Subaru Robin Power Products EY20V manual

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ROBIN AMERICA, INC. ROBIN TO WISCONSIN ROBIN ENGINE MODEL CROSS REFERENCE LIST ROBIN EY08 EY15 EY 15V EY20 EY2OV EY23 EY28 EY3 5 EY40 - EY45V EY2 1 EY44 EY 18-3 EY25 EY27 EH11 EH12 EH15 EH17 EH21 EH25 EH30 EH30V EH34 EH34V EH43V EC13V DY23 DY27 DY30 DY3 5 DY4 1 WISCONSIN ROBIN SIDE VALVE W 1-080 W1-145 W1-145V W1-185 W1-185V W1-230 W 1-280 W 1-340 [...]

CONTENTS Section Title Page 1 . SPECIFICATIONS .......................................... 1 2 . PERFORMANCE ........................................... 2 2-1 Maximum Output ...................................... 2 2-2 Continuous Rated Output ................................ 2 2-3 Maximum Torque and Fuel Consumption Ratio at Max . Output ....... 2 3[...]

Section Title Page 7 . GOVERNOR ADJUSTMENT ................................... 31 8 . CARBURETOR ............................................ 33 8 . 1 Operation and Construction ............................... 33 8-2 Disassembly and Reassembly .............................. 34 9 . BRAKE-IN OPERATION of REASSEMBLED ENGINE ................. 36 10 . R[...]

1. SPEC1 FICATIONS I Bore x Stroke (in) 1 63 mm x 46 mm (2.48" x 1.81") I 67 mm x 52 mm (2.64" x 2.05") I Piston Displacement (cu. in) 1 143 cc (8.73 cu. in) 1 .183cc(11.17cu.in) ~ ~~~ _____ ~~ I Compression Ratio I 6.3 Continuous Rated Output (HP/rpm) 2.213,OOO 3.513.600 2.7/3,600 313,000 ~~ Max. Output (HPIrpm) 0.9512.800 0.71[...]

2. PERFORMANCE 2-1 MAXIMUM OUTPUT The maximum output of an engine is such standard power as developed by the engine, after its initial break- in period with all the moving parts properly worn in, when operating with a fully open throttle valve. There- fore, a new engine may not develop the maximum output in the beginning because the moving parts ar[...]

PERFORMANCE CURVE MODEL EYZOV 1 .o 0.9 5 Recommended Operating'Speed' Range- I I I I I I I) kg-m 2000 3000 3600 r.p.m. Revolution B- 3. FEATURES 1. Compact, lightweight, durable, powerful 4-cycle air-cooled engine embodying ingenious design tech- niques and skilful workmanship. 2. Simple construction, smart appearance, maximum easiness of[...]

4. GENERAL DESCRIPTION of ENGINE CONSTRUCTION 4-1 CYLINDER, CRANKCASE The cylinder and crankcase are single piece alumi- num die casting. The cylinder liner, made of special cast iron, is built into the alminum casting. The in- take and exhaust ports are located on one side of the cylinder, and are also inserted into the casting. The crankcase is s[...]

4-4 CONNECTING ROD and PISTON I The connecting rod is forged of aluminum alloy, 0 small ends. which itself serves as bearings at 'both the large and The piston is cast of aluminum alloy, and has grooves for receiving two compression rings and one oil ring. (See Fig. 5.) Fig. 5 4-5 CAMSHAFT The camshafts are integrally built with a cam gear of [...]

4-7 CYLINDER HEAD The cylinder head is an aluminum die casting, and forms a Ricardo type combustion chamber with am- ple area for high combustion efficiency. (See Fig. 8.) 4-8 GOVERNOR The governor is a centrifugal flyweight type which permits constant operation at the selected speed against load variations. Governor gear is installed on the bearin[...]

4- 11 11 IGNITION The ignition system is a flywheel magneto type with ignition timing set at 23" before TDC. The magneto is composed of a flywheel and ignition coil. The flywheel serving also as a fan is mounted directly on the crank- e shaft, and the ignition coil in the crankcase. (For further details, ' refer to Section the Magneto.) ([...]

4-14 SECTIONAL VIEW of ENGINE MODEL EY15V -8-[...]

Air Cleaner Muffler Cover /::;:: MODEL EY15V -9-[...]

’piston Pin Main Bearing Cover Oil Scraper Crankshaft MODEL EY20V - 10-[...]

Oil Filler’ MODEL EY20V - 11 -[...]

5. DISASSEMBLY and REASSEMBLY 5- 1 PREPARATIONS and SUGGESTIONS 1) When disassembling the engine, remember well the locations of individual parts so that they can be reas- sembed correctly. If you are uncertain of identifying some parts, it is suggested that tags be attached to them. /"- 2) Have boxes ready to keep disassembed parts by group. [...]

Part No. 2069500107 227 95001 07 207 95001 07 “20248 Tool Valve Guide Puller Timing Tester Use For pulling off Valve guide For adjusting timing Applicalbe Model EY 18 EY 15,20 EY25,27 EY10, 13, 14 EY 15,18,20 EY25,27,33 EY35,40,44 EC03,04,05 EC07,10, 17 EC25,37 Shape - 13-[...]

5-3 HOW TO DISASSEMBLE *Length of the bolt indicates the length from the bolt head bottom surface to the threaded end. /"-. Order Item Remarks Tool Procedures (1) Remove the recoil starter. 64 x 8 mm bolt: 4 pcs. 10 mm box spanner 1 Recoil starter 2 FueI tank (1) Close the fuel cock. (2) From the carburetor disconnect the fuel pipe between the[...]

Order Procedures It em I Remarks Tool 9 10 Starting pulley , Flywheel (1) Remove the starting pulley from the fly- wheel. 144 nut: 1 pce. Fit a box or socket wrench over the fly- wheel nut, and strike it hard with a ham- mer to remove the 14 mm nut and spring washer. (1) Remove the flywheel from the crankshaft. Fig. 16 Be careful to damage and the [...]

Order exhaust valve 15 1 Main bearing cover Procedures Remarks (1) Remove the inner and outer tappet covers 64 x 12 mm bolt: 2 pcs. outer circumference from the crankcase. Put the notch on the of the spring retainer (2) Pull out the intake and exhaust valves. Hook the medium (3) Remove the valve spring and the valve on this side. retainer., size (-[...]

Order Tappet Order Item 18 Connecting rod and piston 19 Piston and piston pin 20 Crankshaft Procedures Tool Remarks (1) Remove the camshaft from the crankcase. To prevent the tap- pets from falling or damaging, place the side. (See Fig. 20.) crankcase on the (1) Remove the tappets from the crankcase. Before removing put a mark of intake or exhaust [...]

5-4 MOW TO REASSEMBLE 0 Precaution in reassembling Every and each part should be cleaned thoroughly. Especially, pay utmost care and attention to the clean- 7 liness of the piston, cylinder, crankshaft, connecting rod and bearings. Scrape completely off carbons from the cylinder head and the upper part of the piston; especially the carbon adhered i[...]

3) Dimensions of Crankshaft Pin D (Crankshaft pin Dia.) EY 15V EYZOV 24 dia.-omo37 26 dia.-o*037 -0.050 -0.050 W (Crankshaft pin Width) 23 io” 24 io” PISTON TO CYLINDER AT PISTON SKIRT THRUST FACE 0.020L - 0.059L TOP, SECOND 0.2 L - 0.4 L 0.05L - 0.25L 0.2L - 0.4L 01 L 0.05L - 0.25L PISTON RING GAP I TOP RING 1 0.09OL - 0.135L I 0.050L - 0.095L[...]

5-4-2 PISTON and PISTON RING 1) If no ring expander is available, install the rings by placing the open ring ends over the first land of the piston and spreading the rings only far enough to slip them over the correct ring grooves. 0 Note: fay attention not to break the rings by twisting. Install the oil ring first followed by the second ring and t[...]

5 -4-3 CONNECTING ROD 1) Turn the crankshaft to the bottom dead center, lightly hammer the piston head until the con- necting rod contacts the crankpin, and assemble. 2) When reassembling the connecting rod cap, match the alignment projection mark on the rod. (See Fig. 26.) Note: Use new lock washers, and bend the tabs Note: After reassembly, confi[...]

5-4-5 MAIN BEARING COVER Install the main bearing cover to the crankcase. Note: As the governor gear is mounted on the main bearing cover side, install the main bearing cover white checking that it meshes with the teeth of the cam gear. (See Fig. 28.) Mean- time, if the oil seal need be replaced, press- fit a . new oil' sea/ before installing [...]

5-4-6 INTAKE and EXHAUST VALVES Remove carbon and gum deposite from the valves, valve seats, intake and exhaust ports and valve guides. Note: If the valve face is dinted or warped, replace the valves with new ones. Note: if there is an excessive clearance between the valve guide and valve stem, replace the valve guide with a spare. For replacing, p[...]

5-4-7 TAPPET ADJUSTMENT Lower the tappet all the way down, push the valve, and insert a feeler gauge between the valve and tappet stem to measure the clearance. (See Fig. 33.) Note: The correct tappet clearance for both intake and exhaust valve is 0.7 mm k0.02 mm as measured when ,”. the engine is cold. 1 I Fig. 33 / I Fit t-he oil seal to the va[...]

5-4-8 CYLINDER HEAD Remove carbon from the cy1inde.r head, particularly its combustion chamber, and make clean the cooling fins. Also check the head for distortion. Note: Replace the cylinder head gasket with a new one. ’ Note: DISTINCTION between the GASKET of EY 15V and EY2OV The pitch of the holes for the bolts fastening cylinder head and the [...]

After measuring the air gap between the ignition coil and flywheel, retighten the ignition coil. (See Fig. 38.) Air gap: 0.5 mm 5-4-1 1 FUEL TANK BRACKET With four pieces of the bolt fasten the fuel tank bracket to the crankcase. Note: DISTICTION between FUEL TANK BRACK- ETof EY15Vand THATof EY2OV: For enabling to discriminate the fuel tank bracket[...]

5 -4-1 3 CARBURETOR and ITS RELATIVE PARTS 1) Connect the carburetor throttle-lever with the connecting link, and mount them onto the governor shaft. 2) Connect the speed control lever to the governor lever with the governor spring, and mount it onto the 3) Connect the choke lever to the carburetor with the choke rod, and mount onto the fuel tank b[...]

6. MAGNETO 6-1 MAGNETO The spark for ignition is furnished by a magneto assembly. The magneto consists of a flywheel, ignition coil and contact breaker assembly (including condenser), of which flywheel is mounted on crankshaft and igni- tion coil contact breaker are mounted in crankcase directly. The EY20V type engine normally incorporates a solid [...]

6-3 TIMING ADJUSTMENT (See Figs. 42,43 and 44.) The spark is timed to occur at 23" before the piston reaches TDC on the compression stroke. This spark ad- vance of 23" is controlled by the breaker point opening and this advance is obtained when the breaker point opening is adjusted according to the BREAKER POINT ADJUSTMENT to its proper p[...]

5) Remove the flywheel without turning crankshaft at all. 6) Loosen the lock screw of the breaker point support plate so that the breaker point can be rotated. 7) By rotating the support plate of the breaker point, find the exact point when the buzzer within timing tester starts ringing from being silent. (See Figs. 43 and 44.) 8) Put the flywheel [...]

7. GOVERNOR ADJUSTMENT Model EY 15V and EY20V employ a centrifugal flyweight type governor. The governor is mounted on the governor gear, and the throttle valve of the carburetor is automatically regulated by a lever which is connect- ed to the governor in order to maintain constant engine speed against load variations. The adjustment procedure of [...]

2) With a screwdriver in the groove of the gover- nor shaft, turn it “clockwise” fully until the gov- ernor shaft no longer moves, and then lock the governor lever to the governor shaft with the governor lever tightening bolt. (See Fig. 48.) r Fig. 48 - 32 -[...]

8. CARBURETOR 8-1 OPERATION and CONSTRUCTION (See figs. 49 and 50.) 8- 1 - 1 FLOAT SYSTEM The float chamber is located just below the carburetor body and, with a float and a needle valve, maintains a constant fuel level during engine operation. The fueI flows from the fuel tank into the float chamber through needle valve. When the fuel rises to a s[...]

8- 1 -2 PILOT SYSTEM The pilot system feeds the fuel to the engine during idling and low-speed operation. The fuel is fed through the main jet to the pilot jet, where it is metered, and mixed with the air metered by the pilot air jet. The fuel-air mixture is fed to the engine through the pilot outlet and the by-pass. During engine idling, the fuel [...]

8-2-4 MAIN SYSTEM 1) Remove the bolt (20) and take out float chamber body (18). 2) Remove the main jet (2 1) from. the body ( 14) D 3) Reassembly a) Fasten the main jet securely to the body. Otherwise, the fuel may become too rich and cause engine b) The bolt tightening torque is 70 kg-cm. malfunction. 8-2-5 FLOAT SYSTEM 1) Pull out the float pin ([...]

9. BREAK-IN OPERATION of REASSEMBLED ENGINE An overhauled engine must be operated at low speed break-in the parts. A thorough break-in is indispensable particularly when the cylinder, piston, piston rings or valves are replaced with new ones. The recommended break-in schedule is shown below. LOAD EY15V EY20V SPEED TIME NO LOAD 3,600 rpm NO LOAD 10 [...]

IO. ROBIN SOLID STATE IGNITION ENGINE 10-1 FEATURES Model EY 15V can employ as option a pointless igniton system, called Solid State Ignition, which is the cir- cuit breaker type ignition device, utilizing the power transistor as an element for controling electric current. .This system is outer coil type without pulser and is called T.I.C. (Transis[...]

The following three conditions must be satisfied for satisfactory engine start. 1. The cylinder filled with a proper fuel-air mixture. 2. An appropriate compression in the cylinder. 3. Good sparks at the correct time to ignite the mixture. The engine cannot be started unless these three conditions are met. There are also other factors which make en[...]

1 1 - 1-3 ELECTRICAL SYSTEM Check the followings for lack of sparks. 1) Leads of the ignition coil, spark plug or contact breaker disconnected. 2) Ignition coil damaged and shorted. 3) Spark plug cable wet or soaked with oil. 4) Spark plug dirty or wet. 5) Spark plug electrode gap incorrect. 6) Spark plug electrodes in contact with each other. 7) C[...]

11-5 ENGINE KNOCKS. 1) Low-quality gasoline. % 2) Engine operating under heavy load at low speed. 3) Carbon or lead deposits in the cylinder head. 4) Spark timing incorrect. 5) Loose connecting rod bearing due to wear. 6) Loose piston pin due to wear. 7) Cuases of engine overheat. 11-6 ENGINE BACKFIRES through CARBURETOR. 1) Water or dirt in gasoli[...]

12. INSTALLATION Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost all de- pend on the way in which the engine is installed. Carefully observe the following instructions for installing the engine. 12-1 INSTALLING When mounting the engine, carefully examine its position, the method of connecting it [...]

12-5 WIRING Wire as shown in the wiring diagram below. [BREAKER POINT IGNITION TYPE] Condenser Ignition Coil Magneto Fig. 53 [SOLID STATE IGNITION TYPE] T. I.C. (Standard) Ignition Coil with Built-in Transistor Black - m 0- z 3 - m 9. v) Q 0 G Magneto Fig. 54 -42 -[...]

13. CHECKS and CORRECTIONS After disassembling and cleaning the engine, check and repair, if necessary, according to the correction table. The correction table apolies whenever the engines are repaired. It is important for the servicemen to be familier with the contents of this table. Correct maintenance is recommended by observing the correction s[...]

14. TABLE of CORRECTION STANDARDS T -. USE LIMIT 0.65 0.1 5 - 0.1 0.1 5 0.035 0.25 0.1 5 0.06L 1.5 -0.1 ITEM CORRECTION METHOD ENGINE MODEL I SIZE I TOLERANCE LIMIT Flatness of cylinder head EY15 EY20 Less than 0.1 1 Surface plate, 0.1 0.1 5 0.1 5 Correct L-l= EY20 rnax. & min. 67 dia. 1 0.01 Boring Cylindricity EY15 1 EY2O 0.015 1.2-1.5 I Valv[...]

1 I ITEM ENGINE TOLERANCE I SIZE MODEL CORRECTION STANDARD ~ REMARKS TOOL CORRECTIOP METHOD USE LIMIT - 0.04 LIMIT - 0.04 Micro- meter Piston pin 0. D. EY15 I EY20 I ’* Replace 0 - -0.008 Replace EY15 24 dia. EY 20 26 dia. Large end I. D. +0.013 0 0.1 0.1 Cylinder Micro- meter gauge, Cylinder PU9e Clearance between rod large end I.D. and crankpin[...]

I I CORRECTION >ORRECTIOh METHOD LIMIT USE I REMARKS 1 TOOL 1' ITEM ENGINE MODEL STANDARD SIZE t 1 TOLERANCE LIMIT Free length EY15 1 EY20 Vernier calipers 37 -1.5 Replace Squareness I E::: '.' 1 length I For total Replace Intake Exhaust 6.5 dia' -0.025-4.040 -0.056--0.078 Micro- meter -0.15 Replace Valve stem O.D. Clearance [...]

ITEM Man. Output Continuous Rated output MODEL HP/rpm EY15 4.613600 EY20 3.513600 EY15 313000 EY20 2.2/3000 CORRECTION LIMIT I REMARKS I Below 110% of rated output r ITEM CORRECTION PROCEDURE CORRECTION PRECISENESS titer/hr MODEL 1.1 Fuel Consumption 135% of the standard value and up 3600 rpm at continuous rated output EY20 1.2 ITEM REMARKS USE LIM[...]

I ITEM I MODEL I FREQUENCY OF OIL CHANGE Oil Change EY15 EY20 First time: Change oil after 20 hours operation. Second Time and Thereafter: Change oil every 50 hours operation. ITEM 1 MODEL I kg/cm2/rpm I CORRECTION LIMIT I TOOL I REMARKS 1 EY15 61400 EY 20 5/400 Cylinder pressure 70% of normal value Pressure gauge Reference value and down Crankshaf[...]

15. MAINTENANCE and STORING The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated maintenance intervals are by no means guarantees for maintenance free operations during these intervals. For example, if the engine is operated in extremely dusty conditions, the air cleaner should be cleaned[...]

15-5 EVERY 500 - 600 HOURS (SEMIANNUAL) CHECKS and MAINTENANCE I Checks and maintenance ‘I Reasons for requiring them I Remove cylinder head and remove carbon deposit. The engine will be out of order. Disassemble and clean carburetor. 15-6 EVERY 1000 HOURS (YEARLY) CHECKS and MAINTENANCE I Checks and maintenance Reasons for requiring them I Perfo[...]

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