Robin EC12 Service Manual

SERVICE

MAIINJAL

Model

EC12

OIL MIX & OIL INJECTION ENGINES

puB-Esl173

Rev. 8/98

CONTENTS

Section

Title

Page

1

.

2

.

3

.

4

.

5

.

6

.

7

.

8

.

9

.

4-1

4-2 4-3 4-4

4-5

4-6 4-7 4-8 4-9 4-1

0

4-1

1

MODEL

ECIPD

STD.,

EC12D

1

OIL

INJECTION SYSTEM

Type

of

Number

Bore

Piston Displacement

Horsepower

Max.

Direction

Fuel

Lubricant

Lubrication

cylinder,

x

Stroke

Toque

of

Rotation

Consumption

oil

Continuous

(Mixed

Air-Cooled, 2-Cycle, 1 -Cylinder, Gasoline-Engine

1

7.5

Counterclockwise

Automobile Gasoline

with

Oil.

Mixing

Ratio

360

Gasoline

(Mixing

Oil

Mixing Type

Ratio

25

to

-

54

x

50

1

14cc

.

-.

22

kW

(3.0

2.9 kW

I

g

50:l)

(4.0

N-rn

(0.76

25

to

50:l)

/

HP.

hr

2-Cycle Engine

mrn

(2.13 x 1.97

(6.98

HP)

kg-m

as

viewed

I

0

3.0

I

cu.in)

/

3600

I4000

)

I3000

from

HP/

3600

Oil

O~I

in)

rpm

rprn

PTO

Shaft

Automobile Gasoline

rprn

separate fueling system

Carburetor

Method

spark

Starting System

Governor

Air

Dry Weight

Dimensions Width

of

Plug

Cleaner

ignition

Length

Height

Float Type

Flywheel Magneto

NGK

BMGA I CHAMPION

~ ~ ~

Recoil Starter

12.0

273

326

307

Type

kg

mrn

rnrn

rnm

(Solid State Ignition)

CJ8

(26.0

Ibs)

(10.7

in.)

(12.8

in.)

(12.1

in.)

-1-

2.

2-1

MAXIMUM

OUTPUT

The maximum output

is

the output

of

an engine with its throttle valve fully opened under the condition

that all the moving parts are properly

worn

in after the initial break-in period.

A

new engine may not produce full maximum output while its moving parts are still

not

broken-in.

2-2

CONTINUOUS

RATED

OUTPUT

The

continuous rated output

is

the output

of

an

engine at optimum

governed

speed which is most

favorable from the view point

of

engine’s life and fuel consumption.

When the engine

is

installed on a certain equipment, it

is

recommended. that the continuous output

required from the

engine

be

kept below this continuous rated output.

2-3

MAXIMUM

OUTPUT

The maximum torque is the torque at the output shaft

when

the engine

is

producing

maximum output at

certain revolution.

-2-

2-4

PERFORMANCE

CURVES

Nm

(kgf-m)

HP

4

3

0

kW

3

2

1

-0

2000

3000

4000

5000

REVLOUTION

-

r.p.m.

3.

FEATURES

3-1

COMPACT,

LIGHT

WEIGHT

AND

HIGH

POWER

Compact and light weight engine thanks to

3-2

SUPERB

Rugged design on each engine components and employment a long lasting durability even

3-3

SfMPLE

Maintenance free and governor system. Easy

34

SUITABLE

Robin your equipment,

3-5

OIL

Oil

and gasoline are placed into separate tanks. Therefore, mixing the fuel/oil which troublesome, is Because the fuel Since The mixture ratio has become leaner, which will decrease white smoke during operation.

DURABILITY

STRUCTURE,

start

with decompression

FOR

EC12

INJECTION

only

engine has the identical mounting flange

gasoline

in

harsh applications.

EASY

high

REPLACEMENT ENGINE

EC12

SYSTEM

now

is

engine

done automatically

gasoline, the

is

in the carburetor, there

MAINTENANCE

vibration proof

hole

on

can

replace

(OIL

INJECTION

start

short

connecting rod and aluminum cylinder.

have

exhaust system.

EClO

by

ability

engines.

TYPE)

engine function.

of

the

engine for the reason

will

be

of

high

anti-vibration dust cover enable

been achieved

as

EClO

no

jet choking due to the deterioration

thanks

engines. Without

to the crankcase built in

can

be improved.

any

modification on

often

can

of

be

oil.

4.

GENERAL

4-1

ALUMINUM CYLINDER AND CRANKCASE

Aluminum die-cast cylinder with molded-in cast

iron liner has intake, exhaust on the liner. For easy starting, decompression hole is implemented on the exhaust port. Crankcase is divided into two pieces

(Flywheel

Governor chamber

gasoline-oil mixture fuel lubricates the governor

system.

side) and crankcase

DESCRIPTION

and

scavenging

:

2

(P.T.O.

is

built in

the

crankcase

OF

ports

crankcase

side).

2

and

1

ENGINE

-4-

COMPONENTS

Fig.

4-7

4-2

CYLINDER

HEAD

Alumin’um die-cast made cylinder head has semi-

for

sphere shaped combustion chamber

optimal

combustion and higher efficiency.

49

CRANKSHAFT

AND CONNECTING

ROD

Forged steel crankshaft assembled with hardened

crank

and

connecting rod, precision balanced for low engine vibration, durability, greater shock loading resistance are implemented rod.

As

these

special

jig

and crankshaft assembly crankshaft

or

and

longer life. Needle bearings

on

both

ends

of

the connecting

parts

are

press-fitted together

are

unable to be disassembled,

needs

to

be serviced

in

case

connecting rod need to be replaced.

by

1

Fig.

4-2

4-4

PISTON

High strength aluminum alloy made

two

piston rings.

knocks are pressed

Top

ring is key-stone type and is chromium plated.

Second ring is a plain type and

AND

PISTON

RINGS

piston

To

avoid piston ring rotation,

in

piston ring grooves.

is

parkerlized.

equips

fig.

4-3

Top

Key stone

Chromium

Plain

Parkerlrized

ring

type

plated

type

-5-

4-5

ALL

SPEED

GOVERNOR

Rapid response mechanical flyweight type ernor system for

long'

speed regulation

4-6

COOLING

Forced air

is

fully lubricated with oil mixed fuel

life and which enables more precision

and

better reliability.

SYSTEM

cooling

is done by flywheel

fan.

gov-

Alu-

minum die-cast flywheel fan ensures better cooling and durability.

I

4-7

CARBURETOR

EC12

retor that

is

equipped with a horizontal draft carbu-

has

a float controlled

fuel

system and a

fixed main jet. Carburetor is calibrated carefully

good

for easy starting, sumption

and

sufficient output.

acceleration, low fuel

con-

Fig.

4-6

4-7

-6-

4-8

AIR

CLEANER

Rugged semi-wet dual stage air cleaner with high

0

efficiency, ease

of

service

and

longer engine life.

4-9

IGNITION

SYSTEM

Solid state, high 'energy electric ignition

which

referred to

as

T.

C.

I.

(Transistor Controlled Igni-

tion) gives more precise ignition timing,

no

break-

er points

to

service, ease

of

maintenance and

longer spark.plug life. Ignition system

is

consisted

of

flywheel

magneto and

ignition

coil.

Flywheel

is

installed

on

crankshaft

and

ignition coil is

on

crankcase.

Ignition timing

is

18

BTDC.

(Before

Top Dead Center)

4-10

OIL

INJECTION

SYSTEM

The

oil

injection system

is

a device that uses

an

oil

pump

directly

driven

by

a

crankshaft

to forcefully

feed

lubrication

oil

to

the

air intake

port

of

a

cylinder. According to engine speed, the appropriate amount

of

oil is measured and fed.

Element

\

Fig.

4-8

I

Fig.

4-9

Fig.

4-10

-7-

4-11

SECTIONAL

VIEW

OF

ENGINE

*EC12D

STD.

SPARK PLUG CAP

SPARK

PLUG

CYLINDER

CRANKCASE

2

-8-

I

FLYWHEEL

(COOLING FAN)

GOVERNOR

I

/

LEVER

/

EXHAUST

-9-

*EC12D

OIL

INJECTION

TYPE

SPARK

PLUG CAP SPARK PLUG

CYLINDER

OIL

TUBE

-

10-

MUFFLER

/

EXHAUST

-

17

-

5.

DISASSEMBLY

5-1

PREPARATIONS

AND

SUGGESTIONS

(1)

When disassembling the engine, memorize 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 be

attached to them.

(2)

Have boxes ready

to

keep disassembled

parts

by

group.

(3)

To

prevent losing and misplacing, temporarily assemble each

group

of

disassembled parts.

(4)

Carefully handle disassembled

parts,

and

clean

them

with

washing

oil

if

necessary.

(5)

Use

the

correct tools in the correct

way.

5-2

SPECIAL

TOOL

Tool

No.

US€!

Tool

209-95004-07

For

pulling

off

the

flywheel

Flywheel puller

with

bolt

Table.

5-1

Flywheei puller

fig.

5.1

-

12-

53

DISASSEMBLY

Part

Step

1

1.

1

Air

I

to

remove

cleaner

PROCEDURES

1

(1)

Remove

(2)

Detach

M6

......

I

(3)

Remove cleaner base.

M6

air

cleaner bracket

X

12mm

2

pcs

on

1

pc.

on cylinder

Self

lock

Procedures

cleaner

bolt

air

nut

cover

and

cleaner

.....

and element.

spring

-2

pcs

wahser

1

Detach from

Remarks

air

vent

carburetor.

pipe

I

lOmm

Tools

box

wrench

I

Cleaner cover

1

-

13-

Fig.

5-2

Part

to

remove

Procedures

1

(2)

Disconnect fuel hose

(3)

Remove carburetor carefully unhooking

governor governor lever.

I

rod

and

from

rod

carburetor.

spring

from

I

Be careful governor

governor

I

Remarks

not

rod

or

spring.

to

bend

stretch

Tools

I

Carburetor

I

-

OIL

lNJECTlON

Fig.

14

-

TYPE

(insulator)

5-3

%art

to

remove

ProcedureS

:

Remarks

Speed

control

lever

and

governor lever

(1)

Unhook governor spring lever. not

(2)

Remove Cover, washer

control

M6

(3)

Detach governor lever 'together with adjusting

M6

X

8mm

nut

lever.

flange bolt

~~ ~

plate.

. . ..

.

-1

PC.

from

(fiber)

......

governor

and

1

pc.

speed

Unless

lever lever

Note'governor spring hole

it

is

required,

remove

on

and

governor

from

carankcase.

governor

control

do

lever.

Needle nose

1

Omm

Socket wrench

M6

-

15-

Fig.

5-4

%art

to

remove

Muffler

Procedures

Tools

Remarks

~~ ~

(1)

Remove muffler bracket

on

the

top.

12mm

Socket

M8

X

16mm

bolt

and

washer

. .

..

.

.,4

pcs

wrench

(2)

Remove muffler bracket

on

the

bottom.

M8

X

16mm

bolt

and

washer

......

3

pcs

(3)

Remove muffler.

M8

brass

nut

......

2

pcs

fig.

5-5

-

16-

Step

Part

to

remove

PtO&d"&!.

Remarks

Tools

5.

Cylinder

Recoil starter.

6.

Starter

7.

Blower

housing

pulley

(I)

Detach spark plug

(2)

Unplug spark plug cap

cap.

from

cord.

(3)

Remove cylinder baffle. M6 X 16mm tapping M6

X

8mm

flange

M6 X 12mm flange

(4)

Clamp

removed

(1)

Remove recoil starter.

(2)

Remove starter pulley M6

(1)

(2)

Remove blower housing M6

on

engine stop switch wire

same time.

X

12mm

bolt

X

25mm bolt and washer

Disconnect

X

stop switch

20mm

bolt

M6 X55mmboltandwasher

(3)

(4)

Clamp

Same

Detach

on

blower

time.

grommet

bolt

and washer

and

wire.

and washer

housing

on

high tension

high tension baffle

.....

......

spacer. and spacer

from

to

be

(black)

.3

pcs

1

pc.

1

pc.

to

be

......

4

pcs

.....

-3

pcs

crankcase.

.....

-3

pcs

......

2pcs

removed

cord.

lOmm

Socket

wrench

1

Omm Socket

wrench M6

I

Omm

Socket

wrench

-

17-

'art

to

remove

Ignition

coil Remove ignition coil.

M6

X

20mm

Procedures

bolt

and washer

Remarks

,.

.

. .

.2

pcs

lOmm

wrench

Tools

Socket

Flywheel

Oil

L

pump

(1)

Remove flywheel nut. 19mm Socket

MI4

nut

and

spring

washer

(2)

Remove flywheel (See Fig.

(3)

Remove the key from crankshaft. Be careful

(1)

Remove the body

crankcase.

M6

(2)

Take which

5-8.)

X

20m bolt

out

fixed

the clip of

at

the

using

and

crankshaft.

. .

....

1

PC.

flywheel puller. Flywheel

of

oil

pump

washer

the

.

. . .

.

pump

from

.2

pcs

gear

can

removed head

of

with

the

by

of

the center bolt

the flywheel puller

hammer.

key.

easily

striking

not

to

be

the

lose

wrench Flywheel puller

209-95004-07

U

OIL

INJECTION

TYPE

Fig.

2 x M6

5-9

bolt

and

washer

-18-

Flywheel

I

-

Fig.

5-7

M14

flywheel

I

nut

Step

1

I.

Part

to

remove

Cylinder

head

PTOCedUreS

(I)

Remove spark plug.

(2)

Remove cylinder head.

MSX35mm

*

2

pcs

bolt and washer

on

muffler side

are

.

. . .

-.

*4

special

-

pcs

bolt.

Remarks

Champion

NGK

Gasket, between

cylinder head and cylinder.

US

BM6A

Tools

21

mm

Plug wrench

12mm

wrench

socket

4

12.

x

M8

bolt

Spark

and

Cylinder

Remove cylinder. Cylinder

M8

nut

......

4

pcs

plug

x

M8

/

head

p=

special

bolt

s-

I

\@

12mm

socket

wrench

GaskG

Cylinder

4xM8nut

BID

-

19-

Fig.

5-70

Step

13.

Part

Piston piston

to

remove

and

Procedures

(1)

Remove

(2)

Remove piston

clips.

to

remove piston

needle bearing.

(3)

Remove piston rings from piston.

and

Remarks

Be

careful

not

damage piston.

Be

careful

the

too

rings

by

much

or

not

twisting.

to

break

spreading

~~~ ~

Ring

expander

Piston

ring

~

-

20

Fig.

-

5-1

1

14.

Crankcase

Remove

crankcase

and

M6

bolts

2

governor

X

40rnrn

M6 X 55mm

Procedures

fastening crankcase

1

together to remove crankshaft

sleeve

bolt

and

bolt

washer..

and

washer

. . . .

-. . . .

2pcs

.3pcs

and

Tools

1

Omm

Socket

wrench

Governor

plate

\

Governor

sleeve

bolt

and washer

-

21

-

2 x M6

Fig.

5-72

bolt

/

and

washer

6.

REASSEMBLY

6-1

CLEANING

Check all sliding and rotating parts, such as piston, cylinder,crankshaft and bearings for defect. Wash the disassembled parts them twice, first time remove visible dirt roughly, and second time using fresh kerosene. After washing, blow them thoroughly with compressed air.

Do

not wash electric parts. Wipe them with clean cloth and dry them. Accumulated carbon on the cylinder-head, gasket, piston, cylinder and inside the muffler carefully removed, and finish the piston with oil stone to get smooth surface. Parts

of

air. Check the cable for any damage. Air-cleaner element shall be washed in to 4 kerosene and 1 engine oil, and assemble it after squeezed well.

Take special care not to contaminate the parts with dust and apply mobile oil on the surface to prevent rust.

6-2

CHECKS

After disassembling and cleaning the engine parts, check them and, if necessary, correct them according to the section"CLEARANCE DATA pipes shall

BEFORE

REASSEMBLY

in

kerosene to remove dust, dirt and contaminated oil thoroughly.

Wash

to

carburetor to be washed carefully with gasoline and blow them thoroughly with compressed

the

detergent and dry thoroughly. Then put it to mixture of

in

order

AND

CORRECTIONS BEFORE REASSEMBLY

and

be

replaced with new ones.

LIMITS

/

TORQUE

SPECIFICATIONS."

Gaskets and rubber

be

2

\.

I'

6-3

PRECAUTIONS

(1)

Clean crankshaft, connecting rod and bearings.

(2)

Take care not

(3)

Check lip of oil seals. Replace oil seal if the lip Apply

(4)

Replace all the gaskets with new ones. Use only designated sealing agent. where packings or sealing agents are used.

(5)

Replace keys, pins, bolts, nuts, etc., if necessary.

(6)

Be sure to assemble those parts provided with alignment marks by bringing the marks in alignment.

(7)

Tighten tighten them to torque readings appropriate to'the size. Standard Tightening Torque for screws are as

If small screws are over torqued, they may get broken. When tightening several screws fastening

single part, tighten them all evenly, by alternately tightening diagonally located parts.

(8)

Apply oil to rotating and sliding parts.

(9)

Check and adjust clearances and end plays where specified in this manual.

(10)

During the assembly,

(11)

After the completion of reassembly, turn the engine by hand and check if there is any disorder or loose members.

parts

oil

to

bolts,

6mm gmrn

IOmm

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

FOR

REASSEMBLY

thoroughly before reassembly. Pay most attention to cleanliness of piston, cylinder,

to

contaminate the

the

lip before reassembly.

nuts and screws to the correct torque specified. When there is no torque specification,

parts

with dust during reassembly.

is

damaged.

Do

not apply oil to parts

follows:

90

turn

the moving part

250 370

kgf-cm kgf-cm kgf-cm

(6.5

ft. Ib)

(18

ft. Ib)

(26.7

ft. lb)

by

hand to check for friction and noise.

a

0

'\

1

n

'.

,)

-22-

6-4

REASSEMBLY

6-4-1 CRANKCASE1

(1)

Before reassembling the crankcase, check bearing and

If

there

is

any

(2)

Put crankcase 2 with mounting flange down on a firm stand

PROCEDURES

damage, replace them with

new

ones.

installed.

(3)

Apply oil to the bearings of crankcase and ascertain that there

(4)

Put governor plate Place the notch of governor plate to cylinder

(5)

Assuring that knock pin crankshaft with press (or

and

governor sleeve

on

tap

it with a

on

crankshaft

soft

the

bearing of crankcase

(or

spark plug)

and

notch

hammer) taking

oil

seals.

so

that crankshaft move freely when

is

no

warp

on

the lip of oil seals.

2.

side.

on

governor plate are aligned, assemble the

care

not to damage the oil seal.

it

is

Governor

sleeve

-

23

Fig.

-

6-1

6-4-2

ADJUST

CRANKSHAFT

END

PLAY

Select one spacer

so

that

the

crankshaft end play

to

be

0-

0.2mm(0”-

0.008

’

)

SPACER

THICKNESS

0.1

(0.004”

)

P/N

161-25001-03

0.3 (0.012”

)

P/N

161-25002-03

Crankcase

2

Crankcase

1

Fig.

6-2

6-44

CRANKCASE

2

(1)

Clean

the

join

of

both

crankcases and apply sealing agent (THREE

BOND

1215

or

equivalent).

Joint crankcase

1

with

press (or tap

it

with a

soft

hammer). Fasten

them

with

bolts.

M6

X

40

bolt and washer

Ass’y.

* *

2

pcs

M6

X

55

bolt and washer

Ass’y-

-

3

pcs

88

-

9.8

N

m

90

-

100

kgfocm

6.5

-

7.2

ft

Ib

CAUTION

:When reassembling

the

crankcase,

tighten the

diagonally

located

pairs

of

bolts

according

to

the specified tightening torque.

NOTE

:

After

reassembling the crankshaft

to

the

crankcase, check

if

the

crankshaft

rotates

smoothly.

0

‘\

.

’

-

24

-

6-49

If

then spread the ring only

PISTON

an expander

RINGS

is

unavailable,

far

install

enough

the ring

to

slip over the piston and into

by

placing the open ends

of

the ring

the

correct groove.

on

first

land

of

piston,

CAUTION

E

\

/

:

1)

Be extremely careful not

2)

Put

the

(This

3)

Assemble

Top

ring

Second ring

is

open

to

ends

prevent

the

rings in

.---.-...-

------

f"\

I

Open Ends

Fig.

6-3

of

Piston

to

distort

of

piston rings

the

rings

the

from

order

Chromium Parkerized surface

and break

to

the

rotation while operating

of

the

plated

surface

(looks

\

Ring

the

ring.

lock

pins in

second ring and then

(looks

the

white

grooves.

the

top

silver

dark in color)

lop

ring

Key

stone

Chromium

Plain

type

Parkerlrized

Second

engine.)

ring.

in

color)

type

plated

ring

-

25

-

6-44

1)

2)

PISTON

Position the with the needle bearing by gently striking the piston pin.

CAUTION : Apply oil to the needle bearing before reassembling

Assemble piston pin clip.

“F”

mark

of

piston top to flywheel side and reassemble the piston and connecting rod

it

to piston pin.

rl

0

CAUTION : Replace piston pin clip

3)

Be sure that piston and connecting

646

1)

2)

3)

4)

CYLINDER

Clean carbon deposit

CAUTION

Wipe oil from crankcase Replace cylinder gasket with a new one. Placing open ends

NOTES

:

If

carbon deposits are not removed

be

:

(1)

Apply

(2)

Mark

(3)

After assembling cylinder make

from

damaged

joint

of

piston

oil

to

sure

that

cylinder head and combustion chamber.

when reassembling.

surface

rings

piston

intake

M8nutandwasher

I

TIGHTENING

17.6

-

180

-

13.0

-

TORQUE

215

Nom

220

kgf

-

159.ft-Ib

I

cm

if

there

rod

move smoothly after reassembled.

and

to

the

lock

and

piston pin before reassembling.

and

exhaust

----.----

is

any looseness after reassembling

the

piston and inner

apply sealing agent

pins in the grooves. Install piston to the cylinder.

ports

are

facing

sure

the

crankshaft

4pcs.

(THREE

the

right

rotates

surface

BOND

side

smoothly.

it.

of

1215

or equivalent).

cylinder may

-

26

-

0

6-4-7

1)

2)

CYLINDER

Clean carbon from combustion chamber and dirt from between the cooling fins Check its mounting face for distortion. Use

new

cylinder head gasket.

HEAD

of

cylinder head.

NOTE

3)

Install the cylinder head

M8

NOTE

I

Cylrider head

X

35

mm

bolt and washer

:

Special

~~~~ ~ ~~

17.6

-

21.5 N-m

180

-

220bf-cm

180

-

15.9

bolts

ft*

gasket

so

are

Ib

must

be

placed folded edge

that the alignment marks on the cylinder head and cylinder match.

*

- * -

4pcs.

to

be

instak?d

on

the mumer

side

up.

of

the

roward

cylinder

cylinder head)

head.

Fig.

6-5

6-44

Check Carbon deposits and wear Replace spark plug with a new one

SPARK

Spark Plug

I I

NEW

11.8

-

120

-

8.7

-

PLUG

:

CHAMPION

NGK

SPARK

14.7

10.8

BM6A

TIGHTENING

PLUG

N

150

kgfecm

ft

-

m

on

U8

TORQUE

I

Ib 18.0

the spark plug terminal.

if

necessary.

or

REllGHTENlNG

24.5

-

29.4

N

-

m

250

-

300

kgf

cm

-

21.7

ft

-

Ib

I

-

27

-

64-9

1)

2)

OIL

PUMP

Worm gear Mesh each gear at the proper position, secure with C-clip. Put grease (equivalent to Shell Albania After assembling pump, be rotated a few times by hand to be spread the grease.

How

to eliminate air from oil tube

Remove

Allow

out the remaining air. After checking, reassemble the tube to the inlet, then clamp securely.

the

the tube to

on

tube

(OIL

INJECTION

drive

from

fill

TYPE)

worm

gear about

#3)

the

crankshaft should

oil pump inlet.

with

oil, which will force

0.5

then

cc

fig.

r'

6-6

.

6410

1)

2)

3)

CAUTION

FLYWHEEL

Wipe

Put the

Install

off

the

M14

Nut with spring washer-

I

TlGfiTENlNG

:

1)

When air is size will result.

2)

When air

Then

system. After running

No

oil

and

woodruff

flywheel to the crankshaft. Tighten the nut with spring washer.

mixed fuel/oil must be used

need

grease thoroughly from the tapered portion

key in the key way

TORQUE

in

is

observed

to

I

the

*

-

oil

tube, insufficient oil will

- -

in the

of

1

PC.

tube,

1

mixed

crankshaft.

air must

fuel/oil

be

eliminated by

until

air has been eliminated

tank,

you

of

the crankshaft and flywheel.

carried to the engine

the

above procedure.

may continue with gasoline only.

and

from

engine

entire

I

-

28

-

6-4-1

1

IGNITION

COIL

When installing the ignition unit

on

the crankcase, use a non-metallic feeler gauge to measure the air gap

,

its hold down screws.

between the ignition coil and flywheel. The ignition coil

can

be moved to adjust the air-gap

by

loosening

M6

X

20mm

bolt and washer

-

*

-

- - -

2

pcs.

1

AIR

GAP

0.3

-

0.5mm

0.012

-

0.020

in

Fig.

6-7

6412

BLOWER

HOUSING

Through high tension

cord

from

inside the blower housing and put the .grommet

on

the cord to

the

blower

housing. Then install the blower housing

to

the crankcase. A clamp is fastened together

on

the air cleaner

side bolt.

M6

X

20mm bolt and washer

-

*

-

3

pcs.

M6

X

55mm bolt and washer.

- - -

-

2

P-

64-13

RECOJL

STARTER,

STARTER

PULLEY

AND

SPACER

I)

Install spacer and starter pulley

to

the flywheel.

2)

Install recoil starter. Make sure the recoil

knob

is pointing the right direction.

M6

X

25mm

bolt

and washer

- -

3

pcs.

M6

X

12mm bolt and washer

- - - -

-

4

pa.

64114

CYLINDER

BAFFLE

A

clamp

is

fastened together on the air cleaner side

of

the cylinder baffle.

M6

X

16mm tapping bolt

-

- * -

-

- - -

3

pcs.

M6

X

12mm flange bolt

- - - -

I

PC.

M6

X

8mm

flange bolt

- - - - - - - -

*

-

I

PC.

6415

.MUFFLER

1)

Replace muffler gasket with a new one.

2)

Install muffler and muffler bracket. First temporary tighten nuts

and

bolts

on

the muffler

and

the

bracket.

Then

tighten the

nuts

on

?he muffler and the

bolts

on the bracket.

M8

brass nut

and

spring

washer

- - - - - - -

-

2

pcs.

M8 X 16mm

bolt and spring washer

- -

-

7

pcs.

-

29

-

6416

SPEED

CONTROL

LEVER

AND

GOVERNOR

LEVER

1) Install governor lever

to

governor shaft with adjusting plate being temporary tightened.

M6nutandspringwasher-.-.----.--.-..-

1

PC.

M4

X

8mm

screw and spring washer

-

- -

-

1

PC.

2)

Install governor control lever, washer (fiber) and cover

to

the

crankcase

in

this sequence.

M6

X

8mmflangebolt

-.-....-..........

1

PC.

3)

Hook

governor

spring

to

the governor lever and speed control lever.

Governor lever

M4

screw

and spring washer

Speed

control

lever

Fig.

6-8

-

30

-

6417

1)

2)

3)

CARBURETOR

Install packing and insulator

Connect governor lever and throttle lever install carburetor together with air cleaner base plate.

M6selflocknut

Install air cleaner bracket.

M6

X

12mmboltandwasher---.--..--... 3 pa.

AND

AIR

CLEANER

to

the cylinder. Replace packing

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

on

with

a new one.

the

carburetor by governor rod

2

pa.

and

rod spring. And then

6-4-18

Refer

6-4-19

1)

2)

GOVERNOR

to

section

WIRING

Connect wire from stop switch Connect spark plug cap

-

End

of

the reassembly

ADJUSTMENT

“7-2

Governor Adjustment”

to

high

-

and

primary

tension cord then plug it

wire

from

ignition coil. Clamp wire to cylinder baffle.

to

spark plug.

-

31

-

6-5

BREAK-IN

An

engine that has been completely overhauled by being fitted with a new piston,

assembly

should

Good bearing surfaces operating the engine under reduced speed and loads for a While the engine

OPERATION

be thoroughly

and

running clearances between the various

is

being tested, check

BREAK-IN

for

oil leaks.

before being put

short

back

period

into service.

parts

of

time.

Make final carburetor adjustment and regulate the engine operating speed.

Load

I

%PS

1

2

3

4

5

1.5

3.0

Hp

Hp Hp

Hp

Load

No

or

load

load load

load

40%

75%

Load

Load Load

Load

Table

Engine

61

2500

3OOo

3600

Speeed

rpm

I

Time

IO

min

IO

min

10

min

10

min

10

min

10

min

30

min

30

min

60

min

60

min

rings

can

only be established

.

and crankshaft

by

.-

NOTE : Use

25

:

1

Oil

fuelmix

for

break-in

period.

-

32

-

7.

-GOVERNOR

0

7-1

CONSTRUCTION

A

centrifugal flyweight type governor

installed

As

changes its opening angle and moves the governor sleeve, which in turn rotates the governor shaft through the governor

and this governor lever is connected to the carburetor throttle lever through the governor rod at the other end When the crankshaft speed increases, all the relevant' members move in the direction indicated

C

marks and the carburetor throttle valve

speed and output. When the crankshaft speed decreases, the same members move

indicated by recovering the failing speed and output.

in

the crankcase, and lubricated

the engine speed fluctuates, flyweights on the governor plate, rotating together with the crankshaft,

;

thus the throttle valve

r)

marks and the carburetor throttle valve

AND

yoke.

The governor lever is connected

is

OPERATION

is

used. The governor plate, governor sleeve and governor yoke are

by

the oil mixed fuel.

to

the extending part

opened or closed and engine speed and output are controlled.

closes,

reducing the fuel supply and consequently reducing the

opens,

increasing the fuel supply and consequently

of

the governor shaft

in

the direction

by

-

33

Fig.

-

7-1

7-2

GOVERNOR ADJUSTMENT

The

governor system should be adjusted

1)

Connect governor rod and rod spring to carburetor throttle lever and governor lever, then install

at

reassembly

by

the following procedures.

governor lever to governor shaft.

NOTE

2)

Connect govemor lever and control lever And the governor adjustment

a)

Attach the governor lever

:

Never tighten plate, governor lever

the

on

set screw for the adjusting plate

and

governor

with

is

to be made in the following sequence:

the governor shaft.

b)To the governor shaft, fasten temporarily the

adjusting plate with nut and spring washer.

c)To

the governor lever, fasten temporarily adjusting plate with screw At

this

moment, the adjusting plate is free to

(1)

and nut

(2).

move. (See Fig.7-2.)

Push

d)

the adjusting plate clockwise.

(See Fig.7-3.)

e)

Set the governor lever tighten the screw

(1)

at

the high position and

and nut

(2).

(See Fig.7-4.)

at

this

time,

and do

not

fix

adjusting

shaft.

governor spring, and install control lever to crankcase.

the

fig.

7-2

/

7-3

HIGH

7-3-1

Unless required related parts from. crankcase. (See

SPEED

WHEN

ADJUSTMENT

NO

TACHOMETER

in

the process

crankcase.

Fig.7-5.)

IS

AVAILABLE

of

disassembling,

If it is necessary

Fig.

7-4

do

not remove governor control lever and

to

remove them, never turn high speed stop bolt on

-

34

-

/

or

other

7-3-2

WHEN A TACHOMETER

IS AVAIL;;ABI;E

i

1)

Install control lever and other related parts.

2)

By

turning control lever with governor spring

on

it, gradually increase the engine speed up

to

3)

Locate high speed

stop

bolt

on

the control lever and lock it

so

they it will stop control lever against

specified engine speed.

the stopper plate.

Make sure that the governor spring

is

hooked

in

the same hole

on

the governor lever

as

original.

There are

3

holes

on

the governor lever.

Normally, hook governor spring in the center hole.

Governor

lever

"-

"

Speed

control

lever

Fig.

7-5

-

35

-

8.

MAGNETO

EC12

ignition divice which utilizes the power transister as an element for controlling electric unit. This efficiency because mechanical parts.

8-1

This

As

ignition coil with built-in transistor, and lead wires to spark

engine is equipped with a pointless Solid State Ignition system. This is a circuit breaker type

system' is free from start-up failure due to dirty,

of

moisture, rough breaker point surface and incorrect timing resulting from worn

OPERATION

system is referred

illustrated

OF

in

Fig.S-l.,

Connector

ME

IGNITION

as

T.C.I.

this

SYSTEM

(Transistor Controlled Ignition) system.

is

a simple system, consisting

IGNITION

Black

COIL

Ignition

WITH

burnt

BUILT-IN TRANISITOR

Coil

plug

1

or

oxidized point surfaces, low ignition

of

a flywheel with magnetic fields,

and stop switch.

Spark

k

Plug

an

n

,.,

/

al

TST

Stop

Switch

Fig.

&I

Magneto

WRING

;

Flywheel

DIAGRAM

SOLID

STATE

IGNITION

-

36

-

8-1-1

PRfNCIPLE

1)

Rotation By this voltage, electric current

2)

With further rotation

flows

current

11’

3)

With further move rotation

it

(collector) and E (emitter) Terminals of signal transistor. Current which induct SCR.

4)

Current

This

through power transistor base terminal

(b)

did.

passes its peak. Current

(h)

current change causes high voltage on secondary coil which produces sparks at spark plug.

OF

THE

OPERATION

of

the flywheel generates a voltage

(11)

flows

of

the flywheel, electric current

and

(14)

in

signal transistor. The current

of

the flywheel, the current generated by primary coil starts to decrease

(Is)

starts flowing because there is

turns into current

(16)

with induction

on

the primary side

and it charges condenser.

(h),

(B).

This actuates power transistor and results electric

(14)

charges the condenser reversely as the current

of

the

SCR,

of

the ignition device.

which is reversed of electric current

no

electric potential difference in the

(Is)

this cuts

flows into the gate

off

anent b abruptly.

(G)

of

(h),

as

C

SCR

0

Fig.

8-2

IGNITION

In

the event of malfunction of the ignition Broken, frayed, loose Faulty spark plug-wet, dirty, insulation broken

If difficulty should be checked Remove spark plug-then with the ignition cable connected to it, lay the spark plug part

of

the engine the recoil starter. trouble.

1)

2)

Using a ignition lead and the engine stop switch wire.

This resistance reading should

infinite, this indicates open winding in the ignition unit, a loose failed high tension lead. If a very low reading itself is determined to

If

Check to make sure that the external magnet, mounted Since the solid state ignition unit secondary coil resistance..

good

SYSTEM

is

experienced in starting the engine or if engine misfires,

:

so

If

there is

a

quality ohm-meter, check the secondary coil resistance between the plug terminal of

CHECK

system,

or

disconnected ignition wires.

check the following first:

or

incorrect plug gap.

the

that the gap can be observed as

a good strong spark occurs, the ignition system

weak

spark or no spark at all, check the ignition system as follows:

is

self-contained, the only testing which

be

approximately

is

taken,the secondary coil

be

faulty, then it will

have

you

rotate the crankshaft several times by means of

on

the flywheel is in a good condition.

10,000

is

to be replaced.

to

probably shorted.

12,000

can

ohms.

or

broken spark plug connector or

If,

strength

be eliminated as the source

can

If

the

after testing, the ignition unit

of

the ignition spark

on a convenient metal

be performed

resistance reading

is

on

the

of

is

a

-

37

-

9.

CARBURETOR

9-1

FLOAT

CARBURETO'R

9-1-1

1)

The float chamber body and, with a float and a needle valve,

OPERATION

FLOAT

SYSTEM

is

AND

CONSTRUCTION

located below the carburetor

main-

tains a constant fuel level during engine operation.

Fig.9-2.)

(See

The

fuel

flows

chamber to

through

a

specific level, the float rises,

from

the fuel

tank

.into the

float

needle valve. When the fuel rises

and

when

its

buoyancy and fuel pressure are balanced, the

needle valve closes to shut

off

the fuel, there

by

keeping the fuel at the predetermined level.

PI1

Fig.

9-2

-

30

-

2)

PILOT

The pilot system feeds the fuel to the engine

The fuel is fed

the pilot The fuel-air mixture At idling speed,

3)

MAIN

The main system feeds the fuel to the engine at medium and high-speed operation. The fuel is metered mixed with the fuel through the bleed holes in the main nozzle, and the mixture is atomized out main bore. It which

4)

CHOKE

The choke is used choke, the negative pressure applied to the

starting

SYSTEM

through

air

jet.

the

SYSTEM

is

mixed again with the air taken through the air cleaner into an optimum fuel-air mixture,

is

supplied

up

the engine more

to

during

the main jet to the pilot jet, where it

is

fed to the engine through the pilot outlet and the bypass.

fuel is

by

the engine.

for.

mainly

the main jet

easy starting when ' the engine is cold. When the starter

fed from

and

fed

the

to

main

idling and low-speed operation.

is

metered and mixed with the air metered by

pilot

outlet.

the main nozzle. .The air metered

nozzle increases and draws more fuel accordingly thus

easily.

by

the main air

is

operated with a closed

jet

of

is

the

-

39

-

9-1-2

DISASSEMBLY

AND

REASSEMBLY

A

part from mechanical failures, most of the

carburetor troubles are caused by an incorrect

mixing

ratio, which may arise mainly due to a

clogged

up

air

or

fuel passage in the jets,

or

fuel

level variations.

In

order to assure proper

flow

of

air

and

fuel,

the carburetor must be kept clean at all times. The carburetor disassembly and reassembly procedures are

as

follows : (See Fig.9-3.)

1)

THROTTLE

SYSTEM

a)Remove the Phillips screw

(1)

and throttle

valve

(2),

and

pull

out the throttle shaft

(3).

b)The spring

(4)

can

be taken out

by

removing

the

throttle stop screw

(5).

*

Be

careful

not to damage the throttle valve

ends.

2)

CHOKE

SYSTEM

a) Remove the Phillips screw

(6)

and choke valve

(7),

and pull out the choke shaft

(8).

b)

When reassembling the choke shaft, make sure that the cutout in the choke valve

faces

the

main air jet.

3)

MAlN

SYSTEM

a)Remove the bolt

(9)

and take out the float

chamber body

(10).

b)From the body remove the main nozzle

(11)

and then remove the main jet

(12)

from the

main nozzle

(11).

a)Fasten the main jet securely to the body.

Otherwise, the fuel may become too rich and cause engine malfunction.

c)

Reassembly

b)The

bolt

tightening torque is

5

ft

lb

6

17

3

1

13

10

Fig.

9-3

n

'\

,)

(7Okgf-cm). Be sure to set

the

gasket

(13)

and

washer

(14)

for chamber

(10).

4)

FLOAT

SYSTEM

a) Pull out the float

(15)

and remove the float

(16)

then the clip

(17)

and needle valve

(18).

CAUTlON

:

When cleaning the jets, use neither a drill

nor

a

wire (because

of

possible damage

to

the orifice

which

will adversely affect

fuel

flow).

Be

sure

to

use

compressed

air

to blow them

clean.

b)When

removing

the

needle valve and float, gently tap

on

the reverse side

using

the rod more slender

than the float pin and remove, since

the

float pin

is

calked to the carburetor body.

-

40

-

9-2

DIAPHRAGM

CARBURETOR

9-2-1

1)

OPERATION

PUMP

AND

CONSTRUCTION

The diaphragm of the fuel pump is moved by pressure fluctuations

in

the engine crankcase.

When it moves towards the engine, the inlet valve

(E)

of the pump opens and the outlet valve

shuts, and the pump sucks

diaphragm swings back, the

and the fuel is forced

A

compensating chamber

out

in

fuel. When the

inlet

valve

of

the outlet valve

(W),

situated between

(E)

the inlet and the outlet valves cushions the

(A)

closes

(A).

oscil-

lations of the fuel flowing past. The diaphragm of the chamber sphere fuel pressure builds up,

springs

upwards towards the atmo-

and

contracts again

when the pressure drops. After the pump, the fuel flows through the fine

filter

(F).

This

traps

residual particles

of

dirt,

but

is

not a substitute for the large-area filter, which must be fitted

in the

fuel flow before the carburetor.

2)

PRESSURE

A

diaphragm pressure regulator ensures, almost

REGULATOR

independently of the pump pressure, a constant

vacuum before the jet systems.

If

the vacuum in the carburetor inlet pipe

mitted

moves the regulator lever

(M),

An

to

the pressure regulator via the jets, it

against a spring and

even

flow

of fuel then

(R)

opens

passes

via the diaphragm the feed valve

through the valve

is

trans-

(N).

into the regulator and through the jets into the carburetor port. The diaphragm lever

(R)

and the feed valve

any

to

3)

If

given

HIGH

full power is required

flow

SPEED

quantity.

OPERATION

(M),

the regulator

(N)

constantly adjust

from

the engine, the

throttle valve and choke are fully opened.

The vacuum in the carburetor sucks fuel into

main system via main mixture screw non-return valve tem via idle mixture screw drilling

The fuel

(LA)

flow

(V),

and through the idling

(L),

and the bypass drillings

can be altered by opening and

(H)

the idling outlet

(BP).

the

and the

sys-

closing main mixture screw and idle mixture

screw.

I1

L”7+

Fig.

9-4

3

High

speed

-

41

-

4)

MID-RANGE

If

only

reduced engine output is required and the

throttle valve

vacuum

the

gine. The fuel now system. main system closes, thus preventing air

tering the pressure regulator, where it could im-

pede the fuel flow.

5)

IDLING

When the engine

far

the engine

(LA).

outlet drilling drilling

out.

sufficient to

space between the throttle valve and the en-

As

closed that the vacuum between the valve and

While fuel is being sucked out

(BP),

OPERATION

is

accordingly portially closed,

suck

fuel

is

present only

only

a result,

flows

the

non-return valve

through the idling

(V)

from

OPERATION

is

idling, the throttle valve is

only

acts

on

the idling outlet drilling

of

the idling

(LA),

which mixes with the fuel coming

air

is

entering the bypass

in

in the

en-

so

a

N

The

idling speed

and

the matching fuel quantity with idle mixture

screw

6)

To

throttle valve Each attempt to

uum

through

When starting must first must be flushed out of the carburetor systems. Several attempts at starting-usually essary before the first firing occurs. The choke must then be opened and the next attempt will

(L).

STARTING

start the engine, the choke

in the carburetor

both jet systems.

be

is

set with the stop screw

is

closed, with the

@>

roughly

start

a

hot or cold engine, the carburetor

filled with fuel,

half-open.

the engine produces a vac-

port,

which draws fuel

as

air

and fuel vapour

four,

start

the engine

running.

GAS)

are

nec-

n

-

42

-

Fig.

9-7

9-2-2

DISASSEMBLY

I.

A

part from mechanical failures, most of the carburetor troubles are caused

by

an incorrect mixing ratio,

In order

to

assure proper

flow

of air and fuel; the carburetor must

be

kept clean at all times.

The carburetor disassembly

and

reassembly procedures are

as

follows : (See

Fig.9-8.)

which may arise mainly

due

to a clogged

up

air or fuel passage in the jets,

or

fuel level variations.

1)

FUEL

PUMP

a)

Remove the screw

(1)

and

pump

cover

(2).

b)

Remove pump gasket

(3)

and diaphragm

(4).

c)

Inspect diaphragm

(4),

replace

if

diaphragm

d)

Remove strainer

(5).

shows

any

signs

of

wear

and

curing.

2)

METERING

DIAPHRAGM

a) Remove the screws

(6)

and metering chamber

b) Remove metering diaphragm

(8)

and the

gas-

c)

Inspect metering diaphragm

(8)

for

dirt

and

cover

(7).

ket

(9).

foreign matter.

3)

INLET

NEEDLE

VALVE

a) Remove the

screw

(10)

of

metering lever

(11).

b)

Remove metering lever

(ll),

(12)

and lever

spring

(13).

c)

Remove inlet needle valve

(14).

d) Inspect inlet needle valve

(14).

Rubber tip

should

not

be deformed where

it

contacts

the

seat.

4)

MIXTURE

SCREW

a) Remove idle

(15)

and main

(16)

mixture screw

and

washer

(17).

b)

Remove the spring

(18).

c)

Inspect each screw

(15,

16)

for damage, espe-

cially the needle

points

which should have.

no

deformation of the tapered surfaces.

5)

THROTT'LE

AND

CHOKE

a)

Remove the E-ring

(19)

and

the screw

(20)

and

throttle valve

(21),

and pull

out

the throttle

shaft

(22).

b)

Remove

the

screw

(23)

and

the choke valve

8

7

a

(24),

and pull

out

the choke shaft

(25).

-

43

-

Fig.

9-8

9-2-3

Reassembly

and

Adjustment

Replace all

1)

MIXTURE

Install idle and main mixture screws.

a) For the nominal setting, tighten the screws

turns

In

accordance with the actual operation and fuel consumption condition, adjust the screws

2)

INLET

a)

Inspect

Assemble the lever onto the pin and rotate the

worn

with new ones. Make sure to clean all

parts

before reassembly.

SCREW

fulIy

and

then turn back counterclockwise at the following

;

Idle mixture screw Main mixture screw

2

turns

Turning

NEEDLE

the metering lever

back

for

nominal setting

One

turn

VALVE

the

and

the

Fig.

pin.

9-9

1

and

112

turns

Turning direction

air

fuel ratio adjustment

for

pin.

a

The lever should be

should

b)

Install the inlet needle valve, metering

metering lever,

c)

The free end of the metering lever should to gasket flange

If

the free end of the lever, then carefully push down is the lever.

not

stick.

0.3

rnm

(0

to

of

carburetor body.

the metering lever

on

the inlet needle. If the metering lever

too

low,

pry

up

(Fig.

9-11)

free fit

and

retaining

0.012”)

is

too

carefully

on

the

and

spring,

screw.

be

below the metering

(Fig.

9-10}.

high,

push

down

on

the free end of

on

0

as

necessary.

Push

down

here

n

V

Then push

down

needle here

Fig.

-44-

9-1

1

'

10.

1b-1

(1)

OiI

(2)

Mixture

I I

OIL

SEPARATE

Idle

Load

NJECTION

I

flow

ratio

I I

SYSTEM

OIL

INJECTION / FUEL

19

:

1

@

1600

25

to30

:

1

@3800

rpm

SYSTEM

I I

10-2

BASIC

STRUCTURE

OF

THE

SEPARATE

OIL

ONJECTION 1 FUEL

2000

Fig.

10-1

SYSTEM

Gasoline

4000

r.p.m.

tank

-

45

F;g.

-

10-2

pTA

:

Gasoline

Carburetor

Fig.

10-3

10-3-1

OIL PUMP OPERATION / FUNCTION

OIL PUMP

(1M64-01)

OPERATING

PRINCIPLE

(1)

The

crankshaft

turns

which rotates the gear. The plinger which directly gose to the worm rotates at

(2)

The plinger wilI

by

the spring.

Then

it

moves

motion due

1/17th

to

the configuration

be

left

of

pushed

and

engine speed.

down to the pins

right with a rotating

of

the edge

lead.

(3)

The

sub

plunger will be stabilized into the

plug

by

the spring via E ring.

By

above

stroke, pumping will occur.

worm

of

(2)

Oil

outlet

-46-

Fig.

10-4

Sub

planger

oil

;nlet

I

Piuriger

V

ring

\

I

/

Pinion gear

Detail

A

&

Cam

top

A

mbase

0'.

90'

190'

270"

360"

'1

Lead

configuration

'1

Development

of

lead

height

(P

view)

Fig.

70-5

-

47

-

10-3-2

OIL

INTAKE

AND

DISCHARGE

CYCLE

AT

OIL

PUMP

The plunger rotates

(1)

Intake The plunger remains in the The plunger strokes The volume

of

360

oil

chamber

degree

to

the right.

with

a

closed

is

position.

expanded.

cycle. (Shared area means oil.)

Closed

Cam

top'&

Direction

of

position

plunger roatating

(2)

Discharge The plunger The plunger strokes The

volume

of

is

raised

oil

to

the

to

the left.

chamber

open position

is

decreased.

Oil

inlet

ir'

/m

Fig.

70-6

by

the

pin.

funger

Cam

Direction

Closed

base

of

position

'A

plunger

m

top

roatating

piiiq

Fig.

70-7

-

48

-

10-3-3

(1)

CHECK

Check valve This

valve

VALVE

is

AND

composed seat. The

ball

is

stabilized

by

overrides the spring at time the pressure

ceeds

prevents air

its

setting load.

from

When

entering into oil tube due

vacuum.

Also

this prevents

oil

from

storage.

(2)

Floating switch

This

floating switch

is

located

FLOATING SWITCH

of a ball and body

a

spring. The

ball

ex-

engine stops, this

to

leaking when long

in

the oil

tank.

Lt

Body

Oil inlet

seat

I

t

Ball

Spring

Fig.

Washer

10-8

1.

Structure of floating

switch

(1)

Float located

(2)

Float

located

above

below

limit

This

illustration

shows on position

-

49

Fig.

-

10-3

-.

due

to

exciting

11

-

RECOIL

STARTER

When

Tools

I

(1) Remove the recoil starter (2) Pull the starter

repairing the recoil starter, disassemble and reassemble according

:

Needle nose pliers screw driver.

1

-{,'DISASSEMBLY

from

the engine.

knob

rope

about

on

the reel with the outlet hole rope. Hold the reel with your thumb and pull the starter rope inside the starter case with a screw driver. (See Fig.11-1.) While rewinding the reel, control the rotation

by

holding the starter rope the notch

and pressing the reel with your

12

in.

.

and

(30cm)

pull

to

line

thumb.

out the starter

up

the notch

for

the starter

on

the reel

to

the following procedures.

(3)

Remove the

1.

Center

2.

Ratchet guide

3.

Friction plate

4.

Ratchet

5.

Return spring

6.

Reel

(4)

Untie the starter rope from the

move.

CAUTION

Take

towards the

spring

out

from

quickly

starter

Note

:

If

to

case.

power

section

:

or

parts in

screw

the reel

left

the

spHng

1

the

slowly

and

hook.

spring

escapes

1-2.

following

right

Do

may

order.

knob

and re-

turning it slightly

to

remove

not

remove

escape

from

the reel

from

i

housing

refer

the the

Fig.

11-1

1

2

I

3-

-

50

-

Fig.

1

1-2

11-2

REASSEMBLY

(1)

Put

the starter rope through the starter

knob

and tie it as

shown

in

Fig.11-3-1. (Tie the rope

tightly for safety sake.)

Put

the opposite side of the rope through starter

case and reel. Tie it securely as shown

in

Fig.11-3-2.

and put the knot

in

the reel

com-

pletely. Then apply grease a little to starter shaft and power spring.

(2)

Check that the spring

is

securely

set

in

the reel.

Adjust the position

of

the inner end

of

the

spring to

0.04

”

-

0.08

(1-

2mm)

from

the reel

bush

so

that

it

hooks

on

the hook

in

the starter

case securely.

The

shape

of

the power

spring

inner end can

be

adjusted with a plier

if

necessary.

(3)

Prior

to

installing

the

reel

in

the

starter case,

wind

the

starter rope in the reel for

2.5

turns

in

the arrowhead direction as

shown

in Fig.11-5.

Then let the

rope

out

of

the reel

from

the

reel

notch. Line up the

hook

on

the

starter case with

the

inner end

of

the

spring

and instal the reel

in the starter case.

Check that the inner end

of

the

spring

is

se-

curely hooked

on

the starter case

hook.

I

0.79 - 1.18

in

0.79

-

1

.f

8

in

Fig.

1

1-3-

1

Fig.

1

1-3-2

1.

position

of

the

per

end

Reel

\

n

of

the

inner

end

7

4.

0.04

-

0.08

in

Fig.

1

1-4

(4)

Hold

the starter rope as shown

in

Fig.11-5.

and

I

turn the reel

4

to

5

times

in

the arrowhead direction. Firmly press

the

reel not to allow reverse turn-

ing

and pull

the

starter

knob

to let the starter

rope out

of

the starter case.

Return the

knob’

slowly to let the starter rope

rewind

in

the reel.

(5)

Reassemble the parts

in

reverse order

of

disas-

sembly.

Apply- a small amount

of

lock-tight to

set

screw and torque it.

I

TIGHTENING

TORQUE

I

3.4

-

5.4

N

m

55

kgf

*crn

25.2

-

39.6

ft

Ib

w

Fig.

1

1-5

-

51

-

11

-3

CHECK AFTER REASSEMBLY

(1)

Test the operation and retract properly.

(2)

Pull the starter

If

there

is

once or twice. (See If the starter rope return grease or If it does (After doing If the starter rope does not retract, the power spring is from the first step.

not

of

the recoil starter to

knob

all

the way

starter rope left

Fig.11-1.)

mobile

oil

to rotating and sliding parts.

cure the

so

check that the power spring

problem,

and

in

the groove

is

weak

wind

see

if the rope recoils satisfactorily

check following.

of

the reel, the power spring

or

stops before it completely returns to original position, apply

the

starter rope

is

not

once

or

twice.

over loaded,

not

hooked. Reassemble the recoil starter

by

preceding paragraphs method.)

and

if the ratchets project

is

overloaded. Rewind the reel

,i

114

WHEN POWER SPRING ESCAPES

Make a spring holder

from

a

piece of

the spring assembly over the recess

over

the tension

wire ring-start with the outer loop of the spring and wind

Place

is

holder) and

into

12

the recess

or

tab

for

the power spring-form a ring a little smaller than power spring housing

16

ga.

soft

iron

on

the

reel.

(Fig.ll-4.)

in

the housing.

FROM

wire and twist

in

HOUSING

the

housing,

Carefully press the

the

ends together. Wind the power

in

a counter clockwise direction.

so

that

the

hook

in

the outer

spring

out

Fig.

of

the

7

7-6

spring

loop

wire

of

ring

inside

the

spring

(Spring

I.D.

the

-

52

-

12.

TROUBLESHOOTING

For a gasoline engine to start and

1)

A

proper fuel-air mixture

2)

Appropriate compression in the cylinder.

3) Good spark at correct

If

all the three requirements are not met simultaneously, an engine factors such as contribute to hard

The

most common

12-1

STARTING

Defects in spark plug

Defects in high-tension cord

Defects

heavy

Cause

in

magneto

starting.

causes

DIFFICULTIES

time

load

of

1)

2)

3)

If cord is burnt or damaged, replace ignition coil unit.

1)

2)

run

satisfactorily, the following three requirements must be met:

is

supplied

to

at

starting

engine

ignite

to

the

or

too

troubles

the combustion chamber. mixture.

long an exhaust pipe

are given below.

Remedy

If

contaminated, wash remove foreign matters and dry. If spark plug is broken or lost insulation, replace plug. Adjust spark gap to.025 (.65mm)

If

wire

or insulation is broken, replace magneto. If magnetism the magneto maker) or replace

is

weak, re-magnetize (at

in

gasoline,

flywheel.

the

cannot

causing

be started. There are also other

a

high

back pressure,

Preventive measure

1)

Use spark plugs of specified heat range.

Do

not use poor grade

cleaner and avoid dust entry.

2)

Do not

of

insulator may get damaged.

hit

or bend the center electrode

the spark plug at adjusting or the

oil.

Clean

which

air

in

Other defects system

Gas

leak

gasket or other pans

Defects in piston assembly

Defects in fuel system

Defects in carburetor

electric

through head

tank

1)

If

switch is faulty (short circuit), replace or

repair.

2)

If primary wire is grounded to the engine

body, insulate

1)

If head gasket

2)

ff head

3)

If spark plug

4)

If spark plug

1)

If piston is wom,replace.

2)

If cylinder is worn, rebore and use oversize piston and piston ring.

3)

If piston rings are worn, replace.

4)

tf piston rings are stuck,clean or replace rings.

1)

Clean clogged

2)

Clean clogged fuel strainer.

3)

If incorrect fuel is poured into

water is

fill

it with correct

4)

When fuel pipe discharge

1)

If clogged with dust,clean.

2)

If defective, replace. Clean jets and other orifices, if'they are clogged.

bolts

mixed,.

air.

it

with insulating tape.

is

defective, replace.

are

loose,

tighten.

is

loose, tighten.

is

defective, replace.

tank

outlet.

drain

tank

completely and

fuel.

is

locked

'

tank

with

or

air,

1

)

Keep air cleaner always clean.

2)

Do not use poor grade

1)

Be sure to use a fitter when adding fuel.

2)

Use mixture (gasoline fuel.

oil.

25

to

50:

1)

as

-

53

-

1

Defects

Q

u

S

2!

Excess load

E

os

2%.

s3

uE

Piston

E'

Rod seized

o

e

12-2

SLOWSPEED

Cause

in

carburetor

Or

Connecting

1)

Start engine and half open throttle valve.

2)

Remove drain close fuel cock,repeat starting operation several

If

fuel overflows, check needle valve seat for

wear. Replace, if necessary.

I

1)

If tension of transmission belt reduce tension.

2)

If

1)

If piston seizes,repair or replace.

2)

If connecting rod large end or small end

seize,replace.

out

of

order

times

load is still

Remedy

with

fully open choke valve

plug

from crankcase, and

to discharge excess fuel.

is

too tight,

too

heavy,

install

a

clutch.

Preventive

1)

Never close choke valve when engine

warm.

2)

When stopping the engine, run speed for a while. This practice not only favorably affects next starting,

improves engine

3)

Clogged air-cleaner results in

airfuel mixture. Clean

it

thoroughly.

Be

careful clogged carburetor.

measure

life.

I

1)

Do

not

use

poor grade

2)

Use fuel of proper mixing ratio.

oil.

it

but

too

at

1

is

siow

also

rich

Most defects listed

12-3

OVERHEATING

1)

If

2)

carbon

If

the heat range of the spark plug is too cool, replace it with

deposits have accumulated

CHAMPION

3)

If

the air-fuel mixture is too lean, clein jets

Clean the

4)

If the load is

124

POWER

1)

If

the cylinder, piston or piston rings are

piston and piston

2)

If

the carburetor

3)

If

the spark plug

4)

If

combustion gas leaks through

If

the gasket

5)

If

the

magneto

6)

If

the air cleaner

7)

If

the fuel system

8)

If

the oil seals at the crankshaft are

as

causes for starting difficulty are also causes for faulty slow-speed operating.

and

KNOCKING

CT8.

air

cleaner

in

DROP

is

faulty,replace it.

is

also.

excess, reduce it below the specified continuous load.

rings.

is

faulty,

is

Replace or clean piston rings

out of order, re-adjust or clean it.

faulty (contamination, gas leakage or faulty insulation), dean it or replace

replace

clogged, clean it.

is

clogged, clean it.

in

the combustion chamber, remove them.

correct

and

other passages in the carburetor.

worn,

the

head gasket, re-tighten the clamping screws.

it.

worn

and

replace them or re-bore the cylinder and

if

they are stuck in the grooves.

the compressed gas is leaking, replace them.

one, i.e.

NGR

fit

BM6A

oversize

it.

or

12-5

EXCESSIVE

1)

If

air-fuel mixture is too rich, clean jets and passages in carburetor.

2)

If

the throttle shaft

3)

If

fuel

is

leaking, re-tighten screws or replace faulty part.

4)

If the engine suffers power following step

FUEL

of

7-4.

CONSUMPTION

carburetor

is

drop

worn,

replace throttle shaft. (carburetor)

accompanied with excessive fuel consumption, trouble-shoot by

-

54

-

13.

INSTALLATION

0

Engine life, ease depend installing the engine.

13-1

When mounting the engine, carefully examine its position, the method of connecting it to a machine, the foundation, and the method

Particularly, when determining checked, the spark plug

13-2

Fresh air is necessary for cooling the engine and burning the fuel. In case the engine is operated under a hood or cause vapor lock,loss the engine properly. engine to prevent recirculation of the hot air used for engine cooling, and temperature rise of the machine. Keep the engine room temperature below

on

INSTALLING

VENTILATION

~

of

maintenance and inspection, frequency

the way in which the engine is installed. Carefully observe the following instructions for

of

supporting the engine.

its

mounting position, make sure that fuel can easily be supplied and

can

easily

of

power, piston seizure, shorter engine

It

is

necessary, therefore,

be

checked and the air cleaner can easily be serviced.

in

a small room, temperature rise in the engine room

to

provide a duct

50

"c

(122°F)

of

check and repairs, and operating costs all

life,

etc.,

making

or

baffle to

even in the hottest period

it

impossible to operate

guide

cooling air to the

of

the year.

can

13-3

Exhaust gas is outdoors. engine power. Thus the inside diameter length.

EXHAUST

If

a

long

Exhaust pipe

GAS

DISCHARGE

noxious.

exhaust pipe is used in such a case, the internal resistance increases causing

:

Less

Less than

When operating the engine indoors, be sure to discharge the exhaust gas

than

3x11

(9.8

ft) long, pipe inside diameter 30mm

5.45m

(18

of

the pipe must

ft)

long, pipe inside diameter 33mm

be

increased

in

proportion to the exhaust pipe

(1.18

in)

(1.30

in)

loss

of

-

55

-

13-4

POWER

TRANSMISSION TO

DRIVEN MACHINES

13-4-1

Take the following notes into consideration.

* * * *

*

If

1342

When using a flexible coupling, runout and misalignment between the driven shaft and the engine shaft must be minimized. Runout and misalignment tolerance are specified by

13-5

When remote mounting fuel carburetor fuel inlet) excessive head induces overflow

To

leak at Make the hose length

BELT DRIVE

V-belts are preferable to flat belts. The driving shaft of the engine must be parallel to the driven shaft The driving pulley of the engine Install the engine pulley as close to the engine

If

possible, span the belt horizontally.

Disengage the load when

no

clutch

FUEL

is

used, use a belt tension pulley or the like.

FLEXIBLE

SYSTEM

COUPUNG

to

avoid air lock and vapor lock,carefully examine diameter and car rature

starting

5

-

50cm

must

tank,

(2

of

be in line with the driven pulley

as

possible.

the

engine.

set

the fuel head (height difference between fuel

-

20

in).

Not

enough

carburetors.

fuel

of

the machine.

head causes a pour fuel supply and the

joints.

as

short

as

possible. Fuel filter must be installed in the fuel system.

of

the

machine.

the

coupling manufacturer.

tank

of

fuel hose, heat trasfer and

bottom and

-

56

\

-

14.

CHECKS

After disassembling and cleaning the engine parts,check them, and if necessary,correct them according to

the

correction table. The correction table applies whenever engines are repaired. Its contents should be thoroughly understood by those who undertake the repairing. Its specifications must be abided by to effect correct maintenance. Following are the terms

1)

CORRECTION

All

operations performed on the engine

performance, consisting

2)

STANDARD The design dimension

3)

CORRECTION TOLERANCE The tolerance on the re-finished part dimension

4)

CORRECTION LIMIT

The

limit

on

wear,

bum,

AND

CORRECTIONS

employed

of

in the

repairs, readjustments, and replacements.

correction

table.

parts

for the purpose

SIZE

of

the part without

the part and adjustment, beyond which

and other causes will adversely affect

the

tolerance.

or

on

the

readjusted dimension.

any

dimensional and functional changes, due to

the

normal engine

of

improving or recovering the engine

performance.

5)

USE

LIMIT

The limit,beyond which the

part

is

no

longer usable,due to defects

in

function or strength.

-

57

-

14-1

CORRECTION

TABLE

Uuit

:

rnm

(in)

ITEM

Flatness

of

cylinder

~

Roundness

’

(After rebored)

Cylindricity (After rebored)

Outside diameter

I

Piston in

head

hole

STANDARD

Less

Than

0.1

I

STD

0.S

STD

0.S

r-

(0.004)

454 (21260)

654.25

454.50 (21457)

453.96 (2.1244)

454.21 (2.1343)

454.46 (21441)

~

612

(0.4724)

SIZE

(21358)

TOLERANCE

0

0.01

1

-

0.01

(0.0004)

5

(0.0006)

(

1

CORRECTION

)

-0.004

)

I

454.1

.

454.40

454.65 (2151

453.86 (21

454.1

454.36 (2.1402)

1

+11.965(0.4711)

LIMIT

0.2

(0.008)

5

1

(2.1

31

9)

(21417)

6)

205)

(2.1

303)

U

Width

of

ring groove

Clearance between piston ring

and

I

Clearance between piston and cylinder

I

Frt

piston pin

I

B

cn

Ring width

ii

Piston pin

large

V

piston

~~ ~ ~~~ ~~ ~ ~ ~~~~~

between piston and

O.D.

end

I.D.

2s

Clearance

jS?

large

3Z

pin needle bearing

2

E

-

OS

Small

end

between

I.D.

groove

and

crank

I I

1

I

I I

rod

TOP

(MAX.

WIDTH

(0.0039

1.59

OF

SECOND

1.5 (0.059)

TOP.

SECOND

0.1

-

7.5

(0.059)

4

12

(0.472)

424

(0.945)

4

16

(0.630)

(0.063)

KEYSTONE)

0.25

-

0.0098)

I I

~~ ~

1

I

-0-003

-

+0.02

0

+

0.04

+0.06

0.05

(0.0002

0.040

(0.0002

~~___~_____

0.008

0

0.004

(0.0002

0

+0.011

f+0.0008

(0

(+;::::

-

0.1

-

0.004)

-

0.074

-

0.004)

0.0003

(

0.0003

(4.0001

-0.0003

-

0,022

-

0.0009)

(;0004

)

L

T

)

I

1.44

1.35

0.15

0.25

~1

I

-0.1

I

611.97 (0.471)

0.055

4

(0.057)

(0,053)

(0.0006)

(0.0098)

0.06

(0.0024)

1.5

(0.059)

(0.0039)

(0.002)

16.02

L

(0.631

)

-

58

-

Unit

:

mm

(in)

ITEM

Clearance between end

I.D.

and

needle bearing Large end side clearance

Parallelism and Twist

between large end and

small

end bores

U

0

L

P

Large end small end

"

c.

roundness and cylindricity

g

c c

'

rn

c

Q

%

c

E

"

Distance

end and Crankpin

Crankpin

and

between large

small

0.0.

O.D.

Cylindricity

small

Piston pin

I.D.

end bore

Roundness

1

STANDARD

.

I

,

~

Parallelism

Twist

Roundness

Cylindricity

94

4

18

Roundness

Cylindricity

SIZE

CORRECTION

TOLERANCE

0.003 - 0.023

(0.0001

I I

I

MAX.

-

0.0009)

0.1

-

0.5

(0.004

-

0.020)

0.05 (0.002)

0.1

(0.004)

0.004

(0.0002)

0.004

(0.0002)

0.005

(0.0002)

0,005

(0.0002)

\

I

-

LIMIT

0.055

0.7

0.1

0.3

+

0.25

-0.25

9

17.98

(0.0022)

(0.028)

(0.004)

(0.01

2)

0.01 0)

(0.01

0)

(0.708)

I

Crankshaft

I

Crankshaft end play

Crankshaft deviation

I

Diaof small end needle bearing needle

Spark plug

c

W

Spark timing

-

(before

journal

T.D.C.)

O.D.

w"

0

spark Plug

L

Y

0

W

-

W

Ignition coil air gap

gap

I

Champion

1

4%

CJ8

8

O

62

or

NGK

(Fixed)

BM.6A

I

+o'003

-0.006

0

-

0.05

(0.024

(0.012

(+o*ool

-0.002

0.2

(0.008)

(0.002)

*

2"

0.6

-

0.7

-

0.028)

0.3

-

0.5

-

0.020)

)

I

424.97

0.6

0.1

2

i-

(0.983)

(0.024)

(0.0047)

5"

-

59

-

14-2

TORQUE

SPECIFICATIONS

I

Crankcase

Cylinder

Cylinder head

1

Flywheel

Spark plug

I

M6

1

M8

M10

DESCRIPTION

Bok

and

Bok

and

Bolt

Nut

and

New

Retightening

Nut

spark

1

kgf

cm

90 - 100

180

-

220

180

-220

390

-

420

120

-150

250 - 300

90

250

370

TIGHTENING TORQUE

I

1

N*m

8.8

-

9.8

-

38

24.5

36.2

21.5

-21.5

-

41

-

29.4

8.8

17.6

11.7 -14.7

24.5

I

ft*lb

6.5

-

7.2

-

16

13

-

16

28

-

30

8.7 - 10.8

18

-22

6.5

18

26.7

bn

/'

.,

-

60

-

15.

MAINTENANCE

AND

STORING

0

-

The following maintenance

The indicated maintenance intervals are by

these intervals.

For

example, if the

every day instead

15-1

DAILY CHECKS and MAINTENANCE

I

Checks and Maintenance

Remove dust from whatever parts which accumulated dust.

Check external fuel leakage.

loose

part or replace fautty part.

Check screw tightening. re-tighten.

15-2

EVERY

50

engine

of

every

HOURS

jobs

apply when the engine

is

operated

50

hours.

If

any, retighten the Danger

If

any

loose one

(10

DAYS)

no

means guarantees

in

extremely dusty conditions, the air cleaner

is

found,

CHECK and MAINTENANCE

is

operated correctly under normal conditions.

for

maintenance free operations during

should

i

Reasons

The governor linkage is especially susceptible

of

causing fire.

Loose screws

the engine damage.

and

~~ ~~

for

requiring them

nuts will cause vibration resulting

be

cleaned

to

dust

I

in

r---

1

I

Clean air cleaner

Check spark plug. or polish

15-3

Clean fuel strainer and fuel tank. The carburetor

154

Remove cylinder head Remove carbon deposit from exhaust port and muffler.

with

EVERY

Checks and Maintenance

EVERY

Checks and Maintenance

If

contaminated,

emery paper.

100

to

200

500

to

600

and

wash

in gasoline

HOURS

remove carbon deposit.

(MONTHLY)

(SEMIANNUAL) CHECKS and MAINTENANCE

Clogged air cleaner affects engine operation.

Output

CHECKS and MAINTENANCE

1

bad starting or poor operation.

The

engine

Reasons

power is reduced and starting is made difficult.

~~ ~ ~~

Reasons

will

Reasons

output

for

requiring them

for

requiring them

be clogged

for

power drops.

with

requiring them

dirt

or

dust

causing

I

Disassemble and clean carburetor.

I

-

61

poor operation.

-

.

15-5

EVERY

1000

HOURS

(YEARLY) CHECKS

and

MAINTENANCE

Checks and Maintenance

Perform overhaul, clean, correct or replace

Change piston

Replace fuel

15-6

1)

2)

3)

PREPARATION

Perform the above Drain fuel from the fuel tank, carburetor float chamber and fuel lines.

To

prevent rust

several turns

Turn

the starting pulley

4)

Clean

5)

Cover the engine

rings.

hose

once a year.

for

LONG

13-1

and

in

the cylinder bore, apply

by

hand. Re-install the

by

the

engine outside with oiled cloth.

and

store

STORAGE

13-2

hand and leave it where the resistance

in

dry

parts.

maintenance

oil

spark

plug.

place.

The engine output drops.

Rubber ozone

jobs.

through the spark plug

Reasons

hoses

in

the

may

air.

for

requiring

be hardened and cracked by the

hole

and turn the crankshaft for

is

the greatest.

them

-

62

-

Industrial

Engines