Subaru EA190V manual

EA 190V SER VICE M A NU A L[...]

This m a n u al conta ins inf or m at i on o n how to rout ine m ainta in and how to do t roubl eshoot in g. K eep ser vice manual handy , so y ou can r e f er t o it at any t ime. T his se r v i ce man u a l de scr ibes co rrec t m eth ods of m ain taini ng t his en g ine . As a re sul t of pe rson casual t y and equ ipment damaged caused by t he [...]

I. P AR TS DES CRI PTION ....................................................................................................................................................... 1 1-1 Part desc ription .....................................................................................................................................................[...]

1 I. P ARTS DES CR IP TIO N 1- 1 P ar t de s cr ip tio n 1- 1- 1 Feat ure 1- 1- 2 Model & ser ial number Drain p lug Spar k plug Muf f ler Oil d ips tic k S tar te r hand le A ir c lea n er Fue l tan k c ap Fue l tan k En gi ne stop s w itch Fu el V alv e C hok e Engine mo del S eria l numbe r[...]

2 1-2 Spe cification M ode l Spe c i fi c a ti o n E A 190 L×W×H( not i n cl ud i n g cr a n ks ha f t o ut pu t term inal) 425×360×290m m Dry W eigh t 14 kg ( ir on fl y wh eel) or 13kg (aluminum f lywheel) Engi ne T ype Sing le cylind er vertical,4-str oke, （ OHC ） Disp l acem ent 189m l Bo re × S tr ok e 68mm ×52mm Theo retical Maximum[...]

3 1-3 Ser vice limi t U N I T ： m m P a r t s I t e m S t a n d a r d S e r v i ce li mi t Engin e Max imum s pee d ( N o l oad) Cyli nder com pre ssion 3800±100rpm 1.15Mp a a t 1200 rpm 3650/4000- - Cy linder he a d Sle eve I.D 68.00-68.02 68.160 Cy linder he a d Flatn e ss 0-0.05 0. 100 Pist on Ski r t O . D . Pi st on – t o cy l i nd er c l[...]

4 II . D IMEN S ION AND TORQUE 2- 1 E ng ine dime ns i o n 2- 1- 1 A ppear an ce d imensi on[...]

5 2-1-2 Insta llat i o n h ole p o si t i on 2-1-3 P . T .O dime nsion figure[...]

6 2-2 T orque val ue Not i ce: For unspeci fied bolt , sc rew an d n ut, ref er to th e s tan da rd to r que val ue No . Item Specification Performance class To rque value （ N· m ） 1 Cy li nder hea d M8×65 10.9 28±2 2 Crankcas e c over M 6 ×3 0 8. 8 10±1 3 Oil drai n plug M10×1 5 8.8 22±2 4 Co nnec tin g ro d M6× 35 10.9 13±1 5 Valv e [...]

7 2-3 Standar d tor que valu e Fasteners Thread dia.( mm ) Torque value （ N·m ） 5 mm b o lt, n ut 4.5- 6 6 mm b o lt, n ut 8 -12 8 mm b o lt, n ut 18-2 5 10 mm bo lt, nut 29-3 4 12 mm bo lt, nut 49-5 9 4 mm sc r e w 1 .5 - 2 .6 5 mm s c r e w 3 .5 - 5 6 mm s c r e w 7- 11 5 mm f l a n ge b ol t 3 .6 - 6 .9 6 mm s c r e w 7 - 11 5 mm f l a n ge[...]

8 III. MAIN TE NANCE 3- 1. M a in t en anc e s ch e dule Go od main ten an ce is e sse n tial for sa fe , economical, and trou ble-free opera tion . It w ill als o help re duce air pol lu t i o n. Ex ha u s t gas c on tain s poisonous car bon monoxid e . S hut o ff the e ngi ne be fo re perf o rmi n g an y m ain ten a n ce . If the e n gi n e must [...]

9 3-2 Chan ge oil ·change oil NOTI CE: Dr ain the engine o il ra pidly a nd co mpletely out w hen the engine is hot. （ 1 ） Remove th e drain pl ug and wash er and tilt t he e ngin e to drain engine oil thoroughly . （ 2 ） Rein sta ll the drain plug and washer into s ecu re ly by h and. （ 3 ） T i ght en the o il drain plug ， E A 190 to[...]

10 3-3 AI R CLEANE R NOT IC E: A d irty air c le ane r w ill restrict air fl ow to the ca r buretor . To preven t ca rburetor m alfuncti on, cl ea n t he a i r cl ea n e r e a c h 50 hours (o r thr ee m onths ) and service the ai r cle aner regularly . Service mo re freq uen tly w hen o pera tin g the engine i n extremely dusty ar eas. Using gasoli[...]

11 3-4-2 Fuel ch eck 1 . Re m ove the f u el tan k cap a nd check f ue l leve l . 2. If t he l eve l is t oo l o w , ref uel t he t ank. Pl ease do n’ t ref ue l o ver t he fuel gauge. W A R N I N G ： 1. Gaso line is ext r e me l y f la m ma b le a nd is e xp lo s i ve u nd er cer t ain co nd i t ions. 2. Ref ueli ng in a wel l-vent ila t io n [...]

12 0.60~0.7 0mm Side el ectr o de 3-5 S pa rk P lu g S e rv ice ( 1) Rem ove t he spark plug ca p. Cl ear away d i rt around t he spark p l ug base; (2) Use the plug wren ch t o r em ove the spark p l ug; (3) Vi sua lly inspect t he spark pl ug, if the ins u la t o r is cr acked , repl ace wi t h n ew the s park pl ug , i f de posi t aroun d th e e[...]

13 3-6 V alv e cl earance adjust m ent K eep t he c lea r a nce b etw ee n engi ne va lve ro d e n d a nd dri vi ng par ts f or a voi di ng hea t ex pa ndi ng a nd c ol d s hrin ki ng to e ffect en gi ne pe rform an ce. If the val ve clea r a nce is too big, it can r esult in exhausting unsm ooth, ef f ecti ng en gin e pe rfo rm an ce a nd i ncr ea[...]

14 d ． Recheck valve cleara n ce after ti g hte nin g t he va l ve l oc k nut— —tor q ue valu e: 8 ±1N . m. e ． Set t he n ew gask et a lignin g the pr ojectio n of the new gaskets with the proj ecti on o f the c yli nder head. f ． In sta ll t he valve c over and ti ghten the f our bolts to the specifie d tor que——bo lt tor que valu [...]

15 Adjusting speed ： D on’ t a dj us t t h e s pee d b eca us e it is fixed. If ne ce ssar y, ple ase s end it t o t he a ut hor i zed d eal e r fo r ad ju st ing . If t h e use r has a pro per t o ols a n d r e pa ir in g ca pa cit y, o nl y per m it t he foll owing opera tion: （ 1 ） Star t the engine and all ow it to war m up to nor m al [...]

16 IV . D ISAS SE M BLING AND SE RV ICI NG 4- 1 T ro ubl e sh oo tin g 4- 1- 1 Starti ng di ffic ult TR OU B LE CAUSE REMED Y Th ere is no e nou gh f uel i n f uel ta nk a nd f ue l c oc k i s c l os e d. F ill f uel , open fu el cock. Air vent i n t he fuel f iller ca p is cl ogged Dredge air ven t. Imp roper or clogged carbu retor m ain fuel chan[...]

17 ● Spar k pl ug testing · Mak e su re the re is no sp ille d fuel outs ide t he engine a nd that the spark plug isn’t di pped with f ue l. · T o pre vent f ire, k eep sp ark s far aw ay fr om t he sp ark p l ug m ounting hole. · When te sti ng the spark plug , never ho ld the h i gh tensi on line of the s park plug an d spark plug cap wit [...]

18 Cyl i nder p ressure ch eck · Drain the gasoline in the fuel t ank into the container. ·Dra in the gaso line by loosening th e fuel d rain bo lt o f the ca rburetor ·Rem ove the spark pl ug ca p a n d s pa r k pl u g a n d i ns ta ll t he cyli nder pre ssure meter . ·Fo rcibly pu ll the r ecoi l sta r ter severa l time s a nd me a s u r e c [...]

19 4-1-4 Unabl e ignit ing 4-1-5 Engine over heat TROUBLE CAUSE REMEDY A bno r m al o il vol ume or i nferior oil Ch eck th e o il le vel and qualit y Exhaust pipe blocke d up Clean exhaust pipe Shro ud l ea ki n g Re pa i r da m a g ed pa r t Co ol i n g f i ns b lo c ke d b y f or e i g n ma t t er Cl ea r co oli n g f ins Co ol i n g fa n i s l [...]

20 4-1-6 Abnor m a l so und 4-1- 7 Exhaust gas col o r a bnorm al TR OUBLE CAUSE REME DY Pi ston, pist on rin g or cy li nder is wo rn Replac e the wo rn part Co nnec tio n r od or pi st on pi n and pi st on pi n h ol e ar e wor n R e pl a ce th e wor n pa r t Cr a n ks h a ft mai n n e ck is wor n Re p la c e b ea ri n g B eating so und Piston r i[...]

21 4-2 Pre paration of serv icing 4-2-1 Safety pr ecau tion s W ARNING ： I ndicate a po ssibi lit y o f in valid wa rra n t y a nd p ersona l or e quipment dam age if instr uctions ar e not followed. P l ease pay special a tten ti on t o th e f o l l owi ng: 1. S tr i ctly set t he engine acco rdin g t o t he regulat ed power o n t he n a meplate[...]

22 4-3 Engine 4-3-1 R ecoil starte r /hou sing D i sasse mbl y ： Ser . No. Descripti on Ser . No. Descripti on Ser . No. Descripti on 1 Hex . Flange n ut M6 7 R eturn spring 13 S tarter r ope 2 R ec o il sta rter 8 Driving pawl 14 Starter housing 3 S tarting ro pe grip 9 Compre ssion spring 15 S t ud M 6 X 8 3 4 R o pe g ui de a ss y . 10 W a s h[...]

23 4-3-2 Fuel tan k ● D isass embly/ rea ssembly The fuel tank does not require general m ai nten a nce , but, some tim e s th e du st s a nd va por w ill tr ouble t he f uel syste m , so that, periodically w ashing it with lubric ati on oil a nd ga s o li ne i s r e q ui r e d. WAR N ING : D o n ’t s mo ke or u se f i re n ea r th e f la mmabl[...]

24 4-3-3 Ignition coil/f lywheel ● Ignition coil NOTI CE: Ch eck hig h t ensi o n line in su lat o r fo r c r acked, replace if neces sar y . A sse mb ly ： ① D i sa s se mble e ng ine hou sing, f uel t a nk and r eco il st art er in o rder . ② Measure t he clearance bet ween t he igni t i o n co il a nd f lyw hee l w ith t he f eel e r. ③[...]

25 （ S eco ndary s i de ） M easure t he r esist ance o f t he seco ndar y side of t he co il w it h t he s pa r k p lug cap r em o ved, to u chin g o ne t est l ead t o t he hi gh t ensio n co rd wh ile t o u ch ing t he o t he r t est er l ead to t he co il’ s ir o n c o r e . S eco ndary s ide r esistance val ue ： 5-7 kΩ ● Fl y wheel D[...]

26 FL YWH EEL (CAST IR ON) HOLE HOLE I MP ELL ER POL E POL E ST AR TER CUP 4 - 3 - 4 M u ffle r Fl yw hee l （ a lu m inu m ） Mu ff le r hous i ng S t ud Gas k et Muffler Hex. flange nut M8[...]

27 Disassem b ly/r ea sse mb ly ： The muff ler ca n pr o du ce car bon depo si t s in t he l o ng t ime o p e r at io n and se r io us l y t ro ubl e t he exh au st sy ste m . To g e t th e b e st pe rf orm an ce , t h e m uf fl er m ust b e peri odi c a lly rem o ve d the carbo n depo sits. Li g ht ly tap the m u ffler and bl o w i t with co m p[...]

28 NOTICE  Ch eck f o r da m age o f the a i r c l ean er g a s ke t b ef ore r ea ssemb li ng. If n ece ssar y , pl e ase repl a ce and pa y a tten ti on t o a ssembl i ng dir ect i o n , v i ewi ng f ro m t he ai r c leaner side.  Bef o re a sse mb li ng , ch eck breather hose for deter i orat i o n or da m age . Re pl ace if necessar y . P[...]

29 (such as main jet) f uel pat h an d fl oat ch a mber surf ace. The air enter s in t o t he carburet or t hro ugh air fil t er . Con si d eri ng t he in take can not be t oo m uch resistant and ot her f actor s, t he fil ter can not be t oo dens e a nd therefore part of the air in the t iny i mpuri t ies wi ll e nt er int o t he carbureto r t hro[...]

30 ·Be f ore r ea sse mbli ng, ch eck t he car buret o r t her mal gask et , carburetor gasket, and a i r cleaner gasket f or dam aged, p lease r ep l ace i t if necessar y . Pl ea se pa y a tten ti on t o a sse mbl i ng d i r ect i o n. ● Carburet or W a s h t he carburet or in t he c l ea n p lace, first, cl ean the ou ts i de s urf ace, and w[...]

31 Flo at valve Flo at valve seat Normal W orn （ 1 ） Ch eck t he fl oat valve, fl o at seat and fl oat spri ng f o r w ear . （ 2 ） C l ean wi th c om p re ssed a ir be for e r ea sse mb lin g （ 3 ） Cl ean wi t h c om p re ssed a ir be f o r e r ea sse mb ling Main j et Main no zzl e[...]

32 4-3-7 Thr o ttl e c ontr o l NOT IC E ·Don’ t rand omly repl a ce t hrott l e valve ret ur nin g sp r in g, and g o vern o r spring h ook i n g p osi ti on or re s ul t i n pe rf orm an ce of th e e n gin e uns t able . Governor sprin g h ook p os i t i on ： s h own as f i gure . L ever r ubber sle eve Bo lt M6×1 2 Th ro ttle c o n tro l G[...]

33 4-3-8 Cyli nde r head/ val ve train 1 ） Disassem b ly/r ea sse mb ly ： ① D i sa s se mble r eco il st ar t er/hous in g ； ② D i s a s s e m b l e f u e l t a n k ； ③ D i s a s s e m b l e i g n i t i o n c o il, fl yw he e l ； ④ D i s a s s e m b l e m u f f l e r ； ⑤ D i s a s s e m b l e a i r c l e a n e r ； ⑥ D i s [...]

34 In sp ect th e val ve st em ou ts id e dia m et er with th e mi cr om et e r , if fin di ng out of the standa rd or servi ce l im it, or i f vi sua lly in sp ectin g th e bur n an d d am a ge d on th e va l ve fa ce, pl ea se r epla ce w ith new o ne. ② V al v e s prin g f r ee le ngth Measur e th e fr ee l en gth of th e val ve spr in g s. If[...]

35 Co rr ect Inc o rr ect c) I nst a ll t he new valve gu i des fro m t he valve spr i ng side o f t he cyli nder head.  Exhaust side: Dr iv e t he e xhaust valve gu ide unt il t he c lip i s fu lly s eat ed ( as shown a s fig.)  Int ake side: Dr ive t he in t ake valve g u ide t o t h e specifie d height (m easured fro m the to p of t he val[...]

36 e) If t he c l eara nce is o ver t he ser vice limi t , j udge a new gu i de if i t can make t he c l eara nce co nfor mi ng to servi c e l imi t , if co nf or mi ng to , repl ace t he gu ide a nd rea m t he gu i de, refinish t he va lve whe n r ep l aci n g th e v al v e gui de. ④ V al v e s e at ： a) Thoro ughly clean t he comb ust i o n c[...]

37 e) Use 45°cu tte r t o r e m ov e a ny p os si bl e b u rrs a t th e e dges o f t he s eat. f ) Af ter resur f aci ng s eat, inspect f or even va lve s eat in g w idth. Appl y colorant to t he v a lv e t apered f ace, insert t he v a lve a nd pr e ss i t f o r ce fu lly severa l t imes , be s ur e t he va lve do e s not rotate o n t he s eat . [...]

38 4-3-9 Cr ankcase cover/governor gea r NOTI CE ·Do n’t reuse the crankcase gasket . ·Oil seal ： a) Do n’t r euse ； b ) Appl y t he lubri cat ion o il on t he lip whe n u s ing ； c) P ut t he o il s ea l i nt o t he cr a nkc a s e c o ver w it h sp ec ia l t o o l , d on ’t dam age the e dge of the o il se a l ； d) Ap p ly t he sp [...]

39 4-4-10 Cr ankshaft/piston/crankcase No. Des cr i pt i o n No . Descri pt ion No. Descri pt ion 1 Cran kcase a ssy . 1 1 Gas ke t 21 P i sto n 2 Oil dip stick 12 Br eat h piece a ssy . 22 Cli p 3 Seal r ing 13 Gasket 23 P in 4 Oil dip stick 14 F la t washe r-A c lass 24 Co n n ect in g r o d 5 Bo l t （ M6× 16 ） 15 Govern o r arm 25 Conn ecti[...]

40 Maker mark 120° T op r i n g Secon d ring O il ring ass y . C onnect ing rod R ea ssembly ： Make su re t hat the l onge r e nd m ar k ed is toward th e piston he a d w ith the “↓” “↓”Mark Drive r handle Retaine r a sse m bler Beari ng 6205 Inner retain er a ssem bler Disassembly/r ea sse mb ly ： ① R easse mbly ： a) Pi sto n [...]

41 Too l s ： Driver handle , R etai n er a sse mb ler , Inn er a sse mb ler e) O il s eal ：  A p ply o il t o t he c irc u mf er e nc e o f an o il se a l.  Dr ive t he o il se a l in t he c yl i nder ba rrel usi ng fo ll o w in g too l . Too l s ： Driver handle , R etai n er a sse mb ler  App ly t he lubr i cat i o n o il o n , af t[...]

42 P i sto n ski rt O.D. M easure t he p i st o n sk i rt O.D. wi th o ut si de mic r o met e r , if o u t o f t he se r vic e l imit , rep l a ce i t. b) P i st o n pin bore to pi sto n c l eara nce Separat ely measure t he p i sto n p in b o re I. D and O.D . wi t h i nsi de micr o m et e r and o ut s ide m ic r o me t e r . The n cal cula te cl [...]

43 e) Pis t on rin g e nd gap Flat ly place t h e p i sto n in to t he cyli nder w i t h pushing t h e p i sto n h ead t o wor kin g po si t ion . M e asure th e open i n g cl eara nce w i th feeler , th at cl earanc e s houl d no t be t oo bi g o r not too sm all , b ei ng too bi g ca n resul t in p oor cy lin d e r se a li ng per f or m an ce w h[...]

44 c ） Conn ect ing ro d bi g e nd o il c l eara nce  Wipe o il o ff t he crank p in and co nnect in g r o d beari ng m at in g sur f ace.  Set t he p l ast i c g a uge o n the crank pin , con n ect ing ro d and bo l t to spec if ied t or que. Torque ： 13±1N.m NOTICE : Pla ce t he plastic gau ge axiall y.  Rem o ve co nne c t ing r o [...]

45 · Ch eck inn er d i amet er o f t he ca m shaft bor e , i f bi gger th an th e s e r vi ce l imi t , repl ace t he camshaft. If the spr o cket t eeth da m aged , pl eas e re pl ace t he camshaft w i t h n ew o ne. Camshaft wear ing cause analyses a nd t o engine per f o r m ance influen ce ： P oor l ub r i cat i o n w ill r esult in camshaft [...]

46 4-5 El ect r ic diagram 汽油机开 关 Eng ine swi tch E ngi ne s w itch Spa rk p lug I g n itio n c o il Blac k ON OF[...]

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49 I SSUE EMD-ES 7175 De ce m be r 2010[...]