Subaru Robin Power Products R600 User Manual

Model

.

CONTENTS

Section

SPECIFICATIONS ..........................................

1.

PERFORMANCE CURVES

2.

2-1 AC Output ..........................................

2-2 DC Output ..........................................

FEATURES ..............................................

3.

SERIAL and SPECIFICATION NUMBER LOCATION

4.

SAFETY PRECAUTIONS

5.

5-1 Fire Prevention .......................................

5-2 Precautions for Exhaust Gases.
5-3 Other Precautions

COMPONENT IDENTIFICATION

6.

FUNCTION OF EACH COMPONENT

7.

7-1
7-2

Generator ...........................................

Engine .............................................

Title

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

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

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

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

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

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

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

Page

1

2

2

3

5

6

7

7
7
7

8

11

11
12

DESCRIPTION OF MAIN COMPONENTS

8.

8-1

8-2

OPERATIONAL LIMITS OF THE GENERATOR.

9.

9-1

9-2
9-3
9-4

MEASURING PROCEDURES

10.

Electronic lgnition System
Generator Operation

AC Output ..........................................

DC Output ..........................................

Simultaneous Use the AC/DC Output

Wire Length. .........................................

10-1 Meters .............................................

10-2 Measuring AC Output
10-3 Measuring DC Output

10-4 Measuring Insulation Resistance . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

......................... 20

14

14
15

17

17
19

20

21

21
23
23
23

Section

Title

Page

11.

FUNCTIONAL CHECK OF EACH COMPONENT.. . . . . . . . . . . . . . . . . .

25

11-1 Control Panel

11-2 Stator.....

11-3 Rotor . . . . .

11-4

lgnition Coil
11-5 Condenser
11-6

Rectifier . .

. .

. . .

. . .

.
. .

. . .

.

. .

.

. .

.

.

. .

. . . .

. . .

. . . .

. . .
. . .

. . . .

. . . . .

. . . . . .

. . . .

. . .

......

......

......

......

. . . . .

. . .

25

. .

27

. . . 29

. .

29
. . 30
. . .

30

12.

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

12-1

Preparation and Precautrons

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

31

12-2 Special Tools for Disassembly and Assembly ....................

31

12-3 Disassembly Sequence ...................................

32

12-4 Assembly Procedure ....................................

38

12-5 Carburetor ..........................................

48

13.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

14.

CRITERIA TABLE FOR ADJUSTMENT . . . . . . . . . . . . . . . 68

15.

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

16.

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

16-1 Daily Checks and Maintenance (every 8 hours)

................... 72

16-2 Checks and Maintenance for Every 20 Hours

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

72

16-3 Checks and Maintenance for Every 50 Hours (every 10 days) ......... 72

16-4 Checks and Maintenance for Every 200 Hours (monthly) ............

73

16-5 Checks and Maintenance for Every 500 Hours (semi-annually) ........ 73

16-6 Checks and Maintenance for Every 1000 Hours (annually) ........... 73

16-7 When the Generator is not used for Prolonged Periods: ............. 73

1. SPECIFICATIONS

Model

R600

Engine:

i Type

Forced air-cooled, 4-stroke, side valve,

gas01 ine engine

L--

Displacement

78 cc (4.76 cu.in.1

Fuel tank capacity

2 lit. (0.53 U.S. gal.)

Oil pan capacity

350 cc (0.75 U.S. pints)

Ignition system

Solid state ignition

~~

Starting system

Recoil starter

Rated continuous

Approx. 4 hours (50 Hz)

operating hours Approx. 3.5 hours (60 Hz)

Generator:

Type

2-pole, revolving field type

Exciting system

Self-exciting

Voltage regulating
system

Condenser type

Maximum output 500 w 600 W

Rated output 400 w 500w

AC Frequency

50 Hz 60 Hz

AC Voltage

110, 220,230,24OV

110, 120,220v

DC output 12V - 100 W (8.3 A)

AC receptacle

Standard: 2 ea.

(special: 1 ea.)

DC terminal Two

Over current
protection

Circuit breaker

Frequency meter

Standard equipment

Pilot light

Standard equipment

Dimensions (L x W x H):

370 x 265 x 345 mm
(14.6 x 10.4 x 13.6 in.)

Dry weight

18.5 kg (40.7 Ibs)

-1-

2. PERFORMANCE

2-1 AC OUTPUT

Power Factor . . .

CURVES

1

.o

3

-t

w
3

a

I I I I 1

! 1 I 1 1

I ’

I I

!

1 OUTPUT’

i ,

I

FRECiENC

i/: ‘1 I

1

Y I

i 300

t

240

/ I

/ I I $

CURRENT IA) -

1

I

, ,

I

1 I 1 1 i

, OUTPUT

1.1 j 500

: :

50

i I I

I II

-i----l

49-

/‘\I

// FREQUENCY

400

t
I

I

/

I 1 a
I , :

I

/ I I !

300

260

I

/ : I I

Output Max.

............... 500W

Rated

............... 400W

Frequency.

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

50 Hz

Voltage.

.................. 220V

Output Max.

............... 500W

Rated

............... 400W

Frequency.

................ 50 Hz

Voltage

................... 230V. 240V

vi : I 1

0 0.5 1 1.5 2 2.5 0

CURRENT

(Al -

-2-

w

U

LL

-1

1

w

>

U

a

3

1

Output Max.

Rated

Frequency

Voltage

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

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

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

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

500W

400W

50 Hz

11OV

1

N

I

-

62

tI

3

61

U

w

U

60

LL

59

-1

1

>

w

120

17

110

a

I-

J

100

0

>

0

N

I

-

62

3

61

E

U

60

U

59

240

>

230

(3

a

220

5

210

0

>

CURRENT

1 2

CURRENT

(A)

3

(A)

-

4

-

600

500

400

1

I

3

300

3

0

I-

200

2

100

6

0

600

500

400

300

200

100

1

-

3

-

I-

2

I-

3

0

5

Output Max.

Rated
Frequency
Voltage

Output Max.

Frequency
Voltage.

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

Rated

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

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

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

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

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

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

600W
500W

60

1 1 OV

600W

............... 500W

60 HZ
220V

Hz

a

0.5

1

CURRENT

1.5

(A)

2

-

2.5

a

-4

-

52

51

50

49

0

1 2 3

CURRENT IA)

4 5

-

600

500

400 t

300 +

200 2

6

Output Max. ...............

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

Rated

Frequency .................

Voltage.

3

3

E

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

500W
400W
50 Hz

11OV

I I I I I

62
61
60
59

120
110
100

0

1 2 3

CURRENT IA)

4 5

-

FREQUENCY

r
I

1

400

300

200 ‘0

100

0

6

I

3

f
k

Output Max. ...............

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

Rated

Frequency .................

Voltage.

Output Max.

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

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

Rated ...............

Frequency
Voltage

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

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

600W

500W

60 HZ

11OV

600W

500W
60 Hz
220V

0 0.5

1 1.5

CURRENT (A)

2 2.5

-

-4-

3. FEATURES

l

Robin Exhaust Fan Cooling System for low body temperatures, low noise. longer engine life and reliable performance.

l

Large 78cc

4Stroke

Engine provides enough power for constant 500W (at 60 Hz) rated output.

l

Simple One-Touch Engine Control Switch with the engine and fuel on/off levers and choke all integrated into one

switch.

l

Easy and Reliable Starting with pointless ignition. This generator is also a brush-less type generator for maintenance-free
operation.

l

Simple Design for a clean appearance and easy maintenance.

l

Compact and Lightweight with an easy one-hand carrying handle grip. This generator also offers a high power-to-weight
ratio and economical operation.

l

Circuit Breaker Protection for safe operation. Replacement of fuses is not necessary in case of an overload.

l

Unique Dual Output Design so that two separate A.C. and D.C. electrical appliances can be used at the same time.

-5-

4. SERIAL and SPECIFICATION NUMBER LOCATION

The serial number is stamped on the crankcase at the opposite side of the carburetor.

The specification and specification number are shown on the nameplate located on the rear cover.

Always specify these numbers when inquiring about the e

oenerator or ordering parts in order to get correct parts and accurate

service.

SPECIFICATION

SPECIFICATION NUMBER

SERIAL NUMBER

Fig. 4-7

-6-

” - . . . - . . - -

5. SAFETY- PRECAUTIONS
51

1)

2)

3)

4)

5)

6)

7)

8)

5-2

1)

3

5-3

1)

2)

3)

4)

FIRE PREVENTION

Keep the generator away from combustible materials during operation. Take special precautions with flammable sub­stances.
Do not run the generator in a incline position or while it is slanted at an angle. Avoid moving the generator while it
is in operation to prevent the generator from falling over or leaking fuel.
Do not place a carton or similar object over the generator while the generator is running. If covered, cooling will be
diminished and cause the generator to overheat.
Operate the generator at least lm away from a building or wall.
Be sure to stop the engine before filling fuel into the fuel tank.
If fuel is filled while the engine is running, fuel vapors may rise from the fuel tank resulting in a potential fire hazard.
Fuel used in engine operation is very volatile and highly flammable. Take special precautions not to spill fuel when
filling the fuel tank. If fuel is spilt, wipe it off thoroughly and let dry before starting the engine.
Do not overfill the fuel tank and always be sure to fill iuel only up to the level specified at the fuel supply- port.
Do not smoke or use open flame when filling the fuel tank.

PRECAUTIONS for EXHAUST GASES

Avoid operating the generator in poorly ventilated locations such as an office, warehouse. narrow tunnel. well, hold.
tank. etc..

If the generator is run continuously in such poorly ventilated areas. the operator may suffer carbon mono­xide poisoning.
Always operate the generator with the exhaust port directed toward the open air or where good ventilation is assured.

OTHER PRECAUTtONS

To prevent electric shock. do not touch the generator with wet hands.

For example, when the generator is used to

drive a submersible pump, be sure to connect the earth cord of the generator to the earth cable of the pump.
Do not splash water over the generator during operation.

And also avoid operating the generator in the rain. If the
generator gets wet. it may fail to start or short-circuit. and the operator may possibly receive a severe electric shock.
Do not connect the generator to existing power lines which have been originally installed as the power supply system
of a building. If connected. the generator will burn out.
Avoid running the generator with its cover removed.

-7-

6. COMPONENT IDENTIFICATION

h’UFFLE9
C 0 V E F1

AlFl CLEALER

FUEL T.ANY

Fig. 6- 7

Al=

CLEdYER CO\.‘ER

GEZERATOS

RECOIL STIRTE?

Fig. 6-3

\*’ ” z

FLER C :O\.‘ER

/

Ffg. 6-4

-9-

SPARK PLUG

Fig. 6-5

CAPBLRETOR

#El3 PIPE

AIR \;E’JTl

Fig. 6-6

-

10-

7. FUNCTION of EACH COMPONENT

7-1 GENERATOR

7-1-1 STATOR

The stator consists of a laminated silicon steel sheet core,

a main coil and condenser coil which are wound in the core
slots.
AC and DC output are taken out from the main coil. (DC
output is taken out from the part of main coil which is in
the middle of the main coil.)
The condenser coil excites the stator field coil which
generates AC output in the main coil.

7-1-2 CONDENSER

REAR HOUSING

RECTIFIER

Fig. 7- 7

The condenser is mounted on the rear housing and is connected to the condenser coil which is wound in the stator. The
condenser coil magnetizes the rotor which increases the density of magnetic flux.

7-1-3 RECTIFIER

The rectifier is also mounted on the rear housing and it converts AC current output from the main coil to DC current. The
DC output from the diode of this rectifier is connected to the DC terminal.

7-1-4 ROTOR

The rotor consists of a lamination silicon steel sheet core
and field coil which is wound over the core.
DC current m the field coil magnetizes the steel sheet core.
Two permanent magnets are provided at 90 degrees from

the poles for the primary exciting action.
A securely mounted fan is pressure-fitted on the end of the
rotor shaft to cool the individual coils. iron cores. rectifier.
and other integral parts.
Cooling air from the fan is drawn in from the ventilation

vents in the rear housing. and is discharged from the ex-

haust port in the front housing.

Fig. 7-2

7-l-5 CONTROL PANEL

The panel on the front of the housing has a receptacle with

a ground terminal and AC output is taken out with a male

Plug.

The frequency meter is provided to see if the frequency of
generated power shows 50 Hz (or 60 Hz). DC output is

taken out from the red (positive. +) and black (.negative. -)
terminals.

-11-

Fig. 7-3

7-2 ENGINE

7-2-l CYLINDER and CRANKCASE

The cylinder and the crankcase of the engine are of an one-piece aluminum die-cast design. The cast iron cylinder liner is
cast-fitted inside the cylinder. Both the intake and exhaust ports are positioned at the lateral side of the cylinder and these
ports are formed by using a mold with die-cast cores. The crankcase has its joint face located on the generator side.

7-2-2 MAIN BEARING COVER
The

main bearing cover is aluminum die-cast and is mounted on the generator side. By removing the main bearing cover.

the interior of the engine can be inspected.

7-2-3 CRANKSHAFT

The crankshaft is constructed of forged carbon steel. The crankpin is induction-hardened and has a pressure-fitted crank
gear located on the generator side of the engine.

7-2-4 CONNECTING ROD and PISTON

The connecting rod is constructed of forged aluminum alloy with both the major and minor ends utilized as bearings.

The oil scraper and cap for the major end are cast together. The aluminum alloy casting piston has two compression rings

and one oil ring.

7-2-5 CAMSHAFT

The camshaft is constructed of special cast iron and has intake and exhaust valve drive cams. each of which engages with the
cam gear. An exclusive aluminum alloy is used on each end of the camshaft in the place of bearings.

7-2-6 VALVE ARRANGEMENT

The intake valve is installed at the oil port side and the exhaust valve at the generator side.

7-2-7 CYLINDER HEAD

The cylinder head is die-cast aluminum and has Ricardo type combustion chamber featuring greater volume capacity for
improved combustion efficiency. For easier spark plug maintenance. the cylinder head is positioned at an angle to allow
greater access.

7-2-8 GOVERNOR

The centrifugal weight type governor

ensures

constant engine speed, regardless of load fluctuations (the governor is mecha-

nically linked to the governor drive gear).

-12-

7-2-9 EXHAUST FAN COOLING SYSTEM

Instead of blowing outside air on the engine. the Exhaust Fan Cooling System of this generator intakes the cool air and
forces the hot air outside from one outlet.
This keeps the body temperature lower for greater safety and extends service life.

7-2-10 LUBRICATION SYSTEM

The moving and sliding parts inside the engine are lubricated with the oil scraper fitted on the connecting rod. As the
crankshaft rotates, the connecting rod moves up and down and the oil scraper moves in conjuction with the connecting rod
movements to scrape up oil in the crankcase and splash it over the surfaces of the moving and sliding parts.

7-2-l

1 IGNITION

A flywheeh’magneto ignition system is employed with the ignition timing set at 23” before top dead center. The magneto is

composed of the tl)wheel and ignition coil with the fll-wheel mounted on the rotor shaft. The ignition coil is fitted to the
front housing.

7-2-l 2 CARBURETOR

The horizontal suction type carburetor is adjusted so that the engine will provide excellent starting. good acceleration.
low fuel consumption. and superior output [for details concerning carburetor construction. see the paragraph dealing with
carburetor construction and disassembly/assembly (Page49)]

7-2-13 AIR CLEANER

The air cleaner is a semi-wet type and contains a sponge element.

- 13-

8. DESCRIPTION OF MAIN COMPONENTS OPERATION

8-1 ELECTRONIC IGNITION SYSTEM (Solid State Ignition System)

The electronic ignition system features a polver transistor as the current control element. Therefore. the ignition system is
an electronic contact point-free type that operates with the po\ver transistor impulses controlling the current. This system
also called TIC (transistor igniter circuit) is virtually free of ignition failure which generally results from contamination of
the contact points. a typical problem vvrth contact type ignition systems.
Because this ignition system has no contact points. it is not affected by moisture. oil. dust. or other contaminants. 4s a
result. this electronic ignition system ensures sure and positive ignition lvith reduced maintenance.
The TIC mechanism consists of a transistor-mcorporated ignition coil and a permanent magneto built-in flywheel which is
pressure-fitted on the rotor shaft of the generator.

I

//////

IGNITION COIL

IGNITION

TIMING

DETECTING
CIRCUIT

FLYWHEEL

COOLING FAN

PLUG

Fig. 8- 1

1) When the permanent magneto built-in flywheel starts rotating. power is generated in the primary coil of the ignition
coil and current tlows to the resistor @ _
From the resistor, current flows to the power transistor. RYth this current. the power transistor turns on. releasing

current I(@ Thrs stage corresponds to the closmg of contact points.

2) As the tlywheel comes to the point of ignition. the ignition timing detecting circuit is activated while the current @
is flowing through the circuit.
When the ignition timing detecting circuit is activated. the signal transmitter transistor actuates hzith current 8 flow­ing. \Vhen current ,$$ starts flovving.

current s flowing through the power transistor is cut quickly. As a result. high
voltage is produced in the secondary coil and this voltage is applied simultaneously to the spark plug which ignites for
ignition. This stage corresponds to the opening of contact points.

-14 -

c

.I

8-2

GENERATOR OPERATION

INITIAL EXCITATION
PERMANENT MAGNETO

FIELD COIL i

ROTOR

: I

RESIS

-----

DIODE

8-2-l

1)

GENERATION of NO-LOAD VOLTAGE

2)

3)

41

When the generator starts turning the permanent magneto built-in to the flywheel generates@ 1 to 2\’ of AC voltage

in the main coil and also generates 1 to 4 of AC voltage in the condenser coil.
The capacitor coil is connected to a capacitor so when a voltage is applied to the condenser coil. minimun current

@ flows in the condenser coil. At this time, minimum flus is produced. vvith which the magnetic force of the rotor’s
magnetic pole is intensified. When this magnetic force is intensified. the respective voltages in the main coil and
condenser coil rise. Current 1s flowing in the

condenser coil increases. with the magnetic tlux densit)- of the rotor’s
magnetic pole increasing further. Also. the main coil voltage and condenser coil voltage increases. These voltages
continue rising as this process is repeated.

As current flows in the condenser coil. the magnetic flux density changes. DC voltage is induced in the field coil when
the magnetic flus density varies. Successively. DC current is rectified bl the rectifiers connected to both ends of the
field coil. and DC current @ flows in the field circuit.

With this current. the rotor core is magnetized. allowing the
generator to output steady voltage.
When generator speed reaches 2000 to

2300 rpm (50 Hz specification) or 3000 to 3300 rpm (60 Hz specification). the
current in the condenser coil and field coil increases sudden&. This acts to stabilize the respective coil output voltages.
If generator speed further rises to the rated v-alue. the generator output voltage will reach the rated value.

STATOR

RECEPTACLE

MAIN COIL

CONDENSER

COIL

CONDENSER

L

------

A

Fig. 8-2

8-2-2 VOLTAGE FLUCTUATIONS UNDER LOAD

When load current -s flows from the electric equipment to the generator. the magnetic flux which is produced as current

.s flows in the main coil. this serves to increase current ‘$ flowing in the capacitor coil. With current @increased. the
magnetic flux density across the rotor core rises. As a result. the current flowing in the field coil increases, and the genera­tor output voltage is prevented from decreasing.

-15-

8-2-3 DC OUTPUT

DC output is taken out from the main coil and is fed to the
diode at which time the output undergoes full-wave recti­fication prior to being supplied to the load connected to
the generator. The diode rectifier works to allow the cur­rent to tlow in @ direction but does not allow the current
to flow in s direction as shown in Fig. S-3.

Fig. 84 shows the DC output circuit of the generator.
DC voltage is generated in the main coil; when the voltage
in A is higher than that in C. current !~flows in the direc­tion shown in the figure while no current flows between C
and B because current is cut off by the diode

D2.

Contraq
to the aforementioned, if the voltage in C is higher than that
in

A,

current a flows in the direction as sholvn in the
figure. with no current flowing between A and B. This is
because the diode

Dl

cuts off the current between A and

B.

As a result. voltage generated between the DC terminals has
a waveform with t\vo peaks in one cycle. as in the case of
the output waveform shown in Fig. 8-5.

BETWEEN A AND

B

BETWEEN C AND

B

=w=

MAIN B
COIL

Fig. 8-3

Dl

+

Fig. 8-4

OUTPUT WAVEFORM

CURRENT 0
FLOWING

CURRENT @
FLOWING

BETWEEN

BETWEEN

AAND

B

CAND

B

Fig. 8-5

- 16 -

9. OPERATIONAL LIMITS OF THE GENERATOR

9-1 AC OUTPUT:

Electric appliances normally have rating labels, showing the rated voltage. frequency. power

consumption (input power).
and other listings.
The input power specified on such labels is what is required to drive the appliance.
When an appliance is to be connected to the generator. the power factor. starting current. and other factors of the appli-

ance must be taken into account.

9-l-l NET RESISTANCE LOAD:

Incandescent lamps. electric heaters, etc.. can be run off the generator if its capacity matches the total of the respective

appliances. Each of these appliances normally have a power factor of 1 .O.

Example :

This generator can provide enough power to operate five 1OOW incandescent lamps.

9-l-2 ELECTRIC APPLIANCES WITH A POWER FACTOR LESS THAN 1.0:

Fluorescent lamps and mercury lamps normally have a low po\ver factor. Therefore. the generator is required to generate
approximately 1.2 to 2 times the power consumed by each load appliance.
Example: With this generator. three to five 8OW mercury lamps can be operated.

9-l-3 MOTOR LOAD:

Generally. motors require a large starting current every time they are started. Therefore. when the generator is

used

to run
a motor, the greatest motor starting load is applied.
The rates of power supply which the generator is required to produce for motor loads. are categorized into two sections.

depending on the types of motor and load conditions at time of starting.

1) Motors (mainly rectifier motors) used for electric drills and similar devices:
Sormally, the motors used for electric drills and similar appliances require the generator to produce approximateI>- I.1
to 3 times the power consumed at time of starting.
Example: To drive a 2OOW electric drill. a generator with capacity of about 300 to 600W is necessary.

2) Motors (mainly induction motors) used for pumps and compressors:
Pump and compressor drive motors require the generator to produce 3 to 5 times the power consumed when they are
running. at time of starting. This is because these motors have loads w-hen the>- start.
Example: To drive a 2OOW submersible pump. a generator with a capacity of approximately 600 to IOOOW is neces-

sary.

-17 -

9-l-4 IN THE SITUATION THAT POWER CONSUMPTION IS NOT SHOWN ON THE RATING PANEL:

Occasionally. the rating panel of an electric appliance does not carry its power consumption but only shows the mechanical
equivalent to the power consumption. In such a situation. it is necessary to calculate the power consumption of the device
involved. Depending on the types of load. the calculated power consumption is adjusted according to paragraphs 9-l-l
through 9-I-3 above.

(Power consumption) = (Mechanical equivalent of device) + (Efficiency)

Efficiency

Motors:

0.6 - 0.8

Fluorescent lamps: 0.7 - 0.8

Example :

A

4OW fluorescent

lamp with a lighting output of 40W and assuming that the power consumption of this lamp is

0.7, the power consumption is calculated as follows:
40 + 0.7 = 57W

Further, as per paragraph 9-l-2, the said power consumption is multiplied by a factor of 1.2 to 2. producing a
power consumption of 70 to 11 SW. Therefore. with this generator, four to seven 40W fluorescent lamps can be
used.

Example: In the case of a 2OOW motor. the mechanical equivalent of the motor is 200W. Assuming that the efficiency of

the motor is 0.7. the power consumption is calculated as 200 f 0.7 = 285W. Similar to the above, the calculated
power consumption is then multiplied as per paragraphs 3-1) or 3-2). taking into account the types of motor
and starting conditions. The table below shows the range of loads applicable to this generator.

Electric devices

Range of workable loads

50 Hz 60

Hz

I

Incandescent lamp, electric heater,

etc.

up to 4oow

up to 5oow

I

Fluorescent lamp, mercury lamp, etc. Up to approx. 300W Up to approx. 400W

I

Motor-driven tools etc.

I

Up to approx. 300W Up to approx. 350W

Pump and compressor drive motors

I Up to approx. 150W /

Up to approx. 200W

Table 9- 7

NOTE 7: With motor-driven tools and the motor-driven pumps and compressors specified in paragraphs 9-7-3

and 9-l-4, the generators of the said capacities are required only when starting the motors of the
respective appliance. Once the motor has started, the power which the generator is required to
supply to the motor decreases thereafter to a level approximately 1.2 to 2 times the rated power
consumption .

Therefore, the surplus capacity of the generator may be used for other electric appliances.

NOTE 2: As for the motor-driven devices specified in paragraph 9- 7-3 and 9-l -4, the power requirement for

starting varies according to the types of motor and the load conditions at time of starting.

-

18-

9-2 DC OUTPUT

When the generator is employed to recharge batteries. care must be exercised about the specific gravity of electrolk-te rn
each batter\. case.

9-2-l MEASURING THE SPECIFIC GRAVITY OF ELECTROLYTE:

The specific gravity changes with temperature; therefore. it is converted to another corresponding to 20°C.

S20

= St + 0.0007 (t - 10)

where

S~J = Specific gravity corresponding to 20°C
SI

= Measured value

t = Temperature at time of measurement

9-2-2 REMAINING CAPACITY ESTIMATED WITH REFERENCE TO THE SPECIFIC GRAVITY OF

ELECTROLYTE:

c

I

Specific gravity

Remaining battery

I

(20°C)

(%I

Remarks

1.260

100

1.240 87

I

I

Good charged condition

1.220

75

I

Charging is necessary.

1.200

1.180

1.160

1.140

62

50

,

Immediate charging

is

necessary.

37

25

Table 9-2

9-2-3 BATTERY CAPACITY:

The battery capacity is expressed in units of ampere-hour (AH). One AH stands for the capacity capable of providing one

ampere of current for one hour.

-19-

9-3 SIMULTANEOUS USE THE AC/DC OUTPUT

If you use the AC’DC output simultaneously in this generator, be careful not to exceed the total power consumption.

50 Hz

below 3OOW

60

Hz

below 3OOIV

NOTE: Max. output of DC is 1OOW /12V x 8.3A).

9-4 WIRE LENGTH

When long Lvires are used between the generator and a load, the resistance of each wire increases and a voltage drop occurs.
Consequently. the input voltage to the load declines and occasionall!- damages the load.
Exercise caution Lvhen deciding on wire length. For reference. the table below shows the voltage decreases that occur in

100 m (300 ftt) long wires with different cross sectional areas and varied resistances.

Cross

sectional

area

Allowable

current

No. of con-

ductorsl

conductor

Resistance Current

diameter

mm’

A

No./mm

,0,/l

OOm

1A ’ 3A 5A 8A ’ 10A 12A 15A

0.75

7

30/O. 18 2.477

2.5U 8U

12.5U - ‘- - ;-:
I

:

1.25 12 5OiO.18 1.486

l.5U 5u

7.5u l2U 15u

18U I -

, 8

t

2.0 17

3710.26

0,952 1u 3u

5U 8U

1 1ou

; l2U

15u 0”

8

3.5

23 4510.32 0.517 -

1.5U ’ 2.5U ’ 4U 5U 6.5U - 7.5U ; <
I

>

5.5 35 7OiO.32 0.332 -

1U 2U : 2.5U

3.5u ; 4u 5u

L I

Table 9-3

- 20 -

10. MEASURING PROCEDURES

AC VOLTMETER

DC VOLTMETER

10-l METERS

10-1-l VOLTMETERS

Both AC and DC voltmeters are nesessar! .
The approximate AC voltage ranges of the voltmeters to be
used for various types of generators are as follows:

0 to 1 SOV: Type with an output voltage of 110 or

12ov

0 to 300V: Type with an output voltage of 220.230

or 21OV

Fig. 70-l

10-l-2 AMMETER

Both AC and DC ammeters are necessary.
The AC ammeter must have a scale range from 0 to ap­proximately 10A.

AC AMMETER

DC AMMETER

The DC ammeter must have a scale range from 0 to ap-

proximately 15A.

Fig. 10-2

10-l-3 FREQUENCY METER

The frequency meter must have a scale range from 45 to ap-

proximately 65 Hz.

NOTE: Note the range of input voltage of the frequency
meter.

Fig. 70-3

-2l-

10-l-4 CIRCUIT TESTER

A circuit tester is used for measuring resistances and others.

Fig. 104

10-l-5 MEGGER TESTER

To measure the insulation resistance of the generator. Use
voltage capacity of 5OOV.

Fig. 10-5

10-l-6 TACHOMETER

Use the contact-less tl pe tachometer.

Fig. 10-6

- 22 -

10-2 MEASURING AC OUTPUT

SWlTFf; LOAj

TOACd+)@ km77

With the circuit shown in Fig.lO-7.measurement 1s made of the AC output of the generator. An electric heater or an in-

candescent lamp with a power factor of 1 .O is suitable as a load for the generator.
When the measured AC output of the generator is confirmed to be wnhin the voltage range specified in the table belon.
over its voltage rating. the AC output is normal.
Measurement must

be

made under rated load and at rated speed; sometimes. load and speed adjustments are necessary-.

Voltage

I

rating

11ou

12ou

220u

230,240U

Range of

voltage

108% 12OU

118- 130U 218 - 240U

235 - 260U

10-3 MEASURING DC OUTPUT

Table 10-l

SWITCH

DC TERMINAL

Fig. 10-8

Measurement is made of the DC output of the generator with the witch shown in the abobe circuit turned on while the
generator is kept running at its rated speed. The DC output should be aithin 1 1 to 14V. Lvith the current regulated

at

8.3A

by adjusting the load connected to the generator.

NOTE: If a battery is connected as a load to the generator, the DC output voltage will increase by approximately 1 to 2V.

Therefore, carefully observe the electrolyte level and do not to overcharge the battery.

IO-4 MEASURING INSULATION RESISTANCE

To measure insulation resistance. connect the megger tester
across either one of the two output terminals of the socket
and the earth terminal. When the measured insulation

resistance of the generator is over lMI2. it is normal (over

1OMR at time of shipment).
(Be sure to turn on the circuit breaker when measuring
insulation resistance.)
If the insulation resistance is less than 1X19. drsassemble
the generator. and measure the respective resistances of the

stator.

rotor and control panel.

Fig. 10-9

- 23 -

10-4-1 STATOR

Measure the resistances
the stator and the core.

betlveen red coupler leading from

Fig. lo-10

1 O-4-2 ROTOR

d

Measure the insulation resistance across one of the soldered
terminals of the rotor and the core.

Fig. 10-11

10-4-3 CONTROL PANEL

Measure the insulation resistances between the live parts

and the grounded part.
If the measured resistance of a component is below 1MR.
the insulation is defective.

Promptly replace the defective component because there

may be leakage of current from the generator and a poten-

_

tial danger of electrical shock.

Fig. 10-12

- 24 -

--

11. FUNCTIONAL CHECK of EACH COMPONENT

11-l CONTROL PANEL 11-l-l ENGINE SWITCH

Using the circuit tester. check continuity across the black
and green top terminals of the 6P coupler.
When continuity between the termmals is confirmed with
the engine switch turn2d off. the switch is normal. It is also
normal if there is no continuity between thrse terminals,
when the engine switch is set at RUN or CHOKE position.

Fig. 11-l

1 l-l-2 FREQUENCY METER

Also check with the circuit tester. th2 continuity across the
yellow and blue top tsrminals of the 6P coupler. If con­tinuity is confirmed between these terminals. the frequency

meter is normal.

Fig. 7 l-2

11-1-3 PILOT LIGHT

Using the circuit tester, check continuity between the red

and yellow top terminals of the 6P coupler.

Fig. 1 l-3

- 25 -

11-1-4 AC RECEPTACLES

Using the circuit tester. check continuity between the t\vo terminals at the rear of the XC receptacles while the receptacle is
mounted on the control panel. When continuity is confirmed between the output terminals of the receptacle Lvvlth a \vtre
connected across these terminals. the AC receptacle is normal. When the wire is removed and no continuity- is eonfirmed
between these terminals. the receptacles are also normal.

Fig. 7 7-4(A)

11-1-5 DC TERMINALS

Csmg the circuit tester. check continuity between the DC
terminals at the rear side of the control panel while they are
mounted on the panel.
Ben continuity- is confirmed bet\veen the DC terminals
Lvith a wire connected across these terminals. the DC
terminals are normal. When the wire is removed and no
continuity is <onfirmed between these terminals. the
terminals are also normal.

Fig. 1 l-4(81

Fig. 1 l-5

11-1-6 CIRCUIT BREAKER

Check continuity between each of two terminals at the rear of the circuit breaker while it is mounted on the control panel.
Normally. there is continuity between each of the two lvhen the circuit breaker is on while there is no continuiq when the
circuit breaker is

ofi.

16P coupler wiring]

DARK BLUE
YELLOW
RED
BLACK
BROWN

WHITE

Fig. 11-6

- 26 -

11-2 STATOR

Measure the resistance of each stator coil using the circuit tester.

Classified coil

I

Main coil : Condenser coil

I

!

I

I

Cord color of @

AC coil

For use with the I
frequency

meter /

DC coil : Condenser coil

Measurement
location

50Hz-110V

60Hz-110V

50Hz-120V

j

60Hz-120V

50 Hz - 220V

!

60

Hz - 220V

50

Hz - 230V

50

Hz - 240V

6P coupler j

3.4R ’

2.6

I

3.3 j

2.7 ’

13.9

11.4

15.2

15.2

I

6P coupler

0.2251

0.16

0.22
I

0.16 ,

0.22

0.16 ,

0.22

0.22

I

Rectifier 1

Between

connector j

connectors

I

1.1n I

8.9R : White/Green

I
:

0.9

7.6 White/Red

1.1

8.9 Brown
I

7.6 Blue

0.9

1
I

1.1

8.9 : Gray

0.9

i 7.6 Pink

1.1

8.9 i Orange

1.1 j

8.9 Orange

Table 11-l

(at 21cC)

NOTE: If the circuit tester is not sufficient/y accurate, it may not show the values given and may give erroneous readings.
Erroneous readings will also occur when there is a wide variation of resistance among coil windings or when measurement is

performed at ambient temperatures different from the values specified in the space directly upper the table.

[6P coupler wiring]

DARK BLUE
YELLOW
RED
BLACK
BROWN

- 27 -

FL?. 7 l-7

Fig. 1 l-8

Fi:g. 1 l-9

Fig. 11-10

-28

Table 1 l-2

Fig. 11-11

NOTE 1: Measure the resistance of each coil winding while the diode and each resistor are disconnected with the/r solder

removed.

NOTE 2: If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous read­mngs.
Erroneous -eadings will also occur when there is a wide variation of resrstance among coil windings or v/hen measurement
is performed at ambient temperatures different from the values specified in the space directly below the table.

11-4 IGNITION COIL

[APPROX 162:

Resistance value

0.61’1

7.52

I

Measurement location

B~tl::ee? The con-e and the gree? cord

Betkseen the grew cord and the high-ttvsor cord

Table 7 7 -3

- 29 -

11-5 CONDENSER

Measurement of capacity substitutes for checking the condenser. The capacity of the condenser cannot be measured by
using the circuit tester. Therefore. the generator is run with a new condenser to see whether or not the generator performs
normally. If the generator performs normall>-. the condenser is normal.

Reference: If an instrument ii available for measuring the capacity of the condenser, the total capacity range should be 70

to 7 7pF fat 20°C).

When the condenser displays its total capacity within this range, it is normal.

11-6 RECTIFIER

Using the circuit tester. measure the resistance between

each of the two terminals of the rectifier. The rectifier is

considered normal when the respective resistances have the

values specified below.

NOTE: Each of the given values changes with the polarity
of the circuit tester.

Green Red

White@ [

01

3 :...16RI

.160 1

@

#3

. .

\

Y

,

The polarity of the circuit tester

Table 7 l-4

-30-

-

*-

12. DISASSEMBLY and ASSEMBLY

12-1 PREPARATION and PRECAUTIONS

1) Be sure to remember the locations of individual parts when disassembling the generator so that the generator can be
reassembled correctly. Tie tags noted with the necessary information to facilitate easier and smoother reassembly.

2) For more convenience, divide the parts into several groups and store them in boxes.

3) To prevent bolts and nuts from being misplaced or installed incorrectly. place them temporarily back at their original
positions.

4) Handle disassembled parts with care; clean them before reassembly using a neutral cleansing fluid.

5)

Us2

all disassembly/assembly tools properly, and use the right tool for each specific job.

12-2 SPECIAL TOOLS for DISASSEMBLY and ASSEMBLY

-

Fig. 12- 1

b

\o

3

(D

No.

Tool No. ;

Name of tool

1

2309500107

Valve spring retainer

1

,

Description

For disassembling and assembling the intake

and exhaust valves

2

2309500207

Valve guide puller To pull out the valve guide

3

3589500107 :

Rotor puller To pull out the rotor

Table 12-l

-31-

12-3 DISASSEMBLY SEQUENCE

I

I

Sequence Part to remove I

Description

Precautions

Necessary tools

1

Side cover (Lj

(1 j Remove both the left and right

!

2 PlUj

screw-

and (Rj

co\-2rs. by taking out eight 31-C

driver

I

flang2 screws.

I

-I

Couplsrs (dis-

1 (1) Disconnect th2 (6Pj coupler

of

Pull them under

connection)

the generator from the other (6P) while pressing
extending from the control panel.

1 down the retainer

claws.

622

Fig. 1 Z-2.)

!

3 ’ Choke cab12

(1) Set the engine control to STOP.

rs Minus

I

and remove the screw from the

screw-driver

I

tip of the choke cable to dis­connect the choke cable from
the dial plate.

I

(2)

Disconnect the outer cable of the

1 1Omm box spanner

choke cable from the fuel tank

bracket.

(3) Loosen the M4 screw of the

!

carburetor choke lever swivel to

13 Plus screw-

driver

pull out the inner Loire from the

choke cable.

4

Fuel line

(1) Hold thz fuel line clamp inserted

/

Be careful not to

Pliers

inside the felt strainer using pliers,

’

and pull it backward to remove

damage the hose. :

the fu21 line from inside the

I

strainsr.

I

5

’ Fuel tank

handle

(1) Push up the end of the cover

I

fitted to the handle with finger.

r (2) Pull out the rubber tube use; as

the air vent pipe.

a (3) Remove two bolts (tank). and

1Omm box

remove the handle.

I

I

I spanner

Fig. 12-2

-32-

Sequence

Part to remove Description

Precautions Necessary tools

6

Rear cover

( 1) Remove the rear :over at the 1Omm box

opposing sid2 of the control spannsr
pan21 by unscrewing th2 four

I

$16 flange bolts.

7

Fuel tank (.I) Loosen the set screw of th2 ,z Plus screw-

strainer shaft at th2 rear of the driver
engine control switch.

(2)

Remove two M5 flange bolts

, (,See Fig. 1 Z-3.) !

1Omm box
clamping the front cover and spanner
tank bracket together. and tank
bracket together. and then
remove the fuel tank.

8

Front cover (.l j Rsmove two MS tlange bolts

1Omm box
clamping the front cover to

spanner
the basr to rrmove the front
cover.

,

9

Fuel hose

(1) Using pliers. hold the fuel line

Be careful not

Electricians’
clamp at the fuel support joint to damage the

I

of the carburetor (L-joint

’ fuel line.

! pliers

directed downward) to pull it
aside. Then. pull out the line.

10

Choke cable

(1 j Insert the tip of a screwdriver

(.tlat-headed type) in the groove
of the choke cable bracket pro­truding from the head cover.

3 Minus

screwdriver

11

I Muffler cover

(1) Remove the out2r cover; this is

Take care not to

and muffler

-3 Plus screw-

done by removing seven M5 drop the removed

driver

!

tapping screws.

screws down into

(2) R2move one M6 x 1’ flange the cooling air

! IOmm box

bolt of the muffler bracket. and

1 channel.

two M6 nuts from the muffler

spanner

’ (See Fig. 11.4.)

tlange. Then. remov2 th2 flange.

I

(3) Remove four 315 x 8 lock screws

from inside the muffler t I remove
the inner cover.

3 Minus screw-

driver

I

flUFFI

Fig. 123

Fig. 124

- 33 -

Sequence

1 Part to remove

Description

Precautions

Necessary tools

12

Bas2 platz

(1) Remove one set screw of the

T Plus screw-

earth wire which grounds the

; u

driver

rear housing and base

plate

I

togethsr (Zr)OV system onlv).

I

(2) Rsmove four 5115 x 10 bolts from

j

under the base plate.

Starter pullek

(1

13

Recoil starter

(1) Remove the recoil starter from

the rear housing. by removing
three 516 x 8 flange bolts.

j

Turn the starter pulley b]- hand
to set the piston to the compres­sion stroke limit (lvhere the pulle)
becomes heavy). Csing a hammer
strike the box wrench set ov2r the

I

head of the through bolt to remove

I

the bolt. Then remove the pulleb _

I

(See Fig. 12-S.)

(See Fig. 1 Z-6.)

Smm box spanner

1Omm box

spanner

1 ?mm box

spanner
Handle hammer

Fig. 12-5 Fig. 12-6

Sequence Part to remove

Description Precautions , Necessary tools

15

Stator assemblq- (1 j Remove three M6 x 85 bolts

clamping the rear housing of the
stator assembly. and the front
housing together.

(2j

Remove the stator assembly- from
the front housing. The stator and
rear housing are removed together
by using a plastic hammer to light11
strike the boss of the rzar housing.

(3)

Remove the lead from the clamp

I . .

b_~- taking out one M4 x 8 scre\v.

.

I

’ 1Omm box

spanner

Plastic hammer

(See Fig. 12-7.) j

3 Plus screw-

_ driver

1 (4) Kemove both the capacitor and

I

: Cd Plus screw-

I

diode from the rear housing by

driver
I removing three M5 x 30 scre\\s.
/ (5) Remove the wiring between the

stator and rear housing. Discon-

i

nest three terminals irom the

diode. t\vo terminals from the
capacitor. and the ground \vire
from the r2ar housing.

-34 -

Sequence

Part to remove

16

’ Rotor assembl)

Description

(1) Fit the rotor puller to th2 rotor

shaft. and drive it into place to

Precautions

! Necessary tools

’ Rotor puller

remove the rotor from the engine

shaft.

Plastic hammer

1; Plug cap (1 j Remove the plug cap from th2

spark plug in advance.

(3) Remove the clamp of the high-

voltage power cable.

18

Front housing
and center
baffle

(1 j Remove the front housing and 1 Omm box spanner

center baffle from the engine
main bearing. b) removmg thrze

I

j
M6 x Xmm bolts and one M5
x 55mm bolt. (See Fig. 11.8.) t

CENTER BAFFL

FRO

Fig. 12-7

Fig. 128

Sequence

Part to remove

Description

19

! ~

Air cleaner

(1) Remove the center screw of the

air cleaner cover to remove the
cleaner cover. filter element. and
element retainer.

(2) Remove the M5 screw at the lower

right inside the element chamber.

(3) Remove tvvo M6 flange nuts

clamping the air cleaner and the
carburetor together to remove the
air cleaner.

Precautions

Necessary tools

i?

;s Minus screw-

driver

A

\fi Plus screw-

driver

i 1Omm box

spanner

! (See Fig. 12-9.)

I

AIR CLEANER

ELEMENT & ELEMENT

*

RETAINER

ELEMEN/T

?

Al R ‘CLEANER

COVER

FIQ. 10-9

-35-

Sequence

20

Part to remove

Governor and
related parts

Description

(. 1) Remove the governor lever from

the governor shaft.

(~j

Remove the governor rod, rod
spring. and governor spring.

Precautions

/ Necessary tools
I

Loosen the bolt

1Omm box spanner
(unnecessary to
remove it)

‘1

Carburetor

(1 j Remove the carburetor from

the stud area of the intake side

flange of the crankcase.

I

7-3

--

Head cover , (1 j Remove two M5 screws from the

.B Plus screw-

lateral side of the head cover to driver

I

remove the head cover.

33

24

Qlinder baffle

(1 j Remove the M6 bolt from the

i 1Omm box

crankcase and the $15 bolt from

5 anner

the main bearing cover to remove

5

+ Plus screw-

!he cylinder baffle. driver

Spark plug

(1) Remove the spark plug from the

19mm box

cylinder head.

:

spanner

25

Cylinder head (1 j Remove sev2n M6 x 32 bolts to

remove the cl-linder head.

(3) Remove the head gasket.

; Mark the head

1Omm box

gasket with its

spanner
mounting position
accurately match­ing the cylinder
head, also mark
the gasket mount­ing face of the

, cylinder head.

i Intake valve

(1) Remove both the inner and outer

B2

sure to posi- t 1Omm box

tappet chamber covers from the

crankcase. by removing two Y6

tion the notch in spanner

x 1: bolts.

the spring retain-

: (3) Remove both the intake and

er’s outside peri­phery to the front

exhaust valves.

13 Minus screw-

and hook the

driver

(3) Remove the valve spring and

minus screw-

retainer.

I

i driver (medium

I

side) in the recess

/ (lower side) of

I

a the retainer.

I

Then pull the
spring retainer ’
backward to re­move it.

I@

1

RETAIN­ER

PULL BACK

(1) Remove the Woodruff key from

the crankshaft.

(2) Remove five M6 x 15 bolts locking

1 Omm box
the main bearing cover from the
crankcase.

spanner

’ Plastic hammer

(3) Using a plastic hammer or a

Be

careful not

similar tool. strike the mam

to damage the

bearing cover uniformly around

i lip of the oil seal.

its peripheq to remov-e the cover. ;

-36 -

Sequence Part to remove

Description

I

I

Precautions

Necessary tools

28 ’ Camshaft

(1) Pull out the camshaft from the

Set the crankcase

crankcase.

sideways so that

it will not fall
i and damage the
! tappets.

29 ; Tappets (1 j Remove the tappets from the

I

crankcase.

Be sure to mark

the tappets to
, distinguish them
; from each other;
i one for the intake
1 valve and the

other for the

exhaust valve.

30 Connecting rod ! (1) Scrape off the carbon deposits

i Confirm the 1 e Minus screw-

and piston from the cylinder and piston head. , mounting direc- i

driver

Push open the bend of the connect- tion of the oil

I
I

ing rod lock washer, and remove

two bolts.

scraper. Pliers

(2) Remove the lock washer and con- 1Omm box

netting rod cap from the crank-

spanner

shaft.

(3) Turn the crankshaft until the

piston comes to its top position.
and push the piston from the
upper part of the cylinder.

31

Piston and
piston rings

(1) Remove two clips from the piston

(1) Replace
pin and take out the piston pin. these clips
Remove the piston from the vvit h new
connecting rod. ones: do not

(2) Each of the piston rings can be reuse them.

removed from the piston by open­ing wide the ring joint.

: (2) Be careful

not to

I

1

damage the
minor rod ;
end.

I

(3) Be careful

not to open
the ring

joint exces-

sivelv .

32

Crankshaft (1 j Pull out the crankshaft from the

crankcase. If unable to pull it out
by hand, use a plastic hammer to
gently strike the main bearing

joint tace. and pull the crankshaft

pulled out.

33

Governor shaft

(1) Remove the clip of the governor

!

shaft. and pull out the governor

!

I

I

shaft from the crankcase.

I

I

-37-

12-4 ASSEMBLY PROCEDURE

0 Precautions in Assembly

1) Thoroughly clean each part. When cleaning. take special care for the piston. cylinder, crankshaft, connecting rod, and
bearings.

7) Be

sure to completely remove the carbon deposits on the cylinder head and piston head. Also, thoroughly clean and

remove carbon deposits from each piston ring groove.

3) Apply lubricating oil to the lip of each seal. Confirm that the lip of each oil seal is not damaged. If damaged, replace
with new one.

4)

Replace the gaskets and similar items with new ones; do not reuse old gaskets.

5) Replace the keys. pins, bolts, nuts. etc., with new ones if necessary.

6) Do not apply torque exceeding the specified value.

7) Apply lubricating oil to both moving and sliding parts when they are assembled.

8)

Prior to assembly, check the clearance of each part, and adjust it if necessary.

9) When each of the main components are assembled, turn it by hand to check for smoothness of rotation and unusual
noise.

l

Assembly Sequence and Precautions

12-4-l GOVERNOR SHAFT

Put the governor shaft into crankcase, then drive the clip into position to secure the governor shaft.

124-2 CRANKSHAFT

1) Insert the crankshaft into the ball bearings of the crankcase.

2)

Fig. 104-l shows the dimentional tolerance of the crankpin.

OUTSI DE

-DIAMETER

Fig. 72-10

-38-

l

Tolerances of Newly Installed Parts

Thrust directional tolerance between the cylinder and piston skirt

0.008L - 0.047L

I

I

Top ring

! 0.2L - 0.4L

Clearance of piston ring joint

Second ring 0.2L - 0.4L

’ Oil ring

! 0.05L - 0.25L 1

Spare rings

Top ring

0.09OL - 0.135L

Clearance between piston ring Second ring 1 0.06OL - 0.105L

I

Spare rings

Oil ring

O.OlOL-0.065L ,

Inside and

outslde diameter

Clearance between connecting clearance

0.037 L - 0.063L

rod major end and crankpin

I

Side clearance 0.1 L - 0.7L

Clearance between connecting rod minor end and piston pin

O.OlOL - 0.029L

Clearance between piston pin and piston pin hole

0.009T - 0.01 OL

L = Loose T = Tight

Table 12-2

NOTE: The clearance between the piston and cylinder is checked by measuring the clearance between the piston and
cylinder skirt.

124-3 PISTON and PISTON RINGS

1) If a ring expander is not available. set the ring joint at

OPEN ENDS OF
PISTON RINGS

the first land of the piston. as shown in Fig. 12-l 1 so
that the ring can be slided into its groove.

NOTE: Be careful not to twist or expand exces­sively each ring. The oil ring is fitted first on to the
piston, followed by the second ring and top ring-

The

top

and second rings must be fitted with their

marked sides kept upward.

Fig. 12-l 1

~j The connecting rod is joined to the piston by the piston pin.

NOTE: Before assembly, apply sufficient lubricating oil to the connecting rod minor end
NO JE: Be sure to fit the clips to both sides of the piston pin.

-39-

STD EQUIPMENT ! SPARE PARTS

- Top ring

’ Taper

\

Second ring

Taper

‘\

\

Oil ring

I

Fig. 72-72

Taper

I

. \ ‘,\

x.

Undercut :.

q \ . .

1244 INSTALLING THE CRANKCASE

1) The connecting rod is put into the cylinder while
holding it with the piston ring guide. as shown in Fig.

lo-13 (in the case that a piston ring guide is not
available, press rings inward with fingers and at the
same time. strike down the piston. using a wooden
block). The connecting rod must be mounted in
place with its @ and MA marks directed to the ball
bearing side of the crankcase.

NOTE: Apply a sufficient quantity of oil to the

piston rings, connecting rod surfaces, and cylinder.

NOTE: The top, second and oil rings are fitted to
the piston with their ring joints arranged 90’ off each

adjacent joint.

Fig. 72-73

12-4-5 INSTALLING THE CONNECTING ROD

MAJOR END CAP

1 j Manually turn the crankshaft until the piston reaches

top dead center. Gently strike down the piston head
until the connecting rod touches the crankpin to
install the connecting rod major end cap.

3) The cap is installed with the 011 scraper positioned
right-downward. (See Fig. 13-14.)

NOTE: Be sure to use a new lock washer; and care­fully bend the washer correctly.
NOTE: When the cap has been installed, turn the

crankshaft to see if the connecting rod moves smooth-

Iv.
NOTE: The correct torque for installing the connect-

ing rod major end cap is 60 to 80 kg-cm.
NOTE: See Table 72-2 for details regarding the

clearances between the piston, piston rings, and
connecting rod and their counterparts.

Fig. 72-74

OIL SCI

GUIDE

RAPER

-40-

12-4-6 INSTALLING THE TAPPETS and CAMSHAFT

Install the tappets. and then the camshaft.

NOTE: Align the timing mark at the base of the cam gear
with the timing mark of the crank gear. If the valve timing

is set incorrectly, the engine will not run or operate proper-

ly. (See Fig. 72-75.)
NOTE: If the intake and exhaust valves are installed in
reverse order, tappet clearance will be incorrect.

Fig. 72-75

12-4-7 INSTALLING THE MAIN BEARING COVER

Install the main bearing cover to the crankcase.

NOTE:

The governor gear is already mounted to the bearing cover; therefore, it is necessary to confirm that the governor

gear is meshed with the cam gear. (See Fig. 72-76.)

If the oil seal requires replacement, pressure-fit the new oil seal in position before installing the main bearing cover.

NOTE: Prior to installation, apply oil to the bearing and oil seal.

Apply a small amount of oil to the cover fitting face,

as specified, in preparation for installing the bearing cover packing.

Place the oil seal guide over the crankshaft so that the

oil sea7 lip will not be damaged during installation.

Make sure that the side clearance of the crankshaft is within 0 to 0.2mm.

If necessary, adjust the clearance, using the adjusting collar.

(see Fig. 72- 7 7.)

NOTE:

Torque for the main bearing cover: 80 - 7 00 kg-cm.

MAIN BEARING COVER.

fY;ie;

GOVERNOR GEAR

‘-

Fig. 72-77

-41 -

*Shown in Fig. 12-18. is the method to measure the side
clearance of the crankshaft. According to this method,
measure the clearance between the machined face of the
crankcase and the adjusting collar. The machined face of
the crankcase is mounted with packing so it is necessary to
set the clearance properly by allowing for a packing thick­ness of O.??mm. -I

M6 x 25mm bolt . . . . . . . . . 8 PCS.

M6 x 55mm bolt . . . . . . . . . 1 pc.

Fig. 72-78

12-4-8 INSTALLING THE INTAKE and EXHAUST VALVES

Prior to installing. remove carbon and gum deposits, from the valve, valve seat, intake and exhaust ports, and valve guide.

NOTE: If the valve face is worn, replace the valve with a new one.

NOTE: If the clearance between the valve guide and valve stem is excessively large, replace the valve guide with a new one.

Replace the valve guide by using a pull block and pull bolt as shown in Fig.

72-20.

A

VALVE FACE

VALVE SEAT

- VALVE STEM

VALVE GUIDE

VALVE SPRING

E GUIDE

PULLER

Fig. 72-79

‘VALVE RETAINER

A:

Valve

face angle

B: Valve seat angle

C: Valve guide inside diameter

D: Valve stem outside diameter

Intake valve

Exhaust valve

Fig. 72-20

45”
45O

I

5 59 +0.018

I

0

I

-0.020

I

5’59 -0.032

I

-0.056

5.5@ -0.074

Clearance (clearance between C and D)
between valve guide and valve stem

Intake valve

0.02OL - 0.05OL

Exhaust valve

0.056L - 0.072L

Table 72-3

L: LOOSE

-42-

12-4-9 TAPPET ADJUSTMENT
Set

the tappet at

1112

loa-est position to depress the valve. Then measure the clearance

between

the valve and tappet stem.

using a clearance gauge inserted into the clearance. (See Fig. 12-21.)

NOTE: As with the intake and exhaust valves, the clearance between the valve and tappet stem must be within 0.1 f. 0.02.

INTAKE & EXHAUST VALVE

VALVE SPRING

NCE GAUGE

Fig. 12-27

Fig. 12-22

NOTE: If the clearance is smaller than that specified, slightly grind down the valve stem end using a grinder, then measure
the clearance.
If the clearance is larger than that specified, replace the valve with a new one.

Spot the valve seat and use some compound
to adjust the clearance.
NOTE: After completing adjustment of tapper clearance, install the valve spring retainers, and then recheck the tappet
clearance.

*Installing the valve spring retainer:
Using the special tool. place the retainer over the valve stem
with the notch in the outside periphery of the retainer kept
toward the front.

@

1

FRONT

12-4-10 INSTALLING THE CYLINDER HEAD

Fig. 12-23

Before reinstalling the cylinder head.

be

sure to remove carbon deposits from the combustion chamber. and clean between

the cooling fins. Also check the cylinder head for levelness.

NOTE: Replace the cylinder head gasket with a new one.

The cylinder head is installed using seven 516 x 32mm bolts.

NOTE: Torque for each cylinder head lock bolt: 90 - 7 70 kg-cm

12-4-11 INSTALLING THE SPARK PLUG

Torque for spark plug: 120 - 130 kg-cm

12-4-12 INSTALLING THE CYLINDER BAFFLE

The

cylinder baffle is installed to the crankcase, using the M6 x 20mm screw and to the main bearing cover. using the M5

x 1Omm screw.

The cylinder baftle and

fuel

line clamp are installed. together to the crankcase.

-43 -

12-4-13 INSTALLING THE HEAD COVER

The head cover is installed over each of the left and right parts of the c>-linder head. using the 345 x 1Omm screws.

124-14 INSTALLING THE GOVERNOR and RELATED PARTS

Model EYOSD has a centrifugal iveight type governor which is installed while engaged with the governor gear. With the
governor. the throttle valve of the carburetor is controlled automatically by using a lever link mechanism. Therefore. engine
speed is constantlq- maintained even under load variations.

1)
‘j

3)

Using two $16 x 1Omm bolts. install the speed control assembly to the crankcase.
Temporarily install the carburetor with two h-16 tlange nuts.

4)

5)

6)

Join the throttle lever of the carburetor to the gover­nor rod and rod spring.
Insert the governor lever into the governor shaft.
Insert a minus screwdriver into the groove of the
governor shaft. and turn the screwdriver fully in the
counterclockwise direction. Push the governor lever
clockwise (at this time. the throttle valve is fully
opened) and fasten the governor lever with the lock

bolt.

Torque for the governor lever: 70 - 90 kg-cm

Link the governor lever and speed controller with the
governor spring. one end of which is inserted into the
center hole (of the three) of the governor lever and

Fig. 12-24

IING

the remaining end inserted into the hole of the speed controller.

Fig. 12-25

Fig. 12-26

12-4-15 INSTALLING THE CARBURETOR and AIR CLEANER

Place the carburetor gasket. insulator. gasket. and carburetor in the correct positions. Kest. fit the air cleaner gasket and air

cleaner case. and install them. using the hi6 flange nut and 315 x 1Omm screw. Set the element (small type). element re­tainer. element. and cleaner cover. and tighten them with screws (slot head tk-pej.

Torque for installing the carburetor and air cleaner:

50 - 60 kg-cm

NOTE: See page lo-26 for details concerning disassembly and assembly of the carburetor.

-44 -

.

*.

124-16 INSTALLING THE CENTER BAFFLE and FRONT HOUSING

1 j Set the knock hole of the front housing to the knock of the main bearing cover and assemble them together. During

assembly. place the center baffle between the main bearing cover and front housing.
Torque for the front housing: 80 - 100 kg-cm

12-4-17 INSTALLING THE IGNITION COIL

1) Install the ignition coil and grommet (IG-COIL) to the front housing. Simultaneousl>-. temporarily set the generator
rotor in position.

-4nd assemble the ignition co11 and magnet together while adjusting the air gap between the two to

0.4 to 0.5 mm.
Firmly bond the grommet to the front ensuring that there is no residual clearance.

(use

CEMEDINE 575).

2) Fit the plug cap on the spark plug.

124-18 INSTALLING THE ROTOR ASSEMBLY

Install the rotor assembly to the taper of the crankshaft with their keyways in line.

NOTE: Thoroughly clean the tapers (both male and female tapers) of oily substances.

12-4-19 INSTALLING THE STATOR ASSEMBLY

1) Install the stator correctly into the recess of the rear housing. Sate the leads and their positions.

2) Install the wiring between the stator and rear housing.
Connect the wires from the stator IO the capacitor
(with these wires joined to two black top terminals).
Also connect the wires from the stator to the rectifier
(with these wires joined to three terminals).

GREEN RED

:EJ

Connect the ground cord to the rear housing. using

Refer to paragraph 9-2 for @.

one M6 x 8mm screw.
Install the stator assembly correctly into the recess of the front housing.

If necessary, softly strike the rear housing
with a plastic hammer (be careful not to strike the capacitor and diode).
Fasten the front housing to the rear housing of the stator assembly. using three M6 bolts, while the three bosses of the

front housing are set to their counterparts of the rear housing.
Torque for each bolt: 65 2 10 kg-cm
Clamp the lead of the 6P x coupler and the lead from the ignition coil to the bolts specified in paragraph d above.

using the wire bands.

124-20 INSTALLING RUBBER MOUNT (A)

1) Fit rubber mount (Aj to the bosses (two) at the lower center of the crankcase.

2) Also fit another rubber mount (A) to the bosses at the lower part of the stator assembly of the generator.

124-21 INSTALLING THE STARTER PULLEY

Install the starter pulle) to the rotor shaft using the rotor through bolt.
Torque for the through bolt: 100 - 150 kg-cm

124-22 INSTALLING THE RECOIL STARTER

Install the recoil starter to the rear housing using the M6 flange bolt.

-45-

12-4-23 RUBBER TUBES for USE as AIR VENTS

Connect two rubber tubes to the air vent connectors of the carburetor. Keep theje rubber tubes suspended downward from

the air vent connectors.

12-4-24 INSTALLING THE BASE FRAME

1)

Install the base frame with its rear side facing the
welded nut area of rubber mount (A). Match the
rubber mount (A) which is fitted to the lower part of
the engine and generator. Base frame is installed
using four MZ bolts.

3)

Insert each rubber tube from the air vent connector
of the carburetor into the hole in the base frame.

3)

Fasten the ground terminal of the ZOOV power
system to the rear housing using the $16 bolt.

-/

EASE PLATE

12-4-25 INSTALLING THE MUFFLER and MUFFLER COVER

Fig. 12-27

1) Fit the gasket (for the muffler cover) to the studs of the exhaust flange of the crankcase.

3) Using the 545 scre\vs, install the muffler cover in place.

NOTE: Be careful not to drop the screws into the cooling air channel.

3) Set the gasket (for the exhaust port) on the studs of the exhaust port flange. Then, mount the asbestos sheets to the
upper and lateral sides of the muffler. The muffler is installed while secured to the muffler flange using two M6 nuts,
and also to the muffler bracket by using one M6 bolt.

4)

Install the outer muffler cover place using seven MS tapping screws.
Torque: 70 - 90 kg-cm

124-26 INSTALLING THE CHOKE CABLE

1) insert the inner wire of the choke cable into the swivel of the choke lever.

2) Insert the outer 2nd of the choke cable into the wire bracket of the head cover; temporarily tighten the outer end so
that it will not slip out of the uzir2 bracket.

NOTE: The inner wire is installed later. Leave it loose in the swivel.

12-4-27 INSTALLING THE FUEL LINE

1) Connect the fuel line to the line connector at the fuel supply port of the carburetor. Then. fasten the line so that it
will not come

oii

the line c’onn2ctor.

2) Secure the

fuel

line with the clamp of the cylinder baffle.

124-28 INSTALLING THE FRONT COVER

Using two h16 x 8mm flange bolts. install the front cover installed with the control pan21 to the base plate. Keep the engine
switch set at STOP.

12-4-29 INSTALLING THE FUEL TANK

1 j Keep the strainer shaft at the lower part of th2 fuel tank m a position that will allow the setscrews to be tightened

from the opposite direction of the muffler.

2) Insert the flexible shaft extendmg from the rear side of the engine switch which is mounted on the control panel into
the square hole of thr strainer shaft.

-46-

3) Align the mounting holes at the lateral side of the front cover with those in the bracket which are bolted to the fuel
tank. Then. install the fuel tank. using t\vo $16 x Emm flange bolts.

4) hlake sure that the flexible shait on the control dial side is inserted in the square hole of the strainer shaft. then fasten
the flexible shait .

124-30 INSTALLING THE REAR COVER

Align the mounting holes at the lateral side of the rear co\-er urth those in the

fuel

tank bracket. Then install the rear cover-.

using two 516 x gmm Slang2 bolts.

Also align the holes at the lolver part of the rear cover s-ith those in the base plate. and

install the rear co\-er by two M6 x Smm flange bolts.

124-31 INSTALLING THE FUEL TANK HANDLE

1) Set the bolt (to secure the tank handle) in the handle and assemble the O-ring to this bolt from the opposite side.
Then. tighten the bolt to install the handle to the

fuel

tank.

NOTE:

Be sure to direct the less slanted part of the handle toward the front cover.

2) Insert the rubber tube end over the protrusion oi the bolt (for the

15121

tank)

and push it

down to the base of the pro-

trusion.

NOTE:

Be sure to keep the air bleed hole at the center of the rubber tube directed upward.

3) Place the handle cover over the handle.

12-4-32 INSTALLING THE FUEL LINE

Insert the fuel line end over the fuel strainer joint (be sure to push the line end down to the joint base). and secure it with
the clamp.

12-4-33 INSTALLING THE CHOKE CABLE

1 j Insert the choke cable adjusting screw in its hole on the fuel tank bracket.

2) Secure this adjusting screw with the M6 nut and tighten to the midway point of the threaded part.

3) Set the dial of the control panel to STOP. and connect the locknut of the choke cable end to the panel.

4) Pull the inner wire of the choke cable to clamp the wire to the choke lever. using the setscrew.

124-34 CONNECTING THE COUPLERS TOGETHER

Connect the coupler (6Pj from the generator to the coupler (6P) extending from the control panel.

Also connect the stop wire (green) as required.

12-435 INSTALLING THE LEFT and RIGHT SIDE COVERS

Using the MS flange screlvs. install the left and right side covers in place.

-47-

12-5 CABURETOR

12-5-1 FUNCTION

and

COMPONENTS (See

Fig. 12-28)

1) Float system

The

float chamber is located direct& under the carburetor. Flat and needle valves. maintain a constant

id

level

inside the float chamber.
The fuel in the tank tlo\vs into the float chamber from the needle valve. When a certain quantity of fuel enters the
chamber. the float rises. When the buoyax)-

oi

the flat \-alve balances with the fuel in-flow pressure of the needle

valves. the valves close to keep the fuel at the correct level.

Schematic diagram of the fuel system

CHOKE -

BY PASS;

THROTTLE

r VALVE

,-PILOT OUTLET

PILOT AIR JET

PILOT JETJ’

MAIN AIR JET?

FLOAT

L-d

.“.- MAIN NEEDLE

/.-NEEDLE VALVE

FLOAT i ‘MAIN JET

Fig. 72-28

-48-

2) Pilot jet nozzle system
The pilot jet nozzle system controls the fuel supply for engine speeds ranging from idle to low-speed running. The

sytem operatzs with the

fuel

flowng through the main jet nozzle and up to the pilot jet nozzle where the tuel is

measured. When the fuel is mixed with air. the volume of the air-me1 mixture is also measurzd by the pilot air jet.

From this stage. the mixture is supphed to the engine t‘rom the pilot outlet and bb-pass. During idle.

fuel

is supplied

mainly from the pilot

outlet.

3) Main

jet

nozzle system

The main jet nozzle system supplies

fuel

for middle and high speed operation. The fuel flows to the main jet nozzle
where the fuel quantit) is measured. and then flows to the main nozzle. Air volume. which is measured by the main
air jet ~ enters from the bleed hole of the main nozzle and miszs with fuel to form a gas mist.

The gas mist flows out of the main bore and is again mixed with air from the air cleaner. From this stage. the correct

air-fu21 mixture is supplied to the engine.

4)

Choke
The choke helps in starting the engine in cold weather.

When the engine is started with the choke valve closed. negative pressure applied to the main nozzle rises. allowing
most of fuel to flow through the main nozzle.

-4 mixture with a high gasoline concentration is fed to the engine resulting in easier engine starting.

12-5-2 DISASSEMBLY and ASSEMBLY of CARBURETOR

The most common trouble with the carburstor is failure to provide the correct air-fuel mixture. This is generally caused bl­blockage in the air and fuel channels. at other times it is caused by fuel level fluctuations in the float chamber. In order to
maintain the carburetor in normal operating condition. it is vital that the air and t‘uel channels be kept clean. The following

descriptions are the procedures for carburetor disassembly and assembly. (See Fig. 12-19.)

1) Throttle mechanism
a) Remove Philips-head screw (77): throttle valve

(~8),

and pull out the throttle shaft (39).

b) When removing the throttle stop screw. a spring (3 1 j will also come off. Be careful when handling the throttle

valve to prevent the valve edge from damage.

2) Choke
a) Remove Philips-head screw (12). choke valve (23). and pull out choke shaft (24’).
b) Be sure to keep the notch of the choke valve positioned forward the main air jet side when the choke shaft is

installed.

3) Pilot jet nozzle
a) Remove pilot jet nozzle (?I ). When removin,.

0 use a proper tool so that the nozzle will not be damaged.

b) Firmly secure the jet nozzle when the carburetor is assembled. Otherwise, fuel will leak from the nozzle and

cause engine trouble.

4) Main

jet

nozzle
a) Remove bolt (15). and float chamber bodl- ( 13).
b) Remove main jet nozzle ( 19) from carburetor bodk (9j.
c) Firmly secure the main jet nozzle when assembling. Othzrwise. air-fuel mixture will become excessiveIF rich and

the engine will not operate properly.

d) Torque for bolt (15) is 70 kg-cm.

-49-

5) Float system
Pull out tloat pin (13) and remove float (I 1 j and needle valve

(,30).

* Avoid using a drill or a wire to clean the fuel passages (they map damage the orifice of the pilot and main jet

nozzles’). Use compressed air.

* The float pin is peen-secured to the carburetor body; the needle valve and float can be removed out from the op-

posite side of the peen-secured part b>- lightly striking the float pin with a thin bar-like object.

27

/

28

24

1'

Fig. 72-29

- 50 -

13. TROUBLESHOOTING DIAG: DIAGNOSIS

8

DIAGNOSIS BY THE CUSTOMER

0

DIAG. 01

Engine fails to start.

?-

-)

DIAG. 02

Electricity not generated.

If the generator doesn’t perform properI>- or fails to run after troubleshooring. ask a qualified service dealer to
check it.

n

DIAGNOSIS BY THE SHOP

A. Fails to start

3) DIAG.

11

4) DIAG.

1:

5) DIAG.

13

6) DIAG.

14

7) DIAG.

15

8) DIAG.

16

9)

DIAG. 1’

10) DIAG.

18

11) DIAG.

19

12) DIAG.

20

13) DIAG.

21

B. Engine defective

14)

DIAG. 3 I

15) DIAG.

32

16) DIAG.

33

17) DIAG.

34

18) DIAG.

35

C. Control Panel

19) DJAG.

36

20) DIAG.

37

The fuel tank is emptk­Contaminated by water or dirt

Spark is weak of wire harness
Spark is strong of wire harnzss
Compression is insufficient

Compression is nonexistent
Cloggsd fuel pipe
The fuel doesn’t enter into the carburetor (No flow from the pipe)
The fuel doesn‘t enter into the float chamber (Flow from the pipe)
The fuel doesn’t enter into the combustion chamber (Fuel exists in the float)
Carburetor flooded

Excessive noise (Improper maintenance) . . . . . Check oil element

Oil consumption increases (gets thin)

Excessive noise occurs and engine suddenly stops
Black exhaust fumes (Excessively large fuel consumption)
White fumes produced (Excessively large lubricating oil consumption)

Pilot light fails to light up
The frequency meter fails to show any reading, with the needle resting at zero

D. Engine operates but voltage is not normal

21) DIAG. 41

No AC voltage is output (Resistance load)

23) DIAG. 41

No DC voltage is output (Resistance load)

23) DIAG. 43

No DC voltage is output

14)

DIAG. 44

The DC output voltage is only 50% of the rated value

25) DIAG. 45

130% higher or more DC is output

26)

DIAG. 46

So AC voltage is generated

27) DIAG. 3:

AC output voltage is onl! 20% of the rated value

E. Power lacking and performance poor

28)

DIAG. 5 1

Poor operating condition

29) DIAG. 52

Engine speed does not increase

30)

DIAG. 53

Knocking. engine overheats

31)

DIAG. 54

Failure to generate output. no compression

32)

DIAG. 55

Poor performance (Backfire)

33)

DIAG. -6

Misfire or combustion outside the combustion chamber

-51 -

DIAG.

12

I

1

DIAG.

13

Engine

fails

to

stllrt

Check spat k

Engine fails

to

St;lrt

Check fuel

quality

Engine fails

lo

start
Check fuel
quentity

Spark is

too

weak

of

wire

harness

L1

Parts

I

Fuel tank
Fuel strainer

I

Plug cap

0

Spark plug

L

Rotor

High voltage
code

Coil is

shorted or
wire broken

I

High voltage
code and
conlacl
trouble

Coil

is
shorted or
wire broken

Air gap is

too

wide

Weak
magnet

I

Check

r"

1

v:

Check the air

ga

P

Searcher

Measure the
coil

resist­ance
Circuit tester

Items

to

check and
procedurc

Without

special equip-

ment,

it

doesn't work

Check

I

Check

Clean plug

lz:

cr

I

1

No

fuel

r-

I

=a:

Wire

broken

on:

Sl1ort

Standard

first

:

0.6

1

S2

second

:

7.5

ki2

I

r::1

Air gap

is

too

wide

Standard is

0.4-0.5

Plug cap
cot1tact
defective

Moisture

or

dust exists

Dirt present
Insulation

troublc

Checking
criteria

Weak

magnet

L

I

r-

Remedies

I

Fill

with fuel

El

Replace

Adjust and
reform

Replace the

rotor

Repair

or

replace

Replace fuel

Repair

or

replace

Clean

or

teplacc

--- -.

Sym(~lollls

_. . .-

P0ssil1lc

CilllSCS

___-. -_.

SI icky

I

8

I

_--.. I ,.

(Ilwck lllc

I

gaskcl

(‘heck

-r

- ] . .

--. .---

Lhlllil#Xi

gasket

OI

ovcrst poke

rmgc

-- 1

Mcasurc
dcglcc 111

lcvcl11css

. -_-

I -_ - ..-

Not level

Grmcl lhc

end ol' lhc

wlve

;1nd

F

atljllsl IllC

iappct Spa""

_ ..-_-

-. --

J

Ilclns 10

check and
proccdllt c

Oil

VillVe

SlClIl ilrld

n1ove
sm00111ly

(‘heck

-r

--

..,

I

.-

-. .I..

1

(‘I~ill~ltlCC
Narrow . . .

I.~iltljllSl

Wide . . .

WplilCe

Not SCCUI cd
lighlly
Gasket tlefec-

Over

Ilie

sclvicc liiiiil

(‘hccking
critcliil

._ . _.

ovet the

service liillil

SI Icky

I ivc

I- --

1

---.-

r

-.. -_ ,, .-

DIAC. 18 -1

-71

Ll

Syrnplorns

. .--

-- -,.

T I

PiIrIS

- .-

t-

-_ .- -

-I

No I’ucl t’lows OUI

CVCII wlwn

Ill0

I’IICI

t-tiigitic I’uils IO ~1211

pipe is diswrinccl-

Pucl

tlow II01 ClllCl

irllo llic ~;II~~III~~~I

cd' flOll1 the

c;lrhrelor

L-

?

-.,-

-I

-.. - - -,,..-

I 1

Fuel I’illcr

- --_ - -

L

--_ -_

Dcl’cclivc I’ucl

r 1

I’il~Cl

.--. --_ 1 --- --

.-- _

..- --- .-.

--.
i

--. --. -

- -1 . ._

Fuel sl rnincr :IWI
I’illcr

..- .__ --

- -.- L

-.,

The air hlectl is

cloggc1l

--.
1

..-

I

_-- -

I-...

r 1

Fuci slrniticr

_-.

I

-_-. -.

Fuel pipe

L _

-I

-.

-

-. ..- _

AlXllllllllilll1~l1 01’

ail

----.
I- -

-

-

1. --_

l’lic air bleed is

L I

clogged

1

..- ,-.- -..

-. -.

Possible

I

CiIIISCS

-.

_. ..-_ L- .-

(‘heck

-. .­T- -

1

Chock IIN bolt 01

nihher pipe iri the
Ilanlllc

EXAM 3 I

Items IO

cllcck atld

[“‘occtlllrc

--

-. .-

Clhccking

crilerh

-_-- .-

Clwck

(‘llcck

-_. -1... ,-.-- -

-- _I _--.- .-

Air buhhlc exisls

- -. 7 -‘-

. -.._

I-- -

The ;lir tdcccl is
clogged

l)c~cclivc I’iiel I’illc~

Closed posilion

. . I -

L

__ .A--.

-,

Vent lllc

ilir

1

- L__ . ..- .- ._

1

(‘lci~r, llw I’illcl

Cl~lllCl~l OI’ lCi7lilW

IIIC

SllilillCl

L.. . ., _ ---

..A &..-,- .-.. .- .- --. A

r

.-. .- L-

VICi#Il

or

ICplilCe

1

I

Sel in lhe closed

posil ion

I

L

-- --._.

J

rl

Syl~lploms

-

(‘twk

(Tly lo 111ovc)

-._
I

--.

(‘heck

__ 1 ,_-. .,-

--.I.---

Measure the

tloar hcighl.
The stmit’i­cnt ion is IS 3

111111 t’l0111
body

(‘tlcck

-.

-.

.

.

!I

Synlplollls

Excessive noise

Possihtc

l r

CBUSCS

. .

..,.-

it2

.- ._- ..-. L -._

lJxcossivcly wortl

Li

sliding paris
(llsc ol’old oil)

-.

‘1

---

Cheek lhl!

COIll- I

prcssion
To 111 AC. t 5 or

lb

----- I

Excessively worn
sliding parts

((‘tlilllgC the

oil)

Check 1 tic COIU­prcssioii
To DIAG. IS or

16

Lhn~agetl or
clogged
(Lack ol’ Iilainlc-

IlilIlCC)

Cltlcck

i._..I

Engine opcr;il ion

I

-.

-....--._

-

DIAC. 32

1

dmornial

l.nbric:iting oil
consunipt ion
increases (gels thin)

T' --."-

Check thcjel
(Jut number,
looseness)

-.

Dislalett

Wrong jet

illICe ol’ pislon ring

lirnil

._I.

L :

Fuel

---r

- ..I ,.-

_ .--..

I

-.

r

--

Kcplaco will1
m)rm11 1’ucI

:ind

check

-.,-

-I-

--

r:

Sylllt~IolnS

,, ._-. -

._

I’ossiblc

I.. 1

C'Il1sw

L

-.,...- ._-

C'tlccking

crileria

--

Noise protlucctl and

_-

I --

Scizurc 01 d;magc
ot' ltic piston 01
connecliiig

rod

­__.. -.. I

.-

_ .,,.

(‘llcck

I

j

..- .-.. ‘,

Scizut

c OI' tlillllJlgC

01‘ I tic piston

01

connecling rod

--I

..-.

Lxccssivcly IillgC I’UCI

r-

--.

1. .--.

('ICillNZr ClClllClll

I

I

1 __.-

.-

(‘logging of’ It1e air
clcmcr clcnrcnl

,.- I .--.-

(‘heck

,.. .--

I-

I>ii I

I-

Rich rJJixlurc

- -. 1 --

Cheek IIIC main jcl

(i)r loosc~~css antI ,jct

nlllnhcl

To DIAG. 2 I

-I-

‘-- ‘-1

I)islorlctl . . .

Tighlel1
Wrongjel
To I)tA(;. 2 I

I -

Fuel

L 1

---.

I:ucl riiixctl wit I1

foreigli si~hsl;rnccs

.-

1

--

Repli\cc with normal
I’ucl ;III~I cheek

-.-- I-’ --

Hnginc

Ir011hlc

Ll

Excessively

Wtlilc t’~jlllcs Iqo luhri-

protlucctl

citlirig oil
co~~suriiption

--- _

-. _..-- I -.

WOlIl Ollf

III-

Sticky

­1

.' I .--

.I-

(Ihcck
clcararicc of

pislon ring

-r

I

-. -

I -.-_.

r- -

---- -

Possihlc

c;Iuscs

r

I--

VillVC

WOrll

1Nll and

rctllln

valve

&,gglXl

Cheek

(‘orilnriiina-

I ion (mixed
with ot!iet

ll1illCriillS

like carbon’)

(‘heck

over tt,e

service

limit

C’hcck

(‘heck

1

--.- -

---

Checking

crilerio

Over ttic
slaiidard
qlltiIllily

ACctIlI\IIlil­lioii of’

carboll

Assclllt~lccl
upside

down

Over ltic
service liniil

Oil Icakage

____. ‘T. .._.... -

MAC.

36

I

- ----I

rncler I;lilS

IO StlOW

the needle res(ilig

(‘or~lrot /XlIlCt

Ttlc pilot light

I;lilS

10 light

Op.

-- . _ _.. _ ._ -­7

I

I

-

Sylllptl~llls

.

._ .-

11

PiNlS

._

1

. .

The I’ilamcn~ is

-. -...- _ I-- --

-I

Wile broken

OI

stwrlctl

tkl’cclive

soltlcr,

and leutl broken

Wilt hlc~kcll

OI

‘lie diode is

ShCM 14

tlc(‘cct ive

I

‘W

I

1

__ _ L--

Mc;wrc

ltic

Icsislwlcc

. . L

(Across lhc Icr-

iliiii;ils)

c’ircuil Icslcf

­I

___ _ .._ ___

1 ---.-

Mcasurc LIIC rcsisl-

illlO (LICIOSS 1 tie
t~l3l~ilMlS)
(‘ircuii lesler

Wl1cn 42 .*,

Wire hrokw

WhWl a2 . . .

Stlorlctl

%

I

1

_, .__

- I ..-... .-_

(‘lwk IIIC I’rcctu­cncy nictc~ I’or
clcclrical con-

lirluily

1 -,

1

MCLSIJIC

IIIO

rcsiul~~iicc

‘

(ACIOSS ltic Icrrni-

IlillS)
Circuil tester

I

I

When 42 . . .

Wire hrokcll

(‘lwck the sol&xcd

paI I

Circuil lcslc~

IlClllS lo

clwk and
ploccdurc

Mci\llSrc the

rcsislnncc

(hl’ coiiplcr)

L. I--

I-----

.I-__

Me;lsure I hc
rcsisl*lrlCC

. ‘

(ilCIl!SS lhc ICI’-

miii;lls)

c’itcuil lcslcr

Wilt hlokcn

-

When 42 . . . tt1e

rcatling ol’ Ilic’

7

circuil Icslcr mq Itic

ICiltl Zllld

SOldL!f

LIIC

ttefcc~ive

WllCll 41 . . .

Witc hlokw

wtlcll OS1 . . .

SIIOI lCll

!.

(‘lwcking
CI ilcl i;i

.-

Kerr1cdies

I I

To DlA(;. 40

I

Mcasurc AC outpul

EXAM I

AC voltage is low by

Vc~y low 01 rlotIIing?
hginc is opcr;rtirrg well

MCISIJW

AC output

Measure DC

OIII~UI

EXAM 1

.--- - _ _

_ .__-.. .,.- .

-ir

_. ,. _-. _I_

To DIAG 45

To INAG. 43

To I)IAC. 44

1

Sylllpllm

.--.. -

[_1,

I~eiiiedies

.-, L.

L 1

Slulor IX1 coil

I

--..

.-

I

Wire hrokcn OI
shor INi

Measure Ihc rcsisl-

cliodc terniinds of

Wllerl 42 . . .

Wire blokcn

WllCll OS2 . . .

Stlortcd

The diode is tlct’cctivc

-

--I... .

Measure ~IIC tesislance

(;wwis the lcrniinas)

Circuil leslcr

-_ ,.­lI

.-. I

__ _--.

When

l hc rcsislnnce

differs 1’1om the

1

slandard value

-

-.-

1

. --._.

Stator main coil

I

--

1

Mcasurc

I~IC

resistance
(across the lcrminals
01’ tlw 61’ coupler)
(‘ircuil lcslcr

.._. ., I . -. .-

-I

___. _-

1

WllCll 42 . . .

Wilt broken

wl\cll OS2 . . .

Shorlcd

-

--.,. --.-

DIAC,. 44

-_... _­1

-. __..-

The IX’ oulput
vollagc is only SCYj%
01’ lhc ralctl value

- -I

One diode is def’cctivc

;7

IXiltl

r -1

-

Tile soldered pilrt is Tile soldered pilrt is
dcl’cclivc,

;rd the

lead dcl’cclivc, ;rd the lead

is hrokcn is hrokcn

1

Measure 1 hc resistance
(xross lhe Icroiinals)
(‘iicuil lcslei

-.
1

----

-_ - ..-

---

Whcri tlic resistaucc
tlil’fcrs I’rom lhc

Stillld~lld

Villue

Mciisurc the iosislance Mciisurc the iosislance

(iICrOSS

lllc

Icrniin~ils) (iICrOSS

lllc

Icrniin~ils)

Circuil lcslci Circuil lcslci

..L .-

--.

--.-

-....

..-

r1

Symptoms

--

.

r]

PiirIS

.-. .

IN’%, higher or more

IX: is output

i

l+rigirie running speed
is high

..__

T

-.

A

. . -.. . -

1

-. -

.._-J-

! 1

SlillOr

coiidenser

coil

-.- ._,

T

L.- -.-.

r 1

Condenser

r

-,..-.

..,, .._-

-r

_I. .-

L 1

Staler

tllilill coil

-7’ ---

- _-_-

Wire broken

OI

shortctl

1 ,,

r I-z .-

Mcasure

LIIC rGst:lllcc

(bclwccn llic Icr-

riiimds)

Tlrc

circuit tester

When 42 ..,

Wire hroken

When OS2 . . .

Shorted

-.
I

.- -,.....-

---

I. Wire broken

shorlcd

2. Kotor resistor is
dcl’cct ivc

3.

Kotor tliotlc is

del’ccl ivc

1

-- ,.--

1

Mci\sure the resislancc
across

tlic

resistors,

with solilcr

imoved.

MCiISIJIC

tile resislawc

01’ the rolor rcsislor,
ilntl cllcck

111~

tliotlc

li)r

lll~lIllIilCy

I) When 42 . . .

Wire brokcll

WllCll t-Is2 . . .

Shorlcd

) TIIC

resisI:lrlcc

tliI’l’crs by

as tiiuch

as 10%~ from lhc

slarldard value

1--- .--

r-” 7

-. ._ .---

-_--

McilstJre

the capacily
(circuil tester c;~ii nol
hc used li)r this

Possible

CilllS~S

The cngille running
spcctl is higher lhan

nornd

Wire hrokcn or

shorled

- --I

1

I- -

MCilsurc

111~

resistance

(between the ter-

IlliJliJlS)

The

circuit A lcstcr

1 I-

When 42 . . .

Wire blokcn

WhCll u2 . . .

Shorlcil

-_
T

_-.-. --.. -

I lerris lo

check ;md
lmxedure

To DIAG. 52
C’hcck 111e

governor

~-_.-

(‘hecking
criteria

_ 11 __ _r ..-.- _-,­x

-.--_

..-

I ‘1

. _ .._. _ .-_-

Kcnicdies

AI

L..-----I _-_-.--_ ___ 1

-

____

--l- _--

DilTcrcnl I’rwn

the

slilrltlad

WlilC

-_
I

- .--. -

L . . . _--.

-

Replace the condcnscr

1

I1

L

Keplilce the

rolor

_ - ..-__ ,_-.

-.- J

L. ---1

L., ._... . ___ ,- ..,,, ..A

__--. ,.

r

.-

-

-

--‘-‘--

A(: OUllW1 VOlliIgC

is only 20f% ol’ lhc

ralcti value

._ ._

,1

Rotor

c

(lonclenser

_._- --..-

u

Pitrls

hgine

The cnginc speed is

lower than norrrial

---I- -

-7

The coil is shortcd

- ----‘T’ _ --

Shorting 0I’Ihe coil

rotor resistor

. .-.- .L ..__.. --

Aged or broken

Possible

1

causes

The coil is shorted

--_-_.
1

_-

I

E

I

__

.-A-- -.-

- . ..- - -1.

. . -.. -. -

To DIAG. 53,
Cheek

fhe

governor

.-.

I

_ .., . . . .,

Measure the rcsist-

Circuit tester

Mcasurc the resist-

311Cl!

(6P coupler ler­lninills)
Circuit lcsler

Mensurc the capa­citance (Ihe circuit

lcster can not be
used for I his mea­surement)

Measure the resist­iItlcC (hctwecn the
lerminals)

Circuil tester

llcn1s

lo

cheek and

procedure

Checking

criteria

---

- -.-. - ,...

IS%, lower than

I he

coil

ililllllilId . . .

Shorted

IO’%, tlit’ferciicc

tllilll

llje

resister

stillltl~lKl . . .

Old

Dil’Tcrcnt I’roiri Ihc
standard value

Aged
Broken

TIIC rcsislance is

l Sfjh

lower

1lli111

llle

Slillldilld VillUC . . .

Shorlccl

TIIC rcsist;lucc is

1.5% lower

iliaii

the

standard

vihe ..,

Shorled

El

Remedies

---

Sylllpll~llls

..-

I

I T”

-

Possible

!

C3IISCS

---- -

_- --

Iiems lo

CllCCk ;I1111

produie

._-

-.. _

C’hecking
CrilL’riil

-. -

J

Dcl’ective selliiig

ol’ the governw

lever

illld

level

shnl’t

I

.- --.-..

---

_..-- --

Check ihe set
posil ion

---

_-_.

_

1.

.-

Dc~cctivc wiling

Poor or clcl’cclive

perli)rmullcc

(‘lwck

ihc II~OVC-

1

._ _-.

Incorrecl

llilllg-

ing posiliorl .,.

Kcplacc
Dcl’cctivc govcrritri
spring . . .

KeplilCe

-_ _ -.

T

..-_ .-

Worn

0111 .,,

I

Keplacc

I---

L

I,eilll

nlixlurc

.._

r

-.,_ .I---.---

1

(‘llcck I hc I’ucl pipe
of cnburctor

-___. - ----,

_-,,-

L

.-

1

-_ ­1

C‘0lllillTli~lilli1~ll . . .

ClCilll

T-j- --I

--

: .

‘I’0 I)IAG. I7

_., .._-...

.- -

T

._.-

Possible

r1

C’I 11 scs L

__ .-._

,,, ..--.

I

(‘hccking

crilcriil

. .- ..-.

Ikt’ecl ivc sell irig

-_. --- I -.-

Check the SCI t ing

I

EXAM 54

-7 A

- .- I ~-.-

The

goveinor is in-

correctly set, iulcr­f’eriiig with lhc
lhrolllc valve’s
opciiing.

--I- -

--

_---

,n

Valve

..-,- -.-, -, I ---

. .

The liming ol’ ihe

valves is tlcl’ectivc.

Acljuslmcni ol’cleilr-

iIIlCL! is incorrecl

DIAC. 52

Kngiiic speed 110CS
no1

illcreils~

4

. .-..

_ .--_

I

C’ilrburclor and ilir

a

cleaner

---_- -1. _...- -.~

Mixture is incorrect.

-. .,,_,--.- -

Cheek the carbura­tor.

t;XAM

(‘heck

lhc ;lirclenncr

owner’s iiianuil

- . ..- .-

i=:
I --.-

and iiiul’ller

ilre

(‘heck by eyes

ZIIY

1

I

t%?Clriciil load

---

/ Ovill~;iillil

Correct to the

Stilllcl~rd

hltl

AC ; To WAC; 46
DC; To DIAG 43

--, -_--

L

OWrlOilCi

- _ --. ..- ..---- --

.----

.-.-

l

I.

r 1

ldeclric lid

---I-- --

.__ L-.-.

i,

Spark plug

--

r--- l

.._ -I -.....-

L 1

Cnrburctor

___-_ .--

I

__I ._--

Cylinder

heiltl

I 1

hind cylinder

_. -. .-. _. ._ .-

1

,_______ -l.---.

I 1

(‘ylimler licad

rnul’fler

. .

I

1

PiIrIS

I’ossib lc

) I!

CiIlISCS

.

,-

---I. ._-

-. - -r

,, --.

. . __- ,... -._ 1 _- _.

1

1

AClXllllllliltil~ll Of

carhi

(‘ooling I’;llls

iIN!

clogged.

Overloading

Mcasurc I hc insula-

tion

resklilnc~ * .

* Adjust to the

standard

IWli

AC ; To 111 AC, 46
IX’; To DIAC; 43

_--_ ,.-

-

--. _. _..

J

--

3

wcii

I --.’ ”

8

I

--

___A

Cylinder

hcild

IrXAM SO

Mul‘llcr

I’XAM 65

I. ._.

1

-

llcrlls to

cl\cck

iIIIt1

proccdurc

Checking

critcriii

(‘llcck

Spccilj

ISM K4.A
(NGK)

I’XAM 5 I

OVCdlillll Lilltl

check IIIC corburc-

(or.

Air compressor

IJXAM

-_. ­1

,_-.-_

--J

--

7

-I

Tllcrml ril t ing of’

tllc spilrk plug is

IlOt illlCX~ll~lt~.

Overlootl

Dirt

illld

clogging

I---- --

I--

,.. -L. .,.---

1

l----‘------l

I

IlSilgC Ol’ Sl~lrlliiIrd

IOild.

Replace

with the

spccificd plug.

Kc~tiove the carbun

dcposi I.

I- .-----I

I-.. __--I

I

No trutpu1

Poor

No comprcs-

pdorniancc

-. , ,
siou

Backl’irc

Poor

Misfire or
cond~~stion

performnnce ou,side the

L..- - .J L- .-,--J L_-+

Moisture in

fuel

1

Check

(Inside of

cilrhl~riltl~r

cliambcr)

Dcfccl ivc

soldel

7

--

T

Rich niix­lure.

-r

-_

-- -

Possihlc

CilllSCS I ,

.- .-

-. -.

ltcrlls IO

check

and

procetlul c

Clhcckiug
criteria

Worn out

(‘onlacl

point is
dcl’cclivc

_ --

l --

!

C’hcck 1 hr

IappCl ClCilr-

ilncc.

-.-. -

Check the
,jet fol

llN,scl~ess
((‘heck the
$1 number)

Loscncss . . .

Tighten

Wrong,jel . . .

Keplncc

Replace with
11~2 correct

piIdS illld

chuck

Check the

tappet Ckiir-

ancc.

-,,

-r-- -

Narrow . . .

Adiusl to

COlllilCl

rhc ml of

Ill0

ViilVC

Wiilc . . .

Replace

C:lnltoct

point by
soil is fail

Moisture in

fuel

14. CRITERIA TABLE for ADJUSTMENT

I terns of adjustment

Criteria

, Limit of

application

Description

Tools

Remarks

Levelness of cylinder head

Below 0.1 0.15

Surface plate

and searcher

Repalr

I

Cylinder

lnslde dia.

Seat width of Intake and
exhaust valves

510+o.o19

0

0.5

5 1 .cl6Q

1 a

1 Cylinder gauge

Slide calipers ’ Repair
and cutter

1 lnstde dia. of valve guide

5,50A0.018

. 0

5.656

Center dia.

Cylinder gauge

Replacement

Piston skirt’s outs,de
dia. I” thrust dIrectIon

0

50.9920 -o,02

50.92

I

Micrometer Replacement

I

’ TOP

, ,5 +0.025

0

1.65

Slide calipers Replacement

I
’ Ring groove

width

Second

, ,5 ~0.025

0

1.65

Slide calipers Replacement

Piston

i Pin hole

011

2.5 ao.035
0

2.65

Slide calipers

Replacement

, ,O +0.002

-0.009

11 .O35 Cylinder gauge Replacement

Clearance between piston
skirt and cylmder wall

0.008 - 0.047 0.14

’ Cylinder gauge

and mxrometer ,

Replacement

’

Top 0.090 -0.135 0.26 Searcher Replacement

, Clearance be-

tween ring and Second 0.060 -0.105 0.23 Searcher Replacement
ring groove -

Spare rings

v
’ Oil 0.010 -0.065 0.19 Searcher Replacement

Clearance between piston

and piston pin

0.009T - O.OlOL 0.06L

Winder Saw ’ Replacement
and micrometer

I

Top

0.2 - 0.4

1.5

Searcher

Replacement

I

Joint

gap

Second 0.2 -0.4 1.5

I Oil

Spare rings

0.02 -0.25 1 .5

Piston
rings I Top

-0.09

1.5 -0.11 1.3 Micrometer Replacement

Width

A-

Second

011

’ .5 -0.06

-0.08

1.33

2,5 -0.010

-0.030

2.38

Spare rings

MIcrometer Replacement

!

MIcrometer Replacement

P!ston pin outside dia. “* 0

-0.008

10.060 ’ MIcrometer Replacement

’ lnstde d:a. of large end

20d+0 013

0

20.050

Cylinder gauge Replacement

I Clearance between mslde

dia of large end and crankpin

0.037

-0.063 0.13

1 Cylinder gauge

and mlcrometer

Replacement

Connecting
rod

lnslde dia. of small end

L-0 021

“O-0.01rJ

11.080 ’ Cylinder gauge Replacement

1 Clearance between instde

dla of small end and ptstonpln

0.01 - 0.029

0.12

Cylinder gauge

Replacement

I

and micrometer

Slide clearance of large

i rod end
1

0.1 -0.7

1 .o

Searcher ’ Replacement

I

-68-

Items of adjustment

I

I
I

Criteria

, limit of

application

Description

Tools Ramarks

I

1 Crankpm outside dia.

, 19.920 !

Mtcrometer Replacement

Crankshaft 1

Generator 20e, -0.003

!

Crankshaft

side

-0.012

19.950

I Micrometer Replacement

journal outside
dia.

Counter-

side

, 7. -0.003

-0.011

‘6.950

Micrometer Replacement

Cam crest

18.4%” 18.15 ! Micrometer ! Replacement

Camshaft

Camshaft

i &:erator

,O9-o.O’3

-0.028 :

9.950

Mtcrometer ( Replacement

journal

outside dia.

Counter- -0.01 3

I

side

log -0.028

9.959

Micrometer Replacement

Valve

spring

Free length
Squareness

25

24
1 .o

Slide calipers Replacement

I

Square

Replacement

I

’

Intake 5.50

-0.020

Outside dia.

-0.032

5.440 1

Mtcrometer

Replacement

I

of valve stem

I Exhaust 5.5@

-0.056

-0.074 5.409

Micrometer

Replacement

Clearance be-

Intake 0.02 0.05

-

0.2

tween valve

At valve guide

Cylinder gauge

Replacement

Intake and

stem and

center

exhaust valve guide Exhaust 0.056 - 0.092

0.2

Cylinder gauge

Replacement

valve

’

Intake

I

Tappet

0.08 -0.12

-

0.05 0.25,

i

Searcher

Replacement

l

clearance

I

Exhaust

0.08 -0.12 0.05 - 0.25

Searcher

Replacement

1

’ Clearance

I

I

8

between

Intake

0.1 -0.3 i 0.5

’

, Slide calipers

Replacement ’

groove and

Exhaust

retainer

0.1 -0.3 0.5

1 Slide calpers

Replacement

Valve stem

Intake

3.5

!

2.5 1

Slide caltpers

Replacement

end length

Exhaust /

3.5 2.5

Sltde calipers

Replacement

i Total length

j 20.8 +i.” 20.3 )

I

Slide calipers Replacement

I

Tappet

!

Clearance between stem

1 and guide

0.01 -0.03

I

Spark

Type

BMR-4A (NGKI

I

I

Plug

Electrode gap

0.6 -0.7 1.0

Searcher

Replacement

Fuel con-

’ 50 Hz rating

0.5

I

sumption

I

(l/hr) [ 60 Hz rating

I

0.6

I~- ~~

Lubricating 1 50

Hz rating
Oil con­sumption

(cc!hr) 60

Hz rating

I

4 20 :

I

5 20 1

I

Quantity of lubricating oil cc

350

I I

AutomotIve engine oil of class over SC

Lubricating oil replacement Interval

Compression pressure (kg/cm2/rpm)

I Inittal: 20 hours after start

Regular: Every 100 hours

I

I

I

I

41800

I

Pressure

I

I

1 guage ’

-69-

Items of adjustment
(Tightening torque)

Criteria

Limit of ’

application

Description ’

Tools

1 Connecting rod bolts

60 -80 kg-cm

I

Main bearing cover bolts

80-100

[ Cylinder head bolts

go-110

I

I

Spark plug

120 -150

I

1

I

Air cleaner nuts

Governor lever nuts

50 -60

I

70 -90

I

I

Front housing bolts

80-100

I

I

I

Rotor bolts

100-150

I

I

1 Muffler nuts

I

I

Front cover bolts

55 -75

I

I

I

-

70

-

15. WIRING DIAGRAM

RECTIFIER

CIRCUIT BREAKER

MAIN COIL

r ----- +-----

AC RECEPTACLE

ril

_----

FIELD COIL

CONDENSER
COIL

It-J

/

CONDENSER

4 [DARK BL”E,’ 4 FM ’

’ FREQUENCY

(DARK BLUE1

1 METER

r+ _______ ------~

L--------------A

IGNITION COIL

SPARK PLUG

IGNITION UNIT

& GT

AC lead wire color code

p< ” 1

I

1lOV 50 Hz

White, green

I

White, red

=.I Blue __i

I

22OV.50 Hz

Gray

I

I

230V ‘50 Hz

240V 50 Hz

I

220V ‘60 Hz Pink

I

-71 -

16. MAINTENANCE

The following standard maintenarxe procedurss are necessary to ensure th

2 generator’s normal performance under normal
operating conditions. Therefore. the mstructions described below are for ref2rence only and varl- depending on how th2
generator is operated. For instance. if the gsnsrator is operated in a dusty ar2a the air cleaner must be cleaned daily- ah~h
diffsrs from the interval specified below.

16-l DAILY CHECKS and MAINTENANCE (every 8 hours)

Check and maintenance items

(I) Clean each component of dust

I
I

Description

I

’ (1) If th2 joint of the governor is left in a dust! condition.

the governor ma>- fail to function normally.

(2) Check the fuel piping system and related parts for

leakage. Should leakage be detected. tighten or
replace the defective part.

(2) Ii fuel leakage is not corrected. fuel economy will be

reduced and there is a potential of fire.

(3) Check each part for looseness. Tighten if (3) If the parts are 10052. vibrations will occur. and ma)

necessary. subject the generator to troublz.

(3) Check the quantity of oil inside the crankcase: fill (4) If the engine is run with an insufficient quantity of oil.

oil as necessary-. th2 piston and other moving parts will be damaged.

(5) Check equipments of control panel. when found

(5) Can’t obtain any output which is needed.

damages. replace them.

I

16-2 CHECKS and MAINTENANCE for EVERY 20 HOURS

I

Check and maintenance items

Description

( 1) Drain the oil from the crankcase.

( 1) Replace \vith n2w oil.

The oil used a&r the initial period of operation is
likely to be heavily contaminated with fine metal

I

powder and other foreign substances from various
engine parts.

16-3 CHECKS and MAINTENANCE for EVERY 50 HOURS (every 10 days)

Check and maintenance items

Description

(I ) Clean the air <Isaner at the prrscribed intsnal.

i (1) If th2 air cleaner is continually used in contaminated

condition. it may lead to engine trouble.

(2) Check the spark plug for carbon sontammation.

If found dirt!. clean rt with gasoline. followed

b>- sandpaper.

(2) Should the plug be left m contaminated condition.

an sngine output will decline or it ma! fail

- 72 -

16-4 CHECKS and MAINTENANCE for EVERY 200 HOURS (monthly)

Check and maintenance items

Description

(1 j Drain the oil from the crankcase and replace with

(1) The us2 of contaminated oil will subject parts to

new oil. (every 100 hours)

excessive wear.

(2) Clean the fuel strainer and the fuel tank interior.

I (2) If the contaminated fuel strainer and fuel tank are

used continually. engine performance will be lessened

I

and may led to engine trouble.

16-5 CHECKS and MAINTENANCE for EVERY 566 HOURS (semi-annually)

Check and maintenance items

(1) Remove the cylinder head, and remove carbon

deposits.

(2) Disassembly and cleaning of engine carburetor.

Description

’ (1) If the engine is run with the cylinder head contami-

nated with carbon. it may led to engine trouble.

(2) If the engine is run with the cylinder head contami-

nated with carbon. it may led to to engine trouble.

,

(3) Check the switch of engine and tlexible shaft. (3) If the engine is run with the cylinder head contami-

nated with carbon. it may led to engine trouble.

16-6 CHECKS and MAINTENANCE for EVERY 1660 HOURS (annually)

Check and maintenance items Description

(1) Overhaul the engine for cleaning. adjustment

and parts replacement.

(2) Replace the piston rings.

(1) If the engine is used continually without an annual

overhaul. it may led to engine trouble.
I
’ (2) If the engine is used continually without an annual

,

overhaul. it may led to engine trouble.

(3) Replace the fuel pipe.

j (3) An old fuel pipe is likely to leak.

(4) Check all the relative parts of the generator.

(4) Can’t obtain any output which is needed.

I

16-7 WHEN THE GENERATOR IS NOT USED for PROLONGED PERIODS:

Ij Be sure to check the generator daily as instructed in 16-1 aboLe and it is required that the generator receive the 20-

hour check and maintenance detailed in 16-Z.

~j

Drain the fuel from the tank and from the tloat chamber

of

the carburetor.

3j To prevent the cylinder wall from rusting. remove the spark plug and lubricate the interior at the cylinder. Then. pull

the recoil starter knob two or three times. and replace the spark plug.

4) Keep the piston stationary at the position where the piston stroke f22ls the heaviest.

5) Clean the engine exterior. using an oil impregnated cloth. and then place a vinyl cover or other cloth over the genera­tor in a dry- place where it Lvill not be subject to high humidity.

- 73 -

R&&I Generator

R-America, Inc.

940livelyBlvd.QWoodDale,1160191● Phone:[phone]● Fax[phone]

e-mail: sales @robinamerica.com ● wwwrobinamerica. com

PRINTED IN THE USA