Robin America EY44-2 manual

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ROBIN AMERICA, INC. ROBIN TO WISCONSIN ROBIN ENGINE MODEL CROSS REFERENCE LIST ROBIN EY 08 EY15 EY 15V EY20 EY20V EY23 EY28 EY3 5 EY40 EY45V EY2 1 EY44 EY 18-3 EY25 EY27 EH11 EH12 EH15 EH17 EH2 1 EH25 EH3 0 EH30V EH34 EH34V EH43V EC13V DY 23 DY27 DY30 DY35 DY4 1 WISCONSIN ROBIN SIDE VALVE W 1-080 WI-145 W1-145V W1-185 W1-185V W 1-230 W 1-280 Wl-340[...]

CONTENTS Section Title Page 1 . SPECIFICATIONS ............................................ 1 2 . PERFORMANCE ............................................ 2 2.1 . Maximumoutput ....................................... 2 2.2 . Continuous Rated Output ................................. 2 2.3 . Maximum Torque and Fuel Consumption Ratio at Max . Output .[...]

7 . MAGNETO ............................................... 18 7.1 . Magneto ............................................. 18 7.2 . Breaker Point Adjustment ................................. 18 7.3 . Timing Adjustment ..................................... 18 7.4 . Magneto Service Instructions ............................... 19 8 . GOVERNOR ADJUSTME[...]

1. SPEC1 FICATIONS -1-[...]

2. PERFORMANCE 2-1 MAXIMUM OUTPUT The maximum output of an engine is such standard power as developed by that engine, after its initial run-in period with a1 the moving parts properly worn-in, when operating with the fully open throttle valve. Therefore, it follows that a nev engine may not develop this maximum output in the beginning, because movi[...]

3. FEATURES 1. A compact, lightweight, and highly durable 4cycle aircooled EYseries with high output, embodying ingenious design and advanced machining techniques. 2. Simple construction, good appearance, plus easy start-up. 3. Smooth speed control functions of governor guarantees stable operation under various load conditions over a wide range of [...]

/- FLYWHEEL(COOLI~G FAN) I LIGHTING COIL CRANKCASE -4 -[...]

SEl -5-[...]

4-2 CRANKCASE The crankcase is made of aluminum die-cast and separable on driving shaft side with main bearing cover assembled. Provided on blower side are two ball bearings, each supporting the crankshaft and camshaft. 4-3 MAIN BEARING COVER The aluminum die-cast main bearing cover on the driving shaft side allows easy access to the engine interio[...]

4-10 GOVERNOR The centrifugal flyweight type governor assures constant-speed operation at selected speed, irrespective of load fluctuations. 4-11 COOLING The cooling fan which also serves as a flywheel forcily feeds cooling air to the cylinder head with the aid of cylinder baffles and head cover. 4-12 LUBRICATION The rotating and sliding parts are [...]

5. INSTALLATION Since the installation method affects the service life, ease of maintenance, frequency of check and reapir, and operating costs of engine, the following contents should be carefully examined before installing your engine. For details, refer to the separate “SALES MANUAL”-Engineering Information-. 5-1 MOUNTING When installing the[...]

5-6 WIRING a JIS CB104 female terminal -e JIS CA104 male terminal -@ JIS LA 104 or LA1 08 plate terminal - """ The dotted parts are not supplied with the engine. 5-6-1 ROPE STARTING ENGINE MAGNETO _"""" '.-N / BUZZER (6"- 8W) SPARK PLUG LAMP (12V. 15W) Fig. 5-6-1 5-6-2 ENGINE with STARTING MOTOR MAGNETO [...]

6. DISASSEMBLY and REASSEMBLY 6-1 PREPARATIONS and SUGGESTIONS 1) When disassembling engine, carefully note mounting positions and methods of respective parts in order to be able to reassemble them correctly. Tag parts, if there is a possibility of confusion. 2) Prepare several boxes to keep parts belonging to respective groups together. 3) In orde[...]

Flywheel Puller I Bolt 209 9901 0 07 001 65085 00 (Y790-350) Valve Spring Compressor 209 9901 1 07 (Y790-282) I1 Valve Seat Cutter (45”) 1 (H640-118) Pilot Stem 1 209 9901 2 07 6-3 DISASSEMBLY and REASSEMBLY PROCEDURES 6-3-1 FUEL TANK and TANK BRACKET 1) Disconnect fuel pipe between fuel strainer and carburetor from carburetor. 2) Detach fuel tan[...]

6-3-6 STARTING PULLEY and FLYWHEEL (magneto) Remove 3 pieces mounting bolts to detach starting pulley from flywheel. Remove flywheel from crankshaft. Insert a socket wrench or box wrench into an 18mm nut, and give the wrench a sharp blow with a soft hammer. Remove nut and spring washer. Attach flywheel puller to flywheel as shown in Fig. 6-3-1, and[...]

In reassembly; 1) Clean carbon and gum deposits from the valves, seats, ports and valve stem holes. 2) Replace valves, if badly burned, pitted or warped. 3) Correct the valve seat by using 45" seat cutter tool as illustrated in Fig. 6-3-3. The seat should be finished to 1.2-1 Smm (.04-.05 inch) in width. 4) Cylinder block should be replaced if[...]

6) ADJUSTING TAPPET CLEARANCE (Fig. 6-3-5) * Rotate crankshaft until tappet is in its lowest position, hold valve down and insert feeler gauge between valve and tappet stem. The clearance for both intake and exhaust, with engine cold. 0.13-0.17mm (0.0051”to 0.0067“) * If clearance is less than specified, slightly grind valve stem and measure it[...]

In reassembly; 1) When reassembling main bearing cover, assemble governor lever shaft and governor arm before reinstalling them into crankcase. NOTE: If replacement of oil seal is required, force-fit new oil seal before reassembly. 2) When reassembling main bearing cover, apply oil to bearing surfaces, gear train, tappets, and oil seal lips, and fo[...]

In reassembly; PISTON RING (See Fig. 6-3-10) 1) Use a ring expander tool to prevent ring from becoming distorted or broken when installing onto piston. If an expander tool is not available, install rings by placing the open end of the ring on first land of piston. Spread ring only far enough to slip over piston and into correct groove, being carefu[...]

5) Check if connecting rod moves smoothly after reassembly. Clamping torque of connecting rod cap is 250-300 kg-cm (1 8-21.7 ft-lbs). D (crankshaft pin Dia.) W (crankshaft pin Width) PISTON TO CYLINDER AT PISTON SKIRT THRUST FACE (CLEALANCE) (.0059”L-.0074”L) 0.15OL-0.189L (.0061“L-.0070”L) 0.155L-0.177L (.0020”L-.0098“L) 0.05L-0.25L (.[...]

7. MAGNETO 7-1 MAGNETO In Models EY33-2 and EY44-2, ignition spark is furnished by a magneto. The magneto is composed of the flywheel, ignition coil, lighting (charging) coil, breaker assembly (including condenser). The flywheel is mounted on crankshaft, while ignition coil, lighting coil, and breaker assembly are directly assembled to crankcase. 7[...]

For timing adjustment, the following alighment marks are provided: D type: D mark at lower left crankcase (see Fig. 7-3-1) M mark and slit on flywheel circumference B type: B mark at upper left crankcase M mark and slit on flywheel circumference. FLYWHEEL e- Fig. 7-3- I Fig. 7-3-2 For timing adjustment, the following procedures using a timing light[...]

*CHECKING IGNITION SPARK Remove spark plug from cylinder head and place it on cylinder head fin after connecting ignition cable to it. Crank engine several times by starting pulley, and check if plug gap spark is strong or weak. If spark is weak, check it according to steps 1 )-3) above. Correct plug gap is 0.6 to 0.7mm (.0236"".0276"[...]

8. GOVERNOR ADJUSTMENT EY33-2 and EY44-2 employ a centrifugal flyweight type governor which is mounted on a cam gear to automatically regulate throttie valve of carburetor by mean of a lever, so that the engine speed is kept constant irrespective of load fluctuations. For adjustment, observe following procedures. (see Fig. 8-1 ) 1)' Connect ca[...]

9. CARBURETOR 9-1 OPERATION and CONSTRUCTION (see Figs. 9-1-1 and 9-1-2) 9-1-1 FLOAT SYSTEM The float chamber is located just below carburetor main body and serves to maint ain the fuel I .eve1 at a cons itant height by a joint action of float (F) and needle valve (NV) incorporated. The fuel flows from the fuel tank into float chamber via needle va[...]

9-1-2 PILOT SYSTEM This pilot system feeds fuel to engine during idle and low speed operation. The fuel fed through main jet (MI) is measured by pilot jet (PJ), mixed with air measured by pilot air jet (PAJ), regulated by pilot screw, and then fed to engine through pilot outlet (PO) and bypass (BP). The fuel is mainly fed from pilot outlet (PO) dur[...]

9-2-3 PILOT SYSTEM 1) Remove pilot jet (5) using a suitable tool while taking care not to damage it. 2) Detach pilot screw (6) and spring (7). In reassembly; 1) Clamp pilot jet securely, otherwise fuel leaks, causing engine failures. 2) If the tapered portion of pilot screw is deformed, replace it with new one. Avoid clamping it too tightly. 9-2-4 [...]

10. RUN-IN OPERATION OF ENGINE after REASSEMBLY An overhauled engine must be carefully run-in to get proper engine surface conditions on newly installed parts. A thorough run-in operation is indispensable particularly when cylinder, piston, piston rings, or valves are replaced. The recommended run-in schedule is as tabulated below. LOAD SPEED EY33-[...]

1.1. TROUBLE SHOOTING For a satisfactory starting and running conditions of a gasoling engine, the following three requirements must be met: I. The cylinder filled with a proper fuel-air mixture. 2. An appropriate compression in the cylinder. 3. Good spark at correct time to ignite the mixture. If all three requirements are not met simultaneously, [...]

11-1-3 ELECTRIC SYSTEM When there is no spark, the following must be checked. 3) 11-2 Disconnected cable leading to ignition coil, spark plug or contact breaker. Broken ignition coil winding, causing short circuit. Wet or oil soaked spark plug cable. Dirty or wet spark plug. Incorrect spark plug electrode gap. Short connection of spark plug electro[...]

8) Restricked exhaust gas outlet. Carbon deposit in combustion space. 9) Engine detonating due to low octane gasoline with heavy load at low speed. 11-5 ENGINE KNOCKS 1) Gasoline of poor quality or low octane rating. 2) Engine operating under heavy load at low speed. 3) Carbon or lead deposits in cylinder head. 4) Incorrect spark timing. 5) Losse o[...]

12. CHECKS and CORRECTIONS After dismantling and cleaning the engine parts, check them, and if necessary, correct them, according to the correction table. The correction table applies whenever the engines are repaired. Its contents should be thoroughly understood by those who undertake the repairing. Its specifications must be abided by to effect c[...]

CORRECTION TABLE REMARKS USE I :ORRECTIOF METHOD STANDARD SIZE CORRECTION TOLERANCE " " - " " - - - - " - - - - ENGINE MODEL EY33-2 EY44-2 EY33-2 EY44-2 EY33-2 EY44-2 EY33-2 EY44-2 EY 33-2 EY44-2 EY33-2 EY44-2 EY33-2 EY44-2 EY33-2 EY44-2 EY33-2 EY44-2 EY33-2 EY44-2 EY33-2 EY 44-2 EY 33-2 EY44-2 EY33-2 EY44-2 EY 33-2 EY44-2 [...]

ITEM ENGINE MODEL STANDARD SIZE 2ORRECTIOh METHOD TOOL TOLERANCE EY33-2 -0.008 0 Micro- meter Piston pin O.D. Replace EY44-2 -0.009 0 E Y 33-2 EY44-2 EY 33-2 -0 +0.016 Cylinder gauge Replace Large end I.D. Clearance between rand large end I.D. and crankpin Small end I.D. Clearance between small end I.D. and piston pin Large end side clearance Paral[...]

r ENGINE I STAl:;RD 1 , MODEL CORRECTION TOLERANCE :ORRECTIOF METHOD LIMIT USE 0.05 -1.5 TOOL ITEM Journal O.D. Free length Squarences Valve stem O.D. Clearance between stem and guide Tappet clearance Clearance between groove and retainer Stem end length Total length Clearance between stem and guide Mein jet unscrew Pilot screw unscrew Spark plus S[...]

ITEM HP/rpm MODEL EY 33-2 8.013.600 Max. Output EY44-2 lO.Ol3.600 EY33-2 613,600 Continuous Rated output EY 44-2 813,600 I I CORRECTION LIMIT REMARKS Below 11 0% of rated output ITEM REMARKS CORRECTION LIMIT literlhr MODEL EY33-2 3.1 Fuel Consumption up 135% Standard Consumption at Continuous Rated Output EY 44-2 3.6 I I I I I - - ITEM REMARKS USE [...]

ITEM REMARKS TOOL rpm MODEL EY33-2 Min. accelerating revolution 1,150 Tachometer EY44-2 ITEM Cylinder head clamp nuts Connecting rod bolts Magneto clamp nuts Main bearing cover bolts Spark plug MODEL EY33-2 EY 44-2 EY33-2 EY44-2 EY 33-2 EY44-2 EY 33-2 EY 44-2 EY33-2 EY44-2 kgcm 450-500 250-300 800-1 .OOO 170-190 250-300 ft-lb 32.5-36 18-2 1.7 57.9-[...]

13. 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[...]

13-5 EVERY 500 - 600 HOURS (SEMIANUAL) CHECKS and MAINTENANCE I Checks and maintenance Reasons for requiring them 1 Remove cylinder head and remove carbon deposit. The engine will be out of order. Disassemble and clean carburetor. 13-6 EVERY 1000 HOURS (YEARLY) CHECKS and MAINTENANCE I Checks and maintenance 1 Reasons for requiring them ~~ ~~ -1 Pe[...]

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