Robin EC04 Service Manual

ROBIN

AMERICA, INC.

ROBIN

TO

WISCONSIN

ROBIN

ENGINE

MODEL

CROSS REFERENCE

LIST

ROBIN

EY08

EY15 EY 15V EY20 EY2OV EY23

EY28

EY3

5

EY40

-

EY45V EY2

1

EY44 EY 18-3 EY25 EY27

EH11 EH12

EH15

EH17 EH21

EH25

EH30 EH30V EH34 EH34V EH43V

EC13V

DY23 DY27 DY30 DY3

5

DY4 1

WISCONSIN

ROBIN

SIDE

VALVE

W

1-080

W1-145 W1-145V W1-185 W1-185V W1-230 W 1-280

W

1-340 W 1-390 Wl-45OV EY21W EY44W EY18-3W EY25W EY27W

OVERHEAD

VALVE

WO1-115 wo1-120 WO1-150 WO1-170 wo1-210 WOl-250 WO 1-300 WO1-300V WO1-340

WO

1

-340V

WO 1-43 OV

TWO CYCLE

WT1-125V

DIESEL

WRD

1-230

WRD

1-270

-1-300 WRD1-350 WRD1-410

0

CONTENTS

Section

Title

Page

1.

SPECIFICATIONS" ""."O"""""•"O"O"C".O"""O"O"".O"""'"•""""""S""""""""""""."."""""".--"".--.-......C... 1

2. PERFORMANCE ..."...... ......".........""............ ......"......."".."............. ....."..C.". 2

2-1 Maximum output ...... C................................................"....".................. 2

2-2 Continuous rated output ...................................."............."................ 2

2-3 Maximum torque

................................................................................

2

3. DISASSEMBLY AND REASSEMBLY ......"."....................".."............"..... 3

3-1 Preparations and suggestions ...................................".....".................. 3

3-2 Special tool ............................................................... ........................ 3

3-3 Disassembly procedures .`..............".......................".. ".................."...... 4

3-4 Reassembly procedures .............."..............".. ".................................... 15

4. RECOIL STARTER ...."..... ...............................""................................... 21

4-1 Disassembly .."....."..............".............."... "............."............................. 21

4-2 Reassembly ."..............."............".................""".."............".................... 22

4-3 Checking procedures after reassembly ............................................. 23

4-4 How to do in troubles "........................"........................."................ 23

5. CARBURETOR ..........................".".............................. ....................... 25

5-1 Diagnosis of troubles ....................................................................... 25

5-2 Remedy for trouble ...................."................."................................... 25

6. MAGNETO .-.........."........-...."...."..............".. .........."""............."."............. 27

6-1 Troubleshooting ......"....."..........................................""....................... 27

6-2 Spark testing "".........................................."......................."... "".......... 27

7. BREAK-IN OPERATION OF REASSEMBLED ENGINE ... ................27

8. Troubleshooting ..................."".................• ........ ..................

27

8-1 Troubleshooting ............". "........................................."....................... 27

8-2 Troubleshooting table" ................"............"........................................ 28

9. CHECKS AND CORRECTIONS ..................... ...................... .... 30

9-1 Service data ...............".....................................................".........".".... 30

9-2 Table of tightening torque .... .................................."...................`.... 34

10. MAINTENANCE AND STORAGE ...................... .................. 36

10-1 Daily checks and maintenance ......".................................................. 36

10-2 Every 50 hours (10 days) checks and maintenance ....................... 36

10-3 Every 150 hours (monthly) checks and maintenance ...................... 36

10-4 Yearly checks and maintenance ....................................................... 37

10-5 Preparations for long .storage ......".. "........"....................................... 37

1.

SPECIFICATIONS.

I

Model

Type

:

Bore X stroke

Piston displacement

output

EC03ER

ECO4ER

1

Air-cooled,~2-cycle,

inclined

single

cylinder,

lead

valve,

horizontal

P.T.O.

shaft.

37

X

32mm

(1.46

X

1.26

in)

40.2cm3

(2.45

cu.in.)

34.4cm3

(2.1

0

cain.)

40

X

32mm (1.57

X

1.26

in)

1.2/6000

HP/rpm

1.4/6000

HP/rpm

(0.9/6000

KW/min")

(1.0/6000

KW/mi

n-

'1

.1.8/7000

HP/rpm

2.0/7000

HP/rpm

(1.3/7000

KW/min")

(1.5/7000

KW/min")

Max. torque

0.2/5000

kgf m/rpm

0.23/5000

kgf

m/rpm

I

(2.0/5000

ft.

Ibs/min")

I

(2.3/5000

ft.

Ibs/min")

Direction of rotation

I

Counterclockwise

as

viewd from P.T.O.'shaft side

Cooling system

I

Forced air cooling

Lubrication

I

Oil mixed fuel

Lubricant

Horizontal draft, float type Carburetor

2-cycle engine oil

Mixture fuel (Gasoline

20-25

:

oil

1)

Fuel

Fuel feed system

I-

Gravity type

Fuel tank capacity

Approx. 1.1 liter

(0.29

U.S.

gal.)

Ignition system

I

Pointless flywheel magneto (Solid state ignition)

Spark *.plug

NGK

BPM7A

Starting system

I

Recoi I starter

Dry weight

3.5

kg

(7.7

Ibs)

3.4

kg

(7.5

Ibs)

Dimensions

L-X

W-X

H

1

72 X 280

X

250mm (6.77

X

1

1.02

X

9.84 in)

a re subject

to

change without

-1-

2.

PERFORMANCE

2-1

The maximum output throttle valve fully open after Therefore,

MAXIMUM OUTPUT

of

an

engine is the output power

a

brand-new engine

of

the engine operating with the carburetor

it

has .been broken in properly.

or

an engine which has not been broken in properly may not

produce the maximum output.

2-2

The operation of the engine at the continuous rated output

CONTINUOUS

RATED

OUTPUT

is

most favorable from the view point

of engine life and fuel economy.

It

is

recommended, therefore, that the equipment driven

by

the engine to

be

designed to require

the engine power less than its continuous rated output.

2-3

MAXIMUM

TORQUE

The maximum torque indicates the torque at the output shaft when the engine is producing maximum output.

0

EC03ER

0

EC04ER

4000

.

REVOLUTION

5000

-

6000

kgf

*

m

(N

(2.26)

(2.06)

(1

36)

.

f-?

kgf

.

rn

(N

.

m)

0.21

(2.06)

0.19

(1.86)

0.17 (1.67)

7000

r

.

P .

m.

t

W

3

2

0

F

4000

REVOLUTION

5000

-

6000

r

.P

0.23

0.21

0.19

7000

.m.

-2-

3.

DISASSEMBLY AND REASSEMBLY

3-

1

PREPARATIONS

AND

SUGGESTIONS

(1)

When disassembling an engine , memorize well the locations

of

individual

parts

so

that they

can be reassembled correctly.

If

you are uncertain of identifying some

parts,

it is suggested

that tags to be attached to them.

(2)

Have boxes ready to keep disassembled parts by group.

(3)

To

prevent missing and misplacing small parts such

as

bolts and nuts, etc., temporarily

assemble

as

much as possible in each group

or

set.

(4)

Carefully handle disassembled parts, and clean them with washing oil.

(5)

Use correct tools in correct way.

(6)

Standard tools required

for

disassembling and reassembling

:

a) Work table b) Washing pan c) Disassembling tools

d)

Washing oil (kerosene

or

light oil)

e) Emery paper, waste '.cloth

(7)

Before starting disassembly

of

the engine, drain fuel.

3-2

SPECIAL

TOOL

Tool

No.

Use

Tool

560

-

90020

-

00

For

pulling

off

the flywheel

and

clutch

Clutch puller

"--(NOTE]-

Use tKree

(3)

M5

X

40mm bolts with the puller to remove clutch, and

two

(2)

M6

X

4Omm bolts to

remove

flywheel.

Fig.

1

-3-

3-

3

Step

DISASSEMBLY

Part

to

remove

PROCEDURES

Procedures

Remarks

Tool

1

2

Spark plug

cap

Tank

cap

(1)

Remove spark plug cap from spark plug.

(1)

Remove

(2)

Put

(3)

Remove fuel pipe from carburetor.

(4)

Drain

tank

a

draining

fuel from

cap

pan

tank.

TANK CAP

from

below fuel

~ ~ ~~ ~

fuel

tank.

*

~

SPARK PLUG CAP

Fig.

2

(Option)

Procedures

(1)

Remove clutch center bolt from crankshaft M6

x

16mm

bolt

and

washer

-

*-*

lpce.

(2)

Remove

ki-ee

screws

from clutch.

M5

x

8mm

screw

and

washer

*e*

Spa.

(3)

Attach clutch puller to clutch.

(4)

Pull

out clutch

assembly

using

cluch

,,

puller.

(See

Fig.

3.)

Fig.

.3

~mps

screw

driver

Clutch puller

M5

SCREW

:

3pcs.

Fig.

4

-5-

Step

4

Part

Air

to

remove

cleaner

Procedures

(1)

Remove cleaner cover with element.

Remarks

Tool

rl

5

Carburetor

(1)

Turn

(2)

Loosen

cleaner base

M6 x 65mm

fuel

cock

off.

two

screws

and

carburetor.

screw and washer....2

and

remove

Disassemble

air

reassemble carburetor refering

pcs.

.'5.

CARBURETOR".

to.

and

page

25,

Phillips

screw driver

-

Step

6

-

Part

to

remove

Tank

bracket

and

fuel

tank

Procedures

I

Remarks

Tool

.

I

(1)

Remove

tank

bracket

from

crankcase.

(2)

Remove fuel

tank,

M5

x

14mm

screw

and

washer---.2pcs.

Phillips

screw driver

I

Fig.

6

-7-

I

Step lPart

to

remove1 Procedures

I

Remarks

I

Tool

I

7

8

Rubber cushion

(Option)

(1)

Remove

and

tank

Remove engine base. Engine base

M6

x

12mm

mount

bracket.

bolt

rubbers

and

from

washer

crank-

*

- -

-

3pcs.

MOUNT

RUBBERS

lOmm

box

fl

wrench

M6

BOLT

:

3pcs.

I

Fig.

7

-8-

&=

Step

Part

to

remove

*

cover

Procedures

(1)

Remove muffler cover from muffler.

(2) Remove muffler.

M5

x

8mm

screw

***a

3pc~:

'

M6

bolt and

washer

-

:

*-2pcs.

(1)

Remove cylinder cover.

M5

X

14mm

screw

and

waSher****2pcs..

M5

X

20mm screw

and

washer-.

0.

lpce.

Remarks

(1)

Be

careful

not

to

lose

the washer

Tool

Phillips

screw driver

lOmm

box

wrench

Phillips

scniw driver

.

..

Fig.

8

..

-9-

Step

lpart to

remove1

Procedures

I

Remarks

I

Tool

12

Stop button

Recoil starter

(1)

Disconnect couplers

I.

(1

1

Remove

M5

X

50mm

washer

M5

X

22mm

washer

recoil

socket bolt

lpce.

socket bolt with

- - -

2pcs.

of

starter.

stop button

and

wire.

(1)

Disassemble reassemble

starter

page 21, STARTER".

and

recoil

refering

"4.

RECOIL

4mm

hexagon wrench

to

M5

SOCKET

BOLT

:

Ppcs.

-

10

Fig.

n

9

-