Subaru EX30 User Manual

SERVICE MANUAL

Model

EX30 ENGINES

PUB-ES2268 Rev. 10/06

940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212

e-mail: sales@robinamerica.com • www.robinamerica.com

CONTENTS

Section Title Page

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3. FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . . . 5

5. DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5-1 PREPARATIONS AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5-3 DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5-4 REASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

6. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

7. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

8. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9. ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

10. OIL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

11. AUTOMATIC DECOMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

12. CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

13. RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

14. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

15. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

16. STANDARD REPAIR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

16-1 STANDARD DIMENSIONS AND LIMITS OF USE . . . . . . . . . . . . . . . . . . . . 67

16-2 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

17. MAINTENANCE AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1. SPECIFICATIONS

MODEL EX30D

Type

Displacement mL (cc)

Direction of Rotation

Lubricant

Oil Capacity Liter

Fuel

Spark Plug

Starting System

Dry Weight kg

Dimensions (L x W x H) mm

Valve Clearance (Intake and Exhaust)

Emissions Durability Period (California only)

Air-cooled, 4-cycle single cylinder, overhead camshaft, gasoline engine

287

Counterclockwise, as Viewed from P.T.O. Shaft side

Automotive detergent oil (API/ SE or higher grade, SAE/ 10W-30 etc.)

1.0

Automotive Gasoline (Unleaded)

NGK BR-6HS

Recoil starter /Electric starter

415 x 424 x 319

+0.03

0.12 mm (0.0047 in.)

Note : Adjust the valve clearance while the engine is cold.

500 hours

+0.0012 0

- 1 -

2.PERFORMANCE

2-1 MAXIMUM OUTPUT

The Maximum output is the output of an engine with its throttle valve fully opened and considering that all the moving parts are properly broken in. A new engine may not produce full maximum output while its moving parts are still not broken-in.

NOTE : Power curves shown in the following charts are made in conformity with SAE internal combustion engine standard test code J1349.

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 engin's life and fuel consumption. When the engine is installed on a certain equipment, it is recommended that the continuous output required from the equipment to be kept below this continuous rated output.

2-3 MAXIMUM TORQUE

The maximum torque is the torque at the output shaft when the engine is producing maximum output at a speciﬁ c r.p.m..

- 2 -

2-4 PERFORMANCE CURVES

[HP]

10.0

9.0

8.0

7.0

6.0

7.0

6.5

6.0

5.5

5.0

4.5

MAXIMUM TORQUE

MAXIMUM HORSEPOWER

20.0

19.0

18.0

17.0

2.0

1.9

1.8

1.7

TORQUE

5.0

4.0

OUTPUT

3.0

2.0

1.0

4.0

CONTINUOUS RATED HP

3.5

RECOMMENDED

3.0

HORSEPOWER RANGE

2.5

2.0

1.5

1.0

0.5

2000 2400 2800 3200 3600 4000

- 3 -

r.p.m.REVOLUTION

3. FEATURES

3-1 EXTREMELY EASY START - NO KICK-BACK

Reliable Starting and Less Pulling Force are achieved by:

- Sophisticated Mechanical Compression Release System as well as newly designed Combustion Chamber.

- EX engines start instantly even at minus (-) 10°C, without any perceptible kick-back.

3-2 EXTREMELY EASY MAINTENANCE

Extreme ease of maintenance is realized by:

- Only with ordinary tools, routine maintenance, assembly and disassembly can be performed.

3-3 EXTREMELY ADVANCED TECHNOLOGY

Extreme reliability and durability are achieved by:

- Heavy Duty Chain Driven OHC System

Oval type case-hardened steel links enhance performance and resist stretching, which result in extended maintenance free operation.

- Completely New Main Bearing Cover's Design

Flush-mounted main bearing cover with lower moment of deformation significantly increases reliability and engine life.

- Superior Cooling and Lubrication System

Heat reduction is achieved by more efﬁ cient, larger and more numerous cooling ﬁ ns on crankcase, cylinder and mounting base, as well as by outstanding oil delivery system.

- Large Ball Bearings on both ends of crankshaft for maximum stability under demanding loads.

- Cast Iron Cylinder Liner resists wear

3-4 EXTREME POWER AND PERFORMANCE

Extremely Higher Power and Lower Fuel Consumption are realized by:

- High speed and homogeneous combustion achieved by sophisticated Pentroof Combustion Chamber which includes Intake and Exhaust Valves located at optimum angle.

- Straight Intake Port with minimal air ﬂ ow resistance.

Environmentally friendly

EX engines comply with EPA Phase 2 and CARB Tier II Emission Regulations in the USA.

Extreme application compatibility

With four versatile models, existing slant-cylinder engines can be easily replaced.

- 4 -

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS

4-1 CYLINDER AND CRANKCASE

The cylinder and crankcase are aluminum die-casting as a single piece. A special cast iron cylinder liner is molded into the aluminum die-casting. The crankcase has a mounting surface on the output shaft side to which the main bearing cover is attached. The cylinder is inclined to the right at an angle of 25 degrees from the horizontal as viewed from the output shaft side.

4-2 MAIN BEARING COVER

The main bearing cover is an aluminum die-casting, which is mounted on the output shaft side of the crankcase. By removing the main bearing cover, the inside of the engine can be inspected with ease. Pilots and bosses are machined into the cover to facilitate the direct coupling of the engine with machines such as generators and pumps. There is an oil ﬁ lling port, with oil gauge, on either side of the cover.

4-3 CRANKSHAFT

The crankshaft is made of spheroidal graphite cast iron, and the crank pin is high-frequency inductionhardened. The crank sprocket used to drive the chain and the gear used to drive the governor gear are pressed into the output end of the shaft.

4-4 CONNECTING ROD AND PISTON

The connecting rod is a specially heat-treated aluminum alloy die-casting. Its large and small ends function as bearings. A splasher built into the connecting rod lubricates by splashing engine oil. The piston is an aluminum alloy casting with grooves for mounting two compression rings and one oil ring.

- 5 -

4-5 PISTON RINGS

The piston rings are made of special cast iron. The proﬁ le of the top ring is a barrel face or tapered face, and that of the second ring is a tapered face. There are 2 types of oil ring depending on the engine speciﬁ cation. As those are interchangeable, the cutter ring with coil expander type can be selected as the spare part.

TOP

RING

OIL

RING

BARREL

THREE-PIECE CONSTRUCTION

4-6 CAMSHAFT

The camshaft and the sprocket are made of special sintered alloy. They are constructed as a single piece. The camshaft is provided with intake and exhaust cam, and the decompression release lever is mounted on the sprocket shaft end side.

DECOMPRESSION RELEASE LEVER

4-7 VALVE ARRANGEMENT

This engine has a chain-driven overhead cam and overhead valve construction, with a single cam performing both intake and exhaust operations.

4-8 CYLINDER HEAD

The cylinder head is an aluminum die-casting with a pent roof combustion chamber construction. The intake and exhaust ports are arranged in a cross direction to improve combustion efﬁ ciency.

EXHAUST VALVE INTAKE VALVE

- 6 -

4-9 GOVERNOR SYSTEM

This engine is equipped with a centrifugal flyweight type governor that makes it possible to operate the engine at a constant speed, even with load variations. (The governor ﬂ yweights are mounted on a governor gear.)

GOVERNOR GEAR

4-10 COOLING SYSTEM

The engine uses a forced air-cooling system in which a cooling fan (which also works as a flywheel) forces cooling air into the cylinder and the cylinder head. Bafﬂ es are provided to guide the ﬂ ow of the cooling air.

4-11 LUBRICATION SYSTEM

The rotating parts, sliding parts and valves of the engine are lubricated with oil in the crankcase. The oil is splashed onto the parts by the oil splasher on the connecting rod.

TIMING CHAIN

4-12 TIMING CHAIN

Timing chain system is adopted and designed for lubricating for the upper portion of cylinder head. The timing chain is engaged between the sprocket portion of integrated camshaft in the cylinder head and the crankshaft gear sprocket. The sprocket teeth in particular shape are adopted to enhance the durability and to realize low noise level.

4-13 IGNITION SYSTEM

The ignition system is a transistor controlled magneto system with the ignition timing set at 23 degrees before the top dead center. The magneto consists of a ﬂ ywheel and ignition coil. The ﬂ ywheel (which also works as a fan) is directly mounted on the crankshaft and the ignition coil is directly mounted on the crankcase.

※

Model EX30 has a smooth advanced ignition timing system to improve starting performance. (For further details, refer to page 43, section "7. MAGNETO")

OIL SPLASHER

IGNITION COIL

FLYWHEEL

- 7 -

4-14 CARBURETOR

The engine is equipped with a horizontal draft carburetor. The carburetor setting is calibrated after careful testing for optimum all-round performance (including starting, acceleration, fuel consumption, output power characteristics). Special attention is also paid to the general-purpose use of the engine. (For further information, refer to page 51, section "12. CARBURETOR")

4-15 AIR CLEANER

The engine uses an air cleaner that is quieter than conventional ones. A semi-wet urethane foam element is used in the urethane foam air cleaner.

CLEANER BODY COMP

URETHANE FOAM ELEMENT

COVER COMP

4-16 DECOMPRESSION SYSTEM

The automatic decompression system is mounted on the camshaft. It opens the exhaust valve before the compression top, thereby alleviating the compression pressure and reducing the force required to pull the recoil starter. During engine operation, the decompression system is overpowered by centrifugal force and compression is fully utilized to produce power.

RETURN SPRING

ROCKER ARM (EXHAUST VALVE SIDE)

CAMSHAFT

EXHAUST VALV E

- 8 -

4-17 SECTIONAL VIEW OF THE ENGINE

Cross sectional view - across the shaft

BLOWER HOUSING

DUCT

GOVERNOR SHAFT

STARTING PULLEY

RECOIL STARTER

GOVERNOR LEVER

GOVERNOR GEAR

CRANKSHAFT

CONNECTING ROD

FLYWHEEL OIL SENSOR MAIN BEARING COVER

- 9 -

Cross sectional view - along the shaft

GOVERNOR LEVER

GOVERNOR GEAR

TIMING CHAIN

OIL GAUGE

CHAIN GUIDE

PISTON DUCT

EXHAUST PIPE

EXHAUST VALVE

ROCKER

ARM

INTAKE VALVE

CAMSHAFT

PISTON PIN

PISTON RING

TENSIONER

OIL DRAIN PLUG

CRANKCASE

OIL SENSOR

- 10 -

CRANKSHAFT

CONNECTING ROD

5. DISASSEMBLY AND REASSEMBLY

5-1 PREPARATIONS AND PRECAUTIONS

(1) When disassembling the engine, memorize the location of each part so that you can reassemble the engine

correctly. If necessary, attach identiﬁ cation tags with the required assembly information to the parts. (2) Store groups of parts in separate boxes. This will make reassembly easier. (3) To prevent parts from being mislaid, keep each group provisionally assembled after removing the parts from

the engine. (4) Handle the disassembled parts with the utmost care. Clean them with cleaning oil if necessary. (5) Use the correct tools in the correct way when disassembling and reassembling the engine.

5-2 SPECIAL TOOLS

Tool name Use

Commercially available product

Flywheel puller For pulling off the ﬂ ywheel

FLYWHEEL PULLER

- 11 -

5-3 DISASSEMBLY PROCEDURE

Step Parts to remove Remarks and procedures Fasteners

1 Drain the engine oil (1) Remove a drain plug (M14 x 12mm)

located on both sides of the case. Take care not to lose the gaskets.

(2) To discharge oil quickly, remove the oil guage.

2 Drain the fuel (1) Drain fuel from the carburetor drain.

(See Figure STEP2-A)

(2) Disconnect the fuel pipe from the carburetor.

(See Figure STEP2-B)

OIL GAUGE

GASKET

14 mm spanner

GASKET

DRAIN PLUG

STEP 2

STEP2-A STEP2-B

STEP 2

- 12 -

STEP 1

Step Parts to remove Remarks and procedures Fasteners

3 Air cleaner cover Remove the air cleaner cover. 14 mm spanner

4 Air cleaner Remove the element, and remove the air cleaner

while pulling the breather pipe away from the rocker cover.

CLEANER BODY COMP

ELEMENT

STEP 4

AIR CLEANER

10 mm box spanner M6 nut : 2 pcs. M6 x 20 : 1 pc.

STEP 3

COVER COMP

M6 x 20 FLANGE BOLT : 1 pc.

M6 FLANGE NUT : 2 pcs.

BRACKET

GASKET

- 13 -

CLAMP

BREATHER PIPE

Step Parts to remove Remarks and procedures Fasteners

5 Stop switch

(Float C/U CP5)

6 Recoil starter Remove the recoil starter from the blower housing. 10 mm box spanner

7 Blower housing

Bafﬂ e 1 (case) Bafﬂ e 2 (head)

PURSE LOCK

Disconnect the wire and remove the stop switch from the blower housing.

(1)Remove the blower housing from the crankcase. (2)Remove the bafﬂ e 1 (case) and bafﬂ e 2 (head).

M4 x 12 TAPPING SCREW : 2 pcs.

STEP 5

STOP SWITCH (FLOAT C/U CP5)

M6 x 14 BOLT : 4 pcs.

M6 x 14mm : 4 pcs.

10 mm box spanner M6 x 14mm : 4 pcs. 10 mm box spanner or spanner M6 x 12mm : 1 pc. (Bafﬂ e 2 (head))

M6 x 14 BOLT&WASHER : 4 pcs.

STEP 6

M6 x 12 BOLT : 1 pc.

RECOIL STARTER

SPONGE 4

BLOWER HOUSING

STEP 7

BAFFLE 2 (HEAD)

- 14 -

Step Parts to remove Remarks and procedures Fasteners

8 Duct (case) Remove the Duct (case) from the crankcase. 10 mm box spanner

M6 x 12mm : 3 pcs

9 Exhaust pipe Remove the Exhaust pipe from the cylinder head.

Take care not to lose the gasket.

Take care not to cut your hand with the mufﬂ er

※

gasket.

Seal the exhaust port with adhesive tape or plug it

※

with cloth to prevent nuts and other objects from falling inside.

DUCT (CASE)

M6 x 12 BOLT : 3 pcs.

STEP 8

EXHAUST PIPE

12mm box spanner M8 nut : 4 pcs.

STEP 9

M8 NUT : 2 pcs.

GASKET EXHAUST

GASKET(MUFFLER) (It has two faces)

- 15 -

Step Parts to remove Remarks and procedures Fasteners

10 Governor system (1) Loosen the bolt and remove the governor lever

from the governor shaft. There is no need to

remove the bolt. (2) Remove the governor spring. (3) Remove the governor rod and the rod spring from

the carburetor.

11 Carburetor, Insulator (1) Remove the carburetor from the cylinder head.

(2) Remove the insulator.

12 Speed control lever and

Bracket

Remove the speed control lever and bracket from the cylinder head.

GOVERNOR SPRING

GOVERNOR ROD and ROD SPRING

STEP 10

GOVERNOR LEVER

M6 x 12 BOLT : 2 pcs.

14 mm spanner

10 mm box spanner M6 x 12mm : 2 pcs.

GOVERNOR SHAFT

GASKET

STEP 12

SPEED CONTROL LEVER and BRACKET

GASKET

CARBURETOR

INSULATOR

STEP 11

- 16 -

Step Parts to remove Remarks and procedures Fasteners

13 Ignition coil Remove the spark plug cap from the spark plug and

remove the ignition coil from the crankcase.

14 Starting pulley Wear work gloves during operation to avoid a possible

injury by a sharp edge. Remove the starting pulley from the ﬂ ywheel. Fit a box wrench or a socket wrench on the ﬂ ywheel nut and loosen the nut by knocking the wrench sharply with a hammer. (See Figure STEP14-A) NOTE:

1) Do not insert a screwdriver or other object between the ﬂ ywheel blades, otherwise the risk of damaging the blades might be occured.

2) Knock the wrench with a hammer in a counter clockwise direction.

15 Flywheel Remove the ﬂ ywheel from the crankshaft. Leave

the nut temporarily to prevent the ﬂ ywheel from dropping out. Fit the ﬂ ywheel puller as shown in Figure STEP15-A and remove the ﬂ ywheel from the crankshaft by rotating the bolt at the center in a clockwise direction. (Knock the center bolt with a hammer sometimes)

10 mm box spanner M6 x 25mm : 2 pcs.

24 mm box spanner or socket wrench M18 nut

Flywheel puller

STEP 15

FLYWHEEL

ATTACH NUT TEMPORARILY

FLYWHEEL PULLER

STEP14-A STEP15-A

STARTING PULLEY

M18 NUT : 1 pc.

STEP 14

M6 x 25 BOLT and WASHER : 2 pcs.

STEP 13

IGNITION COIL

- 17 -

Step Parts to remove Remarks and procedures Fasteners

16 Electric starter (option)

Control box, Diode rectiﬁ er, Magnetic switch

ELECTRIC STARTER (option)

STEP 16

(1) Disconnect the grounding cable from battery. (2) Disconnect the wire leading from the key switch

“ST” terminal to the magnetic switch.

(3) Disconnect the wire that connects the positive

terminal of the battery to the magnetic switch.

(4) Remove the electric starter.

M8 NUT : 1 pc.

M8 x 28 BOLT : 2 pcs.

12 mm box spanner M8 nuts 12 mm box spanner

- 18 -

Step Parts to remove Remarks and procedures Fasteners

17 Bafﬂ e 1 (case) Remove the bafﬂ e 1 (case) M8 x 12mm : 1 pc.

18 Charge coil (option) Remove the charge coil.

(Remove the wire clamp together)

19 Spark plug Remove the spark plug from the cylinder head. 21 mm plug wrench

M8 x 12 FLANGE BOLT : 1 pc.

For the model without electric starter.

box spanner M6 x 20mm : 2 pcs. + screwdriver

STEP 17

BAFFLE 1 (CASE)

STEP 18

CHARGE COIL (OPTION)

M6 x 20 SCREW & WASHER : 2 pcs.

- 19 -

SPARK PLUG

STEP 19

CLAMP

CHARGE COIL

VIEW A

Step Parts to remove Remarks and procedures Fasteners

20 Rocker cover (1) Remove the rocker cover from the cylinder head.

(2) Remove the gasket (rocker cover).

21 Rocker arm Remove the pin (rocker arm) and the rocker arm from

the cylinder head at the compression top dead center. (See Figure STEP21-A)

ROCKER ARM (EXHAUST VALVE SIDE)

PIN (ROCKER ARM)

ROCKER ARM (INTAKE VALVE SIDE)

The position of compression top dead center

10 mm box spanner M6 x 12mm : 4 pcs.

Punch marks

STEP21-A

STEP 21

ROCKER ARM (INTAKE VALVE SIDE)

CLOSE-UP A

GASKET (ROCKER COVER)

STEP 20

ROCKER ARM (EXHAUST VALVE SIDE)

PIN (ROCKER ARM)

- 20 -

ROCKER COVER

M6 x 12 BOLT : 4 pcs.

Step Parts to remove Remarks and procedures Fasteners

22 Main bearing cover Remove the ﬂ ange bolts of main bearing cover from the

crankcase. Remove the main bearing cover while tapping gently around the cover using a plastic hammer or similar tool. (See Figure STEP22-A) Be careful not to damage the oil gauge or oil seal or not to lose the pipe knocks.

STEP22-A

12 mm box spanner M8 × 35mm : 7 pcs.

M8 x 35mm : 7 pcs.

STEP 22

PIPE KNOCK

MAIN BEARING COVER

- 21 -

+ 54 hidden pages