SERVICEMANUALEX30ENGINESModelPUB-ES2268Rev. 10/06
- 7 -4-9 GOVERNOR SYSTEMThis engine is equipped with a centrifugal flyweight type governor that makes it possible to operate the engine at a constant
- 8 -4-14 CARBURETORThe engine is equipped with a horizontal draft carburetor. The carburetor setting is calibrated after careful testing for optimum
- 9 -4-17 SECTIONAL VIEW OF THE ENGINECross sectional view - across the shaftDUCTBLOWER HOUSINGSTARTING PULLEYRECOIL STARTERFLYWHEEL OIL SENSOR MAIN B
- 10 -Cross sectional view - along the shaftEXHAUST PIPECONNECTING RODCRANKSHAFTCRANKCASEOIL DRAIN PLUGTIMING CHAINGOVERNORGEARGOVERNOR LEVERPISTON DU
- 11 -5-1 PREPARATIONS AND PRECAUTIONS(1) When disassembling the engine, memorize the location of each part so that you can reassemble the engine corr
- 12 -5-3 DISASSEMBLY PROCEDUREStep Parts to remove Remarks and procedures Fasteners1 Drain the engine oil (1) Remove a drain plug (M14 x 12mm)located
- 13 -Step Parts to remove Remarks and procedures Fasteners3 Air cleaner cover Remove the air cleaner cover. 14 mm spanner4 Air cleaner Remove the ele
- 14 -Step Parts to remove Remarks and procedures Fasteners5 Stop switch(Float C/U CP5)Disconnect the wire and remove the stop switch from the blower
- 15 -Step Parts to remove Remarks and procedures Fasteners8 Duct (case) Remove the Duct (case) from the crankcase. 10 mm box spannerM6 x 12mm : 3 pcs
- 16 -Step Parts to remove Remarks and procedures Fasteners10 Governor system (1) Loosen the bolt and remove the governor lever from the governor shaf
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- 17 -Step Parts to remove Remarks and procedures Fasteners13 Ignition coil Remove the spark plug cap from the spark plug and remove the ignition coil
- 18 -Step Parts to remove Remarks and procedures Fasteners16 Electric starter (option) Control box,Diode rectifi er, Magnetic switch (1) Disconnect th
- 19 -Step Parts to remove Remarks and procedures Fasteners17 Baffl e 1 (case) Remove the baffl e 1 (case) M8 x 12mm : 1 pc. 18 Charge coil (option) Rem
- 20 -Step Parts to remove Remarks and procedures Fasteners20 Rocker cover (1) Remove the rocker cover from the cylinder head.(2) Remove the gasket (r
- 21 -Step Parts to remove Remarks and procedures Fasteners22 Main bearing cover Remove the fl ange bolts of main bearing cover from the crankcase. Re
- 22 -Step Parts to remove Remarks and procedures Fasteners23 Tensioner, Camshaft (1) Remove the tensioner. (See Figure STEP23-A)Do not lose the pin
- 23 -Step Parts to remove Remarks and procedures Fasteners24 Cylinder head,Chain guide(1) Remove the cylinder head from the crankcase.(2) Remove the
- 24 -Step Parts to remove Remarks and procedures Fasteners26 Connecting rod and piston (1) Scrape off any carbon from the cylinder and the piston hea
- 25 -Step Parts to remove Remarks and procedures Fasteners28 Crankshaft (1) Remove the woodruff key (for the fl ywheel magneto). (2) Remove the cranks
- 26 -5-4 REASSEMBLY PROCEDURE5-4-1 NOTES ON REASSEMBLY(1) Clean the each parts carefully, taking special care with the piston, cylinder, crankshaft,
CONTENTSSection Title Page1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. PER
- 27 -(3) PISTON AND PISTON RINGSInstall each piston ring in the correct groove of the piston by widening it enough to slide it over the piston.NOTE:
- 28 -(5) CONNECTING ROD(a) Install the piston and connecting rod assembly into the cylinder by holding the piston rings with the ring guide, with the
- 29 -EXHAUST VALVEINTAKE VALVECYLINDER HEADVALVE SPRINGVALVE SPRINGCOLLET VALVECOLLET VALVESPRING RETAINERSPRING RETAINERSTEM SEAL(6) INTAKE AND EXHA
- 30 -(8) CYLINDER HEADInspect and repair any scratches on mounting surface and replace head gasket to new one before installing.Cylinder head boltsT
- 31 -(10) MOUNTING THE CAMSHAFT ON THE CYLINDER HEADMount the camshaft on the cylinder head by inserting the pin (camshaft) through the head. Fix th
- 32 -(12) MAIN BEARING COVERApply oil to the bearing and the oil seal lip when mounting the main bearing cover. Also apply sealant (Three Bond "
- 33 -(13) Pass the pin (rocker arm) through the rocker arm and mount them on the cylinder head.NOTE1: Conduct this job at the compression top dead
- 34 -(15) ROCKER COVERReplace the gasket with a new one, and mount the rocker cover.M6 × 12mm fl ange bolt : 4 pcs.Tightening torque5.0 - 7.0 N●m(50 -
- 35 -(18) FLYWHEEL AND STARTING PULLEYNOTE1: Wear work gloves during operation to avoid a possible injury by a sharp edge.NOTE2: When mounting the
- 36 -(20) SPEED CONTROL LEVER, BRACKET AND BAFFLEMount the speed control lever and bracket, baffl e 2 (head) on the crankcase.(21) CARBURETOR(a) Repla
- 1 -1. SPECIFICATIONSMODEL EX30DTypeAir-cooled, 4-cycle single cylinder, overhead camshaft, gasoline engineDisplacement mL (cc)287Direction of Rotati
- 37 -(22) GOVERNOR LEVER(a) Pass the governor rod through the rod spring, then connect to the throttle lever of the carburetor.(b) Attach the govern
- 38 -(23) EXHAUST PIPE and DUCT(CASE)Mount the Exhaust pipe and the gasket on the cylinder head.EXHAUST PIPE SIDE (RIGHT SIDE)GASKET(Attention to the
- 39 -(25) AIR CLEANER BASEInsert the breather pipe into the rocker cover and then mount the air cleaner base.M6 fl ange nut : 2 pcs.Tightening torque6
- 40 -(26) STOP SWITCH (FLOAT C/U CP5) (a) Mount the stop switch on the blower housing.(b) Refer to the wiring diagram (See page 45 and 46) for wirin
- 41 -(28) EXTERNAL INSPECTIONReassembly is completed. Check that the wiring is correct and that there are no loose nuts and bolts or any other faults
- 42 -Using engine oil of the correct grade and viscosity greatly lengthens engine life and improves performance. Too much or too little oil can also
- 43 -7-1 MAGNETOThe Robin Engine uses a T.I.C. type breakerless magneto ignition system.(1) T.I.C. (TRANSISTOR IGNITER CIRCUIT) has the ignition coi
- 44 -7-3 IGNITION SYSTEM7-3-1 IGNITION COIL INTERNAL CIRCUIT7-3-2 IGNITION TIMING CHARACTERISTIC7-3-3 BASIC THEORY(a) Revolution of the fl ywheel gen
- 45 -8-1 MODEL WITHOUT ELECTRIC STARTER8. WIRING DIAGRAM8-2 MODEL WITH ELECTRIC STARTERStop switchFlywheelIgnition coil(with built-in transistor)Blac
- 46 -8-3 MODEL WITH OIL SENSORTo LED LampYellowYellow / RedBlackOil sensorcontrol unitOrange OrangeBodyearthBlack / WhiteBlackTo stop switchSparkplug
- 2 -2-1 MAXIMUM OUTPUTThe Maximum output is the output of an engine with its throttle valve fully opened and considering that all the moving parts ar
- 49 -10-1 SPECIFICATIONS10. OIL SENSORTypeFloat type (with lead switch incorporated)Resistance (at FULL oil level)100 M ohms or overOperating Tempera
- 50 -11-1 FUNCTIONS AND CONSTRUCTIONEX series engines employ an automatic decompression system as a standard feature. This enables easy starting of t
- 51 -12-1 SPECIFICATIONS12. CARBURETOR12-2 FUNCTIONS AND CONSTRUCTION12-2-1 FLOAT SYSTEMThe fl oat chamber is located below the carburetor body. Throu
- 52 -FUEL SYSTEM OUTLINEFLOAT CHAMBERFUELNEEDLEVALVEFLOATPILOT OUTLETBYPASSPILOT AIR JETCHOKE VALVEAIR INTAKE PORTMAIN AIR JETMAIN NOZZLEPILOT JETFLO
- 53 -12-3 DISASSEMBLY AND REASSEMBLYMechanical failures aside, most carburetor malfunctions occur when the fuel/air ratio of the mixture is not corre
- 54 -The procedures for overhauling the carburetor are described below.12-3-1 THROTTLE SYSTEM(1) When the throttle stop screw is removed, the sprin
- 55 -Tools to be prepared: Driver, Pinchers (Pliers), Protective Glasses and Work gloves.13. RECOIL STARTER13-1 DISASSEMBLY STEPS(1) Relieve the spri
- 56 -Since the spiral spring is set in the reel, do not drop or shake it. Put it on a fl at place.WARNING-2: Hold up the real gradually and slowly, an
- 57 -The spring power is at its maximum when the reel is being wound. Do not put off your hand nor loosen the pressure of your fi nger unintentionally
- 58 -13-3 CHECK AFTER REASSEMBLY(1) Pull the starter knob a few times to check if :A. The starter knob is too heavy to pull, check that each part has
- 3 -2-4 PERFORMANCE CURVES2000 2400 2800 3200 3600 400000.51.01.52.02.53.03.54.04.55.05.56.06.57.0kW17.018.019.020.0[HP]r.p.m.REVOLUTIONTORQUEOUTPUT0
- 59 -Installation has a decisive infl uence on engine life, ease of maintenance and inspection, frequency of inspection and repair, running costs and
- 60 -14-5 POWER TRANSMISSION TO DRIVE MACHINES14-5-1 BELT DRIVENote the following:● Use a V-belt rather than a fl at belt.● The drive shaft of the eng
- 61 -If the engine shows any sign of malfunction, the cause should be determined immediately and appropriate countermeasures should be taken to preve
- 62 -Problem and possible cause RemedyPoor output1. Insuffi cient compression 1) Loosen spark plug Retighten; replace gasket2) Leakage from cylinder h
- 63 -Problem and possible cause RemedyExcessive engine oil consumption1. Oil leakage 1) Loose oil drain plug Tighten2) Faulty oil drain gasket Replac
- 64 -OKDoes the crank run?Does the starter run?ELECTRIC STARTERCheck battery charged state and battery terminal connection or corrosion for any abnor
- 65 -Problem and check itemDescription Remedy(1) Starter does not run or only "click" sound is heard.1. Checking of continuity of wiringCh
- 66 -Problem and check itemDescription Remedy(2) Starter runs but engine notCheck engaged state of pinion and ring gear.Motor idles and engine does n
- 67 -"STD" in the following table is the parts dimension from the brand new engine or the spare parts.Whereas, "Limit" shows the
- 68 -ITEM STD LimitCYLINDER* Inner diameter* Roundness after reboring* Cylindricity after reboringStandard75.000 - 75.019(2.9528 - 2.9535)To be rebor
- 4 -3-1 EXTREMELY EASY START - NO KICK-BACKReliable Starting and Less Pulling Force are achieved by:- Sophisticated Mechanical Compression Release Sy
- 69 -ITEM STD LimitPISTON* Ring groove side clearance* Piston pin hole* Piston pin outer diameter* Clearance between piston and cylinder at skirt* Pi
- 70 -ITEM STD LimitCONNECTING ROD* Large end inner diameter* Clearance between large end and crank pin* Small end inner diameter* Clearance between
- 71 -ITEM STD LimitCAMSHAFT* Cam peak height (intake and exhaust)* Cam sprocket inner diameter* Pin (cam sprocket) outer diameterCam peak height29.43
- 72 -ITEM STD LimitVALVE SPRING FREE LENGTH27.4(1.0787)VALVE SEAT ANGLE(INTAKE AND EXHAUST)* Valve cutter angle (a)* Valve contact width (b)Intake Ex
- 73 -16-2 TIGHTENING TORQUEITEMTightening TorqueN●m kgf●cm ft●lb.Cylinder head boltsM8 × 68 fl ange boltRe-use 25.0 - 27.0 250 - 270 18.1 - 19.5When r
- 74 -The maintenance jobs described below apply to correct use of the engine under normal conditions.The maintenance intervals mentioned in this sect
- 75 -17-5 INSPECTION AND MAINTENANCE EVERY 300 HOURSMAINTENACE ITEMS REASON / REMARKS(1) Inspect the intake and exhaust valve clearance. Adjust if n
PRINTED IN THE USA
- 5 -4-1 CYLINDER AND CRANKCASEThe cylinder and crankcase are aluminum die-casting as a single piece. A special cast iron cylinder liner is molded int
- 6 -4-5 PISTON RINGSThe piston rings are made of special cast iron. The profi le of the top ring is a barrel face or tapered face, and that of the sec
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