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ROBIN AMERICA, INC.

-
ROBIN TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST

ROBIN WISCONSIN ROBIN

EY08 Wf-080
EY15 W1-145
EY 15V W1-145V
EY20 W1-185
EY20V W1-185V
EY23 W 1-230
EY28 W 1-280
EY35 W 1-340
EY40 W1-390
EY45V W 1-450V
EY2 1 EY21W

-
EY44 EY44W
EY 1 8-3 EY 18-3 W
EY25 EY25W
EY 27 EY27W

EHll wo1-115
EH12 wo1-120
EH15 WO1-150
EH17 WO1-170
EH21 wo1-210
EH25 wo1-250
EH30 WO 1-300
EH3 OV WO 1-300v
EH34 WO 1 -340
EH3 4V WO 1-340V
EH43V WQ 1-430V

TWO CYCLE

EC13V WT1-125V

DlESEL

DY23 WRD1-230
DY27 WRD 1-270
DY30 WRD 1-300 1

DY3 5 WRD1-350
DY4 1 WRD1-410
CONTENTS

.
See tion Title Page

1. SPECIFICATIONS .......................................... 1

2. PERFORMANCE ........................................... 2

2-1 Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


2-2 Continuous Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2-3 Maximum Torque and Fuel Consumption Ratio a t Max Output . . . . . . .. 2

3. FEATURES .............................................. 4

4 . GENERALDESCRIPTION of ENGINECONSTRUCTION ............... 4

4-1 Cylinder. Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


4-2 MainBearingCover ..................................... 5
4-3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-4 Connecting Rod andPiston ............................... 5
4-5 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-6 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-7 Valve Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-8 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 -9 Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-10 Decompression Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-11 Cooling Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-12 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-13 Ignition Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-14 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.5Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-16 Diode Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-17 Sectional View of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 . DISASSEMBLY and REASSEMBLY .............................. 12

5-1 Preparations
and
Suggestion ............................... 12
5-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-3 How to Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-4 How to Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tappet Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Ignition Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Governor Setting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
See rion Title Page

6. CARBURETOR ............................................ 26

6-1 Operation
and Construction ............................... 26
6-2 Disassembly
and
Reassembly .............................. 27

7. BREAK-INOPERATION of REASSEMBLEDENGINE ................. 28

8. ROBINSOLIDSTATEIGNITIONENGINE(OPTION) ................. 29

8-1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-2 Basic Circuit andOperatingTheory of S.S. I . System . . . . . . . . . . . . . . . 29
8-3 Checking S.S.I. Unitwith Tester . . . . . . . . . . . . : . . . . . . . . . . . . . . . 29
8-4 MeasuringResistances of Exciter Coil andPulser Coil . . . . . . . . . . . . . . 29

9. TROUBLESHOOTING. ...................................... 30

9-1 Starting Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30


9-2 EngineMisfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-3 Enginestops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-4 Engine
Overheat ....................................... 31
9-5 EngineKnocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9-6 EngineBackfires through Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . 32

10 . INSTALLATION ........................................... 33

10-1 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-3 Exhaust Gas Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-4 Fuelsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-5 PowerTransmission to Driven Machines . . . . . . . . . . . . . . . . . . . . . . . 34
10-6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

11 . CHECKS and CORRECTIONS .................................. 37

12. TABLE of CORRECTIONSTANDARDS ........................... 38

13 . MAINTENANCE and STORING ................................. 43

13-1 Daily and


Maintenance .................................. 43
13-2 Every 20 Hours Checks andMaintenance . . . . . . . . . . . . . . . . . . . . . . 43
13-3 Every 50 Hours (10 days)Checks andMaintenance . . . . . . . . . . . . . . . . 43
13-4 -
Every 100 200 Hours (Monthly) Checks andMaintenance . . . . . . . . . . 43
13-5 Everv 500- 600 Hours(Semiannual)ChecksandMaintenance . . . . . . . . 44
13-6 Every 1000 Hours (Yearly) ChecksandMaintenance ............... 44
13-7 Preparation for Long Abeyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1. SPECIFICATIONS

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.

-2-
- rpm
PERFORMANCE CURVE
MODEL EY40D

kg-m

t
2.2 (4.4)

2.1 (4.2)
10

HP

I
6

-3-
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. Ma-
chine 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 re-
coil 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
of the engine can readily be checked by simplyremoving the cover. It is provided with a flange and boss for directly mount-
B ing 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 Fig. 3

4-3 CRANKSHAFT
INDUCTION HARDENING
(PORTION of C R A N K P I N )
The crankshaftis forged of carbon steel, and the crankpin is
induction-hardened. It has 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 lubri-
cating 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 . ) Fig. 6

4-6 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. 8

-6-
4-8 GOVERNOR

The governor is a centrifugal flyweight type which permits


constant operation a t the selected speed against load varia-
tions. (See Fig. 9.)

Fig. 9
4-9 BALANCER

The balancer is assembled with the main bearing cover. Un-


balanced moments of inertia generated in vertical and hori-
zontal 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 re-
ducing 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.)

TAPPET
EXHAUST IN TAPPET IN TAPPET

'.O.
SHAFT
SIDE

EXHAUST-CAM IN C A M

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 scoop-


ing 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 IGNITI~NCOIL

Fig. 13 Fig. 14
4-14 CARBURETOR

A horizontal draft carburetoris employed. It has been care-


fully 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 Reassem-
blY1.
(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 - CRANKCASE BALANCER
(OPTION)

MODEL EY35D. 40D

- 10 -
FUEL TANK CAP

INTAKE & EXHAUST VALVE

F U E L COCK

BALANCER

MODEL EY35D, 40D

- 11 -
5. DISASSEMBLY and REASSEMBLY
5-1 PREPARATIONS and SUGGESTIONS

1) 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 Shape
Model

EY10,13,14

EY15,18,20

Flywheel Puller For pulling off EY25,27,33


2099500407
(with bolt) Flywheel
EY35,40,44

EC05,07,10

ECf 7,25,37

EYIQ, 13.14
For mounting and
Valve Spring dismounting Valve EY15,18,20
2079500307
Retainer Spring Retainer
and Retainer Lock EY25,27,33

EY35,40,44

EYlO, 13,14

EY15,18,20

EY25,27,33

"20248 riming Tester For adjusting EY35,40,44


timing
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 Bolts, nuts, etc. used

1 Engine Drain engine oil. Be careful not tolose the Flange bolt
Drain plugs on bothsides of the the gasket.
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 8 mm (No.2) nut . . . 4 pcs.
bracket. SpI-ing washer . . . 4 pcs.
3 Tank bracket Remove tank bracket. 10 mm flange nut . . . 4 pcs.
(tightened together with
cylinder head)
4 Air cleaner (1) Remove air cleaner cover and
element.
(2) Remove choke knob. Swivel
(3) Remove the bottom plate of 6 x 12 mm flange bolt
air cleaner. . . . 2 pcs.
5 Muffler cover Remove muffler cover. 6 x 8 (5T) Flange bolt
* . . 4 pcs.

6 Muffler (1) Remove the flange portion 8 mm brass nut . . . 2 pcs.


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 Remove the governor lever. Be careful of the position 6 mm special n u t . . , 1 pce.
lever of the governor spring. Washer . . . 1 pce.
6 x 25 (7T) bolt . . . 1 pce.

Fig. 18

- 13 -
I I I I I
Order Item Procedures Remarks Bolts, nuts, etc. used

9 Speed control Disassemble. Remember the assembling Circle clip . . . 1 pce.


order of component parts. 8 mm butterfly n u t . . . 1 pce.
(See Fig. 19.)

Fig. 19

-
Order Item Remarks Bolts, nuts, etc. used

10 Operation (1) Disconnect the high voltage (See Fig. 20.)


case wire connecting the electric
starter to the magnetic switch
on the side of the switch.
(2) Remove the bolts. (3 pcs.) Two of the three 6 x 8 (5T)
flange bolts tighten the
cylinder buffle and fan cover
together.

11 Electric Remove electric starter. 8 x 30 reamer bolt . . . 2 pcs.


starter Spring washer . . . 2 pcs.
Washer . . . 2 pcs.

Fig. 20

- 14-
Order Item I Procedures I Remarks I Bolts, nuts, etc. used
-
12 Fan cover (1) Remove the fan cover. Removable by loosening 6 x 8 flange bolt . . . 6 pcs.
bolts
(2) Remove the head cover.
(3) Remove the cylinder buffle. 6 x 8 flange bolt . . . 1 pce.
-
13 Starting pulley Remove starting pulley. (See Fig. 21 .) 8 x 12 (ST)bolt . . . 3 pcs.
14 Flywheel I Remove
flywheel. Be sure to use thefly-
wheelpuller. Do not
18 mm nut . . . 1 pce.
Springwasher . . . 1 pce.
crankshaft.
-

Fig. 21 Fig. 22

b
-- 15 -
Order Item Procedures Remarks Bolts, nuts, etc. used
I
15 Electric (1) Remove point cover. 4 x 12 screw and washer
devices . . . 2 pcs.
4 x 8 screw and washer
(2) Remove contact breaker. Be careful of the primary . . . 1 pce.
lead connecting direction.
(3) Remove ignition coil and con- Remove the lighting coil 6 x 25 screw and washer
- denser. before disassembly. . . . 2 pcs.
16 Cylinder head (1) Remove spark plug.
(2) Remove cylinder head. 10 mm flange nut . . . 8 pcs. 1
17 Tappet cover
(breather
plate)
Remove Tappet cover.
Be mounting
valve Of the breather
position
and the order of assembl-
I
I
6 x 14 flange bolt . . . 2 pcs.
I
ing packings.
(See Fig. 23.)
Intake and (1) Remove intake valve. Intake and exhaust valve Use valve spring retainers.
exhaust valves (2) Remove exhaust valve. springs, retainers and re-
tainer locks are common;
but be sure to set up them
on the original valves.
(See Fig. 24.)

Fig. 23 Fig. 24

- 16-
Irder I Item

19 Main bearing
~~~ ~ ~ ~~~~~
Procedures

(1) Set the piston to the TDC, re-


r Remarks

(See Fig. 25.)


I Bolts, nuts,
used
etc.

6 x 8 flange bolt . . . 1 pce.


cover move blind plugin the lower Gasket (aluminium) . . . 1 pce.
part of the front side of bear-
ing cover, and insert the 4 mm
stick.
(2) Remove bolts. 8 x 35 (7T)set bolt . . . 8 pcs.
(3) Strike the side of main bear- In caseof TypeB, be care-
ing coverwith a plastic ham- ful not toremove camshaft
mer or the like to remove the together.
cover from crankcase. *Crankshaft and camshaft
have adjustingshims.
(TYPe B)
~

20 Camshaft Remove camshaft. Camshaft can easily be


pulled by hand. Be care-
ful not to let the tappets
drop. 1

Fig. 25 Fig. 26

Order Item Procedures Remarks Bolts, nuts, etc. used


~ ~~

21 Intake/ex- Remove intake/exhaust tappets. Intake and exhaust tap-


haust tappets pets are the same, but be
sure to intall them in their
original positions because
~~
1 of the valve clearance.
22 Connecting (1) Return the lock washer.
rod and piston (2) Remove bolts. 8 x 46 reamer bolt . ~ . 2 pcs.
(3) Push the piston up out of
the topof cylinder.
I

23 Crankshaft Hold crankshaftwithhand.and I Be carefulof oil seal on I


gently
tap
the
flywheel
end.
the crankcase
magneto
side.

- 17 -
5-4 HOW TO REASSEMBLE

5-4-1 PRECAUTION IN REASSEMBLY


r'
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 at-
tention 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.

EY35 E Y40

I W (Crankshaft Pin Width) I 29 +0.1


0

Bore 78 dia. 40.019 I 84 dia. ,


+0.022

Piston Outside Diameter (In SkirtThrust Direction)

I Piston to Cylinder a t Piston Skirt Thrust Face I 0.049L - 0.108L 1 0.049L - 0.11 1 L
Piston Ring Gap (Top Ring - Second Ring) 0.1 L - 0.3L
I

-
Piston Ring Side Clearance in Grooves
(Top Ring Second Ring)
0.05 - 0.09

Clearance between Connecting


Clearance between Inside 0.070 - 0.102L
Rod Large End and Piston Pin
and Outside Diameter
Side Clearance 0.020L - 0.042L

Clearance between Connection


Rod Small End and Piston Pin
0.1 L- 0.4L
Clearance between Piston Pin and Pinston Pin Hole 0.1 1T - 0.01 1 L

L: LOOSE
Fig. 27

- 18 -
5-4-3 ASSEMBLING ORDER and PRECAUTIONS
. .
1) Place the tappets into the crankcase.
TIMING MARK ON CAMSHAFT SIDE
NOTE: The intake and exhaust tappets are the same,
(Punch 2 pcskl
but mark them differently whendisassembl-
ing 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 TIMING MARK ON CRANKSHA??
of the
balancer gear as shown in Fig. 28. So, (Punch 1 pce.)

match these timing marks on the crankshaft


Fig. 28
and
camshaft 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 UPPER R A I L LOWER R A I L

in this order. The openends of each ring must


be as shown in Fig. 29.

Fig. 29

ASSEMBLY TYPE OIL RING


Fig. 30 Fig. 3 1

- 19-
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 cov-
er side.
NOTE: Tightening bolt . . . . . . . 8 x 46 (special)
-
Tightening torque . . . 250 300 kg-cm
Use new lock washers,and bend their edges
securely.
u__

Fig. 32

Install the main bearing cover.


CRANKSHAFT SPACER
NOTE: If the oil seal is damagedwhen the governor \

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 thick-
ness 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. 34 Fig. 35

- 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 fast-
en the balancer as shown in Fig. 36.
Tightening bolt . . . . .. . 8 x 35 (7T)
Tightening torque . . .170 - 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.


4O
* Intake and exhaust valve specifications are as follows: F
A.4 I

GUIDE

VALVE and VALVE GUIDE CLEARANCE


EY35 E Y40

A-VALVE FACE ANGLE

6-SEAT ANGLE
+0.036
C-GUIDE INSIDE DIA. 8dia.
~~~~ ~ ~

INTAKE
D-VALVE STEM OUTSIDE DIA. dia. -0.070
-0.090

MAXIMUM ALLOWABLE
INTAKE 0.030L - 0.091 L

CLEARANCE 8ETWEEN C and D 0.070L - 0.126L

Fig. 37

-21 -
.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 re-
tainer 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 . . . . . . . . . . . 8 pa.
Tightening torque -
. . . 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 ob-
tained. The ignition timing of the engine depends on
the point gap. If the gap is correctly adjusted, the igni-
tion 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 fly-
wheel 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. 43 Fig. 44

- 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.
Spring washer . . . . . . . . . . . . . . 1 pce.
Washer. . . . . . . . . . . . . . . . . . . 1 pce.
-
Tightening torque . . .800 1000 kg-cm
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 brack-
e 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.
Spring washer . . . . . . . . . . . . . . 2 pcs.
Washer. . . . . . . . . . . . . . . . . . . 2 pcs.
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 . . . . . . . . . . . . . 1 pce.
Clip.. . . . . . . . . . . . . . . . . . . . 1 pce.

Fig. 45

- 24 -
.GOVERNOR SETTING METHOD
* Set the speed control lever to the high-speed posi-
tion, 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.)

Install the starter motor. Fig. 46


8 x 30 reamer bolt . . . . . . . . . . . 2 pcs.
Spring washer . . . . . . . . . . . . . . 2 PcS.
Washer. . . . . . . . . . . . . . . . . . . 2 pes.
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) ....... 2 pcs.
Washer. . . . . . . . . . . . . . . . . . . 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.
and cover in t h s order.
After mounting the cleaner bottom plate, install the choke knob, element retainer, element
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 EY35 I E Y40

BV26-20 BV26-19
Model
Part No. 2246230100 2236230100
Main Jet #107.5 #112.5
Main Air Jet $1.2 $1.5
Pilot Jet #57.5 #55
Throttle Valve #135 #150

1 Pilot Screw
(Return)
I 1 turn

6 -1 OPERATION and CONSTRUCTION

PI LOT

FUEL

NEEDLE VALVE

FLOAT

FLOAT CHAMBER

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 pres-
sure 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 mal-
function.
6 - 2 -5 FLOAT SYSTEM
When removing the needle valve (21) and float (20), gently
tap the reverse side using therodmore slender thanthe
float pin (19) and remove because the float pin is calked to IA 17
the carburetor body. -18
*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 coun-
terclockwise 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.
Make a final adjustment when the engineis in normal Fig. 49
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
EY35 EY40

NO LOAD 2,500 rprn 10 minutes


~

NO LOAD 3,000 rpm 10 minutes

NO LOAD 3,600 rprn 10 minutes

3.5 HP 4.0 HP 3,600 rpm 30 minutes

7.0 HP I 8.0 HP ~ 1 3,600 rpm I 60 minutes 1


- 28 -
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
mechanical wear,and featuresmaintenance-free performance,
dirty or burnt contact point, oxidation during long storage,and
ill effects of water, oil dust, and moisture.
proper sparking, and freedom from the

8 - 2 BASIC CIRCUIT and OPERATING THEORY of


S.S. I. SYSTEM IGNITION UNIT
1) As the flywheelandmagneto rotate, a voltage is in-
duced in the exciter coil, and flows through the pri-
"-1
IGNITION COIL

mary 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 prima-
ry side of the ignition coil. D Thus, a high voltage is
L
generated on the secondary side of the ignition coil to
Fig. 50
produce a spark in the spark plug. E

8-3 CHECKING IGNITION UNIT with TESTER


The ignition unit can be checked with an ordinary circuit
tester.
Checkit as shown in the table at right, and
if the test results
Connect (+) terminal of tester.
I
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 Pulser Coil


A - t B A + B

STD 0.97Q * 20% 66Q * 20%


150W 4.5R * 20% t

Fig. 51 * Values in the


table above
apply
where ambient
temperature
is 20C.

- 29 -
9. TROUBLE SHOOTING
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 dif-
ficult, 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 -
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

0 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 50Ceven 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 in-
crease 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.
lines in the diagram arenot normally supplied with the engine.
The parts indicated by dotted

[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

SPARK PL.UG

STOP BUTTON
I

J,
BUZZER
6V8W @
* 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 Red
E L Z R I C STARTER

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
* Current flowing time (continuous, intermittent)
* Wire length
* Mechanical strength of wire against vibration
* Wire size versus resistance

No. of conductors/ Albwable curre1


Size (mm2I Resistor (Wml 2OoC
conductor diameter (mml (I
0.50 7r0.32 0.03250 9
0.85 11r0.32 0.02050 12
1.25 16r0.3 2 0.01410 1.5
2.0 2610.32 0.00867 20
3 .O 41 10.32 0.00550 27
5 .O 6510.32 0.00374 37
8.0 5010.45 0.00228 47
15.0 8410.45 0.00136 59
20.0 4 110.80 0.00087 84
30 .O 70f0.80 0.00051 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.
* 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 can-
not 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
ENGINE STANDARD T CORRECTION T USE
REMARKS TOOL
CORRECTION
MODEL SIZE TOLERANCE LIMIT LIMIT METHOD

Surface
Flatness of cylinder EY35 0.05 0.1 5 plate, Correct
head EY40 Feeler

EY35 S.T.D. 7 8 dia. Dif. between


Bore max. & min. 0.1 5 0.65
EY40 84 dia. +0.019 0

Roundness EY35 0.01 Boring


EY40

Cylindricity EY 35 0.01 5
EY40
-
Valve seat contact EY35
width EY40 1.2-1.5 2.5 Correct

EY 35 +0.036 At middle
Valve guide I.D. 8 dia. 0.1 5 0.1 5 Replace
EY40 0 portion

S.T.D. 77.951 dia.


O.D. at skirt, i n B 78.201 dia.
EY35
thrust direction C 73.451 dia.
(incl. oversize)
0 - 0.1 -0.1
Micro-
Replace
S.T.D.83.951 dia. -0.04 meter
B 0.25
EY40 B 84.201
dia.
C 0.5
C 84.451
dia. -
EY35 Top, 2nd 2 Top
+0.06
+0.04
-
Width of ring Vernier
groove EY40
Oil 4
oil +0.055
+0.2
- 0.1 5 0.1 5
caliwrs
Replace

Piston pin hole EY35 20 dia. +0.002 0.035 0.035


EY40 -0.01 1

EY35 0.048
0.108
- Max. cylin-
der dia. and Cylinder
Clearance between piston dia. gauge,
piston and cylinder
EY40 0.048
0.1 11
- 0.025 0.025 at skert in
thrust direc-
tion
Micro-
meter
Replace

EY35
Top
2nd
0.05
0.09
-
Clearance between
pisition ring and 0.1 5 0.1 5 Replace
ring groove
EY40

Cylinder
F i t between piston EY35 0.011 T gauge,
and piston pin EY40 0.011 L Micro-
meter

EY35
TOP

2nd
0.1 - 0.3 1.5 1.5
Ring gap Replace
EY40
Oil 0.2 - 0.9
-

EY35 Top.2nd 2 TOP -0.01 Mircro-


Ring width 2nd -0.03 - 0.1 -0.1
meter
EY40 Oil 4

- 38 -
ITEM
1 ENGINE1
MODEL
t
STANDARD
SIZE
1 CORRECTION
LIMIT
USE
TLO
IM
1 REMARKS
L IETR A N C E 1 CORRECTION
METHOD

I
+
Micro-
Piston p i n 0.D. -0.03 Replace
meter

Large end I. D EY35


EY40
1 +0.016
dia.34 -0 0.1
IOql
Cylinder
gauge
Replace

rod large end I.D.


and crankpin EY35
EY40 I 0.2 1 Cylinder
gauge,
Micro-
meter
Replace

33
Small end I.D.
EY15
20 dia. I +o.02 1 0.08 0.08
Cylinder
gauge
Replace

:L."--
a
EY15
EY20
I 0.02 - 0.042
0.12 0.12 I Cylinder
gauge,
Micro-
Replace

1
meter
V
Large end side
clearance
0.1 - 0.4 1.0 1 Feeler
gauge
Re-machine
or Replace

Parallelism between Test bar


Re-machine
large end and 0.1 or Replace
gauge

Distance between Test bar


large end and
I and Micro-
meter
Replace

1
small end bores
0'15

Crankpin O.D.
EY35
EY40
I -0.070 - -0.080 I 0.1 5
I
Micro-
meter
Re-machine
or Replace

Crankpin O.D.
roundness
EY15
EY20
1 Less than 0.005
0.5

Micro-
meter
Re-machine
or Replace

1
EY15 Micro- Re-machine

Eb cylindricity
Crankpin O.D.
EY20
Less than 0.005
meter or Replace

Crankpin O . D .
parallelism EY 20
EY15 I Drive 5. 25 dia.
Less than 0.01

~~~~ ~
Re-machine Dial
gauge or Replace

Mag. s. 25 dia. -0.003 Micro-


Crankshaft Replace
journal O.D. meter
Drive,s.
-0.014
dia.
25
EY40
Mag. s. 25 dia.

I Cam lobeheight

EY35B
Intake
36

Exhaust 35.5

Drive S. 35 dia.
to.1

-0.003
-0.014
-0.003
-0.25
I
-0.25
Micro-
meter
Replace

Mag. S. 25 dia. Micro-

Drive S. 17 dia.
,.
-0.012
n.
-0.01 6 P
- 0.05
0.05 0.05 meter
Replace

EY35D -0.027
I."&,

Mag. S . 17
dia. -0.01 6
-0.01 7

- 39 -
1
ITEM
LIMIT 1 REMARKS 1 TOOL CORRECTIOP
METHOD

i
-0.003
Drive S. 35 dia.
-0.014
EY4OB
4- -0.003
.4-
Mag. S. 25 dia. -0.01 2 Micro-
5 Journal OD. 0.05 0.05 Meter
Replace
-0.016
Drive S. 17 dia.
-0.027
EY40D
-0.027

EY35
EY40
46 1 -1.5 -1.5
Vernier
calipers
Replace

EY35
EY40
1 !Square
feeler
Qawe
Replace

Valve stem O.D.


Exhaust 8 dia.
- 0.030
-0.055
-0.070
-0.15
I Micro.
meter
Replace

EY35 Intake 0.030-0.091


Clearance between
0.3 0.3 mA
i dtd l e Replace
EY40 Exhaust 0.070-0.126

Correct
w

4= II
I Clearance between
grooveandretainer
0.04-0.1 5 Replace

1 1
E - 1I
Stem end length

Total length
EY35
EY40
5.3 -0.5

-L
-0.5 I
Vernier
calipers

Vernier
calipers
Replace

Replace

Clearance between
stemandguide
EY35
EY40
1 0.025-0.062 0.2
Cylinder
gauge &
Micro-
Replace
meter

I
I I
EY35I
( 1
+1/4
Pilot screw I
unscrew EY40 I 1%

71 Spark plug
EY35
EY40 B-6HS

EY40
EY35 I 0.6 - 0.7 I 1.0
Adjust or
replace

EY35 i 3O f 5"
Timing
23'before T.D.C. . tester
Adjust
EY40

0.35 EY35 f 0.05 f 0.1

I Point opening
EY40
Adjust

-40 -
ITEM MODEL
~~~

EY35 8.514000
Max. Output Below 1 10% of rated output
EY40 10.0/3,600

EY35 7.013600
Continuous Rated
output
EY40 8.013600
I

ITEM MODEL literlhr CORRECTIONPRECISENESS REMARKS

EY35 2.9
Fuel Consumption Up 135% of standard consumption At continuous rated output
EY40 3.5
1 I I 1

ITEM MODEL cc/hr USE L I M I T cc/hr REMARKS

Lubricant
EY35 25 - 30 60
Consumption
EY40 30 - 40 80

- ITEM MODEL liter REMARKS

EY35
Fixed quantity
1.2
of Lubricant
EY40

ITEM MODEL liter REMARKS

Use the class SC or higher grade Engine Oil


Winter
(lower
than 0C) SAE 1 OW-30
Autumn
SAE
Spring
and #20
Summer SAE #30
I I I 1

ITEM FREQUENCY OF OIL CHANGE MODEL

EY35
First time: Change oil after 20 hours operation.
Oil Change
Second Time and Thereafter: Change oil every 50 hours operation.
EY40

ITEM
I
MODEL

EY35
I
I
kg/cm'/rpm
I
CORRECTION LIMIT
I
TOOL
I
REMARKS
1

- 41 -
- ITEM MODEL rpm TOOL REMARKS

,-

Min. accelerating
Crankshaft
revolution

r ITEM I MODEL I kgcm


T ft-lb TOOL REMARKS

EY35
Cylinder head
340- 390 24.6-28.3 Torque wrench
clamp nuts
EY40

EY35
Connecting rod
bolts EY40
250 - 300 18-21.7 Torque wrench

Magneto
clamp
nuts 1 EY35
EY40 1 800-1000
57.9-72.3 Torque wrench

Main bearing cover 170-190 Torque wrench


12.3-13.7
bolts
EY40

Spark plug
EY 35

EY40
260 - 290 18.8-21 Torque wrench

-42 -
13. MAINTENANCE and STORING
The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated main-
tenance 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

Checks and maintenance I Reasons for requiring them

Remove dust from whatever parts which The governor linkageis especially susceptible to dust.
accumulated dust.
Check external fuel leakage. If any, retighten or Not only wasteful butalso dangerous
replace.

Check screw tightening.If any loose one is found, Loose screws and nuts will result in vibration
I re-tighten. 1 accidents.

Check oil level in crankcase and add up as necessary.


I If the engine is operated without sufficient oil, it will
fail.

13-2 EVERY 20 HOURS CHECKS and MAINTENANCE

maintenance
Reasons and Checks for
themrequiring 1
I Change crankcase oil. 1 TO remove run-in wear particles I
13-3 EVERY 50 HOURS (10 DAYS) CHECK and MAINTENANCE

Checks and maintenance Reasons for requiring them

Change crankcase oil. Contaminated oil accelerates wear.


~ _ _ _ _

I Clogged air cleaner harms engine operation.


1 Check spark plug. If contaminated, wash in 1 Output power is reduced and starting
gasoline or polish with emery paper. is made difficult.

13-4 EVERY 100- 200 HOURS (MONTHLY) CHECKS and MAINTENANCE

I maintenance
and
Checks Reasons for requiring them 1
Clean fuel filter and fuel tank. The engine will be out of order.
Clean contact breaker points. The engine output drops.

-43 -
13-5 EVER'.' 502 - 600 HOURS (SEMIANNUAL) CHECKS and MAINTENANCE

Checks and maintenance Reasons for requiring them

Remove cylinder head and remove carbon The engine will be out of order.
deposit.
Disassemble and clean carburetor.

13-6 EVERY 1000 HOURS (YEARLY) CHECKSand MAINTENANCE

I Checks and maintenance I Reasons for requiring them

Perform overhauls, clean, corrector replace The engine output drops and become out of order.
parts.
Change piston rings.

I Replace fuel pipe


once
year.
a 1 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