Robin EY45V Service Manual

ROBIN AMERICA,

INC.

ENGINE

MODEL

CROSS

REFERENCE

LIST

ROSIN

TO

WISCONSIN ROBIN

I

ROBIN

EY08
EYl5
EY 15V
EY20
EY20V
EY23
EY28
EY3

5

EY40
EY45V
EY2

I

EY44

EY

18-3
EY25
EY27

EHl1
EH12
EHl5
EH17
EH2 1
EH25
EH3

0

EH30V
EH34
EH34V
EH43V

EC13V

DY

23

DY27
DY30

DY3

5

DY4

1

WISCONSIN

ROBIN

SIDE

VALVE

W 1-080
w1-145
W1-145V
W1-185
W1-185V
W 1-230
W 1-280
W 1-340
W 1-390
W 1 -450V
EY2 1 W
EY44W
EY 18-3 W
EY25W
EY27W

OVERHEAD

VALVE

WO1-115
wo1-120
WO1-150
WO1-170
wo1-210
WO1-250
WO1-300

WO

1

-300v

WO1-340
WO 1 -340V

WO

1-43

OV

TWO

CYCLE

WTI-125V

DIESEL

WRD

1-230

WRD

1-270

WRD

1-300
WRD1-350
WRDI-410

CONTENTS

Section Title Page

1 . SPECIFICATIONS

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

1

2

.

PERFORMANCE

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

2

2-1 Maximum Output

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

2

2-2 Continuous Rated Output

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

2

2-3

Maximum Torque

at

Maximum Output

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

2

3

.

FEATURES

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

3

4 . GENERAL DESCRIPTION

of

ENGINE CONSTRUCTION

..........

3

4-1 Cylinder. Crankcase

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

3

4-2 Main Bearing Cover

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

4

4-3 Crankshaft

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

4

4-4 Connecting Rod and Piston

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

4

4-5 Camshaft

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

5

4-6

Valve Arrangement

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

5

4-7 Cylinder Head

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

5

4-8 Governor

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

6

4-9 Cooling

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

6

4-

10

Lubrication

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

6

4-11 Ignition

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

6

4-12 Carburetor

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

7

4-

13

Air Cleaner

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

7

4-14 Balancer

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

7

4-15 Sectional View

of

Engine

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

8

5

.

DISASSEMBLY

and

REASSEMBLY

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

10

5-

1

Preparation and Suggestion

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

10

5-2 Special

Tool

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

10

5-3 HowTo Disassemble

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

11

5-4

How To Reassemble

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

20

6

.

ENGINE SPEED SETTING

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

29

7 .

MAGNETO

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

30

7-1 Features

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

30

7-2

Basic

Theoryof T

.

I.C.

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

30

7-3 Wiring Diagram

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

30

7-4 Checking Procedures

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

31

Section

Title

Page

8

.

CARBURETOR

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

32

8-

1 Operation and Construction

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

32

8-2

Disassemblyand Reassembly

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

33

9

.

STARTING MOTOR

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

35

9-1 Disassembly

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

35

9-2

Inspection and Repair

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

38

9-3 Reassembly

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

41

10

.

BREAK-IN OPERATION

Of

REASSEMBLED ENGINE

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

42

11

.

TROUBLESHOOTING

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

43

11 -1 Starting Difficulties

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

43

11

-2

Engine Misfires

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

44

11-3 Enginestops

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

44

11 -4 Engine Overheats

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

44

11 -6 Engine Backfires through Carburetor

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

45

12 .

INSTALLATION

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

46

11 -5 Engine Knocks

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

45

12-1 Installing

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

46

12-2 Ventilation

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

46

12-3 Exhaust

Gas

Discharge

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

46

12-4 Power Transmission to Driven Machines

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

46

13

.

CHECKS

and

CORRECTIONS

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

47

14

.

TABLE

of

CORRECTION STANDARDS

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

48

15

MAINTENANCE

and

STORING

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

.

53

15-

1

Daily Checks and Maintenance

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

53

15-2 Initial 20 Hours Check

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

53

15-3

Every

50

Hours

(10

days) Checks and Maintenance

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

53

15-4 Every 100

-

200

Hours (Monthly) Checks and Maintenance

.....

53

15-5 Every

500

-

600 Hours (Semiannual) Checks and Maintenance

...

54

15-6 Every

1000

Hours (Yearly) Checks and Maintenance

...........

54

15-7 Preparation for Long Storage

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

54

.

1

SPEC1

F

ICATIONS

Model

TY

Pe

Bore

x

Stroke

~~

Piston Displacement
Maximum
Maximum Torque
Direction of Rotation

Lubrication
Lubricant

Carburetor

Fuel
Fuel Feed

Horse

Power

I

Air-Cooled, 4-Cycle, Vertical Shaft, Single Cylinder Gasoline Engine

90

mm x 70 mm (3.54" x 2.75")

445 cc (27.15 cu. in)

12 HP/3600 r.p.m. (SAE Code-J607a)

2.5

kg-m/2600 r.p.m. (18.08 ft-lbs./2600 r.p.m.)

Counter-clockwise

Automobile Oil SAE

Horizontal Draft, Float Type

Automobile Gasoline

EY45V

as

viewed from

Forced Air Cooling Cooling System

Oil Pump

Gravity Type

#20

P.T.

-

30, Class

0.

shaft side

SC

Governor Centrifugal Flyweight Type

Ignition System

Spark Plug

Charging (Lighting) Capacity

Starting System

Dry Weight

Length

Dimensions

1

Width

I

Height

I

I

Flywheel Magneto Type (Solid

NGK BPMGA

DC 12V-1.5A Battery Charge

AC12V-15W or 1OOW Lighting Coil (Optional)

Electric Starter (Recoil Starter: Optional)

Approx. 35 kg (77.1

(1

41 5.5 mm

373.5 mm (14.7")

312 mm (12.28") excluding

6.35")

State

lbs.)

P.T.

Ignition)

0.

Shaft

-1-

2.

PERFORMANCE

2-7 MAXIMUM OUTPUT

The maximum output

fully opened after its initial break-in period when all the
engine may not produce the maximum output in the beginning because the moving parts are not in a proper­ly worn-in condition.

2-2

CONTINUOUS RATED OUTPUT

The continuous rated output of an engine is such a power as produced by the engine when running continu­ously at an optimum speed, and most favorable from the viewpoint of engine life and fuel consumption ratio,
with the governor in operation.
anism, with this engine as prime mover, the continous power requirement of that mechanism
the continuous rated output specified.

2-3

MAXIMUM TORQUE AT MAXIMUM OUTPUT

These mean the maximum torque of the output shaft at the maximum output of an engine.

of

an engine is such a standard power as produced by the engine with its throttle valve

moving

It

is suggested, therefore, that when designing a driving system

PERFORMANCE CURVES

parts are properly worn in. Therefore, a new

for

any

be

kept below

Kg-m

mech-

12

6

2.5

2.3

f

5

Revolution

-

r.p.m.

3.

FEATU

I.

The cylinder and crankcase is a light weight one-piece aluminum diecasting. The dimensions are
as those of a 10-horsepower engine.

2.

The engine is powerful with a wide torque range from low speed to high.

3.

The vibration-free design with twin balancer shafts.

4.

A pointless electronic ignition system is adopted as standard, which makes the ignition system mainte-

nance-free.'
timing.

5.

The engine employs a special cast iron cylinder liner, a forged steel crankshaft, main ball bearings at both
sides and forced spray lubrication by oil pump for prolonged durability. All this adds up to improved
durability.

RES

You

will no longer be troubled by worn contact points or faulty sparking from wrong ignition

as

small

4.

GENERAL

4-1

CYLINDER. CRANKCASE

The cylinder and crankcase

diecasting. The cylinder liner, made
iron,

is

molded into the aluminum casting. The in­take and exhaust ports are located on one side of
the cylinder.
The crankcase has a fitting surface on the output
shaft side, where the main bearing cover is attached.
(See Fig.

1

.)

DESCRIPTION

is

single piece aluminum

of

of

special cast

ENG

-3-

NE CONSTRUCTIO

Fig.

1

4-2

MAIN BEARING COVER

The main bearing cover is an aluminum diecasting, which is mounted on the output shaft side of the crank-

case. Remove the main bearing cover to expose the inside

of

the engine for inspection.

n

The main bearing cover also serves

as

an oil pan, with a trochoid oil pump, oil filler and oil drain plug. (See

Figs.

2

and

3.)

Fig.

2

4-3

CRANKSHAFT

The crankshaft is forged carbon steel, and the crank
pin

is

induction-hardened. The output end of the
shaft has a crankshaft gear and balancer gear that are
pressed into position. (See Fig.

4.)

4-4

CONNECTING

ROD

and

PISTON

The connecting rod is forged aluminum alloy, and
its large and small ends serve as bearings. The piston
is

an

aluminum alloy casting, and carries two

com-

pression rings and one oil ring. The piston pin hole

is

offset from the center

of

the piston to reduce hit-

ting noise and improve durability.

(See

Fig.

5.)

Fig,

3

Induction Hardening
(Portion

of

Crankpin)

Crank Gear
(Press-fit)

Fig.

4

Fig.

5

-4-

The camshaft is a hollow special cast iron integrally
molded with the camshaft gear. The governor plate
is riveted to it, and one end of.the camshaft has a
pin

for

driving the oil pump. (See Fig.

6

.)

4-6

VALVE ARRANGEMENT

The intake valve is located at flywheel side of the
crankcase.
Hard alloy valve seats are molded in the cylinder
block for added durability. (See

Fig.

7.)

4-7

CYLINDER HEAD

Fig.

6

Exhaust

intake

Valve

Fig.

7

The cylinder head is an aluminum die casting, and
forms a Ricardo type combustion chamber with am­ple area for high combustion efficiency.

Fig.

8

-5-

The governor is a centrifugal flyweight type

which

permits constant operation at the selected speed
against load variations. Governor gear

is

installed on

the bearing cover, and it engages with the cam gear
after reassembling. (See Fig.

9.)

4-8

GOVERNOR

-

Fig.

9

4-9

COOLING

The cooling fans on the flywheel cool the cylinder and cylinder head by forced air cooling. Cylinder baffles
is provided

for

guiding the cooling air.

4-

10

LUBRICATION

The trochoid

oil

pump is mounted inside of the

main bearing cover.

Oil

pump

is

driven by the camshaft to supply

oil

for

the

rotating

or

sliding parts. (See Fig.

10.)

4-11

IGNITION

The ignition system is a flywheel magneto type with
ignition timing set at

23"

before TDC. The magneto

is

composed

of

a

flywheel and ignition

coil.

The fly­wheel is mounted directly on the crankshaft, and
ignition coil

on

the crankcase. (See

Fig. 1 1

.)

(For further details, refer

to

page

30,

Section

"7.

MAGNETO".)

&

Camshaft

/

Oil Filter

Holder

(Camshaft

Oil Pump (Inner)

Oil

Pump (Outer)

Fig.

10

I

Ignition Coil

-6-

4-12

A

been carefullyset after thorough tests

CARBURETOR

horizontal draft carburetor

is

employed. It has

to

assure satis­factory start up, acceleration, fuel consumption, out­put performance, etc. (See Fig.

For construction and other details, refer to page
Section

"8.

CARBURETOR".

12.)

32

Fig.

12

4-13

AIR CLEANER

The air cleaner is a semicyclone type with double

Fig.

elements. (See

4-14

BALANCERS

Unbalanced moments

13.)

of

inertia that are generated in
the vertical and horizontal directions are balanced
by the two balancers that rotate

1

to

1

with the
crankshaft to effectively reduce vibration.
(See

Fig.

14.)

'leaner

Case

Cleaner Element

~

Fig.

Cleaner Cover

13

-7-

Fig.

14

4-15

SECTIONAL VIEW

of

ENGINE

Flywheel

/-(Cooling Fan)

f

Ignition

Coil

Housing

-8-

'

Head

r

Tappet Air Cleaner

Intake

and

Exhaust Valve

Muffler

rSpark

“Spark

Plug

Cap

1

Oil Filler Starting Motor

-9-

5.

DISASSEMBLY

5-1

PREPARATIONS

1)

When disassembling the engine, memorize well the locations of individual parts

sembed correctly.

and

and

If

you are uncertain of identifying some parts,

REASSEMBLY

SUGGESTIONS

so

that they can be reas-

it

is

suggested that tags be attached to

them.

2)

Have

boxes

ready to keep disassembed parts by group.

3)

To

prevent missing and misplacing, temporarily assemble each group

4)

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

5)

Use the correct tools in the correct way.

5-2

SPECIAL

TOOLS

of

disassembed parts.

For your reference, the following table shows special tools for disassembling Robin Engines.

Part

No.

209 95004

207

95003

Flywheel Puller

07

07

Valve Spring

Tool

(with bolt)

Retainer

Use

For

pulling

Flywheel

For mounting and
dismounting Valvc
Spring Retainer
and Retainer

off

Lock

Applicalbe

Model

EY10,13,14
EY15,18,20
EY25,27,28
EY33,35,40

EY44.45
EC05.07,lO
EC17,25,37

EY10, 13,14
EY15,18,20
EY25,27,28
EY33,35,40
EY44.45

Shape

-

10-

5-3

HOW

TO

DISASSEMBLE

*Bolt

length

is

the length from bolt end to the bottom surface of bolt head.

Order

item

Engine

(Oil

drain plug)

Muffler and
bracket

E

Remove

(1)

(2)

oil

drain plug and discharge

Remove muffler bracket.

Turn

up heat deflector tabs,

nuts.

Procedure

and

oil.

remove

Remarks

Be

careful

gasket.

not

to

lose

Tool

17

mm box wrench

10

mm box wrench

12

mm box wrench

Muffler

-

11

-

Order

I

item

Governor lever

Procedure

(1)

Remove governor lever from shaft.

(2)

Remove governor spring
from governor lever.

and

governor rod

I

Remarks

~ ~~~

Memorize or

the

governor spring

hooking

mark

position.

I

10

mm

Tool

box

wrench

I

’

+

(1)

(2)

Remove speed control assembly from crank­case.

Remove choke rod from speed control
assembly.

10

mm box wrench

Control

,”-

Rod

Go

V

I

Ylarburetor Governor Lever

Spring Choke

Fig.

-

12

Rod15

15

-

\

Governor

Choke Lever

ltrol

Spring

Order

Item

Air

cleaner

Carburetor and
intake manifold

Procedure

I

(1)

Remove wing nuts, cleaner cover, and ele­ment.

(2)

Remove cleaner case.

(1)

Remove support (elbow) bolt on crankcase
side.

(2)

Remove intake manifold nuts, and assembly
of intake manifold, carburetor and elbow
from engine.

(3)

Separate carburetor and elbow from intake
manifold if necessary.

Remarks

I

Disconnect breather
pipe at elbow side
end.

Tool

10

mm wrench

10

mm box wrench

12

mm box wrench

12

mm box wrench

Oil

filler

(1)

(2)

L

Clamp

(Oil

Filler)

Oil

Filler

Remove clamp
Pull out

oil

filler from main bearing cover.

(oil

filler).

/Crankcase

Be careful not to

O-ring.

lose

10

.I#"-

%=.

mm box wrench

Wing

Nut

Washer

Grommet

-Cleaner Cover

Intake Manifold

-

13

-

1

Order

I

8

I

9/

I

Item

I

Starting motor
Rotating

screen

I

I

Remove starting motor.
Remove rotating screeen and spacer.

Procedure

I

Remarks

Tool

1

12

mm

box

wrench

12 mm box wrench

I
I

/

I

I

I

lo

Blower

and

I

housing

head cover

(1 j Remove blower housing.

(2 j Remove cylinder baffle.

(3

j

Remove head cover.

1

10

mm box wrench

I

1

-

14

-