Robin America EH30, Service Manual

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Page 2: ...EH12 EHl5 EH17 EH2 1 EH25 EH30 EH30V EH34 EH34V EH43V EC13V DY23 DY27 DY30 DY35 DY4 1 WISCONSIN ROBIN W1 080 W1 145 W1 145V Wl 185 W1 185V W1 230 w1 280 W1 340 W1 390 W1 450V EY21W EY44W EY25W EY27W EY18 3W v WO1 115 wo1 120 WO1 150 WOI 170 wo1 210 WO1 250 WO1 300 WOI 3oov WO1 340 WO1 340V WO1 430V TWO CYCLE WT1 125V DIESEL WRD1 230 WRD1 270 WRD1 300 WRDI 350 WRD1 410 ...

Page 3: ...6 46 47 4 1 Cylinder And Crankcase 4 2 MainBearingCover 4 3 Crankshaft 4 4 Connecting Rod And piston 4 5 PistonRings 4 6 Camshaft 4 8 Cylinder Head 4 9 GovernorSystem 4 1 1 Lubrication 4 12 Ignition System 4 13 Carburetor 4 14 Air Cleaner 4 15 Balancers 4 16 Decompression System 4 17 Sectional View Of Engine 5 DISASSEMBLY AND REASSEMBLY 5 1 Preparations And Suggestions 5 2 Special Tools 5 3 Disass...

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Page 5: ...e OilSAE 20 30 or 1OW 30 Carburetor Automobile Gasoline Fuel HorizontalDraft Float Type Fuel Consumption Ratio 230 gr HP h At Continuous Rated Output Fuel Feed System GravityType Fuel TankCapacity Flywheel Magneto Solid State Ignition System 6 liters 1 58 U S gal Spark Plug NGK BP6ES CHAMPION N9Y Charging Capacity I 12V 1 3A I I 12V 1 3A Starting System Recoil and Recoil Starter ElectricStarter El...

Page 6: ...t I 1 2 liters 0 32 U S gal Carburetor AutomobileGasoline Fuel HorizontalDraft FloatType Fuel Consumption Ratio I 230 gr HP h At Continuous Rated Output I Fuel Feed System GravityType Fuel Tank Capacity Flywheel Magneto Solid State Ignition System 6 liters 1 58 U S gal Spark Plug 12V 1 3A 12V 1 3A Charging Capacity NGK BP6ES CHAMPION N9Y Starting System Recoil and Recoil and Recoil Starter Electri...

Page 7: ...oken in 2 2 CONTINUOUS RATED OUTPUT The continuous rated output is the output of an engine at optimum governed speed which is most favorablefromtheviewpoint of engine s life andfuelconsumption When theengine is installed on acertainequipment it is recommended that the continuous output required from theengine be kept below thiscontinuousratedoutput 2 3 MAXIMUM TORQUE The maximum torque is thetorqu...

Page 8: ...2 4 PERFORMANCE CURVES OEHBOD B 9 8 7 6 5 4 3 2 1 0 2000 2400 2800 3200 1 000 1 200 1 400 1 600 3600 1 800 REVLOUTION r p m Kg m CONTINUOUS RATED OUTPUT RECOMMENDABLE HORSEPOWER RANGE 4 ...

Page 9: ... EH34D B HP A 52 B w c n 0 I 2000 2400 2800 3200 3600 1000 1 200 1 400 1 600 1 800 REVLOUTION r p m Kg m w 3 0 CONTINUOUS RATED OUTPUT RECOMMENDABLE HORSEPOWER RANGE 5 ...

Page 10: ...ngthearrangementsfor cooling air flow much easier in thedesign of powerequipment 4 GENERAL DESCRIPTION OF ENGINE COMPONENTS 4 1 CYLINDER AND CRANKCASE The cylinder and crankcase is single piece aluminumdiecasting Thecylinderliner made of special cast iron is molded into the aluminum casting Thecrankcasehas a mountingsurfaceonthe output shaft side where the main bearingcover is attached See Fig 1 F...

Page 11: ...rge and small ends function as bearings The piston is an aluminum alloy casting andcarriestwo compression ringsand one oil ring See Fig 4 4 5 PISTON RINGS The Pistonringsaremade of special cast iron The profile of the top ring is barrel face and tile S W O J I ring has a tapered face with an m d e r CUT l he oil ring consists of a cutter ring and a coil expander far better sealing and less o i l x...

Page 12: ...ll bearings are employed on the both sides for supporting the shaft See Fig 6 1 4 7 VALVE ARRANGEMENT Theintakevalve is located on flywheelside of thecylinderhead Hard alloy valve seats are moIded in the cylinder head and stellite is fused to the exhaust valve face The cylinder baffle leads cooling air to the exhaustvalveareafortheoptimum cooling See Fig 7 I B TYPE Fig 6 VALVE I Fig 7 4 8 CYLINDER...

Page 13: ...led in the crankcase and driven by the balancer shaft See Fig 9 1 Fig 9 4 10 COOLING SYSTEM Thelargefins on theflywheelprovidesufficientcoolingaircapacity for the inlet andexhaust areaandcylinder Thecylinderbafflehelpsthecoolingairflowefficiently 4 11 LUBRICATION A11 therotatingandslidingparts are splash lubricated by the oil scraper on the connecting rod See Fig 10 I OIL SCRAPER Fig 10 9 ...

Page 14: ...rting See Fig 11 4 13 CARBURETOR The engines are equipped with a horizontal draftcarburetorthathasafloat controlledfuel systemandafixedmain jet Thecarburetorsarecalibratedcarefully for the sure starting good acceleration low fuel consumptionandsufficientoutput For the datails refer to page 46 section 8 CARBURETOR See Fig 12 I Fig 1 1 Fig 12 4 14 AIR CLEANER Theair cleaner is aheavy dutytypewitha d...

Page 15: ...th thecrankshaft to effectively reduce vibration See Fig 1 4 4 16 DECOMPRESSION SYSTEM An automatic decompression mechanism which opensexhaustvalvebeforethepistonreaches compression top is assembled on thecamshaft for easy starting See Fig 15 BALANCER 1 Fig 14 AUTOMATIC DECOMPRESSOR SYSTEM Fig I5 1 1 ...

Page 16: ...4 17 SECTIONAL VIEW OF ENGINE FUEL 1 FUEL TANK FLYWHEEL COOLING FAN MAIN BEARING COVER 12 ...

Page 17: ...PLUG COVER ROCKER ARMS DRAIN PLUG BALANCER SHAFT 2 13 ...

Page 18: ...m 2 Have boxesreadytokeepdisassembed parts by group 3 To preventlosingandmisplacing temporarilyassembleeach group of disassembed parts 4 Carefullyhandledisassembedparts andcleanthem with washing oil if necessary 5 Use thecorrect tools inthecorrect way 5 2 SPECIAL TOOLS Tool No Use Tool 209 95004 07 For placing piston ring Piston ring compressor 228 95003 07 For pulling off theflywheel Flywheel pul...

Page 19: ...LY PROCEDURES Step Tool Remarks Procedures Part to remove 1 14mm box wrench Be careful not to lose 1 Remove oil drain plug and drain o i l Oil drain 2 To discharge oil quickly remove o i l the gasket gauge Fig 17 15 ...

Page 20: ...ove washer and gasket for 3 Loosen screwon swivel and pull out 4 Remove two flange nuts and a bolt P u l l off breather pipe lonun box wrench element wing bolt choke knob and remove cleaner base from cleaner base M6 flange nut 2pcs M6 X 12mm bolt and washer lpce M6 FLANGENUT 2pcs M6 BOLT AND WASHER CLEANER COVER CLEANER BASE WING BOLT Fig 18 16 ...

Page 21: ...andwasher 2pcs 4 Loosen flange bolt and remove bracket M6 x 8mm frange bolt 0 Ipse 4 Carburetor 1 Close fuel valve 2 Disconnectfuel pipe from fuel strainer 3 Remove carburetor carefully unhooking governor rod and rod spring from governor lever Remarks Be careful not to bend governor rod or stretch rod spring Tool 8mm box wrench l o r n box wrench KEY SWITCH Fig 19 17 BRACKET ...

Page 22: ...d governor lever 1 Unhook governor spring from governor lever 2 Remove clip wing nut stop plate friction plate and speed control lever 3 Loosen the bolt and remove governor lever Note governor spring hole on governor lever ROD SPRING GOVERNOR LEVER I GOVERNOR SPRING ER Fig 20 18 ...

Page 23: ...move oil sensor unit damage stick and bearing cover Be very careful not to Remove oil sensor bracket 11 Loosen two flange nutsand a bolt muffler gasket 2 Remove muffler and muffler cover 12mm box wrench Be careful not to lose from stud bolts M8 flange nut 2pcs M8 X 16mm bolt and washer lpce M8 FLANGE NUT Ppcs MUFFLER COVER Fig 21 GASKET M6 SCREW AND SPRING WASHER 2 s 19 ...

Page 24: ...2pcs M8 washer 2pcs 1 Disconnectwires green white 2 1 white 2 Remove diode rectifier and bracket from crankcase M6 X 12mm flange bolt lpce Reattach terminal nut to starter to keep it from missing Magnetic magnetic switch switch Loosen two flange bolts and remove M6 X 12mm flange bolt 2pcs Tool 12mm socket wrench lOmm box wrench ELECTRIC STARTER Fig 22 BLACK WIRE MAGNETIC SWITCH M6 FLANGE BOLT 2pcs...

Page 25: ...ks Procedures Part to remove 12 Wipe off spilt fuel Loosen four flange nuts from bottom of Fuel tank fuel tank and remove fuel tank 12mm socket M8 flange nut 0 4pcs thoroughly wrench FUEL TANK FUEL STRAINER Fig 23 21 ...

Page 26: ...marks Tool 13 Recoil Remove recoil from blower housing l O m m box wrench starter M6 X 8mm flange bolt 4pcs 14 Blower Remove blower housing from crankcase 1 O m m box wrench housing M6 x 8mm flange bolt 4pcs BLOWER HOUSING 1 Fig 24 22 ...

Page 27: ...from crankcase lOmm box wrench Fuel tank Remove the fuel tankbracket M6 x 8mm flange bolt lpce baffle lOmm box wrench Remove the cylinder baffle from cylinder Cylinder M10 x 25mmbolt and washer a 4pcs Bracket 14mm box wrench I I I I I SPARK M10 FLANGE BOLT 4pcs PLUG CAP I CYLINDER BAFFLE M6 FLANGE BOLT FUEL TANK BRACKET M I 3BOLT AND WASHER I PPCS Fig 25 23 ...

Page 28: ...crankshaft M16 nut lpce See Fig 26 M8 x 1 2 m bolt 3pcs See Fig 28 1 SeeFig 29 Remove the charge coil M6 X 20mm screw 2pcs M6 x 1Omm screw lpce Remarks Flywheel can easily be removed by striking the head of thecenter bolt of the flywheel puller with a hammer Be careful not to lose the key Tool I 24mm socket wrench 12mm socket wrench Phillips screwdriver I Fig 28 Fig 29 24 ...

Page 29: ...d Remove exhaust manifold and gasket from cylinder head M8 flange nut 2pcs Remove intake manifold and gasket from cylinder head M8 x 28mm bolt and washer 2pcs Remove spark plug from cylinder head 12mm box wrench 12mm box wrench I I I I I SPARK PLUG M8 FLANGE NUT ZPCS Fig 30 25 ...

Page 30: ...ker arms 3 Pull out rocker shaft from theintake side of the cylinder head See FIg 31 4 Remove the push rods from cylinder 5 Remove cylinder head and gasket M10 X 75mm flange bolt 4pcs M10 x 42mmflangebolt e lpce Remarks Mark rocker arms and push rods so they be reinstalled in their original positions Tool 10mm box wrench 14mm box wrench 26 ...

Page 31: ...lt 2pcs Remove gasket Breather cover breather plate and gasket Breather plate SPRING RETAINER VALVE SPRING WASHER OIL SEAL VALVE GUIDE 27 Remarks Put marks on valves springs and retainers so they be reinstalled in their original positions Clean carbon and gum deposit from the valves valve seats ports and guides Inspect valves valve seats and guides Be careful of stem seal on intake valve Tool r Fi...

Page 32: ...ng main bearing M8 x 4Omm bolt and washer 7pcs 2 Remove main bearing cover from crankcase See Fig 3 5 Remarks Be careful not to damage the oil seal Use a soft hammer and evenly tap around outer surface of cover Tool 12mm box wench I Fig 35 MAIN BEARING COVER GASKET M8 BOLT AND WASHER 7pcs Fig 36 28 ...

Page 33: ...rom crankcase 2 Remone tappets from crankcase I Position piston at top dead center and remove balancer 1 and balancer 2 Remarks Tool I To prevent tappets from gettingdynages put crankcase cylinder side down See Fig 37 2 Put marks on tappets to distinguish intake from exhaust Fig 37 Fig 38 29 ...

Page 34: ...necting rod of piston from upper I I I and piston assembly through top of cylinder end of cylinder lOmm box wrench 30 Piston and piston pin 1 Remove clips and piston pin to remove connecting rod from piston 2 Remove piston rings from piston Be careful not to give damages to piston and COMecting rod Be careful not to break rjngs by spreading too much or twisting Ring expander I I 1 PISTON RING PIST...

Page 35: ...Step Tool Remarks Procedures Part to remove 31 See Fig 40 crankshaft to move from crankcase 1 Tap lightly on flywheel end of Crankshaft t Fig 40 f i g 41 31 ...

Page 36: ...ts to specification refering to the TORQUE SPECIFICATIONS 7 Apply oil torotatingandsliding portions 8 Check and adjustclearancesandendplayswherespecified in this manual 5 4 1 CRANKSHAFT 1 Installcrankshaft on crankcaseusing an oil sealguideto avoid damageto oil seal See Fig 42 2 Install woodruff key for flywheel on crankshaft OIL SEAL GUI Fig 42 5 4 2 PISTON AND PISTON RINGS I Install oil ringfirs...

Page 37: ...tch themark DF on thepiston with the mark DF on connecting rod On B type engine match themark BF on the piston with the mark BF on connecting rod See Fig 46 Oil small end o f connecting rod before installing pistonandpiston pin Use clips on the bothside of the piston pin to securepistonpininposition N MARK Fig 45 OF MARK A Fig 46 33 ...

Page 38: ...other before assembly See Fig 48 1 5 4 4 CONNECTING ROD I Turn crankshaft to bottom dead center lightly taptop of the pistonuntil largeend of the rodmeetcrankpin 2 Installconnecting rod cap and oil splasher to connecting rod matching alignment marks See Fig 49 Torque connecting rod bolts to specification M8 X 46 mm connecting rod bolt 0 2pcs I Tightening torque I 225 275 kg cm 22 1 27 0 N m 16 3 1...

Page 39: ...at governor gears mesh properly todrive gears on balancer shaft 2 incorrect timing of the gears will cause malfunction of the engine and may results in damage due to interference of the parts fig 50 5 4 6 TAPPETS ANDCAMSHAFT 1 Oil tappets and install in their original position Push in fully to avoid damage during camshaftinstallation 2 Lubricatebearingsurfaces of camshaft Align timingmark on crank...

Page 40: ...pe D CAMSHAFT SIDE CLEARANCE 0 0 2 rnm 0 1 3 0 29 mm 0 0 2 rnm 0 0 2 mm T 0 6mm T 0 6mm T 0 8 rnrn T 0 8 mrn T 1 0 mrn T 1 Omm T 0 7rnrn T 0 7mrn T 0 8 mm T 0 8mm T 0 6 mm T 0 6 mm ADJUSTING SPACER Takethethickness of GASKET BEARING COVER intoaccount as 0 26mm when calculating the side clearance CRANKSHAFl MAIN BEARING COVER GASKET BEARING COVER I SPACER SPACER CRANKCASE Fig 52 36 ...

Page 41: ...r head oil valvestemsandinserttheminto valve guide Then place cylinder head on flattable installwasher valve springandspringretainer 4 Valve guides should be replaced when valve stem clearance exceeds specifications See SERVICE DATA Draw valve guidesoutandpress new guides in Refer to SERVICE DATA for clearance specifications Afterreplacingvalvesandguides lapvalvesinplaceuntilauniformring shows aro...

Page 42: ...e 3 Installrocker cover andgasket Rocker cover M6 x 12 mm bolt 0 0 4 pcs 5 4 12 SPARK PLUG Install spark plug tocylinderhead Sparkplug NGK BPGES or CHAMPION N9Y Tightening toque New spark plug Retightening 120 150 kg cm 230 270 kg cm 11 8 14 7 N rn 16 6 1 9 5 f t Ib 8 7 1 0 9 ft Ib 22 6 26 5 N rn 5 4113 INTAKEAND EXHAUSTMANIFOLD 1 Installintake pipe to cylinder head with gasket Tighten three bolts...

Page 43: ...nstall starting pulley to flywheel Tightening togue 70 90 kg cm 5 1 6 5 ft Ib 6 9 8 8 N m 5 4 15 CYLINDER BAFFLE AND FUEL TANK BRACKET Installcylinderbaffleand fuel tankbrackettocylinderhead 5 4 16 IGNITION COIL Installignition coil to crankcase Adjust air gap between ignition coil and flywheel using a thickness gauge andtighten bolts See Fig 56 I Air gap I 0 3 0 5 mm 0 0 12 0 020 in Fig 56 5 4 17...

Page 44: ...ensorbracket 3 Screw in sensor probe intothe oil filler D TYPE Type D engines Insertsensor probe into the muffler side filler neck carburetor side Type B engines Insertsensorprobe into MUFFLER SIDE CARBURATOR SIDE Fig 57 5 4 22 GOVERNOR SPEED CONTROL SYSTEM 1 Installgovernorlever to governor shaft Tighten locking bolttemporarily 2 Install speed control lever to crankcase with return spring frictio...

Page 45: ...to the high speed position and fix it by tightening wing nut See Fig 60 b Check that governor lever is pulled by governor spring and carburetor throttle valve is fully open c Turngovernorshaft counterclockwise all the way usingascrewdriver andtighten lock bolt tosecurethe lever on theshaft See Fig 60 GOVERNOR R Fig 59 Fig 60 HOOKING POSITION OF THE GOVERNOR SPRING Rated 3000 rpm 50Hz applications ...

Page 46: ... canonlybeestablished by operatingtheengineunderreduced speed andloads for a short period of time While theengine is being tested check for oil leaks Make finalcarburetoradjustmentandregulatetheengineoperating speed I Steps I Load 6 MAGNETO 6 1 FLYWHEEL MAGNETO The ignitionsystem of the EH30 EH34 is pointless flywheel magneto with automaticadvancing characteristic Being differentfromthebreakerpoin...

Page 47: ... inthehigh voltagegeneratedinthesecondary coil which produces sparksatthespark plug 3 Athigherenginerevolution theadvancingcontrollcircuitoperates at the 1 ignitiontimingto runthe base current k toturnthesignaltransistor B 0N allowing thecurrent I1 to bypass ascurrent Is Atthis moment the power transistor turns 0FF and thecurrent Iz is abruptly shut resulting inthehighvoltagegeneratedinthe seconda...

Page 48: ...TANDARD Spark Plug 775 Ignition Coil I c Flywheel Stop Button Connector Black 1 ElNGlNE WITH ELECTRtC STARTER I I I I I I I I I I I I I I I I I I I I I DIODE RECTIFIER I I r L 1 l 12VOLT BATTERY MINIMUM 24 AMP HR Fig 63 44 ...

Page 49: ...peningtheexhaust valve to release compression CRESCENT EXHAUST LEVER Fig 64 When the crank speed reaches a certain revolution the flyweight of the release lever moves outward bythecentrifugal force turningthe releaselever toretract the crescent cam Thustheexhaust valve closes allowing a sufficient compression for the engine to start up FLYWEIGHT RELEASE LEVER CRESCENT CAM EXHAUST CAM CAMSHAFT Fig ...

Page 50: ...operation See Fig 66 The fuel flowsfrom the fuel tank into thefloat chamber through needle valve When the fuel rises to aspecificlevel thefloatrises and when its buoyancy and fuel pressure are balanced the needle valve closes toshut off the fuel thereby keeping the fuel atthepredetermined level Fig 66 PILOT OUTLET PILOT JET I BY PASS f _ _ I PILOT AIR JET I MAIN AIR JET MAIN AT MAIN JET Fig 67 46 ...

Page 51: ... much fuel accordingly thus easily startupthe engine 8 2 DISASSEMBLY AND REASSEMBLY Apart from mechanicalfailures most of carburetortroublesare caused by anincorrect mixing ratio which may arise mainly due to a clogged up air or fuel passage in jets or fuel level variations In ordertoassureproper flow of airand fuel thecarburetormust be kept clean at all times Thecarburetordisassemblyandreassembly...

Page 52: ... engine malfunction chamber 13 8 2 5 FLOAT SYSTEM 1 Pullout thefloatpin 20 and remove thefloat 21 andthen remove the clip 22 and needle valve 23 If the needle valve need to be replaced replace itwithrubber needle When cleaning thejets use neither a drill nor awire because of possible damage of the orifice which will adversely affectfuel flow Be sure to use compressed air to blow them clean 2 When ...

Page 53: ...SEMBLE D Type 1 Remove recoil starterfrom engine 2 Pull starter knob andpulloutstarterrope for 30 40cmto line up notchonreelwith outlet hole for starter rope Hold reelwiththumb and pull starter rope insidethestarter case withscrewdriver See Fig 69 Rewind reel clockwise until the rotation stops When rewinding the reel control the rotation byholding starterropeusingthe notchon the reel andpressingth...

Page 54: ...nd tie it as shown in Fig 72 Tie the rope tightlyforthesafety sake Puttheoppositeside of the rope through starter case and reel Tie it in the same way asstarterknob end and put the knot in the reel complely 2 Check that spring is securely set in the reel Adjust the position of inner end of the spring so it hooks on hook in thestarter case securely The shape of starterspring inner end can be adjust...

Page 55: ...rder of disassembly Check thatratchetsare pushedbyratchet springstowardthecenter of recoil Installfrictionplatewithitstwo bosses set inside of thebentportion of rachets Apply smallamount of lock tight to center screwandtorque it 1 Thightening torque 4 0 kg cm 3 9 N m 2 9 ft Ib 5 Hold starter ropeas shown in Fig 76 and turn reel 4 times in the arrowhead direction Firmlypress the reel not to allowre...

Page 56: ...d thespringintothe housing 8 Lubricatetherotatingparts slidingpartsandspringwithheatresistantgrease or mobile oil whenreassembling recoil and priorto long termstorage 9 2 ELECTRIC STARTING MOTOR OPTION 9 2 1 DISASSEMBLY 1 The 6mm terminal nuts 2pcs Remove the 6mm terminal nuts Zpcs I Fig 77 2 M terminalbush No l 3 The 5mm throughbolts Zpcs Remove the M terminalbush No 1 The rear cover is disassemb...

Page 57: ...er 5 The 6 The 7 M The mov 4mm screws 2pcs I brush holder terminalbush No 2 brush holde is disassembled by re ing the 4 mm screws Zpcs Remove the M terminalbush No 2 8 Yoke assembly Remove the yoke assembly 4 Fig 79 6 7 Fig 80 f i g 81 53 ...

Page 58: ...I 1 Pinion returnspring 12 Pinion assembly The pinion stopper pinion return spring and the pinion assembly can be dis assembled once the pinion stopper clip has been removed 13 Armature 14 Thrustwashers 4pcs 15 Front cover Thearmature thrust washers 4pcs front cover and the yoke assembly can be disassenbled once therear cover Fig 82 11 12 Fig 83 15 J Fig 84 54 ...

Page 59: ...ts 2pcs 2 M terminalbush No 1 3 The5mmthroughbolts 2pcs 4 The Rear cover 5 The 4mm screws 2pcs 6 Thebrushholder 7 M Terminal bush No 2 8 Yokeassembly 9 The pinion stopper clip 10 Pinionstopper 11 Pinionreturnspring 12 Pinionassembly 13 Armature 14 Thrustwashers 4pcs 15 Frontcover 55 ...

Page 60: ...ter to check for continuity betweenparallelpoints on the commutator If There is continuity thearmature is still good No continuity Disconnected coil Replace thearma ture c Insulation test for thearmature coil Use a tester to check for continuity between a point on the commutator and theshaft or the core If Thereis no continuity thearmature is still good Continuityexists Shortcircuitedcoil Replace ...

Page 61: ... 0 05 Max 1 O K Max 1 Q 0 COMMUTATOR I Fig 89 e Check theSurface of theCommutator If the commutator surface is rough then please use No 500 600 sandpaper to make it smooth Fig 90 f Check the Depth of theInsulating Material from the CommutatorSurface If the depth of theinsulatingmaterial from thecommutatorsegments is less thanthe limit then please repair it by filing it down Unit mm Standard New Li...

Page 62: ...3 BRUSH HOLDER a InsulationTestfortheBrushHolder Check for continuity between the brush holder s top Positive side and its base Negativeside If there is no continuity then it is still good Continuity Exists Unsatisfactory Insulation Replace thebrush hold er b Inspection of the BrushSprings Check the weight of thebrushsprings Fig 93 I Fig 94 58 ...

Page 63: ...everse the direction of rotation to confirm that it locks In theevent of any irregularity replace it Fig 95 9 2 3 REASSEMBLY Reassembly is intherevrseorder of disassembly howeverpleasenotethefollowingpoints 1 ThePlacesto Apply Grease Theslidingsurfaces of thepinionandthe shaft s spline Themetalsholdingtheshaft atthefrontandrearcovers 59 ...

Page 64: ...ping the float chamber with the grip of a screwdriver or the like 6 If thecarburetor overflows excessivefuel runsintothecylinder when startingthe engine makingthefuel airmixture too rich toburn If thishappens remove thesparkplug and turnthestarting pulleya few turnsinordertolettherichfuel airmixtureout of thespark plug hole intothe atmosphere Keep the chokevalveopen during this operation Dry the s...

Page 65: ...oline 2 Vaporlock i e gasolineevaporatinginthefuellinesduetooverheataroundthe engine 3 Vapor lock inthefuellines or carburetorduetothe use of toovolatilewintergasinthe 4 Air vent hole inthefueltankcapplugged 5 Bearing parts seized dueto lack of oil 6 Magneto or ignition coil faulty hot season 10 4 ENGINE OVERHEATS 1 Crankcase oil level low Add oil immediately 2 Spark timingincorrect 3 Low grade ga...

Page 66: ...linderhead 4 Spark timing incorrect 5 Loose connectingrodbearingdue to wear 6 Loose piston pin due to wear 7 Cuases of engine overheat 10 6 ENGINEBACKFIRESTHROUGHCARBURETOR 1 Water or dirt in gasoline or low grade gasoline 2 Intakevalvestuck 3 Valves overheated or hotcarbon particles in the combustionchamber 4 Engine cold 62 ...

Page 67: ...lation of he hotairusedforengine cooling andtemperaturerise of the machine Keep the engine room temperature below 50 C eveninthehottestperiod of theyear 11 3 EXHAUST GAS DISCHARGE Exhaust gas is noxious When operatingthe engineindoors besure to discharge the exhaustgas outdoors If a long exhaust pipe is used insuch acase theinternalresistanceincreasescausing loss of engine power Thus pipeinside di...

Page 68: ...CLEARANCE DATAAND LIMITS Unit mm in ITEM CYLINDER HEAD Flatness Valve seatcontact width Valveguideinsidedia IN EX T EH EH34 i Limit 0 05 0 002 0 1 0 004 0 7 1 O 0 028 0 039 2 0 0 079 6 600 6 622 0 260 0 261 1 6 75 0 266 64 ...

Page 69: ...STD 78 21 78 23 3 079 3 080 st O I 2nd o s 78 46 78 48 3 089 3 090 Lmit To be rebored when the difference betweenmax and min of diameter reached to 0 1 0 004 SBD 84 000 84 022 3 307 3 308 Ditto 84 250 84 272 3 31 7 3 31 8 84 500 84 522 3 327 3 328 0 01 0 004 0 015 0 0006 77 87 83 96 83 98 3 066 3 305 3 306 78 12 84 21 84 23 3 076 3 31 5 3 316 78 37 84 46 84 48 3 085 3 325 3 326 Lmit To berebored w...

Page 70: ...5 0 0004 0 0026 0 15 0 006 0 01 0 065 0 0004 0 0026 20 995 21 008 0 8266 0 8271 Piston pin hole 21 035 0 8281 20 995 21 008 0 8266 0 8271 21 035 0 8281 Pistcm pin outsldn dta 20 960 0 8251 20 991 21 OOO 0 8264 0 8268 20 960 0 8251 20 99 1 2 1 OOO 0 8264 0 8268 0 025 64 0 001G 0025 0 2 0 4 0 0079 0 01 57 0 1 4 3 Clearance between piston and cylinder at skirt area U rJ25 0 067 0 0010 0 0026 0 25 0 0...

Page 71: ...e clearance I CRANKSHAFT 38 000 38 01 6 1 4961 1 4967 0 030 0 060 0 0012 0 0024 21 010 21 023 0 8272 0 8277 0 010 0 032 0 0004 0 001 3 0 1 0 3 0 0039 0 01 18 37 956 37 970 1 4943 1 4949 34 986 34 997 1 3774 1 3778 I Clealance between I 1 journal and main bearing 0 009 0 01 4 0 00035 0 00055 67 Limit 0 2 0 0079 21 080 0 8299 0 12 0 0047 1 O 0 0394 37 85 1 4902 ...

Page 72: ...19 980 0 7861 0 7866 19 950 0 7854 6 450 0 2539 VALVE Valve stem outside dia 6 535 6 550 0 2573 0 2579 IN 6 522 6 544 0 2568 0 2576 6 450 0 2539 EX Clearance between valve guide valve stem dia and 0 050 0 087 0 0022 0 0034 0 30 0 01 18 IN EX 0 056 0 1 00 0 0022 0 0039 0 30 0 01 18 IN EX cold 0 085 0 1 15 0 0034 0 0045 ...

Page 73: ... armshaft clearance VALVE SPRING FREE LENGTH EH30 EH34 STD 8 960 8 975 0 3528 0 3533 9 00 9 01 5 0 3543 0 3549 0 025 0 055 0 001 0 0 0022 11 986 1 1 994 0 471 9 0 4722 12 006 12 024 0 4727 0 4734 0 012 0 038 0 0005 0 001 5 39 5 1 5551 1 Limit 8 93 0 351 6 9 08 0 3575 0 15 0 0059 11 92 0 4693 12 07 0 4752 0 15 0 0059 69 ...

Page 74: ...mit 2 0 0 079 DESCRIPTION TIGHTENING TORQUE kg cm I I N m f t Ib Cylinder head bolts 61 5 68 7 83 4 93 2 850 950 Flywheel nut 16 3 19 9 22 1 27 0 225 275 Connecting rod cap bolts 24 6 30 4 33 3 4 1 2 340 420 Main bearing cover bolts 16 6 19 5 22 6 126 5 230 270 Retightening 8 7 10 9 11 8 14 7 120 150 New spark plug 12 3 13 7 16 7 18 6 170 190 Spark plug 70 ...

Page 75: ...aualitv Single grade Multi grade Comparison between oil viscosity and temparature t 20 10 0 10 20 30 4oT 4 14 32 50 68 86 104 F Use oil classified as SC or higher Multi grade oil tends to increase its consumption at high ambient temperature 7t ...

Page 76: ...heck fuel leakage from fuel system If any retightenfasteners orreplace necessary parts 3 Inspect for loose hardwares and retighten if necessary 4 Check oil level and add to full mark REMARKS Governor linkage is especially sensitive to dust Loose bolts and nuts may come off and result in breakage of otherparts 13 2 INITIAL 20 HRS MAINTENANCE MAINTENANCE To remove sludgefrom run in operation 1 Chang...

Page 77: ...ne Clean andcorrectparts Replace piston ringsand othernecessary parts I 2 Replace fuel lines once a year I Avoid hazards caused by fuel leakage 1 Performtheabove 13 1 and 13 2 maintenance jobs 2 Drain fuelfromthefueltankandcarburetorfloatchamber 3 To preventrust in thecylinderbore apply oil throughthe spark plug hole andturnthe 4 Turnthestarting pulley by handand leave it where theresistanceistheh...

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