ey35, ey40

ROBIN AMERICA, INC. ROBIN TO WISCONSIN ROBIN

ENGINE MODEL CROSS REFERENCE LIST

ROBIN

EY08 EY15 EY 15V EY20 EY20V EY23 EY28 EY35 EY40 EY45V EY2 1 EY44 EY 1 8-3 EY25 EY 27

E H l l EH12 EH15 EH17 EH21 EH25 EH3 0 EH3 OV EH34 EH3 4V EH43V

EC13V

DY23 DY27 DY30 DY3 5 DY4 1

WISCONSIN ROBIN - Wf-080 W1-145 W1-145V W1-185 W1-185V W 1-230 W 1-280 W 1-340 W1-390 W 1 -450V EY21W EY44W

EY25W EY27W

EY 18-3 W - wo1-115 wo1-120 WO1-150 WO1-170 wo1-210 wo1-250 WO 1-300 WO 1 -300v WO 1 -340 WO 1 -340V WQ 1 -430V

TWO CYCLE

WT1-125V

DlESEL

WRD1-230 WRD 1 -270 WRD 1-300 WRD1-350 WRD1-410

1

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 . GENERAL DESCRIPTION of ENGINE CONSTRUCTION . . . . . . . . . . . . . . . 4

4- 1 4-2 4-3 4-4 4-5 4 - 6 4-7 4 -8 4 -9 4-10 4-1 1 4-12 4-13 4-14 4 . 1.5 4-16 4-17

Cylinder. Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Main Bearing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Connecting Rod and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valve Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Decompression Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cooling Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ignition Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Diode Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 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-IN OPERATION of REASSEMBLED ENGINE . . . . . . . . . . . . . . . . . 28

8 . ROBIN SOLID STATE IGNITION ENGINE (OPTION) . . . . . . . . . . . . . . . . . 29

8-1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8-2 Basic Circuit and Operating Theory of S.S. I . System . . . . . . . . . . . . . . . 29 8-3 Checking S.S.I. Unit with Tester . . . . . . . . . . . . : . . . . . . . . . . . . . . . 29 8-4 Measuring Resistances of Exciter Coil and Pulser Coil . . . . . . . . . . . . . . 29

9 . TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

9-1 Starting Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 9-2 Engine Misfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 9-3 Enginestops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 9-4 Engine Overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 9-5 Engine Knocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 9-6 Engine Backfires 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 Power Transmission to Driven Machines . . . . . . . . . . . . . . . . . . . . . . . 34 10-6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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

12 . TABLE of CORRECTION STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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

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

1. SPECIFICATIONS

w

i - 1 -

2. PERFORMANCE 2-1 MAXIMUM OUTPUT

The maximum ouput of an engine is such standard power as developed by the engine, after its initial break in period with all the m,oving parts properly worn in, when operating with a fully open throttle valve. Therefore, a new engine may not develop

the maximum output in the beginning because the moving parts are not in a properly worn-in condition.

- rpm - 2 -

PERFORMANCE CURVE MODEL EY40D

kg-m 2.2 (4.4)

2.1 (4.2) t 10

9

8

7

HP I 6

5

4

3

2

1

0

- 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 selection of a suitable cam shaft profile and optimum clearances 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 of machines. The engines have two oil drain ports, and their recoil starter can be pulled

in any desired direction. Various optional parts are also available. All these combine to increase adaptability to 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 aluminum casting. The intake and exhaust ports are

located on one side of the cylinder, and are also 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 BEARING COVER

B 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 simply removing the cover. It is provided with a flange and boss for directly mount-

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 .)

RING for CENTERING

OIL GAUGE

Fig. 2 Fig. 3

4-3 CRANKSHAFT INDUCTION HARDENING (PORTION of CRANKPIN) The crankshaft is 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

The connecting rod is forged of aluminum alloy, which it-

self serves as bearings at both the large and small ends. The

large end has 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.)

SECOND RING

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 with a

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 integrally assembled with a cam gear. The two ends of the shaft serve as plain bearings so no ball bearings are used.

(See Fig. 6. )

4-6 CYLINDER HEAD

The cylinder head is an aluminum die casting, and forms a

Ricardo type combustion chamber with ample area for high combustion effeciency. The spark plug is tilted for easy

mounting of the fuel tank.

(See Fig. 7.)

0

Fig. 6

Fig. 7

4-7 VALVE ARRANGEMENT . " . ". .._ _.

The exhaust valve is located upstream of the cooling air with

the result that the exhaust valve is intensively cooled for

improved engine durability. The inner side of the valve head

is reinforced with hard alloy fused to 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 variations. (See 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 the same

rate as the crankshaft in opposite direction thereto, thus re-

ducing vibration due to unbalanced moments of inertia.

(See Fig. 10.)

4-10 DECOMPRESSION DEVICE

The intake cam has a special profile and the intake valve is sligh

of compressed air out to make starting easy. (See Fig. 11 .)

EXHAUST TAPPET IN TAPPET

'.O.

EXHAUST-CAM

DECOMP L I F T

SHAFT SIDE

Fig. 9

Fig. 10

.tly raised during the compression stroke to let a slight amou

IN TAPPET

IN CAM

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 cooling air go through. The cooling fan employs curved blades so 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 1 SO-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.)

POINT COVER

Fig. 13

FLYWHEEL

IGNITI~N COIL

Fig. 14

4-14 CARBURETOR

A horizontal draft carburetor is employed. It has been carefully set after thorough tests to assure satisfactory start up,

acceleration, fuel consumption, output performance etc.

For construction and other details, refer to the Section 6 . CARBURETOR (Construction, Disassembly and Reassem-

blY 1. (See Fig. 15.)

4-15 AIR CLEANER

Cyclone type semi-wet double element air cleaner is used.

(See Fig. 16.)

4-16 DIODE RECTIFIER

The engines with an electric starter have a diode rectifier

which converts the alternating current generated by the

charging coil into a direct current and charges the battery.

(See Fig. 17.)

L ,

Fig. 15

Fig. 16

Fig. 17

- 9 -

4-17 SECTIONAL VIEW OF ENGINE

/ RECOIL STARTER - I

(OPTION) CRANKCASE BALANCER

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) When disassembling the engine, remember well the locations of individual parts so that they can be reassembled

correctly. I f you are uncertain of identifying some parts, it is 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.

2099500407

2079500307

"20248

Tool

Flywheel Puller (with bolt)

Valve Spring Retainer

riming Tester

~

Wse

For pulling off Flywheel

For mounting and dismounting Valve Spring Retainer and Retainer Lock

For adjusting timing

Applicable Model

EY10,13,14

EY15,18,20

EY25,27,33

EY35,40,44

EC05,07, 10

ECf 7,25,37

EYIQ, 13.14

EY15,18,20

EY25,27,33

EY35,40,44

EYlO, 13,14

EY15,18,20

EY25,27,33

EY35,40,44

EC03,04,05

EC07,10,17

EC25,37

- 12 -

Shape

,"-

5-3 HOW TO DISASSEMBLE

Order

1

2

3

4

5

6

7

8

Item

Engine

Fuel tank

Tank bracket

Air cleaner

Muffler cover

Muffler

Carburetor

Governor lever

*Length of the bolt indicates the length from the bolt head bottom surface t o the threaded end.

Procedures Remarks

Drain engine oil.

case the gasket. Drain plugs on both sides of the Be careful not to lose the

(1) Close the strainer cock. (2) Move the fuel pipe clamp (on

strainer side) downward. (3) Remove the tank from tank

bracket.

Remove tank bracket.

(1) Remove air cleaner cover and

(2) Remove choke knob. (3) Remove the bottom plate of

element.

air cleaner.

Remove muffler cover.

(1) Remove the flange portion

(2) Remove the muffler bracket. of the muffler.

Remove the carburetor. etc. Be careful of the packing

Joint sheet, insulator, and then paper packing, in t h s order from the engine side

Remove the governor lever. Be careful of the position of the governor spring.

Bolts, nuts, etc. used

Flange bolt

8 mm (No.2) nut . . . 4 pcs. SpI-ing washer . . . 4 pcs.

10 mm flange nut . . . 4 pcs. (tightened together with cylinder head)

Swivel 6 x 12 mm flange bolt

. . . 2 pcs.

6 x 8 (5T) Flange bolt * . . 4 pcs.

8 mm brass nut . . . 2 pcs.

8 x 16 (ST) Bolt & washer . . . 2 pcs., Washer . . . 1 pce

6 mm nut . . . 2 pcs.

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

6 mm special n u t . . , 1 pce. Washer . . . 1 pce. 6 x 25 (7T) bolt . . . 1 pce.

Fig. 18

- 13 -

I I I I I

Order

Speed control 9

Bolts, nuts, etc. used Remarks Procedures Item

Circle clip . . . 1 pce. Remember the assembling Disassemble. order of component parts. (See Fig. 19.)

8 mm butterfly n u t . . . 1 pce.

- Order

10

1 1

Item

Operation case

Electric starter

h

Fig. 19

(1) Disconnect the high voltage wire connecting the electric starter to the magnetic switch on the side of the switch.

(2) Remove the bolts. (3 pcs.)

Remove electric starter.

Remarks Bolts, nuts, etc. used

(See Fig. 20.)

Two of the three 6 x 8 (5T) flange bolts tighten the cylinder buffle and fan cover together.

8 x 30 reamer bolt . . . 2 pcs. Spring washer . . . 2 pcs. Washer . . . 2 pcs.

Fig. 20

- 14-

Order

12 -

- 13

14

-

Item I Procedures I Remarks I Bolts, nuts, etc. used

Fan cover 6 x 8 flange bolt . . . 6 pcs. Removable by loosening (1) Remove the fan cover. bolts

(2) Remove the head cover. (3) Remove the cylinder buffle. 6 x 8 flange bolt . . . 1 pce.

Starting pulley 8 x 12 (ST) bolt . . . 3 pcs. (See Fig. 21 .) Remove starting pulley.

Flywheel I Remove flywheel. Be sure to use the fly- 18 mm nut . . . 1 pce. wheel puller. Do not Spring washer . . . 1 pce.

crankshaft.

Fig. 21 Fig. 22

b -- 15 -

Order

15

- 16

17

Item

Electric devices

Cylinder head

Tappet cover (breather plate)

Intake and exhaust valves

Procedures

(1) Remove point cover.

(2) Remove contact breaker.

(3) Remove ignition coil and condenser.

(1) Remove spark plug. (2) Remove cylinder head.

Remove Tappet cover.

(1) Remove intake valve. (2) Remove exhaust valve.

Remarks Bolts, nuts, etc. used

4 x 12 screw and washer . . . 2 pcs. 4 x 8 screw and washer

I

Be careful of the primary lead connecting direction.

. . . 1 pce.

before disassembly. 6 x 25 screw and washer Remove the lighting coil . . . 2 pcs.

10 mm flange nut . . . 8 pcs. 1 Be Of the breather I 6 x 14 flange bolt . . . 2 pcs. valve mounting position and the order of assembl- I I ing packings. (See Fig. 23.)

Intake and exhaust valve springs, retainers and re-

Use valve spring retainers.

but be sure to set up them tainer locks are common;

on the original valves. (See Fig. 24.)

Fig. 23

- 16-

Fig. 24

Irder I Item

19 Main bearing cover

~

20 Camshaft

I

Procedures ~~~ ~ ~ ~~~~~

(1) Set the piston to the TDC, remove blind plug in the lower part of the front side of bearing cover, and insert the 4 mm stick.

(2) Remove bolts. (3) Strike the side of main bear-

ing cover with a plastic ham- mer or the like to remove the cover from crankcase.

Remove camshaft.

r

Order

Intake/ex- 2 1

Item

haust tappets

22 Connecting rod and piston

23 Crankshaft

Remarks I Bolts, nuts, etc. used

(See Fig. 25.)

In case of Type B, be careful not to remove camshaft together. *Crankshaft and camshaft have adjusting shims. (TY Pe B)

6 x 8 flange bolt . . . 1 pce. Gasket (aluminium) . . . 1 pce.

8 x 35 (7T) set bolt . . . 8 pcs.

Camshaft can easily be pulled by hand. Be careful not to let the tappets drop. 1

Fig. 25 Fig. 26

Procedures Bolts, nuts, etc. used Remarks ~ ~~

Remove intake/exhaust tappets. Intake and exhaust tappets are the same, but be sure to intall them in their original positions because 1 of the valve clearance.

~~

(1) Return the lock washer. (2) Remove bolts. (3) Push the piston up out of

the top of cylinder.

8 x 46 reamer bolt . ~ . 2 pcs.

I

Hold crankshaft with hand. and I Be careful of 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

Every and each part should be cleaned thoroughly. Especially, pay utmost care and attention to the cleanliness of the

piston, cylinder, crankshaft, connecting rod and bearings.

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, when reassembling.

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

Piston Outside Diameter (In Skirt Thrust Direction)

78 dia. 40.019 I 84 dia. ,, +0.022

I Piston to Cylinder a t Piston Skirt Thrust Face I 0.049L - 0.1 08L 1 0.049L - 0.1 1 1 L

Piston Ring Gap (Top Ring - Second Ring) I

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

Clearance between Connecting Rod Large End and Piston Pin and Outside Diameter

Clearance between Inside

Side Clearance

0.1 L - 0.3L

0.05 - 0.09

Clearance between Connection Rod Small End and Piston Pin

Clearance between Piston Pin and Pinston Pin Hole

0.070 - 0.102L

0.020L - 0.042L

0.1 L - 0.4L

0.1 1T - 0.01 1 L

r'

L: LOOSE Fig. 27

- 18 -

5-4-3 ASSEMBLING ORDER and PRECAUTIONS

1) Place the tappets into the crankcase. . .

NOTE: The intake and exhaust tappets are the same,

but mark them differently when disassembl-

ing because of different valve clearances; and

fit them into their origianl place. Apply oil to

the tappets beforehand.

Assemble the crankshaft and camshaft at the same

time.

NOTE: The same timing mark as on the crankshaft

side is punched on the crankshaft gear inward

TIMING MARK ON CAMSHAFT SIDE (Punch 2 pcskl

TIMING MARK ON CRANKSHA?? of the balancer gear as shown in Fig. 28. So, (Punch 1 pce.)

match these timing marks on the crankshaft

and camshaft sides before installing these

shafts in the crankcase.

3) Assemble the connecting rod with the piston.

Fig. 28

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 pin and fitting the clip on, be careful not to damage the piston surface.

4) Fit the piston rings on the piston. 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 RAIL

in this order. The open ends of each ring must

be as shown in Fig. 29.

Fig. 29

ASSEMBLY TYPE OIL RING

Fig. 30 Fig. 3 1

- 19-

5 ) Assemble the piston and connecting rod that were

readied in Steps 3) and 4).

NOTE: The symbol @FAN mark on the connecting

rod must be on the magneto side.

NOTE: Be careful of the match mark on the cap. I f

the match mark is 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.

Install the main bearing cover.

NOTE: If the oil seal is damaged when the governor

yoke is installed, replace it with a new one.

NOTE: Adjust the side clearance to anywhere be-

tween 0.05 and 0.2 mm. The side clearance

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.

* The side clearance can also be measured as

shown in photos below. (Figs. 34 and 35)

~ MATCH

u__

Fig. 32

CRANKSHAFT SPACER \

MAIN BEARING

BALANCER

Fig. 33

Fig. 34

- 20 -

Fig. 35

NOTE: Check the main bearing cover joint for flaw,

and correct if necessary.

Fit the governor sleeve into the cam gear

with new packing.

* Move the piston up to TDC, insert the 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-

ly runs.

7) Install the intake and exhaust valves.

* Intake and exhaust valve specifications are as follows:

VALVE and VALVE GUIDE CLEARANCE

A-VALVE FACE ANGLE

6-SEAT ANGLE

C-GUIDE INSIDE DIA. ~~~~ ~ ~

INTAKE D-VALVE STEM OUTSIDE DIA.

MAXIMUM ALLOWABLE CLEARANCE 8ETWEEN C and D

INTAKE

Fig. 36

4O A.4 IF

GUIDE

EY35 E Y40

8dia. +0.036

dia. -0.070 -0.090

0.030L - 0.091 L

0.070L - 0.1 26L

Fig. 37

- 2 1 -

.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 - 0.1 7 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 p a .

Tightening torque . . . 340 - 390 kg-cm

- 22 -

10) Electrical installation

* Install the ignition coil and capacitor.

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

Point gap . . . . . . . . . . . . . . . .0.35 k0.05 mm

rKER

Fig. 4 1

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 point gap 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. .IGNITION TIMING CHECK

Use a timing tester, Part N0.M-20248

Fig. 42

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 temporarily install 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 spark is 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) Install the flywheel.

NOTE: Before installing the flywheef, clean the crankshaft and the tapered part of the flywheel of oil.

16mmnut . . . . . . . . . . . . . . . . 1 pce. 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 direction may vary with machine make.

6 x 8 flange bolt . . . . . . . . . . . . 4 pcs.

15) Install the carburetor. 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.

Cl ip . . . . . . . . . . . . . . . . . . . . . 1 pce.

0

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.) * Check that the carburetor and throttle valve are

fully open.

* Turn the governor shaft counterclockwise, and fasten the governor lever. (See Fig. 46.)

Fig. 46 Install the starter motor.

8 x 30 reamer bolt . . . . . . . . . . . 2 pcs.

Spring washer . . . . . . . . . . . . . . 2 PcS.

Washer. . . . . . . . . . . . . . . . . . . 2 pes.

Install the operation case. (with the electric starter)

6 x 8 flange bolt (5T) . . . . . . . . . 3 pcs. * Two of the three flange bolts tighten the case together with the cylinder buffle 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 muffler cover.

6 x 8 flange bolt (5T) . . . . . . . . . 4 pcs.

Install the air cleaner.

NOTE: Make sure that the tip of the breather pipe out of the tappet cover is clear off the element retainer.

6 x 12 flange bolt . . . . . . . . . . . 2 pcs.

After mounting the cleaner bottom plate, install the choke knob, element retainer, element and cover in t h s order.

Install the tank bracket.

10 mm flange nut . . . . . . . . . . . 4 pcs.

(also for cylinder head)

Install the fuel tank.

8 mm No.2 nut . . . . . . . . . . . . . 4 pcs.

Spring washer . . . . . . . . . . . . . . 4 pcs. Connect the fuel pipe.

Clamp the pipe securely.

Supply 1.2 liter engine oil.

- 2 5 -

6, CARBURETOR

SPECIFICATION

I EY35 I E Y40

Model

2246230100 2236230100 Part No.

BV26-20 BV26-19

Main Jet

#57.5 #55 Pilot Jet

$1.2 $1.5 Main Air Jet

#112.5 #107.5

Throttle Valve #135 #150

Pilot Screw 1 (Return) I 1 turn

6 -1 OPERATION and CONSTRUCTION

PI LOT

FUEL

NEEDLE VALVE

FLOAT

FLOAT CHAMBER

A

W

Fig. 48

- 26 -

6-1 -1 FLOAT SYSTEM

The float chamber is located just below the carburetor body and, with a float and a needle valve, maintains a constant fuel

level during engine operation.

The fuel flows from the fuel tank into the float chamber through the needle valve. When the fuel rises to a specific level, the

float rises; and when its buoyancy and fuel pressure are balanced, the needle valve close to the shut off the fuel, thereby

keeping the fuel at the reference level.

6-1 -2 PI LOT SYSTEM

The pilot system feeds the fuel to the engine during idling and low-speed operation.

The fuel is fed through the main jet to the pilot jet, where it is metered, and mixed with the air metered by the pilot air jet.

The fuel-air mixture is 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 fuel to the engine 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 mixture is atomized out of the main 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 the main nozzle increases and draws much fuel accordingly; thus easily start up the engine.

6-2 DISASSEMBLY and REASSEMBLY

Apart from mechanical failures, most of carburetor troubles are caused by an incorrect mixing ratio, which may arise 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 are as 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 the valve 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, make sure 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 pilot screw is out of shape, replace it with a new one.

- 27 -

6-2 -4 MAIN SYSTEM

1) Remove the bolt (1 3) and take out float chamber

body (15).

2) Remove the main jet (1 7) and main nozzle (1 8), using

correct tool to avoid damage to 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 the rod more slender than the

float pin (19) and remove because the float pin is calked to

the carburetor body.

*When cleaning the jets, use neither a drill nor a wire

(because of possible damage of the orifice which will

adversely affect fuel flow). Be sure to use compressed

air to blow them clean.

Fully tighten the pilot screw and then loosen it coun-

terclockwise by one turn for Model EY35, or one

turn and a half for Model EY40. When fully closing

the pilot screw, do not tighten it too hard. Otherwise,

the needle at the tip might become damaged.

Turn the throttle stop screw clockwise to a normal

idling speed of 1200 rpm.

Make a final adjustment when the engine is in normal

I A ‘17

19

-18

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, piston rings or valves are replaced with new ones.

Thl e recommended break-in schedule is shown below.

LOAD SPEED TIME

EY35 EY 40

NO LOAD 10 minutes 2,500 rprn ~

NO LOAD

30 minutes 3,600 rpm 4.0 HP 3.5 HP

10 minutes 3,600 rprn NO LOAD

10 minutes 3,000 rpm

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

- 28 -

8. ROBIN SOLID STATE IGNITION ENGINE (OPTION)

8-1 FEATURES

The S.S.I. system is free of the weak points of the conventional point type ignition system, that is, ignition failure due to a

dirty or burnt contact point, oxidation during long storage,and mechanical wear,and featuresmaintenance-free performance,

proper sparking, and freedom from the ill effects of water, oil dust, and moisture.

8-2 BASIC CIRCUIT and OPERATING THEORY of

S.S. I. SYSTEM

1) As the flywheel and magneto rotate, a voltage is in-

duced in the exciter coil, and flows through the pri-

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) At the ignition time, electric power flows from the

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

generated on the secondary side of the ignition coil to

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 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 circuit tester, not a 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.

IGNITION UNIT

"-1 IGNITION COIL

L Fig. 50

Connect (+) terminal of tester. I

8-4 MEASURING RESISTANCES of EXCITER COIL and PULSER COIL

Exciter Coil A - t B A + B

Pulser Coil

STD

t 4.5R * 20% 150W

66Q * 20% 0.97Q * 20%

Fig. 51 * Values in the table above apply where ambient temperature is 20°C.

- 29 -

9. TROUBLE SHOOTING

The following three conditions must be satisfied 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., a heavy load on the engine when it is about to start at low speed, and a high back pressure due to a long exhaust

pipe, just to say a few.

The most common causes of engine troubles are given below:

9-1 STARTING DIFFICULTIES

9-1 -1 FUEL SYSTEM

NO gasoline in th fuel tank; or the fuel cock is closed.

The carburetor is not choked enough, particularly when the engine is cold.

Water, dust or gum in the gasoline block flow of the fuel to the carburetor.

Inferior grade gasoline or poor quality gasoline is not gasfied enough to produce the correct fuel-air mixture.

The carburetor needle valve is 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 the grip of a screwdriver

of the like.

If the carburetor overflows, excessive fuel runs into the cylinder 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 try to start again.

9-1-2 COMPRESSION SYSTEM

If starting difficulties and loss of power are not due to the fuel system or ignition system, the following must be 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) Incorrect Tappet Clearance

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.

0 9-3

1)

9-4

Leads of the ignition coil, spark plug or 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.

ENGINE STOPS

Fuel tank empty. Water, dirt, gum, etc. in gasoline.

Vapor lock, i. e., gasoline evaporating in the fuel lines due to overheat around the engine.

Vapor lock in the fuel lines or carburetor due to the use of too volatile winter gas in the hot season.

Air vent hole in the fuel tank cap plugged.

Bearing p.arts seized due to lack of oil. Magneto or ignition coil faulty.

ENGINE OVERHEAT

Crankcase oil level low. Add oil immediately.

Spark timing incorrect.

Low grade gasoline is used, or engine is overloaded.

Cooling air circulation restricted.

Cooling air party misdirected causes loss of cooling efficiency.

Cylinder head cooling fins clogged up with dirt.

Engine operated in an enclosed space 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 to heavy 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 method of connecting it to a load (machine), the foundation,

and the method of 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 oil can 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, piston seizure, 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 the hot air used for engine cooling, and temperature rise of the load (machine).

Take steps as necessary to keep the engine room temperature below 50°C even in the hottest period of the year.

10-3 EXHAUST GAS DISCHARGE

Exhaust gas is noxious. When operating the engine indoors, be sure to 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, pipe inside 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 tank is too high, on the other hand, it can cause the carburetor to overflow.

Be careful of heat conduction, pipe size, bends, and leaks from the joints in piping and make the fuel pipe as short as possible

to prevent air and vapor from being trapped. The standard fuel pipe diameter is 4 to 5 mm.

10-5 POWER TRANSMISSION to DRIVEN MACHINES

10-5-1 BELT DRIVE

Take the following notes into consideration.

* V-belts are preferable to flat belts.

* The driving shaft of the engine must be parallel to the driven shaft of the load.

* The driving pulley of the engine must be in line with the driven pulley of the load.

* Install the engine pulley as close to the engine as possible.

* If possible, span the belt horizontally.

* Disengage the load when starting the engine.

If no clutch is used, use a belt tension pulley or the like.

- 33 -

10-5-2 F L E X I B L E COUPLING

When using a flexible coupling, runout and misalignment between the driven shaft and engine shaft must be minimized.

Runout and misalignment tolerance are specified by the coupling manufacturer.

10-6 WIRING

Models EY35 and EY40 are available in types that have the ignition and starting systems shown in the wiring diagrams

below. The parts indicated by dotted lines in the diagram are not normally supplied with the engine.

[RECOIL STARTER TYPE and LIGHTING COIL]

MAGNETO Note: Standard type is not equipped

with the lighting coil. STOP BUTTON

E - - - - - - - - - 1

SPARK PLUG Green/Yellow

Fig. 52

BUZZER

[ELECTRIC STARTER TYPE] MAGNETO

KEY SWITCH

ELECTRIC STARTER MAGNETIC SWITCH

Fig. 53 [S.S.I. with RECOIL STARTER and LIGHTING COIL]

MAGNETO

1

STOP BUTTON

I

SPARK PL .UG

BUZZER 6V8W @ * QLAMP 12V15W

J,

Fig. 54

- 34 -

[S.S.I. with ELECTRIC STARTER] KEY SWITCH

BATTERY 12W24AH

[S.S.I. 15OW with ELECTRIC STARTER]

EXCITER COIL RedIWhite

CHARGING COIL

12V24AH

- ""_ ""-I [ A E L Z R I C STARTER Black/White Red

Fig. 56

* The symbols shown in the wiring diagrams above signify the following. """- Not mounted on the engine

- - JIS CB104 jack

--D JIS CA104 plug

@ JIS LA104 or LA108 plate terminal * In the wiring diagram showing the circuit with a recoil, the ignition coil is optional, and therefore is not supplied on

the standard models.

- 35 -

10-7 VINYL-INSULATED WIRE

Recent engine sets become complex, and an increasing number of them 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

Size (mm2 I

0.50 0.85 1.25 2.0 3 .O 5 .O 8.0

15.0 20.0 30 .O

No. of conductors/ conductor diameter (mml

7r0.32 11r0.32 1 6r0.3 2 2610.32 41 10.32 6510.32 5010.45 8410.45 4 1 10.80 70f0.80

Resistor (Wml 2OoC Albwable curre1 ( I

0.03250 9 0.02050

120 0.00051 84 0.00087 59 0.00136 47 0.00228 37 0.00374 27 0.00550 20 0.00867 1.5 0.01410 12

* 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 expressed by 00 square (SQ).

- 36 -

11. CHECKS and CORRECTIONS

After disassembling and cleaning the 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 standards specified.

The meanings of the terms used in the correction table are as follows:

1) Correction

Repair, adjustment or replacement of any engine parts.

2) Correction Limit

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) Standard Dimensions

The design dimensions of new parts minus tolerance.

5) Correction Tolerance

Tolerance on the dimensions of engine parts refinished or adjusted.

- 37 -

12. TABLES OF CORRECTION STANDARDS T T - USE

LIMIT TOOL CORRECTION CORRECTION

METHOD ENGINE MODEL

EY35 EY40

EY35

EY40

EY35 EY40

EY 35 EY40

EY35 EY40

EY 35 EY40

EY35

EY40

EY35

EY40

EY35 EY40

EY35

EY40

EY35

EY40

EY35 EY40

EY35

EY40

EY35

EY40

STANDARD SIZE ITEM REMARKS

TOLERANCE LIMIT

Surface plate, Feeler

Flatness of cylinder head

Bore

Roundness

Cylindricity

Valve seat contact width

Valve guide I.D.

O.D. at skirt, in thrust direction (incl. over size)

B 0.25 C 0.5

Width of ring groove

Piston pin hole

Clearance between piston and cylinder

Clearance between pisition ring and ring groove

F i t between piston and piston pin

Ring gap

Ring width

0.05 0.1 5 Correct

Dif. between max. & min.

+0.019 0

S.T.D. 78 dia.

84 dia. 0.1 5 0.65

0.01 Boring

0.01 5

-

2.5 1.2-1.5 Correct

Replace +0.036 0

At middle portion 8 dia. 0.1 5 0.1 5

-0.1

0.1 5

S.T.D. 77.951 dia. B 78.201 dia. C 73.451 dia. S.T.D.83.951 dia. B 84.201 dia. C 84.451 dia.

Top, 2nd 2

0 -0.04

Micro- meter

- 0.1

-

0.1 5

Replace

Top +0.04 +0.06 -

oil +0.055 - +0.2

Vernier caliwrs

Replace Oil 4

+0.002 -0.01 1

20 dia. 0.035 0.035

0.048 - 0.108

Cylinder gauge, Micro- meter

Max. cylinder dia. and piston dia. at skert in thrust direc- t ion

Replace 0.025 0.025 0.048 -

0.1 11

Top 0.05 - 2nd 0.09

0.1 5 0.1 5 Replace

Cylinder

Micro- meter

gauge, 0.011 T 0.011 L

TOP

2nd 0.1 - 0.3

1.5

-

- 0.1

-

Replace 1.5

-0.1

Oil 0.2 - 0.9

Top.2nd 2

Oil 4

TOP -0.01 2nd -0.03

Mircro- meter

- 38 -

ITEM 1 ENGINE1 STANDARD 1 CORRECTION

L IMIT USE 1 REMARKS 1 METHOD

CORRECTION MODEL LIMIT TOLERANCE SIZE

t Micro- meter Replace -0.03 I Piston pin 0. D. +

EY35 1 EY40 34 dia. +0.016 - 0 0.1

Cylinder gauge Replace

Cylinder gauge,

meter Micro- Replace

Cylinder gauge

Replace

Cylinder gauge, Micro- meter

Replace

Oql I Large end I. D

rod large end I.D. and crankpin

Small end I.D.

EY35 EY40 I 0.2 1 EY15 +0.033

20 dia. I +o.02 1 0.08 0.08

a :L."-- EY15 I EY20 0.12 I 0.02 - 0.042 0.12

1 0.1 - 0.4 1.0 1 V Large end side clearance

Feeler or Replace gauge Re-machine

Test bar

gauge

Re-machine or Replace

Parallelism between large end and

Distance between large end and small end bores

0.1

Test bar and Micro- meter

Micro- meter

Micro- meter

0'15 I Replace

EY35 1 EY40 I I -0.070 - -0.080 0.1 5


0.5 I Crankpin O.D.

EY15 1 EY20


Crankpin O.D. roundness Less than 0.005

E Crankpin O.D. cylindricity

b Crankpin O.D. 1 parallelism

EY15 EY20

Micro- or Replace meter Re-machine

Less than 0.005

EY15 I EY 20 Dial Re-machine gauge or Replace

Less than 0.01

~~~~ ~

Drive 5. 25 dia.

Mag. s. 25 dia.

Drive,s. 25 dia. -0.014

Mag. s. 25 dia.

-0.003

EY40

Micro- meter Replace Crankshaft

journal O.D.

I -0.25

Intake 36

Exhaust 35.5 to .1 -0.25

Micro- meter Replace I Cam lobe height

Drive S. 35 dia. -0.003 -0.014

Mag. S. 25 dia. -0.003 -0.012 -0.01 6 Drive S. 17 dia. -0.027

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

EY35B

- 0.05

EY35D

EY35B

,. n. P 0.05 I."&,

Micro- meter

Replace 0.05

- 39 -

LIMIT 1 REMARKS 1 TOOL ITEM

1 CORRECTIOP

METHOD

i Drive S. 35 dia.

Mag. S. 25 dia.

-0.003 -0.014

-0.003 -0.01 2

EY4OB .4- 4-

5 Journal OD. Micro- Meter 0.05 Replace 0.05

Drive S. 17 dia. -0.016

EY40D -0.027

-0.027

EY35 EY40

1 -1.5 -1.5 Vernier calipers 46 Replace

EY35 1 EY40

!Square feeler Qawe

Micro. meter

Replace

I - 0.030 -0.055

-0.070 -0.15

Exhaust 8 dia. Replace Valve stem O.D.

0.3 At middle EY35 Intake 0.030-0.091

EY40 Exhaust 0.070-0.126 0.3

Clearance between Replace

Correct w

4 I I Clearance between Replace 0.04-0.1 5 = I groove and retainer

EY35 1 5.3 EY40 1 -0.5 -L Vernier

calipers Stem end length

Total length

Replace

Replace Vernier calipers -0.5 I

E 1- Clearance between EY35 1

EY40

Cylinder gauge & Micro- meter

Replace 0.025-0.062 0.2 I stem and guide

EY35 I 1 I I I( +1 /4 I Pilot screw unscrew EY40 I 1%

7 Spark plug

EY35 EY40 1 B-6HS

EY40 EY35 I 0.6 - 0.7 I 1.0

Adjust or replace

Timing tester

EY35 i 3O f 5"

EY40

EY35 0.35 f 0.05 f 0.1

23'before T.D.C. . Adjust

Adjust I Point opening EY40

-40 -

ITEM

Max. Output

Continuous Rated output

MODEL ~~~

EY35

EY40

EY35

EY40

8.514000

1 0.0/3,600 Below 1 10% of rated output

7.013600

8.013600

I

ITEM REMARKS CORRECTION PRECISENESS literlhr MODEL

Fuel Consumption EY35

EY40

2.9

3.5 Up 135% of standard consumption At continuous rated output

1 I I 1

ITEM REMARKS USE L IMIT cc/hr cc/hr MODEL

EY35 60 25 - 30

Consumption Lubricant

EY40 80 30 - 40

ITEM REMARKS liter MODEL - Fixed quantity of Lubricant

EY35

EY40 1.2

ITEM REMARKS liter MODEL

Use the class SC or higher grade Engine Oil Winter (lower than 0 ° C ) SAE 1 OW-30 Spring and Autumn SAE #20 Summer SAE #30

I I I 1

ITEM FREQUENCY OF OIL CHANGE MODEL

Oil Change EY35

EY40

First time: Change oil after 20 hours operation. Second Time and Thereafter: Change oi l every 50 hours operation.

ITEM REMARKS TOOL CORRECTION LIMIT kg/cm'/rpm MODEL I I I 1 I I I

EY35

- 41 -

ITEM

Min. accelerating revolution

MODEL REMARKS TOOL rpm -

-

r ITEM I MODEL I kgcm

Cylinder head clamp nuts

EY35

EY40 340- 390

Connecting rod EY35

bolts EY40 250 - 300

Magneto clamp EY35 nuts 1 EY40 1 800-1000

Main bearing cover bolts

170-190 EY40

Spark plug EY 35

EY40 260 - 290

T

,-

Crankshaft

ft-lb REMARKS TOOL

24.6-28.3 Torque wrench

18-21.7 Torque wrench



18.8-21 Torque wrench

- 4 2 -

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 these intervals.

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 DAILY CHECKS and MAINTENANCE

Checks and maintenance I Reasons for requiring them

Remove dust from whatever parts which accumulated dust.

The governor linkage is especially susceptible to dust.

Check external fuel leakage. If any, retighten or

replace.

Not only wasteful but also dangerous

Loose screws and nuts will result in vibration Check screw tightening. If any loose one is found,

I re-tighten. 1 accidents.

Check oil level in crankcase and add up as necessary. If the engine is operated without sufficient oil, it will I fail.

13-2 EVERY 20 HOURS CHECKS and MAINTENANCE

Checks and maintenance Reasons for requiring them 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 Checks and maintenance Reasons for requiring them 1 Clean fuel filter and fuel tank.

The engine output drops. Clean contact breaker points.

The engine will be out of order.

-43 -

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

Checks and maintenance Reasons for requiring them

Remove cylinder head and remove carbon

Disassemble and clean carburetor.

deposit.

The engine will be out of order.

13-6 EVERY 1000 HOURS (YEARLY) CHECKSand MAINTENANCE

I Checks and maintenance I Reasons for requiring them

Perform overhauls, clean, correct or replace

parts.

The engine output drops and become out of order.

Change piston rings.

I Replace fuel pipe once a year. 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

ey35, ey40

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