOTE After adjusting the valve clearances rotate the crankshaft and check again that the intake and exhaust valve clearance are correct ROCKER ARM Fig 5 49 Temporarily fit the nut Fig 5 50 THICKNESS GAUGE 5 NUT 9mm ADJUSTMENT SCREW ROCKER ARM A EXHAUST em lt VALVE SIDE SYN 90 OROCKER ARM INTAKE VALVE SIDE Fig 5 51 B 16 ROCKER COVER Replace the gasket with a new one and mount the
58. rocker cover M6 x 12 mm flange bolt 4 pcs Tightening torque 5 0 7 0 Nem 50 70 cm 3 6 5 1 ft Ib 17 SPARK PLUG Remove any carbon deposits from the spark plug and inspect the electrode for damage before mounting Replace with a new one if necessary Spark plug NGK BR 6HS 21 mm plug wrench 0 6 0 7 mm Electrode gap 924 0 028 in Tightening torque New spark plug Re tightening torque 12 0 15 0 Nem 120 150 kgf cm 8 7 10 8 ft lb 23 0 27 0 Nem 230 270 kgf cm 16 6 19 5 ft Ib 18 BAFFLE 1 CASE The projection upper on the baffle 1 with the crankcase and mount it under with the bolt MODEL WITHOUT ELECTRIC STARTER 8 12 mm bolt 1 pc MODEL WITH ELECTRIC STARTER Mount the electric starter and the charging coil referring to the illustrations of disassembly 36 SPARK PLUG GASKET uf ROCKER COVER ROCKER COVER T M6 x 12 BOLT 4 pcs Fig 5 52 PROJECTION pd i M8 x 12 BOLT 1 pc BAFFLE 1 CASE OE ON 7 d gt Vu Fig 5 53 ES 19 FLYWHEEL COOLING BLOWER and STARTING PULLEY NOTE When mounting the flywheel be sure to wipe off any oil on the tapered portion of the crankshaft and flywheel Mount the flywheel on the crankshaft b Install cooling blower and starting pulley to the crankshaft Tighten crankshaft nut wit
59. spring 1 or 2 turns taking care not to over stress the spring c If there is a sound indicating that the spring is off the hook and the starter rope does not be wound back reassemble the recoil starter from the beginning 14 1 4 OTHER GUIDES 1 If the spring escapes from the reel during disassembly a Hook the outer end of the spring onto the gap in the reel and rewind the spring holding the spring with your fingers so as to prevent it from springing out of the housing unit Hook the outer end of the Wear protective gloves when doing this spring onto the gap in the reel Fig 14 10 b Hook the inner end of the spring onto the oa SPRING projection on the starter case Refer to the assembly procedure for more details 2 About lubrication Lubricate the rotating and frictional parts and the APPLY GREASE UW lt 4C gt ant spring with grease heat resistant grease recommended or engine oil when the starter is disassembled and prior to long term storage Va Bi 5 gt 7 7 STARTER CASE Fig 14 11 62 15 INSTALLATION Installation has a decisive influence on engine life ease of maintenance and inspection frequency of inspection and repair running costs and other related aspects Before installing the engine be sure to plan the installation with care taking the points below into account 15 1 INSTALLING When in
60. stalling the engine pay special attention to the position of installation the method for coupling with working equipment and the foundations and supports for the engine Position the engine so that tasks such as gasoline and oil replenishment and inspection spark plug inspection air cleaner maintenance oil drainage and so on can be carried out as easily as possible 15 2 VENTILATION An engine requires fresh air for cooling and for burning fuel When an engine is covered with a bonnet or is operated in an enclosed space the temperature around the engine rises and this causes such problems as vapor lock oil deterioration increased oil consumption power loss engine seizure and reduced engine life making it difficult for the engine to function normally It is thus necessary to install ducts and dampers to guide fresh air so as not to recycle the hot air used to cool the engine and to prevent the working equipment from heating up Be sure to keep the engine room temperature below 50 C all year round and to prevent the accumulation of hot air in the engine room 15 3 EXHAUST EQUIPMENT Exhaust gas is noxious When operating the engine indoors make sure that exhaust gases are discharged outdoors However if the exhaust pipe is long resistance increases and this lowers engine output Therefore the longer the exhaust pipe the larger its inner diameter should be Exhaust pipe length Less than 3 m Pipe inner diameter 30 mm Exhaust pip
61. t 6 Leakage from intake manifold gasket Retighten replace gasket 7 Leakage from carburetor gasket Retighten replace gasket 8 Insufficient tightening of spark plug Retighten 66 Problem and possible cause Remedy 1 Insufficient compression 1 Loosen spark plug Retighten replace gasket 2 Leakage from cylinder head gasket Retighten replace gasket 3 Piston ring seizure or wear Replace 4 Piston or cylinder wear Repair or replace 5 Incorrect valve and seat contact Repair or replace 6 Valve stem seizure Repair or replace 7 Improper valve clearance Adjust E 2 Ignition system problems 1 Faulty spark plug Replace 2 Faulty ignition coil Replace 9 3 Improper air gap between ignition coil and flywheel Adjust 4 Demagnetization flywheel magneto Replace 3 Fuel system malfunction 1 Carburetor clogged Overhaul clean 2 Fuel strainer and or hose clogged Clean or replace 3 Air in fuel lines Check and retighten joints 4 Poor quality gasoline or water in gasoline Replace 4 Low air intake volume 1 Air cleaner clogged Clean or replace 2 Throttle valve malfunction Repair or replace 1 Engine 1 Cooling air flow obstructed at inlet or cylinder baffle Clean portion 5 2 Poor quality engine oil Replace 5 3 Lean fuel air mixture Check and adjust carburetor S 4 Excessive back press
62. the cam profile because the centrifugal force applied to the flyweight becomes larger than the force of the return spring on the weight and thus it is shifted to the position shown in the illustration below ROCKER ARM RELEASE LEVER EXHAUST e ROCKER ARM EXHAUST ROCKER ARM INTAKE CAM CRESCENT AC P CAMSHAFT RELEASE LEVER Fife DETAIL A 12 2 INSPECTION When assembling the release lever make sure that it works smoothly 53 13 CARBURETOR 13 1 SPECIFICATIONS EX35 EX40 A C Type URETHANE DUAL URETHANE DUAL Main Jet 109 107 113 110 Slow Jet 40 44 49 51 Venturi Bore mm 17 19 13 2 FUNCTIONS AND CONSTRUCTION 13 2 1 FLOAT SYSTEM The float chamber is located below the carburetor body Through the operation of the float and the needle valve the float chamber maintains a constant fuel level while the engine is working The fuel flows from the tank into the float chamber through the needle valve When the fuel rises to a specific level the float rises When the buoyancy of the float is balanced with the fuel pressure the needle valve shuts off the fuel passage thereby maintaining the fuel at the predetermined level 13 2 2 SLOW SYSTEM The slow system supplies fuel to the engine during idling and low speed operation Fuel is initially metered by the main get and then metered once again by the slow jet The fuel air mixture is fed to the engine through
63. the pilot outlet and the bypass During idling fuel is fed to the engine mainly through the pilot outlet 13 2 3 MAIN SYSTEM The main system feeds fuel to the engine at medium and high speed operation Fuel is metered by the main jet and flows into the main nozzle Air metered by the main air jet is mixed with fuel through the bleed holes of the main nozzle The fuel air mist is injected into the Venturi and mixed once again with air from the air cleaner This fuel air mixture is now of optimum concentration and is fed into the combustion chamber of the engine 13 2 4 CHOKE SYSTEM The choke system is for easier start of the engine in cold weather conditions When the engine is started with a closed choke the negative pressure applied to the main nozzle increases This causes a larger amount of fuel to be drawn into the carburetor which in turn makes it easier to start the engine 54 FUEL SYSTEM OUTLINE PILOT OUTLET F Fuel and air Flow Fuel and air Flow for Main system for Slow system
64. ure of exhaust system Check and clean or replace 5 Overloading Adjust to rated load 1 Carburetor system 1 Low idling speed Adjust 2 Slow system passage clogged Check and clean 3 Hunting after engine stop SE Se E 2 Intake system 1 Air mixing from air intake system joints Check and tighten 5 replace gasket 5 3 Oylinder head 1 Gasket faulty blow by Replace 4 Valve system 1 Improper valve clearance Adjust 2 Leakage from valve seat Repair 3 Excessive clearance between valve stem and guide Replace 5 Ignition system 1 Weak spark Check adjust or replace plug 67 5 Excessive oil level Problem and possible cause Remedy 1 Oil leakage 1 Loose oil drain plug Tighten E 2 Faulty oil drain gasket Replace 3 Loose main bearing cover bolts Tighten 5 4 Faulty main bearing cover gasket Replace 8 5 Crankshaft oil seal front rear defect Replace 2 Oil up 1 Faulty piston oil ring Replace 2 2 Piston ring seizure wear or poor contact Replace gt 3 Excessive wear of piston and or cylinder Replace 3 4 Faulty stem seal Replace Adjust oil level 6 Breather defect Repair or replace S 1 Fuel system 1 Clogged air cleaner Clean or replace E 2 Faulty needle valve and or high fuel level in float chamber Repair or replace 3 Choke does not open fully Repair or replace 5 2 Engine core components
65. ut and misalignment between the driven shaft and the engine shaft should be minimized The permissible margin of run out and misalignment is specified by the flexible coupling manufacturer 15 5 3 BELT PULLEY INSTALLATION ONTO KEYWAY TYPE CRANKSHAFT Pulley When installing the belt pulley and or clutch onto Key keywaytype crankshaft PTO shaft proper and NN J Bolt correct arrangements are needed The following illustration shows the correct installation of the Washer applicable component parts PTO shaft Fig 15 1 Metric keyway type crankshaft EX35 40 Washer Thickness mm 6 0 or over Washer Use the washer material SS41P with the thickness described below ROBIN genuine part 020 01002 20 Washer Thickness 6 0 40 10 5 Material 5541 EX35 40 Effective thread length 18 to 27 specified tightening torque as mentioned mm Strength 8T or higher Bolt Select the proper bolt and tighten it to the below Tightening Torque 40 50 Nem kgfecm 408 510 ROBIN genuine parts 011 01003 00 Flange Bolt Screw length mm 30 64 Key Location When using the belt pulley with the extended boss on both side as shown in the illustration put the spacer so that the key stays in the keyway portion of the crankshaft Improper Key should be within this portion
66. ut the throttle shaft and seal 6 as dust proof When removing the throttle valve take care not to damage the valve edge 13 3 2 CHOKE SYSTEM 1 Remove the choke valve 49 Then pull out the choke shaft 3 and seal polyurethane as dust proof 2 When reassembling the choke shaft be sure to position the cutout on the choke valve facing the pilot air jet 13 3 3 SLOW SYSTEM 1 Remove the slow jet 49 Use the correct tool so as to avoid damaging the jet 2 When reassembling the slow jet be sure to firmly tighten it otherwise fuel may leak leading to engine malfunction 13 3 4 MAIN SYSTEM 1 Remove the bolt 8 and remove the float chamber body 5 and spacer carburetor 3 2 Remove the main jet 17 from the spacer carburetor Do not dis assemble because of the main nozzle is press fit 3 When reassembling the main system be sure to fasten the main jet and main nozzle firmly to the body otherwise the fuel concentration in the fuel air mixture may become too rich leading to engine malfunction 4 The tightening torque of the bolt B is 4 N m 40 kgf cm 2 9 ft Ib Be sure not to forget to mount the washer 13 3 5 FLOAT SYSTEM 1 Take out the float pin and then remove the float and the needle valve 2 2 When reassembling the float system follow the step of the needle valve 42 the float float pin 0 O ring and O ring spacer 2 Since the needle valve 2 is linked to the float
67. various parts can only be established by operating the engine under reduced speed and loads for a short period of time While the engine is being tested check for oil leaks Make final carburetor adjustment and regulate the engine operating speed Step Model EX35 Model EX40 Engine Speed Time Step 1 No Load 2500 r p m 10 min Step 2 No Load 3000 r p m 10 min Step 3 No Load 3600 r p m 10 min Step 4 4 3 HP 4 8 HP 3600 r p m 30 min Step 5 8 5 HP 9 5 HP 3600 r p m 30 min 44 6 ENGINE OIL Using engine oil of the correct grade and viscosity greatly lengthens engine life and improves performance Too much or too little oil can also result in serious problems including engine seizure 6 1 CLASSIFICATION BY OIL GRADE API American Petroleum Institute Classification SA SB sc SD se 5 cb Grades suited for Robin Engine SE or higher SG SH or SJ in recomended 6 2 CLASSIFICATION BY OIL VISCOSITY SAE Society of Automotive Engineers a 10W a Single grade LES 100 302 Ambient 10 0 10 20 30 40 C temperature 4 14 68 86 104 F Be sure to use automobile engine oil of the viscosity shown in the table above depending on environmental air temperature When the air temperature falls below 20 C or rises above 40 C be sure to choose engine oil of appropriate viscosity and grade according to the prevailing con
68. vinyl tape and insert the crankshaft into the crankcase taking care not to damage the oil seal lip b Insert the woodruff key for the flywheel magneto NOTE Do not insert the woodruff key before inserting the crankshaft into the crankcase Fig 5 30 27 3 PISTON AND PISTON RINGS a Install each piston ring in the correct groove of the piston by widening it enough to slide it over the piston NOTE Be careful not to twist the rings too much as they may be damaged Install the oil ring first followed by the top ring When installing the piston ring make sure that the R mark is face up OPEN ENDS OF PISTON RING PINE See Fig 5 33 Fig 5 31 TAPER A THREE PIECE 7 CONSTRUCTION D Fig 5 32 MARK R 28 Fig 5 33 4 PISTON AND CONNECTING ROD The piston is attached to the connecting rod by the piston pin When assembling the piston and connecting rod make sure to align the mark on the piston head with the MAG mark on the connecting rod NOTE 1 Before assembling the connecting rod apply oil to its small end NOTE 2 Be sure to insert the clips in the two ends of the piston pin and check the clips for any play 5 CONNECTING ROD a Install the piston and connecting rod assembly into the cylinder by holding the piston rings MAG mark on the connecting rod on the f

8. ignition system - Subaru Industrial Power

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