Robin EH09 Service Manual

SERVICE MANUAL

Models

EH09, EH12-2 Rammer ENGINES

PUB-ES1330 Rev. 12/01

4-16 SECTIONAL VIEW OF ENGINE

EH09D

INTAKE VALVE

EXHAUST VALVE

MUFFLER

PISTON

PISTON RING

CYLINDER HEAD

PISTON PIN

IGNITION COIL

BLOWER HOUSING

RECOIL STARTER

P.T.O. SHAFT

MAIN BEARING COVER

ADAPTER (

FLANGE

)

FLYWHEEL

CRANKCASE

Fig. 4-15

ROCKER COVER

PUSH ROD

ROCKER ARM

SPARK PLUG

CONNECTING ROD

CARBURETOR

AIR CLEANER

TAPPET

CAMSHAFT

GOVERNOR LEVER

SPEED CONTROL

LEVER

OIL GAUGE

PLUG

Fig. 4-16

CRANKSHAFT

STIFFENER

EH12-2D

INTAKE VALVE

EXHAUST VALVE

PISTON

PISTON RING

P.T.O. SHAFT

CYLINDER HEAD

IGNITION COIL

BLOWER HOUSING

PISTON PIN

MAIN BEARING COVER

CRANKCASE

Fig. 4-17

RECOIL STARTER

FLYWHEEL

ROCKER COVER

PUSH ROD

ROCKER ARM

SPARK PLUG

MUFFLER

CONNECTING ROD

CARBURETOR

AIR CLEANER

TAPPET

GOVERNOR

LEVER

CAMSHAFT

OIL GAUGE

CRANKSHAFT

Fig. 4-18

SPEED CONTROL

LEVER

PLUG

5. DISASSEMBLY AND REASSEMBLY

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 TOOLS (EH12-2D)

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FLYWHEEL PULLER

Fig. 5-1

5-3 DISASSEMBLY PROCEDURES

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EH09D

M8 NUT : 4 pcs.

OIL LEVEL GAUGE

M8 WASHER : 4 pcs.

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GASKET

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STEP 1

OIL DRAIN PLUG

GASKET

M8 SPRING WASHER : 4 pcs.

ADAPTER

STEP 2

M8 x 30 BOLT AND WASHER : 2 pcs.

STIFFENER

M8 x 25 BOLT AND WASHER : 4 pcs.

Fig. 5-2

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EH09D

STEP 4

M6 x 8 FLANGE BOLT

BLOWER GUIDE CP

M4 TAPPING SCREW : 2 pcs.

STOP SWITCH

CLAMP

: 1 pce.

M6 x 12 FLANGE

BOLT : 1 pce.

M6 x 12 FLANGE BOLT : 1 pce.

M6 x 12 FLANGE BOLT : 2 pcs.

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STEP 3

M6 x 12 FLANGE BOLT: 1 pce.

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EH12-2D

STEP 4

CLAMP

M4 TAPPING SCREW : 2 pcs.

STOP SWITCH

M6 x 8 FLANGE BOLT: 1 pce.

BLOWER HOUSING CP

M6 x 8 FLANGE BOLT : 4 pcs.

STEP 3

M6 x 55 FLANGE BOLT : 4 pcs.

BLOWER HOUSING CP

Fig. 5-3

EH09D

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M6 x 8 FLANGE BOLT : 2 pcs.

SPACER

SPEED CONTROL LEVER AY

STEP 9

BASE PLATE CP

M6 BOLT AND WASHER AY : 1 pce.

RETURN SPRING

ROD SPRING

GOVERNOR LEVER

FRICTION WASHER

INSULATOR

GOVERNOR ROD

GOVERNOR SPRING

M6 PIVOT BOLT

: 1 pce.

GASKET (INSULATOR

CARBURETOR

STEP 8

STEP 7

)

Fig. 5-6

EH12-2D

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GASKET

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.revel

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M6 NUT : 2 pcs.

M6 x 40 BOLT AND WASHER : 1 pce.

STEP 8

INTAKE PIPE

INSULATOR

CARBURETOR

STEP 9

WIRE BRACKET

ROD SPRING

GOVERNOR

LEVER

STEP 7

M6 BOLT AND WASHER AY : 1 pce.

M6 x14 FLANGE BOLT : 1 pce.

Fig. 5-7

GOVERNOR ROD

GOVERNOR SPRING

NUT

GASKET (

INSULATOR

M6 PIVOT BOLT : 1 pce.

)

STEP 9

SPEED CONTROL LEVER

M6 x 12 FLANGE BOLT : 1 pce.

PROTECTOR

M8 x 16 BOLT AND WASHER AY : 1 pce.

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ALUMINUM BAR

Fig. 5-9 Fig. 5-10 Fig. 5-11

SPARK PLUG CAP

SPARK PLUG

STEP 12

IGNITION COIL CP

STEP 10

M6 x 25 BOLT AND WASHER AY : 2 pcs.

FLYWHEEL CP

M12 SPRING WASHER : 1 pce. (EH09D) M14 SPRING WASHER : 1 pce. (EH12-2D)

STARTING

PULLEY

M12 NUT : 1 pce. (EH09D) M14 NUT : 1 pce. (EH12-2D)

STEP 11

WOODRUFF KEY

Fig. 5-8

Fig. 5-12

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EH09D EH12-2D

M6 x 60 BOLT AND WASHER AY : 4 pcs.

M8 x 55 FLANGE BOLT : 4 pcs.

STEP 13 STEP 13

ROCKER COVER

M6 x 40 FLANGE BOLT : 4 pcs.

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ROCKER COVER

GASKET

CYLINDER HEAD CP

STEP 14

GASKET

PUSH ROD

M8 x 65 FLANGE BOLT : 4 pcs.

CYLINDER HEAD CP

Fig. 5-13

GASKET

SPACER (

BREATHER

GASKET

STEP 14

PUSH ROD

)

STEP 15

M6 x 30 BOLT AND WASHER AY : 9 pcs.

MAIN BEARING COVER CP

M8 x 16 FLANGE BOLT : 2 pcs.

SUPPORT (

MAIN BEARING COVER

STEP 15

MAIN BEARING COVER CP

M6 x 30 BOLT AND WASHER AY : 8 pcs.

)

GASKET (

BREATHER COVER

BRACKET (

MAIN BEARING

COVER

M6 x 16 FLANGE BOLT : 2 pcs.

M8 x 16 FLANGE BOLT : 1 pce.

)

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STEP 18

CRANKSHAFT

Fig. 5-19

Fig. 5-20

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STEP 19

BOLT (PIVOT) : 2 pcs.

ROCKER ARM

COLLET

Fig. 5-22

SPRING RETAINER

VALVE SPRING

EXHAUST VALVE

M6 NUT : 2 pcs.

GUIDE PLATE

INTAKE VALVE

Fig. 5-21

5-4 REASSEMBLY PROCEDURES

● PRECAUTIONS FOR REASSEMBLY

1) Clean parts thoroughly before reassembly.

Pay close attention to the cleanliness of piston, cylinder, crankshaft, connecting rod and bearings.

2) Scrape off all carbon deposits from cylinder head, piston top and piston ring grooves.

3) Check lip of oil seals. Replace oil seal if the lip is damaged. Apply oil to the lip before reassembly.

4) Replace all the gaskets with new ones.

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

6) Torque bolts and nuts to specification refer to the "TORQUE SPECIFICATIONS" (See page 76).

7) Apply oil to rotating and sliding portions.

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

5-4-1 CRANKSHAFT

(1) Install crankshaft in crankcase wrapping the

keyway with pol y viny l ta pe to av oi d dam age to oil seal.

(2) Install woodruff key for flywheel on crankshaft.

CRANKSHAFT

5-4-2 PISTON AND PISTON RINGS

(1) Install oil ring first, then second ring and top

ring. Spread ring only far enough to slip over pis-

ton and into correct groove. Use care not to distort ring.

Install second ring with punch ed mark bes ide the gap face upward. (See Fig. 5-26a, 26b)

POLYVINYL TAPE

Fig. 5-23

OPEN ENDS OF PISTON RING

Fig. 5-24

①

TOP

RING

EH09D EH12-2D

BARREL

MARK "RN"

② ③

Fig. 5-25

SECOND RING

OIL RING

MARK "R"

EH09D

EH12-2D

EH09D

EH12-2D

TAPER

TAPER UNDER CUT

CUTTER

CUTTER RING WITH COIL EXPANDER

RING

Model: EH09D Model: EH12-2D

Fig. 5-26a

5-4-3 PISTON AND CONNECTING ROD

(1) EH09D

The direction of piston on connecting rod is not specified.

EH12-2D

When installing the piston on the connecting rod, place the valve recess of the piston crown as shown in the illustration to the “MAG” side of the connecting rod.

(2) Apply oil to the small end of connecting rod,

piston and piston pin before assembling. Be sure to use clips on the both side of the

piston pin to secure piston pin in position.

"MA" MARK

Model: EH09D

Fig. 5-26b

"MAG" MARK

VALVE RECESS

Model: EH12-2D

Fig. 5-27

(3) Install piston and connecting rod assembly

into cylinder. Use a piston ring compressor to hold piston

rings. The “MA” mark (EH09D) ,“MAG” mark (EH12-

2D) of the connecting rod is to face the flywheel side of the engine when assembled.

Note:

PISTONRING COMPRESSOR

CONNECTING ROD

("MA"SIDEEH09D)

("MAG"SIDE EH12-2D)

(1) Apply enough oil to lubricate the pis-

ton rings, connecting rod bearings and cylinder bore before assembly.

(2) Set gaps of the piston rings 90 de-

grees apart from each other before assembly.

5-4-4 CONNECTING ROD

(1) Turn crankshaft to bottom dead center, lightly

tap top of the piston until large end of the rod meet crank pin.

(2) Install connecting rod cap to connecting rod.

Make sure to match the alignment marks on the rod caps.

CRANKCASE (FLYWHEEL SIDE)

Fig. 5-28

SECOND RING

OIL RING

TOP RING

Fig. 5-29

Torque connecting rod bolts to specification. M5 x 25 mm connecting rod bolt : 2 pcs. (EH09D) M6 x 34 mm connecting rod bolt : 2 pcs. (EH12-2D)

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(3) Check for free movement of connecting rod

by turning crankshaft slowly.

ALIGNMENT MARK

Model: EH09D Model: EH12-2D

ALIGNMENT MARK

Fig. 5-30

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