Robin America EH12-2, EH17-2, EH25-2 Service Manual Download Page 1

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Summary of Contents for EH12-2, EH17-2, EH25-2

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Page 2: ...CONTENTS Section Title 1 2 3 4 5 6 7 8 Page 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 1 4 4 15 4 1 6 4 1 7 ...

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Page 4: ...or 1OW 30 Class SE SF or higher I Carburetor I Horizontal Draft Float Type IFuel I Automobile Gasoline 310 g KW h 230gr HP h At Continuous Rated Output I Fuel Feed m I Gravity Type FuelTank Capacity Flywheel Magneto Solid State Ignition System 3 6 L 0 95U S gal ISpark Plug NGK BGES Charging Capacity Starter Recoil Starter Starting System 12V 1 3A 12V 1 3A Recoil and Electric Starter Recoil and El ...

Page 5: ...ant Horizontal Draft Float Type Carburetor 0 65 L 0 17 U S gal _ _ _ _ _ _____ Automobile OilSAE 20 30 or 1OW 30 Class SE SF or higher Fuel 310g KW h 230gr HP h At Continuous Rated Output Fuel Consumption Rate Automobile Gasoline Fuel Feed System 3 6 L 0 95 US gal Fuel Tank Capacity Gravity Type Flywheel Magneto Solid State Spark Plug 12V 1 3A 12V 1 3A Charging Capacity NGK B6HS IStarting System S...

Page 6: ...ash Type Capacityof Lubricant 1 O L 0 26 U S gal Carburetor Fuel Horizontal Draft Float Type Automobile Gasoline Fuel ConsumptionRate Fuel Feed System 310g KW h 230 gr HP h At Continuous Rated Output GravityType Fuel Tank Capacity Flywheel Magneto Solid State Ignition System 6 0 L 15 9 U S gal Spark Plug 12V 1 3A 12V 1 3A Charging Capacity NGK B6HS Starting System Recoil Starter Starter Recoil and...

Page 7: ...not broken in 2 2 CONTINUOUS RATED OUTPUT Thecontinuousratedoutputistheoutput of anengineatoptimumgovernedspeedwhichismost favorable from the view point of engine s life and fuel consumption Whentheengine is installed on a certainequipment it is recommendedthatthecontinuousoutput required from the enginebe kept below this continuous rated output 2 3 MAXIMUM TORQUE The maximum torque is the torque ...

Page 8: ...2 4 PERFORMANCECURVES 8 0 EHlPD B HP kW 4 3 3 l2 n 0 3 1 0 2 1 for B type 2000 3000 1000 1500 REVOLUTION r p m 4000 2000 5 ...

Page 9: ...0 EH17D 6 for B tvDe 1000 REVOLUTION r p m N m kgfam 3000 4000 1500 2000 6 ...

Page 10: ... r I I I I I I I I I I I I 1 MAXIMUM TORQUE AL I I I I I kW I IMAXIMUM HORSEPOWER NET I 6 5 4 I RECOMMENDED I i N m kgf m 16 5 33 15 5 31 14 5 29 1 7 3 4 1 6 3 2 1 5 3 0 1 4 2 8 c 2000 3000 4000 1000 1500 2000 REVOLUTION r p m 7 ...

Page 11: ...evibrationlevel of theengine EH25 2 engine equips single through balancer shaft as an option resulting in more power from Iess fuel and prolonged engine life 4 GENERAL DESCRIPTIONOF ENGINE COMPONENTS 4 1 CYLINDER AND CRANKCASE The cylinder and crankcaseis single piece aluminum diecasting Thecylinderliner made of specialcast iron is molded into the aluminum casting The crankcase has a mounting surf...

Page 12: ... alloy diecasting and its largeandsmalIendsfunctionasbearings The piston is an aluminum alloy casting and carries two compression rings and oneoil ring 4 5 PISTONRINGS The piston rings are made of special cast iron Theprofile of thetopring is barrelfaceandthe second ring has a tapered face The oil ring consists of a cutter ring and a coil expander for better sealing and less oil consumption B TYPE...

Page 13: ...haft and the ball bearingsareemployed on both sidesforsupporting the shaft 4 7 VALVEARRANGEMENT The intake valve is located on flywheel side of the cylinder head The hard alloy valve seatsaxe molded in the cylinder head and stellite is fused to the exhaust valve face The cylinder baffle leads cooling air to the exhaust valve area for the optimum cooling 4 8 CYLINDER HEAD The cylinder head is an al...

Page 14: ...acity for theinletandexhaustarea and cylinder Thecylinderbafflehelpsthecoolingairfloweffi ciently GOVERNOR GEAR Fig 4 9 4 11 LUBRICATION All the rotating and sliding parts are splash lubricated by the oil scraper on the connecting rod I OIL SCRAPER Fig 4 10 4 12 IGNITION SYSTEM Theignitionsystemis atransistorcontrolledmag neto ignition system which cosists of a flywheel and an ignition coil witha ...

Page 15: ...sufficient output 4 14 AIR CLEANER The air cleaner is a single urethane foam element system As an option heavy duty type with a double element type is available CLEANER CASE Singleelement type Fig 4 13 I 4 15 BALANCER Option for EH25 2 Unbalanced inertia force is balanced by the balancer which rotates at the same speed with the crankshaft to effectively reduce vibration CLEANER COVER Double elemen...

Page 16: ...ECOMPRESSION SYSTEM An automatic decompression mechanism which opens exhaust valve before the piston reaches com pressiontop is assembledonthecamshaftforeasy starting AUTOMATIC DECOMPRESSOR SYSTEM Fig 4 14 13 ...

Page 17: ...4 17 SECTIONAL VIEW OF ENGINE FUELTANK FLYWHEEL MAIN BEARING COVER 1 4 ...

Page 18: ...a ROCKER ARM PUSH ROD 15 ...

Page 19: ...adyto keep disassembed partsby group 3 To prevent losing and misplacing temporarily assemble each group of disassembed parts 4 Carefully handle disassembed parts and clean them with washing oil if necessary 5 Use the correct tools in the correct way 5 2 SPECIAL TOOLS Tool No Use Tool 209 95004 07 For pulling off the flywheel EH25 2 Flywheelpuller withbolt Market parts For pulling off the flywheel ...

Page 20: ...RES Step Tool Remarks Procedures Partto remove I 1 14mm box wrench Be careful not to lose the 1 Remove oil drain plug and drain oil Oil drain 2 To discharge oil quickly remove oil gasket gauge GASKET I Fig 5 2 DRAIN PLUG 17 ...

Page 21: ...ose fuel valve 2 Disconnect fuel hose between fuel strainer and carburetor 3 Remove fuel tank from cylinder head M6X14mm bolt 4pcs EH12 2 17 2 M8X20mm bolt 0 4pcs EH25 2 Wipe off spilt fuel thoroughly 1Omm 12mm socket wrench EH12 2 17 2 EH25 2 FUEL HOSE Fig 5 3 18 ...

Page 22: ...X 8mmflangebolt 4pcs 1Omm box wrench Ihousing 5 Oil sensor Option I 1 Remove blower housing from crankcase M6X i2mm flange bolt 4pcs lOmm box wrench 1 Remove oil sensor probe Be careful not to damage stick and sensor since these are sensitive and an erratic operation may result BLOWER HOUSING Fig 5 4 19 ...

Page 23: ...exhaust pipe cover M6X lOmm flange bolt 0 Spcs 2 Remove muffler from crankcase and cylinder head M8 nut 2pcs M6X 12mmflange bolt 1PC M8X 16mmflange bolt 1pc EH25 2 EHl2 2 17 2 I Remarks Be careful not to lose muffler gasket Tool 8mm lOmm and 12mmsocket wrench M8 NUT 2 pcs MUFFLER COVER c Fig 5 5 20 ...

Page 24: ...ect wires blue 1 diode rectifier light blue 1 diode rectifier black 1 magnetic switch 2 Remove black wires from electric starter 3 Remove controlbox 12mm socket wrench 4 Loosen two bolts and remove electric Fastened together with fuel tank starter M8 bolt 2pcs to 21 ...

Page 25: ... Remove head cover from crankcase 1Omm M6X 12mm flange bolt 1pc socket wrench 1 Remove cleaner coverand cleaner lOmm Fastened together with element M6 flange nut 2pcs socket wrench carburetor 1 2 Remove cleaner case c GASKET CLEANER CASE c c Fig 5 7 22 ...

Page 26: ...t wrench Speed control 1 Remove stop plate friction plate and lever speed control lever M6X 14mmflange bolt 1PC lOmm socket wrench Intake pipe 1 Remove intake pipe from cylinder head Be careful not to lose 10mm 12mm M6 flange nut 2pcs EH12 2 17 2 insulator and gasket socket wrench M6X 25mmflange bolt 1pc M8X28mm bolt and washer EH12 2 17 2 a P C S EH25 2 STOP PLATE M6 FLANGE NUT 2 PCS EH12 2 17 2 ...

Page 27: ...terpulley from flywheel Place socket wrench on flywheel fastening nut and strike tip of the lever with hammer Refer to the illustration below See Fig 5 9 14mm nut lpc EHl2 2 17 2 18mmnut 1pC EH25 2 Do not place bar or screw driver in flywheel fin to loosen flywheel nut I 19mm EH12 2 17 2 24mm EH25 2 socket wrench c EH12 2 17 2 EH25 2 Fig 5 70 24 Fig 5 9 ...

Page 28: ...ller as 1 Remove flywheelfrom crankshaft Flywheel 2 Remove key from crankshaft illustrated below SeeFig 5 12 See Fig 5 11 17 1 Remove chargecoil Chargecoil I Option M6X 25mm Screw 2pcs 18 21mrn 1 Remove sparkplug from cylinder head Spark plug socket wrench Fig 5 1 1 FLYWHEEL 25 ...

Page 29: ...ad 2 Remove gasket rocker cover M6X 12mmflange bolt 4pcs 1 Remove cylinderhead from crankcase M8x65mm flange bolt 4pcs MIOX75mmflangebolt 4pcs EH12 2 17 2 EH25 2 2 Detach cylinder head gasket from cylinder 3 Remove push rods head M6 FLANGE BOLT 4 pcs Tool 1Omm socket wrench 12mm 14mm socket wrench Fig 5 74 26 ...

Page 30: ...30mm boltand washer 8pcs M8X30mm bolt and washer 8pcs 2 Remove mainbearing cover usingplastic EH12 2 17 2 EH25 2 hammer See Fig 5 15 I I L Fig 5 15 Remarks Be careful not to damage oil seal MAIN M6 BOLT and WASHER 8 pcs EH12 2 17 2 M8 BOLT and WASHER 8 pcs EH25 2 1Omm 12mm socket wrench L Fig 5 16 27 ...

Page 31: ...onfor EH25 2 Tappet 1 Remove cam shaft from crankcase 2 Remove balancer shaft Option for EH25 2 1 Remove tappets from crankcase Remarks Tool t To prevent tappets from gettingdamaged put the crankcase upside down See Fig 5 17 Puta tag on tappets to identify intakeand exhaust 28 ...

Page 32: ...upper side of crankcase after rotating crankshaft so that piston comes up to top dead center i 25 Piston and 1 Remove clips and piston pin Piston rings 2 Remove piston from connecting rod 3 Remove piston rings from piston CLIP PISTON RING PISTON c PISTON PIN CONNECTING ROD N CONNECTING Remarks Tool lOmm socket wrench Do not damage the smaller end of connecting rod Do not expand or twist piston rin...

Page 33: ...Step Too Remarks Procedures Partto remove 26 Be careful not to damage 1 Remove crankshaft tapping at the Crankshaft flywheel end oil seal c Fig 5 20 c CRANKSHAIT Dtype c fig 5 21 30 ...

Page 34: ... Press down spring retainer take out collet valve and then remove spring retainer and valve spring 4 Remove intake and exhaust valve SeeFig 5 23 Remarks Inspect valves valve seats and guide Do not remove valve guides unless they are worn beyond the limit shown in page 58 INTAKE VALVE EXHAUSTVALVE Fig 5 24 M6 NUT Tool 3 1 ...

Page 35: ...nd nuts to specification referring to the TORQUE SPECIFICATIONS 7 Apply oil to rotating and sliding portions 8 Check and adjust clearances and end plays where specifiedin this manual 54 1 CRANKSHAFT 1 Install crankshaft on crankcase lapping the shaft with polyvinyl tape to avoid damage to oil seal 2 Install woodruff key fortheflywheel on critnk shaft 54 2 PISTON AND PISTON RINGS 1 Install the oil ...

Page 36: ...n crown as shown in the illustration to the MAG side of the connecting rod Apply oil to the small end of the connecting rod piston and piston pin before installation Be sure to use clips on the both end of the piston pin to secure thepin in position R MARK EH12 2 EH17 2 N MARK EH25 2 Fig 5 29 I MAG SIDE VALVERECESS Fig 5 30 33 ...

Page 37: ...ROD CRANKCASE FLYWHEELSIDE Fig 5 31 SECOND RING 0 RING Fig 5 32 54 4 CONNECTING ROD 1 Turn crankshaft to bottom dead center lightly tap top of the piston until large end of the rod meet crankpin 2 Installtheconnectingrodcaptotheconnecting rod matching alignment marks Torque connecting rod bolts to specification M6 X 34 mm flangebolt2pcs EH12 2 M7 X 37 mm flange bolt 0 2pcs EH17 2 M8 X 46mm flange ...

Page 38: ...RKS Fig 5 34 Push in fully to avoid damage during the installation of the camshaft Align the timing mark on the crankshaft gear with the timing mark on the camshaft and install the camshaft in the crankcase as shown in the illustration 2 Lubricate the bearing surfacesof camshaft I Incorrect valve timing will cause engine s I malfunction m 5 4 7 ADJUST CRANKSHAFT AND CAMSHAFT END PLAY 1 Adjust end ...

Page 39: ...inner race of the camshaft bearing 2 Measure the height B2 From the mating surfaceto the camgear innerboss A2 0 3 B2 SIDE CLEARANCE mm SIDE CLEARANCE 0 2 THICKNESS OF CAMSHAFT SHIM mm A2 0 012 B2 SIDE CLEARANCE in SIDE CLEARANCE 0 008 THICKNESSOF CAMSHAFT SHIM in Following are availalbe spacer shims EH12 2 EH17 2 type CRANKSHAFT CAMSHAFT T 0 6 rnm 0 024 T 0 6 mm 0 024 SPACER SHIMS T l Omrn 0 039 3...

Page 40: ... on crankshaft and camshaft Use an oil seal guide when installing the main bearing cover to avoid damaging the seal Tap the cover into place with a soft hammer Main bearing cover EH12 2 17 2 M6 X 30 mm bolt and washer 8 pcs EH25 2 M8 X 30 mm bolt and washer e 8 pcs Tightening torque EH12 2 17 2 Tightening torque EH25 2 17 18 5 Nom 80 100 kgwn 170 1 90 kgocrn 12 5 13 5 ftelb 37 ...

Page 41: ...e stepsby the following tightening torque Cylinderhead M8 X 65 mmflangebolt 4 PCS EH12 2 17 2 seats and valve guides 5 Install cylinder head to cylinder with new head gasket M10 X 75 mm flangebolt 4pcs EH25 2 Tightening torque EH12 2 17 2 1st step final step 2nd step 5 Nom 100 kgcm 50 k g w n 23 26 N m 10 Nom 17 30 ft lb 7 2 ft lb 3 6 ft lb 230 270 kgcm Tightening torque EH25 2 1st step final step...

Page 42: ...nder head Spark plug EHl2 2 NGK B6ES EH17 2 25 2 NGK B6HS Tighteningtorque New spark plug Retightening 11 8 14 7 N m 2216 26 5Nom _ _ _ _ 120 150kg cm 230 270 kg crn 8 7 1 0 9 fblb 16 6 19 5 fblb 5 4 12 FLYWHEELMAGNETO 1 Install the charge coil to the crankcase Option Be careful not to pinch coil wire between charge coil and crankcase 2 Putthewoodruffkeyinthekeyway of crank shaft Wipe off oil and ...

Page 43: ...pipe to the cylinder head with gasket EH12 2 17 2 M6 flange nut 2pcs M6 X 25mm flange bolt 1PC EH25 2 M8 X 28mm bolt and washer 3 pcs Tightening torque 9 8 13 7 N m 7 2 10 1ft4b 100 1 40 kgocm Then put the gasket and the insulator on the intake pipe 54 15 CARBURETOR Install the gasket and the carburetor to the intake pipe 54 16 GOVERNOR SYSTEM 1 Connect the governor lever and the throttle lever on...

Page 44: ... in the carburetor is at the wide open position See Fig 5 43 For the generator applications there are two different governor springs existing according to the speed setting of the engine The governor springs may be distinguished by the following table The governorspringemployedonthe 6OHz applicationis sameastheonefromthestandardspecifi cations rI SPEEDCONTROLLEVER GOVERNOR SPRING l t GOVERNOR LEVE...

Page 45: ...hten the muffler bracket portion M6 X 12mm flange bolt a 1PC EH12 2 17 2 M8 X 16mm flange bolt 1PC EH25 2 Install the muffler cover and exhaust pipe cover M6 X 10mm flange bolt e 5 pcs 54 20 BLOWER HOUSING RECOIL Install the blower housing and the recoil Insert the high tension cord from the ignition coil into the notc of the blower housing so that not to pintch the cord 54 21 FUEL TANK Install th...

Page 46: ...he T I C Transistor Igniter Circuit pointless ignition system ASoptional parts these ignition system may be implemented with lamp coi1 charge coil and excitor coil 6 2 BASIC THEORY To ensure the easy startability of the engine the step advancing ignition timing system is incorporatedin the ignition coil This system enables the engine to have basically two different ignition timings according to th...

Page 47: ...hiscurrentinducesthe collectorcurrent It andwillbypassthecurrent I toshutdownthecurrent IZ abruptlybecausethe power transistor is turned off Thissuddencurrentchangegeneratesabigvoltage on thesecondaryside of theignitioncoiland which will spark the spark plug Theignitiontimingcontrolcircuitfor the higherenginespeedisactivatedsoonerthanthecontroI circuit for the lower speed and not activated when th...

Page 48: ...6 3 WIRING DIAGRAM STANDARD Stop switch Connector Black Black Spark Plug Ignition Coil Flywheel ElNGlNE WITH ELECTRIC STARTER DIODE RECTIFIER I _ I L 12VOLT BATTERY MtNIMUM 24 AMP HR Fig 6 3 45 ...

Page 49: ... tappet which in turns opens up the exhaust valve slightlyto release the compression The release lever has a flyweight on its end and another end of the lever is a crescent cam When the engine is cranked the crescent cam projects the camshaft cam profile and lifts up the tappet because the gravity force on the weight is larger than the centrifugal force on the weight i TAPPET I LEVER CRESCENT EXHA...

Page 50: ... the engine operation The fuel flows from the fuel tank into the float chamber through the needle valve When the fuel rises to a specificlevel thefloatrises and when its buoyancy and fuel pressure are balanced the needle valve shuts off thefuel therebykeepingthefuelatthepredeter mined level FI Fig 8 1 PILOT OUTLET BY PASS Z I I PILOT AIR JET AT I 1 MAIN AIR JET k I I i r J MAIN JET Fig 8 2 47 ...

Page 51: ...he main nozzle increases and draws more fuel accordingly this starting up the engine more easily 8 2 DISASSEMBLYANDREASSEMBLY Apartfrommechanicalfailures most of carburetortroublesarecausedbyanincorrectmixingratio which may arise mainly due to a clogged up airor fuel passage in jets or fuel level variations In order to assureproperflow of airandfuel thecarburetormustbekeptcleanat a11 times Thecarb...

Page 52: ...her 18 for chamber malfunction 13 8 2 5 FLOAT SYSTEM 1 Pull out the float pin 20 and remove the float 21 and then remove the clip 22 and needle valve 23 If the needle valve needs to be replaced replace it with rubber needle When cleaning the jets be sureto use compressed air to blow them clean Never use a drill or a wire because of possible damage of the orifice which will considerably affect fuel...

Page 53: ...erota tion of the reel stoos I Fig 9 1 r The spring power is at its mostwhen the rope is fully extracted Therefore do not abruptly putoff your hand nor loosen the pressureof your finger unintentionally 2 Setting the attachments off Fig 9 2 1 Fix the case and loosen the set screw 2 Put off the set screw the latchet guide the friction springandthelatchet in thesame order from above 3 Setting the ree...

Page 54: ...e shafthook part and theinnerend of thespringarehookedto gether Dropthereelgentlyfromaboveinto the case Fig 9 3 4 Move the reel slightly counter clockwise and make sure the springis hooked THE END TOUCHES THE RIB OF THE BEARING Fig 9 4 2 Setting the attachments 1 Set the latchet into the reel Fig 9 5 THE LATCHETIS KEPT AT CLOSE POSITION Fig 9 5 2 Holding the latchet set the sub assembly Fig 9 6 la...

Page 55: ...nd nor loosen the pressure of your finger unintentionally 5 Setting the rope 2 persons required 1 Set the end of the rope through the rope guide and the ropehole of the reel and pull the end about 20 cm outof the reel Fig 9 7 2 Fasten the endof the rope 3 Put the rope into the reel whereby make sure that the rope willnot float up Fig 9 9 4 Holdtheropefirmlywithonehandatthe position about 50 cm fro...

Page 56: ...l starter to the engine 7 If the spring escapes from the reel when disassembling the recoil hook the outer end of the spring onto the notchof the reel and rewind the spring into the housing 8 Lubricate the rotating parts sliding parts and spring with heat resistant grease or mobile oil when reassembling the recoil and priorto long term storage 53 ...

Page 57: ...ping the float chamber with the grip of a screwdriver or the like 6 If the carburetor overflows excessive fuel runs into the cylinder when starting the engine making the fuel airmixture too rich to burn If thishappens removethesparkplug andturnthestartingpulleya few turns in orderto let the rich fuel air mixture out of the spark plug hole into the atmosphere Keep the choke valve open during this o...

Page 58: ...e 2 Vapor lock i e gasoline evaporatingin the fuel lines due to overheat around the engine 3 Vapor lock in the fuel linesor carburetor due to the useof too volatile winter gas in the hot season 4 Air vent hole in the fuel tank cap plugged 5 Bearing parts seized due to lack of oil 0 6 Magneto or ignition coil faulty 104 ENGINEOVERHEATS 1 Crankcase oil level low Add oil immediately 2 Spark timing in...

Page 59: ...er head 4 Spark timing incorrect 5 Loose connecting rod bearing dueto wear 6 Loose piston pin due to wear 7 Cuases of engine overheat 10 6 ENGINE BACKFIRES THROUGH CARBURETOR 1 Water or dirt in gasoline or low grade gasoline 2 Intake valve stuck 3 Valves overheated or hot carbon particles in the combustion chamber 4 Engine cold 56 ...

Page 60: ...on of he hot air used for engine cooling and temperature riseof the machine Keep the engineroom temperature below 50 C even in the hottest periodof the year 11 3 EXHAUST GAS DISCHARGE Exhaustgas is noxious Whenoperatingtheengineindoors besuretodischargetheexhaustgas outdoors If a long exhaust pipe is used in such a case the internal resistance increases causing loss of engine power Thus pipe insid...

Page 61: ...e If the measurement exceedsbeyond the Limit the part needs to be replaced and orrepaired 12 1 CLEARANCE DATA AND LIMITS r Flatness 1 Valve seat contact width I Valve guide inside dia IN EX EH12 2 EH17 2 EH25 2 r Unit mrn in EH12 2 17 2 25 2 STD LESS THAN 0 05 0 002 0 7 1 O 0 028 0 039 5 500 5 518 0 21 65 0 2172 6 035 6 053 0 2376 0 2383 Limit 0 1 0 004 2 0 0 079 5 65 0 2224 6 15 0 2421 58 ...

Page 62: ...6484 1st reboring 2nd reboring Ditto Ditto 60 500 60 519 2 3819 2 3826 67 500 67 519 2 6575 2 6582 0 Roundinessafter reboring 0 Cylindricity after reboring LESS THAN 0 01 0 004 LESS THAN 0 01 0 004 LESS THAN 0 015 0 0006 LESS THAN 0 015 0 0006 PISTON 0 Piston size At skirt in thrust direction 59 96 59 98 2 3606 2 3614 59 87 2 3571 66 98 67 00 12 6370 2 6378 66 89 2 6335 STD 60 12 2 3669 67 23 67 2...

Page 63: ...STD 1 s t 01s 2nd OJS r EH25 2 STD 75 000 75 019 2 9528 2 9535 75 250 75 269 2 9626 2 9633 75 500 75 519 2 9724 2 9732 LESS THAN 0 01 0 004 LESS THAN 0 015 0 0006 74 98 75 00 2 9520 2 9528 75 23 75 25 2 9618 2 9626 75 48 75 50 2 9717 2 9724 Lmit 0be rebored hen the ifference letween m a md min of liameter eached to 0 1 0 004 Ditto 74 89 2 9484 75 14 2 9583 75 39 2 9681 60 ...

Page 64: ...ing Piston pin hole m 12 991 13 002 0 51 15 0 5119 13 035 0 51 32 15 991 16 002 0 6296 0 6300 16 035 0 6313 0 Piston pin outside dia 12 992 13 000 0 51 15 0 5118 12 960 0 51 02 15 992 16 000 0 6296 0 6299 15 960 0 6284 Clearancebetween pistonand cylinder a t skirtarea 0 015 0 074 0 0006 0 0029 0 25 0 010 0 015 0 074 0 0006 0 0029 0 25 0 01 0 Piston ring endgap TOP 2nd 0 2 0 4 0 008 0 016 1 5 0 059...

Page 65: ...d gap 2nd Oil ring TOP 2nd oil ring EH25 2 STD 0 050 0 090 1 0020 0 0035 0 030 0 070 0012 0 0028 0 010 0 065 1 0004 0 0026 17 991 18 002 1 7083 0 7087 17 992 18 000 3 7084 0 7087 0 025 0 064 0 0001 0 0025 0 1 0 3 0 004 0 012 0 1 0 3 0 004 0 0 12 Limit 0 15 0 006 0 15 0 006 0 15 0 006 7 8 035 0 7100 17 960 0 7071 0 25 0 010 1 5 0 0591 1 5 0 0591 62 ...

Page 66: ... 0 0008 0 0018 0 2 0 008 I 0 Small end inside dia 13 08 0 51 50 13 010 13 021 0 51 22 0 51 26 0 Clearance between small end and piston pin 0 Big end side clearance 0 0 10 0 029 0 0004 0 0011 0 12 0 0047 0 1 0 7 0 004 0 028 1 o 0 040 I CRANKSHAR 0 Crankpin outsidedia 25 967 25 980 1 0223 1 0228 25 85 1 01 77 0 Journal dia Dl D2 24 988 24 997 0 9839 0 9841 1 63 ...

Page 67: ...0 Clearance between small end and piston pin Big end side clearance I CRANKSHAFT 0 Journal dia Unit mm in 30 000 30 016 1 1811 1 1817 0 020 0 049 0 0008 0 0019 16 01 0 16 021 0 6303 0 6308 0 010 0 029 0 0004 0 001 1 0 1 0 7 0 004 0 028 29 967 29 980 1 1798 1 1803 Dl D2 24 988 24 997 0 9838 0 9841 64 Limit 3 0 1 1 1850 0 2 0 008 16 08 06331 0 12 0 0047 1 o 0 040 29 85 1 1752 ...

Page 68: ...a I 34 000 34 016 1 3386 1 3392 0 025 0 057 0 0010 0 0022 18 01 0 18 021 0 7091 0 7095 0 010 0 029 0 0004 0 0011 0 1 0 7 0 004 0 028 33 959 33 975 1 3370 1 3376 Dl D2 1TYPE Z9 991 30 000 29 988 29 99 1 1807 1 1806 1 1 81 1 1 1810 3 TYPE 1 1807 27 991 30 0001 1 o 1 1811 27 988 27 99 1 1022 Limit 34 10 1 3425 0 2 0 008 Unit mm in w 18 08 0 71 18 0 12 0 0047 1 o 0 040 33 85 1 3327 65 ...

Page 69: ...7 16 95 0 6673 D l D l 14 973 14 984 0 5895 0 5899 14 95 0 5886 D2 VALVE Valvestemoutside dia 5 440 5 455 0 21 42 0 2148 5 35 0 2 106 IN 5 426 5 444 0 21 36 0 21 43 5 35 0 21 06 EX 0 Clearancebetweenvalve stem dia and valve guide 0 045 0 078 0 001 8 0 0031 0 3 0 012 IN 0 056 0 092 0 0022 0 0036 0 3 0 01 2 Ex Valveclearance IN EX cold 0 08 0 12 0 0031 0 0047 66 ...

Page 70: ...Valveclearance D2 IN Ex IN EX IN EX cold EH25 2 I Limit 30 6 30 8 1 205 1 213 30 45 1 199 24 967 24 980 0 9823 0 9830 0 9835 24 95 14 973 14 984 0 5886 0 5895 0 5899 14 95 5 975 5 990 0 2303 0 2352 0 2358 5 85 5 960 5 975 0 2303 0 2346 0 2352 5 85 0 045 0 078 0 01 2 0 001 8 0 0031 0 3 0 060 0 093 0 01 2 0 0024 0 0037 0 3 0 08 0 1 2 0 0031 0 0047 67 ...

Page 71: ...M TAPPET 0 Stem outside dia 0 Guide inside dia 0 Tappet guide clearance VALVE SPRING FREE LENGTH Unit rnrn in 1 STD 7 960 7 975 0 3 134 0 3 140 8 000 8 015 0 3150 0 3 156 0 025 0 055 0 0010 0 0022 Limit 68 ...

Page 72: ...LVESPRING FREE LENGTH I ITEM VALVE SEATANGLE IN EX 0 Valve cutterangle a 0 Valve contact width b a EH25 2 STD Limit 7 960 7 975 0 31 34 0 3140 8 000 8 015 0 31 50 0 3 156 0 025 0 055 0 001 0 0 0022 35 5 1 4 1 Unit rnm in EH12 2117 2 125 2 STD limit a 90 b 0 7 1 O 0 028 0 039 2 0 0 079 69 ...

Page 73: ...6 8 8 11 2 EH17 2 EH12 2 EH17 2 EH12 2 EH17 2 New spark plug 16 6 19 5 230 270 22 6 26 5 Retightening 8 7 10 9 120 150 11 8 14 7 Spark plug EH25 2 type TIGHTENING TORQUE Nom ft lb kg cm DESCRIPTION Cylinder head bolts 43 47 600 650 58 8 63 7 Flywheel nut 16 3 19 8 225 275 21 3 26 9 Connecting rod cap bolts 24 6 30 3 340 420 33 3 41 2 Main bearing cover bolts 1 16 7 18 6 I 170 190 I 12 3 13 7 I New...

Page 74: ...Single grade Multi grade Comparison between oil viscosity and temparature I I I I I 1 I I I 20 10 0 10 20 30 40 C 4 14 32 50 68 86 104 F Use oil classified as SE or higher Multi grade oil tends to increase its consumption at high ambient temperature 71 ...

Page 75: ... Check fuel leakage from fuelsystem If any retighten fasteners or replace necessary parts 3 Inspect for loose hardwares and retighten if necessary 4 Check oil level and add to full mark REMARKS Governor linkage is especially sensitive to dust Loose bolts and nuts may come off and result in breakage of other parts 13 2 INITIAL 20 HRS MAINTENANCE MAINTENANCE REMARKS L I 1 Change crankcaseoil To remo...

Page 76: ...ANCE REMARKS 1 Overhaul engine Clean and correct parts Replace piston rings and other necessary parts 2 Replace fuel lines once a year Avoid hazards caused by fuel leakage 13 7 ENGINESTORAGE 1 Perform the above13 1and 13 2 maintenance jobs 2 Drain fuel from the fuel tank and carburetor float chamber 3 To preventrustinthecylinderbore apply oil through the sp several turns by hand Reinstall the plug...

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Page 78: ...SU6ARU bin America Inc 940 LivelyBlvd l WoodDale IL 60191 l Phone 630 350 8200 l Fax 630 350 8212 e mail sale s robinamerica com l www robinamerica com PRINTED IN THE USA I ...

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