Robin-Subaru EX21 - Manuals

Page 3 - CONTENTS; Section

CONTENTS Section Title Page 1. SPECIFICATIONS ...................................................................................................... 12. PERFORMANCE ...................................................................................................... 23. FEATURES ......................

Page 4 - Model

- 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 6...

Page 5 - -2 CONTINUOUS RATED OUTPUT

- 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 themoving 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 curv...

Page 6 - kW; REVOLUTION; -4 PERFORMANCE CURVES

- 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 TORQ UE MAXIMUM HORSEPOWER OUTPUT CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE 0.7 0.8 0.9 2-4 PERFORMANCE CURVES EX13D

Page 9 - TORQ

- 6 - 2000 2400 2800 3200 3600 4000 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 5.0 0 1.0 2.0 3.0 4.0 9.0 8.0 7.0 6.0 5.0 6.5 6.0 5.5 4.5 15.0 16.0 17.0 18.0 19.0 7.0 kW [HP] MAXIMUM TORQUE MAXIMUM HORSEPOWER r.p.m. REVOLUTION TORQ UE OUTPUT CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE 1.5 1.6 1.7 1.8 1.9...

Page 10 - II

- 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 capaci...

Page 11 - GENERAL DESCRIPTION OF ENGINE COMPONENTS

- 8 - 4-1 CYLINDER AND CRANKCASE The cylinder and crankcase are aluminum die-castingas a single piece. A special cast iron cylinder liner ismolded into the aluminum die-casting.The crankcase has a mounting surface on the outputshaft side to which the main bearing cover is attached.The cylinder is in...

Page 12 - -7 VALVE ARRANGEMENT

- 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...

Page 13 - -13 IGNITION SYSTEM; LUBRICATION SYSTEM; GOVERNOR GEAR; FLYWHEEL; TIMING CHAIN

- 10 - 4-13 IGNITION SYSTEM The ignition system is a transistor controlled magnetosystem 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 w orks as a fan) is directlymou...

Page 14 - -17 DECOMPRESSION SYSTEM; STD Type

- 11 - 4-14 CARBURETOR The engine is equipped with a hor izontal draftcarburetor. The carburetor setting is calibrated aftercareful testing for optimum all-round perf ormance(including starting, acceleration, fuel consumption,output power characteristics). Special attention is alsopaid to the genera...

Page 16 - Cross sectional view – along the shaft

- 13 - Fig. 4-17 FUEL TANK OIL GAUGE OIL DRAIN PLUG TIMING CHAIN FILLER PLUG PISTON PIN PISTON RING CONNECTING ROD STARTING MOTOR (OPTION) MAGNETIC SWITCH MUFFLER PISTON CHAIN GUIDE GOVERNOR LEVER MUFFLER COVER GOVERNOR GEAR FUEL STRAINER TENSIONER OIL SENSOR (OPTION) CRANKSHAFT CRANKCASE ROCKER ARM...

Page 17 - DISASSEMBLY AND REASSEMBLY; -1 PREPARATIONS AND PRECAUTIONS; Tool name; Commercially available product; Flywheel puller

- 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...

Page 18 - Drain the engine oill; OIL GAUGE; -3 DISASSEMBLY PROCEDURE

- 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 ...

Page 19 - AIR CLEANER COVER; DUAL ELEMENT TYPE; URETHAN FOAM

- 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 away from the rocker cover. 10 mm box spanner M6 nut: 2 pcs. M6 × 20 : 1 pc. M6 x 20FLA...

Page 20 - Step

- 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...

Page 21 - FUEL PIPE

- 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...

Page 23 - Step Parts to remove

- 20 - STEP 12 STEP 13 STEP 14 GROMMET (EX13,17,21 only) STARTING PULLEY FLYWHEEL M14 NUT : 1 pc. (EX13,17,21) M18 NUT : 1 pc. (EX27) M6 x 25 BOLT and WASHER : 2 pcs. Fig. 5-9 Step Parts to remove Remarks and procedues Fasteners 12 Ignition coil Remove the spark plug cap from the spark plug and remo...

Page 25 - Remove the charge coil.

- 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 spanner M6 × 20...

Page 26 - Rocker cover

- 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...

Page 28 - sprocket and then take out the camshaft.

- 25 - TENSIONER SPRING(TENSIONER) CHAIN PIN (TENSIONER) PIN (CAMSHAFT) CAMSHAFT CHAIN STEP 22 STEP 22 M6 x 12 BOLT : 1 pc.Bolt used to prevent the pin (camshaft) from coming out Fig. 5-17 Fig.5-19 Fig.5-18b CAMSHAFT CHAIN Fig.5-18a PIN (TENSIONER) M6 x 12 BOLT : 1 pc.Bolt used to prevent the pin (c...

Page 29 - Push

- 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 the pipe knocks. (3) Remove the chain guide from the top sid...

Page 31 - Crankshaft

- 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 plastic hammer, taking care not to damage the oil seal. (See Fig. 5-24) Plastic hamme...

Page 32 - removing carbon from the piston ring grooves.; CRANKSHAFT; NOTE: Do not insert the woodruff key before inserting

- 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 Fig...

Page 33 - OPEN ENDS OF PISTON RING

- 30 - (3) PISTON AND PISTON RINGS Install each piston ring in the correct groove ofthe piston by widening it enough to slide it overthe piston.NOTE: Be careful not to twist the rings too much, as they may be damaged. Install the oilring first, followed by the second ring andthen the top ring.When i...

Page 34 - (a) Install the piston and connecting rod assembly into

- 31 - (4) PISTON AND CONNECTING ROD The piston is attached to the connecting rod b ythe piston pin.When assembling the piston and connecting rod,make sure to align the mark on the piston head withthe ‘MAG’ mark on the connecting rod.NOTE 1: Before assembling the connecting rod, apply oil to its sma...

Page 35 - ALIGNMENT; (d) Check for free movement of the connecting rod by; Tightening torque

- 32 - (b) Rotate the crankshaft down to the bottom dead center and lightly tap the piston head until the large end ofthe connecting rod touches the crank pin. (c) To mount the connecting rod, line up the matching marks and fit the clinch portions firmly together. Fig. 5-37 ALIGNMENT MARKS ALIGNMENT...

Page 36 - Mount the chain guide to the crankcase.; (2) When replace to new cylinder head and flange; Cylinder head bolts; step; When replace to new cylinder

- 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 ...

Page 37 - Number of oval steel link

- 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 ...

Page 38 - (10) MOUNTING THE CAMSHAFT ON THE CYLINDER HEAD

- 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) throug...

Page 39 - NOTE: Incorrect alignment of the timing marks

- 36 - (13) MAIN BEARING COVER Apply oil to the bearing and the oil seal lip when mounting the main bear ing cover. Also apply sealant(Three Bond ì1215î) to the surface of the crankcase. To avoid damaging the oil seal lip, wrap the crankshaftkey-way portion with polyvinyl tape before mounting the ma...

Page 40 - NOTE 1: Conduct this job at the compression top

- 37 - (15) VALVE CLEARANCE ADJUSTMENT Temporarily fit the flywheel.Rotate the crankshaft up to the compression topdead center and inser t the thic kness gaugebetween the valve and the adjusting scre w ofrocker arm to measure the clearance. [Adjustment method] Loosen the nut on the adjustment screw ...

Page 41 - or CHAMPION RL86C

- 38 - (16) ROCKER COVER Replace the gasket with a new one, and mountthe rocker cover.M6 ✕ 12mm flange bolt : 4 pcs. SPARK PLUG ROCKERCOVER 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 . ...

Page 42 - Air gap; To STOP; NOTE: When mounting the flywheel, be sure to

- 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 ofthe crankshaft and flywheel. Mount the flywheel on the crankshaft...

Page 43 - GASKET

- 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...

Page 44 - shaft. Do not adjust the bolt on the governor lever yet.; Variation of the governor spring

- 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. (...

Page 46 - NOTE : Be sure to remove any tape or cloth used; MUFFLER SIDE; Tightening torque for fuel strainer; NOTE : Make sure the fuel pipe is located on the boss,

- 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...

Page 48 - Mount the air cleaner element and cleaner cover.; STOP SWITCH

- 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

Page 49 - Engine oil volume

- 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 on...

Page 50 - when the air temperature is high.; -3 ADDING AND CHANGING ENGINE OIL; (add engine oil up to the designated maximum level)

- 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 CLASSIFICAT...

Page 51 - -2 INSPECTING THE MAGNETO

- 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 specialized...

Page 53 - LINEAR ADVANCING

- 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...

Page 54 - Flywheel

- 51 - Stop s witc h 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 re...

Page 55 - -4 MODEL WITH OIL SENSOR; Oil sensor as option

- 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 / ...

Page 56 - -2 OPERATING PRINCIPLES

- 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 ar...

Page 58 - 0-2 CONSTRUCTION AND OPERATION; OIL SENSOR; MAGNETIC FORCE; NOTE : With regards to the wiring diagram,

- 55 - 10. OIL SENSOR 10-1 SPECIFICATIONS 10-2 CONSTRUCTION AND OPERATION The oil sensor is composed of the float, per manentmagnet incorporated into the float and the oil sensor.In accordance with the oil level, the float moves up anddown.When the oil level is upper level, the float moves up. Fig.1...

Page 59 - AUTOMATIC DECOMPRESSION SYSTEM; 1-1 FUNCTIONS AND CONSTRUCTION

- 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...

Page 60 - 2-2 FUNCTIONS AND CONSTRUCTION

- 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 needlevalve, the float chamber maintains a constant fuel level while the engine is working.The fuel flows f...

Page 61 - FUEL SYSTEM OUTLINE

- 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 NEEDLEVALVE FLOAT Fig. 12-2 Fig. 12-1 FUEL SYSTEM OUTLINE

Page 62 - 2-3 DISASSEMBLY AND REASSEMBLY

- 59 - Fig. 12-3 MODEL EX13, 17, 21 MODEL EX27 1 22 23 3 5 11 98 4 10 12 13 2 14 24 28 18 16 17 2526 21 67 19 20 27 13 14 21 18 20 25 26 3 5 98 4 2223 1 11 12 24 10 67 12-3 DISASSEMBLY AND REASSEMBLY Mechanical failures aside, most carburetor malfunctions occur when the fuel/air r atio of the mixtur...

Page 66 - Ratchet guide sub-assembly; -1 Gr ip the case and tur n the reel 6 times

- 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 setscrew. Fig. 13...

Page 68 - 3-1-3 CHECKING THE RECOIL STARTER AFTER REASSEMBLY; back, reassemble the recoil starter from the beginning.; SPRING

- 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 o...

Page 69 - 4-3 EXHAUST EQUIPMENT; Less than 3 m

- 66 - 14. INSTALLATION Installation has a decisive influence on engine life, ease of maintenance and inspection, frequency of inspectionand repair, running costs and other related aspects. Before installing the engine, be sure to plan the installationwith care, taking the points below into account....

Page 70 - 4-5 POWER TRANSMISSION TO DRIVE MACHINES

- 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 machin...

Page 71 - Star

- 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 Replace Repair or replace 3) Improper air gap betw...

Page 77 - STANDARD REPAIR TABLES; 6-1 STANDARD DIMENSIONS AND LIMITS OF USE; ITEM

- 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 r...

Page 82 - VALVE SPRING FREE LENGTH; Oil consumption has been measured under-following condition :

- 79 - ITEM STD Limit VALVE SPRING FREE LENGTH EX13 EX17 EX21 EX27 27.4 (1.0787) VALVE SEAT ANGLE (INTAKE AND EXHAUST) * Valve cutter angle (a) * Valve contact width (b) Intake Exhaust EX13 EX17 EX21 EX27 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...

Page 83 - 6-2 TIGHTENING TORQUE

- 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 new cylinder head and flange 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 Connecting ...

Page 84 - MAINTENANCE AND STORAGE; 7-2 INSPECTION AND MAINTENANCE AFTER THE FIRST 20 HOURS; 7-4 INSPECTION AND MAINTENANCE EVERY 100 TO 200 HOURS (EVERY MONTH); MAINTENACE ITEMS; Governor linkage is especially sensitive to dust.; MAINTENACE ITEMS; polish with sandpaper if dirty.; MAINTENACE ITEMS; (2) A clogged air cleaner can cause engine

- 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 requiredduring those intervals.For example, when the engine is used in dus...

Page 85 - 7-5 INSPECTION AND MAINTENANCE EVERY 300 HOURS; gently 2 or 3 times and then put back the spark plug.; power output and engine malfunction.; (1) Incorrect clearance can cause low power output

- 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 tank...

Page 87 - SERVICE INFORMATION

Page 89 - DESCRIPTION OF FUEL SYSTEM; PREFACE; This

CONTENTS Section Title Page 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. DESCRIPTION OF FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3. DISASSE...

Page 91 - THROTTLE BODY AY

- 2 - 2. DESCRIPTION OF FUEL SYSTEM This engine is equipped with electronic fuel injection. The fuel system consists of a throttle body assembly, power generation module, wire harness, cylinder head air pulse hose, fuel pressure return pipe and a fine mesh fuel filter. The fuel system is calibrated ...

Page 92 - DISASSEMBLY AND REASSEMBLY; -1 PREPARATIONS AND PRECAUTIONS; removing the parts from the engine.

- 3 - 3. DISASSEMBLY AND REASSEMBLY 3-1 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 o...

Page 96 - (2) Connect the fuel pressure return pipe and fix it with a clamp.

- 7 - 3-4 REASSEMBLY PROCEDURES (DIFFERENCE) (22) THROTTLE BODY (a) Replace the gasket of insulator with a new one and mount the insulator on the cylinder head intake side. (b) Mount the throttle body keeping the wire harness plugged into the throttle body. Re-connect the fuel pump pulse line from t...

Page 97 - MODEL WITH EFI

- 8 - 4. WIRING DIAGRAM MODEL WITH EFI Stop switch Power coil Ignition coil Black Throttle body Black Black Red Orange Yellow Oil sensor Temperrature sensorThrottle bracket Crankcase Spark plug EFI system Fuelinjection

Page 98 - This engine is equipped with electronic fuel injection.; -2 FUNCTIONS AND CONSTRUCTION; The fuel pump chamber is located below the throttle body.

- 9 - 5. THROTTLE BODY 5-1 SPECIFICATIONS This engine is equipped with electronic fuel injection. The fuel system consists of a throttle body assembly, power generation module, wire harness, crankcase air pulse hose, fuel pressure return pipe and a fine mesh fuel filter. The fuel system is calibrate...

Page 99 - The ECU uses this input to adjust to engine conditions.; -3 FUEL SYSTEM OUTLINE; PULSING PRESSURE; -4 FUEL SYSTEM TESTING AND DIAGNOSIS

- 10 - 5-2-4 POWER GENERATION MODULE The power generation module is installed under the flywheel. This module provides power to the ECU. 5-2-5 WIRE HARNESS The wire harness for the EFI system connects key system components to the ECU. The EFI wire harness contains a temperature sensor that measures ...

Page 106 - MAINTENANCE AND STORAGE; -2 INSPECTION AND MAINTENANCE AFTER THE FIRST 20 HOURS; -3 INSPECTION AND MAINTENANCE EVERY 100 HOURS (EVERY 10 DAYS); -4 INSPECTION AND MAINTENANCE EVERY 100 TO 200 HOURS (EVERY MONTH)

- 19 - 8. 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 d...

Page 107 - -5 INSPECTION AND MAINTENANCE EVERY 300 HOURS; (2) Drain fuel from the fuel tank and carburetor float chamber.

- 20 - 8-5 INSPECTION AND MAINTENANCE EVERY 300 HOURS MAINTENACE ITEMS REASON / REMARKS (1) Inspect the intake and exhaust valve clearance. Adjust if necessary. (1) Incorrect clearance can cause low power output and engine malfunction. 8-6 INSPECTION AND MAINTENANCE EVERY 500 TO 600 HOURS (EVERY 6 M...

Page 109 - -2 ADJUSTING FOR THE ENVIRONMENT

- 2 2 - 9-2 ADJUSTING FOR THE ENVIRONMENT In addition to a regular maintenance routine, some application circumstances require special care, such as high altitudes, heat and cold. Altitudes above 5,000 feet may cause engines to start hard and perform poorly. Emissions also are typically higher, and ...

Page 110 - -3 SUITING UP FOR STORAGE

- 2 3 - 9-3 SUITING UP FOR STORAGE Whether it’s the off-season or other circumstances prevent operating your engine-powered equipment for more than 30 days, special steps need to be taken to protect the engine. The first step in preparing an engine for storage is performing all of the suggested dail...