Robin-Subaru 17 - Manuals
Robin-Subaru 17 – Manual in PDF format online.
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Manual Robin-Subaru 17
Summary
CONTENTS Section Title Page 1. SPECIFICATIONS ...................................................................................................... 1 2. PERFORMANCE ...................................................................................................... 2 3. FEATURES ....................
- 1 - 1. SPECIFICATIONS * Specifications are subject to change without notice. Model EX13D EX17D EX21D EX27D Type Air-Cooled, 4-Cycle, Slant Single-Cylinder, Horizontal P.T.O. Shaft, OHC Gasoline Engine Bore & Stroke mm(in.) 58 x 48 (2.28 x 1.89) 67 x 48 (2.64 x 1.89) 67 x 60 (2.64 x 2.36) 75 x ...
- 2 - 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 c...
- 3 - 2000 2400 2800 3200 3600 4000 0 0 0.5 1.0 1.0 1.5 2.0 2.0 2.5 3.0 3.0 3.5 4.0 7.0 8.0 9.0 4.0 5.0 kW [HP] r.p.m. REVOLUTION MAXIMUM TORQUE T ORQ UE MAXIMUM HORSEPOWER OUTPUT CONTINUOUSRATED HP RECOMMENDEDHORSEPOWERRANGE 0.7 0.8 0.9 2-4 PERFORMANCE CURVES EX13D
- 7 - 3. FEATURES 3-1 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: - A reduction in mechanical noise realized by employing sophisticated OHC system. - Employment of an optimized capa...
- 8 - 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 ...
- 9 - 4-5 PISTON RINGS The piston rings are made of special cast iron. The profile of the top ring is a barrel face or tapered face, andthat of the second ring is a tapered face. There are 2 types of oil ring depending on the engine specification.As those are interchangeable, the cutter ring with co...
- 10 - 4-13 IGNITION SYSTEM The ignition system is a transistor controlled magneto system with the ignition timing set at 23 degrees (EX13/ 17/21)[27 degrees (EX27)] before the top dead center. The magneto consists of a flywheel and ignition coil. The flywheel (which also works as a fan) is directly...
- 11 - 4-14 CARBURETOR T h e e n g i n e i s e q u i p p e d w i t h a h o r i zo n t a l d ra f t carburetor. The carburetor setting is calibrated after careful testing for optimum all-round performance (including star ting, acceleration, fuel consumption, output power characteristics). Special att...
- 13 - Fig. 4-17 FUEL TANK OIL GAUGE OIL DRAIN PLUG TIMING CHAIN FILLER PLUG PISTON PIN PISTON RING CONNECTING ROD STARTINGMOTOR(OPTION) MAGNETICSWITCH MUFFLER PISTON CHAIN GUIDE GOVERNOR LEVER MUFFLER COVER GOVERNORGEAR FUEL STRAINER TENSIONER OIL SENSOR (OPTION) CRANKSHAFT CRANKCASE ROCKER ARM INT...
- 14 - Fig. 5-1 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) Stor...
- 15 - Step Parts to remove Remarks and procedures Fasteners 1 Drain the engine oill (1) Remove a drain plug (M14×12mm) located on both sides of the case.Take care not to lose the gaskets. (2) To discharge oil quickly, remove the oil guage. 14 mm spanner Fig. 5-2 OIL GAUGE GASKET GASKET DRAIN PLUG S...
- 16 - Fig. 5-3 Step Parts to remove Remarks and procedures Fasteners 2 Air cleaner cover Remove the air cleaner cover. 3 Air cleaner Remove the element, and remove the air cleaner while pulling the breather pipe awayfrom the rocker cover. 10 mm box spanner M6 nut: 2 pcs.M6 × 20 : 1 pc. M6 x 20FLANG...
- 17 - Fig. 5-4 STEP 4 STEP 5 STEP 6 STEP 6 M6 x 8 BOLT : 4 pcs. M6 x 12 BOLT : 4 pcs. STOP SWITCH BAFFLE 2 (HEAD) BAFFLE 3 (EX21 ONLY) M4 TAPPING SCREW : 2 pcs. RECOIL STARTER BLOWER HOUSING M6 x 12 BOLT : 1 pc. M5 TAPPING BOLT : 2 pcs. Step Parts to remove Remarks and procedures Fasteners 4 Stop s...
- 18 - A A STEP 7 STEP 8 FUEL TANK M6 x 25 BOLT : 1 pc.(EX13, 17, 21)M8 x 25 BOLT : 2 pcs.(EX27) M6 NUT : 2 pcs.(EX13,17,21)M8 NUT : 2 pcs.(EX27) M8 NUT : 2 pcs. GASKET (It has two faces) M6 x 10TAPPING BOLT : 2 pcs. M6 x 8FLANGE BOLT : 1 pc. M8 x 12 BOLT : 1 pc. MUFFLER Seal the exhaust port with a...
- 22 - Fig.5-12 Step Parts to remove Remarks and procedures Fasteners 16 Baffle 1 (case) Remove the baffle 1 (case) M6 × 12mm : 1 pc.(Models EX13, 17 and 21)M8 × 12mm : 1 pc.(Model EX27) 17 Charge coil (option) Remove the charge coil.(For EX27, remove the wire clamp together) box spannerM6 × 20mm : ...
- 23 - Fig. 5-14a Step Parts to remove Remarks and procedures Fasteners 19 Rocker cover (1) Remove the rocker cover from the cylinder head. (2) Remove the gasket (rocker cover). 10 mm box spanner M6 × 12mm : 4 pcs. 20 Rocker arm Remove the pin (rocker arm) and the rocker arm from the cylinder head a...
- 24 - Fig. 5-16 Step Parts to remove Remarks and procedures Fasteners 21 Main bearing cover (1) Remove the flange bolts of main bearing cover from the crankcase.Remove the main bearing cover whiletapping gently around the cover usinga plastic hammer or similar tool.(See Fig. 5-16)Be careful not to ...
- 26 - Fig.5-20 Fig.5-21 Step Parts to remove Remarks and procedures Fasteners 23 Cylinder head,Chain guide (1) Remove the cylinder head from the crankcase. (2) Remove the cylinder head gasket from the cylinder head. Take care not to lose thepipe knocks. (3) Remove the chain guide from the top side ...
- 27 - Step Parts to remove Remarks and procedures Fasteners 25 Connecting rod andpiston (1) Scrape off any carbon from the cylinder and the piston head, then remove theconnecting rod bolt. (2) Remove the connecting rod cap.(3) Rotate the crankshaft until the piston comes to its top position. Push t...
- 28 - Step Parts to remove Remarks and procedures Fasteners 27 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 plastichammer, taking care not to damage the oilseal. (See Fig. 5-24) Plastic hammer ...
- 29 - OIL SENSOR SHIELD PLATE(OS) M6 x 12 BOLT : 1pc. M6 x 16BOLT : 2pcs. CLAMP (1) OIL SENSOR (a) Mount the oil sensor and fix the wire with the clamp. (b) Mount the shield plate only for charge coil type. (c) Mount the control unit. Fix the ear th wire of the control unit at the same time. (See F...
- 30 - (3) PISTON AND PISTON RINGS 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 second ring and then the top ring. ...
- 33 - (7) CHAIN GUIDE Mount the chain guide to the crankcase. Fig. 5-39b Model EX21mounting position Models EX13, 17 and 27 mounting positions CHAIN GUIDE Fig. 5-39a (8) CYLINDER HEAD Inspect and repair any scratches on mounting surface and replace head gasket to new one before installing. Tighten ...
- 34 - TIMING MARK The position of top dead center MARK PLATE MARK PLATE MARK PLATE MARK PLATE MARK PLATE MARK PLATE TIMING MARK ROLL PIN ROLL PIN ROLL PIN TIMING MARK TIMING MARK TIMING MARK TIMING MARK CHAIN GUIDE FITTING POSITION CHAIN GUIDE FITTING POSITION CHAIN GUIDE FITTING POSITION The mark ...
- 35 - TENSIONER SPRING(TENSIONER) CHAIN PIN(TENSIONER) PIN(CAMSHAFT) CAMSHAFT CHAIN M6 x 12 BOLT : 1 pc.Bolt used to prevent the pin (camshaft) from coming out Fig. 5-42b (10) MOUNTING THE CAMSHAFT ON THE CYLINDER HEAD Mount the camshaft on the cylinder head by inserting the pin (camshaft) through ...
- 37 - (15) VALVE CLEARANCE ADJUSTMENT Temporarily fit the flywheel. Rotate the crankshaft up to the compression top dead center and inser t 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 scre...
- 38 - (16) ROCKER COVER Replace the gasket with a new one, and mountthe rocker cover. M6 ✕ 12mm flange bolt : 4 pcs. SPARK PLUG ROCKER COVER M6 x 12 BOLT : 4 pcs. GASKET(ROCKER COVER) (18) BAFFLE 1 (CASE) Align the top and bottom of the baffle 1 (case)with the crankcase and mount it with the bolts....
- 39 - Fig. 5-51 Air gap Fig. 5-52 Fig. 5-53 FLYWHEEL STARTING PULLEY IGNITION COIL THICKNESSGAUGE To STOP SWITCH (19) FLYWHEEL 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 crankshaf...
- 40 - Fig. 5-54 M6 x 12 BOLT : 2 pcs. M6 x 12 BOLT : 1 pce. SPEED CONTROL LEVERand BRACKET CARBURATOR BAFFLE 2 (HEAD) BAFFLE 3(EX21 ONLY) M5 TAPPING BOLT : 2 pcs. INSULATOR A Detail A GASKET GASKET (21) SPEED CONTROL LEVER, BRACKET AND BAFFLE Mount the speed control lever and bracket, baffle 2 (hea...
- 41 - (23) GOVERNOR LEVER (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. ...
- 42 - ■ 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 var...
- 43 - (25) MUFFLER (1) Mount the muffler and the gasket on the cylinder head. (2) Mount the muffler cover on the muffler. M6 ✕ 8 mm flange bolt : 1 pc. M6 ✕ 10 mm tapping bolt : 2 pcs. NOTE : Be sure to remove any tape or cloth used to cover the exhaust port when the enginewas disassembled. M8 ✕ 12...
- 45 - Dual element STD Type Fig. 5-62 (29) AIR CLEANER Mount the air cleaner element and cleaner cover. (28) STOP SWITCH (1) Mount the stop switch on the blower housing. (2) Refer to the wiring diagram (See page 51 and 52) for wiring details. Fig. 5-61 STOP SWITCH
- 46 - (32) 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 various parts can ...
- 47 - 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) 6-2 CLASSIFICA...
- 48 - 7. MAGNETO 7-1 MAGNETO The Robin Engine uses a T.I.C. type breakerless magneto ignition system. (1) T.I.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 specializ...
- 49 - 7-3 IGNITION SYSTEM (EX13 ,17, 21) 7-3-1 TYPE OF IGNITION SYSTEM EX13, 17 and EX21 have the T.I.C. (Transister, Igniter, Circuit) pointless ignition system.As optional parts, these ignition system may be implemented with lamp coil, charge coil and excitor coil. LowSpeed Ignition Timing Contro...
- 50 - 7-4-3 BASIC THEORY (a) Revolution of the flywheel generates electricity on the primary side of the ignition coil ( ① ), and the base current I 1 flows to the power transistor ( ② ). Current I 1 turns the power transistor “ON” and the electric current I 2 flows. This is the same situation when...
- 51 - Stop swit ch Flywheel Ignition coil (with built-in transistor) Black Spark plug 8. WIRING DIAGRAM 8-1 MODEL WITHOUT ELECTRIC STARTER (Models EX13, 17, 21 and 27) 8-2 MODEL WITH ELECTRIC STARTER (Models EX17 and 21) Fig. 8-1 Fig. 8-2 +M -M ST B LA106 LA406 LA306 Black Red Charge coil Diode rec...
- 52 - 8-3 MODEL WITH ELECTRIC STARTER (Model EX27) Fig. 8-3 +M -M ST B LA108 LA408 Black Red Charge coil Diode rectifier Ignition coil Spark plug Key switch Battery (12V24AH) Electric starter Magneto Key switch 066-00003-30 -M +M B S OFFONSTART 8-4 MODEL WITH OIL SENSOR To LED Lamp Yellow Yellow / ...
- 53 - 9. ELECTRIC STARTER 9-1 SPECIFICATIONS Models EX17, 21 Model EX27 Voltage (V) 12 Power (kW) 0.6 0.6 Weight (kg) 1.6 3.4 9-2 OPERATING PRINCIPLES The battery is connected to the 6 or 8 mm diameter terminal of the magnetic switch. The figure below shows the state when the starter is ON. There a...
- 55 - 10. OIL SENSOR 10-1 SPECIFICATIONS 10-2 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 up and down. When the oil level is upper level, the float moves up. Fi...
- 56 - A A ROCKER ARM (EXHAUST) ROCKER ARM (EXHAUST) ROCKER ARM (INTAKE) CAM CRESCENT CAM RELEASE LEVER RELEASE LEVER ROCKER ARM (EXHAUST) ROCKER ARM (INTAKE) CAM CRESCENT CAM CAMSHAFT ROCKER ARM (EXHAUST) CAMSHAFT RELEASE LEVER RELEASE LEVER DETAIL A DETAIL A Fig. 11-2 11. AUTOMATIC DECOMPRESSION S...
- 57 - 12. CARBURETOR 12-1 SPECIFICATIONS 12-2 FUNCTIONS AND CONSTRUCTION 12-2-1 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...
- 58 - PILOT OUTLET BYPASS PILOT AIR JET CHOKE VALVE AIR INTAKE PORT MAIN AIR JET MAIN NOZZLE FLOAT CHAMBER PILOT JET FLOAT MAIN JET FUEL NEEDLE VALVE FLOAT Fig. 12-2 Fig. 12-1 FUEL SYSTEM OUTLINE
- 59 - Fig. 12-3 MODEL EX13, 17, 21 MODEL EX27 1 22 23 3 5 11 9 8 4 10 12 13 2 14 24 28 18 16 17 25 26 21 6 7 19 20 27 13 14 21 18 20 25 26 3 5 9 8 4 22 23 1 11 12 24 10 6 7 12-3 DISASSEMBLY AND REASSEMBLY Mechanical failures aside, most carburetor malfunctions occur when the fuel/air ratio of the m...
- 62 - GREASE SHAFT HOOK Position where the inner end of the spring touches to the rib of the bearing. 13-1-2 REASSEMBLY PROCEDURE (1) Put the reel back into the case -1 Apply grease to the surface of the case. (Fig.13-3) -2 Adjust the position of the inner end of the spring in the reel. (Fig. 13-4)...
- 63 - (2) Mount the components -1 Mount the ratchet into the reel. (Fig. 13-5) -2 Mount the ratchet guide assembly, taking care not to move the ratchet. (Fig.13-6) (3) Tighten the set screw -1 Hold the ratchet guide gently by your hand to prevent it from rotating, then tighten the set screw. Fig. 1...
- 65 - 13-1-3 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 ...
- 66 - 14. 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 accoun...
- 67 - 14-5 POWER TRANSMISSION TO DRIVE MACHINES 14-5-1 BELT DRIVE Note the following: • Use a V-belt rather than a flat belt. • The drive shaft of the engine must be parallel to the drive shaft of the driven machine. • The drive pulley of the engine must be in line with the driven pulley of the mac...
- 68 - Problem and possible cause Remedy 1. Ignition system problems 1) Spark plug ・ Improper spark plug gap ・ Insulation defect ・ Carbon deposits Adjust the gap Replace Clean 2) Ignition coil ・ Insulation defect or discontinuity ・ Poor contact or broken wire ReplaceRepair or replace 3) Imprope...
- 70 - Problem and possible cause Remedy 1. Oil leakage 1) Loose oil drain plug Tighten 2) Faulty oil drain gasket Replace 3) Loose main bearing cover bolts Tighten 4) Faulty main bearing cover gasket Replace 5) Crankshaft oil seal (front, rear) defect Replace 2. Oil up 1) Faulty piston oil ring Rep...
- 74 - 16. 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...
- 79 - ITEM STD Limit VALVE SPRING FREE LENGTH EX13EX17EX21EX27 27.4 (1.0787) VALVE SEAT ANGLE(INTAKE AND EXHAUST)* Valve cutter angle (a)* Valve contact width (b) IntakeExhaust EX13EX17EX21EX27 a: 90 ° b: 0.7 - 1.0 (0.0276 - 0.0394) 2.0 (0.0787) CHAIN LENGTH EX13 263.1 (10.3583) 266.0 (10.4726) EX1...
- 80 - 16-2 TIGHTENING TORQUE ITEM Tightening Torque N ・ m kgf ・ cm ft ・ lb. Cylinder head bolts M8 × 68 flange bolt Re-use 25.0 - 27.0 250 -270 18.1 - 19.5 When replace to newcylinder head andflange bolts 28.0 - 30.0 280 - 300 20.3 - 21.7 M8 × 35 flange bolt 17.0 -19.0 170 - 190 12.3 - 13.7 Connect...
- 81 - 17. MAINTENANCE 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 ...
- 82 - 17-5 INSPECTION AND MAINTENANCE EVERY 300 HOURS 17-6 INSPECTION AND MAINTENANCE EVERY 500 TO 600 HOURS (EVERY 6 MONTHS) 17-7 MAINTENANCE EVERY 1,000 HOURS (ANNUAL MAINTENANCE) 17-8 ENGINE STORAGE (1) Carry out the maintenance jobs described in step 16-1 above. (2) Drain fuel from the fuel tan...
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