Robin America EH63 Service Manual Download Page 74

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CYLINDER
* Inside dia.

* Roundiness after reboring.

* Cylindricity after reboring.

STD

PISTON
* Piston size (At skirt in thrust direction)

80.000 - 80.019

(3.1496 - 3.1504)

84.000 - 84.022

(3.3071 - 3.3080)

EH63
EH64
EH65

EH72

To be rebored when
the difference between
max. and min. of
diameter reached to
0.1 (0.004).

80.250 - 80.269

(3.159 - 3.160)

84.250 - 84.272

(3.3169 - 3.3178)

EH63
EH64
EH65

EH72

1st

reboring

80.500 - 80.519

(3.169 - 3.170)

84.500 - 84.522

(3.3268 - 3.3276)

EH63
EH64
EH65

EH72

2nd

reboring

0.01

(0.0004)

EH63

EH64

EH65

EH72

STD

79.968 - 79.988

(3.148 - 3.149)

83.980 - 84.000

(3.3063 - 3.3071)

EH63
EH64
EH65

EH72

80.218 - 80.238

(3.158 - 3.159)

84.230 - 84.250

(3.3161 - 3.3169)

EH63
EH64
EH65

EH72

1st o/s

80.468 - 80.488

(3.168 - 3.169)

84.480 - 84.500

(3.3260 - 3.3268)

79.878

(3.145)

83.890

(3.3028)

80.128

(3.155)

84.140

(3.3126)

80.378

(3.164)

84.390

(3.3224)

EH63
EH64
EH65

EH72

2nd o/s

Ditto

0.015

(0.0006)

EH63

EH64

EH65

EH72

16 mm

STD

Unit : mm(in.)

ITEM

Limit

Summary of Contents for EH63

Page 1: ...SERVICE MANUAL EH63 64 65 and EH72 ENGINES Models PUB ES2158 Rev 08 09 ...

Page 3: ...REPARATIONS AND SUGGESTIONS 15 5 2 SPECIAL TOOLS 15 5 3 DISASSEMBLY PROCEDURES 16 5 4 REASSEMBLY PROCEDURES 32 5 5 BREAK IN OPERATION 48 6 LUBRICATION SYSTEM 49 7 FUEL SYSTEM 52 8 ELECTRIC SYSTEM 57 9 TROUBLESHOOTING 63 10 INSTALLATION 69 11 SERVICE DATA 11 1 STANDARD DIMENSIONS AND SERVICE LIMITS 70 11 2 TIGHTENING TORQUE 76 12 MAINTENANCE AND STORAGE 77 ...

Page 4: ...Oil SAE 20 30 or 10W 30 Class SE or higher Lubricant 1 55 0 41 Capacity of Lubricant Down Draft Float Type Down Draft Float Type With Accel Pump Carburetor Automotive Unleaded Gasoline Fuel Diaphragm Pump Pulse type Fuel Feed System Flywheel Magneto Solid State Ignition System NGK BP6ES Spark Plug Charging Capacity Electric Starter Starting System Centrifugal Flyweight Type Governor System Double ...

Page 5: ...ade in conformity to SAE internal combustion engine standard test code J1349 2 2 CONTINUOUS RATED OUTPUT The continuous rated output is the output of an engine at optimum governed speed which is most favorable from the view point of engine s life and fuel consumption When the engine is installed on a certain equipment it is recommended that the continuous output required from the engine be kept be...

Page 6: ...MANCE CURVES EH63D 2000 2400 2800 3200 3600 5 6 7 10 13 4 15 20 1 REVOLUTION r p m HORSEPOWER kW HP TORQUE N m kgf m 45 4 59 35 3 57 CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE MAXIMUM TORQUE MAXIMUM HORSEPOWER ...

Page 7: ... EH64D 2000 2400 2800 3200 3600 5 6 7 10 13 4 15 20 1 REVOLUTION r p m HORSEPOWER kW HP TORQUE N m kgf m 45 4 59 35 3 57 CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE MAXIMUM TORQUE MAXIMUM HORSEPOWER ...

Page 8: ... EH65D 2000 2400 2800 3200 3600 5 6 7 10 13 4 15 20 1 REVOLUTION r p m HORSEPOWER kW HP TORQUE N m kgf m 45 4 59 35 3 57 CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE MAXIMUM TORQUE MAXIMUM HORSEPOWER ...

Page 9: ...2D 2000 2400 2800 3200 3600 10 13 4 5 6 7 15 20 1 20 26 8 REVOLUTION r p m HORSEPOWER kW HP TORQUE N m kgf m 55 5 61 45 4 59 CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE MAXIMUM TORQUE MAXIMUM HORSEPOWER ...

Page 10: ...ensures a good lubrication environment Ball bearing installed in the throttle bearing of the carbureter Reliability Unusually high dust proofing by a double compartment air cleaner and inner vent type carbureter Carbureter equipped with acceleration pump and receives excellent throttle response A fine distribution suction pipe and effective combustion chamber shape provide greater cubustion stabil...

Page 11: ...se has a mounting surface on the output shaft side where the main bearing cover is attached 4 2 MAIN BEARING COVER The main bearing cover is an aluminum die casting which is mounted on the output shaft side of the crankcase Pilots and bosses are machined on the cover for direct mounting of the engine onto such machines as generators and pumps It is easy to inspect inside of the engine after removi...

Page 12: ...p ring is barrel face and the second ring has a tapered face The oil ring is designed for better sealing and less oil consumption in combination with 3 pieces 4 6 CAMSHAFT The camshaft is made of special cast iron and camshaft gears are casted together in one piece Each 2 cam robs are provided for intake and exhaust valves correspondingly Both sides of the shaft fit into the plane bearings on the ...

Page 13: ...cooling fins and passages design lead cooling air to the exhaust valve area for the optimum cooling Hard alloy valve seats are molded in the cylinder head INTAKE VALVE EXHAUST VALVE 4 9 GOVERNOR SYSTEM The governor is a centrifugal flyweight type which ensures constant operation at the selected speed against load variations The governor gear with governor weights is installed inside of main bearin...

Page 14: ...s pressurized engine oil through the full flow type oil filter to the journal and pin portions of crankshaft and camshaft 4 12 IGNITION SYSTEM The ignition system is a transistor controlled magneto ignition system which consists of a flywheel and an ignition coil with a built in transistor installed onto the crankcase FLYWHEEL IGNITION COIL CHARGE COIL CABLE EXTENDED REGULATOR CHARGE COIL REGULATO...

Page 15: ...ng on when the key switch is turned to off Accelerator pump is provided for obtaining quick and good throttle response EH72D 4 15 AIR CLEANER The air cleaner is a heavy duty type with a dual element system primary side is urethane foam half wet and secondary side is dry type ACCELERATOR PUMP FUEL CUT SOLENOID VALVE URETHANE FOAM ELEMENT WING NUT CLEANER COVER 4 16 FUEL PUMP The engine is equipped ...

Page 16: ... 13 4 17 SECTIONAL VIEW OF ENGINE CARBURETOR OIL PUMP IGNITION COIL FLYWHEEL INTAKE MANIFOLD OIL PUMP FILTER MAIN BEARING COVER P T O SHAFT ...

Page 17: ...R CLEANER GOVERNOR LEVER ROCKER ARM CRANKCASE CRANKSHAFT CONNECTING ROD PISTON PIN PISTON OIL FILTER OIL COOLER EH72D PISTON RING CAMSHAFT PUSH ROD INTAKE AND EXHAUST VALVES TAPPET ELECTRIC STARTER SPARK PLUG ...

Page 18: ...ily assemble each group of disassembled parts Carefully handle disassembled parts and clean them with washing oil if necessary Use the correct tools in the correct way When disconnecting electric wirings be sure to hold and disconnect the connector housing 5 2 SPECIAL TOOLS No Special Tool is needed for disassembling and reassembling the engine For pulling off the flywheel universal type puller be...

Page 19: ...Drain plug 2 pcs 2 Muffler cover M6 x 14 Flange bolt 4 pcs M6 x 8 Flange bolt 2 pcs 3 Muffler M8 SUS Flange nut 4pcs 4 Muffler bracket M8 x 20 bolt and washer 2pcs A A STEP 4 STEP 3 STEP 2 MUFFLER BLACKET MUFFLER COVER M6 FLANGE BOLT M6 FLANGE BOLT M8 BOLT WASHER M6 FLANGE BOLT GASKET MUFFLER M8 SUS FLANGE NUT STEP 1 GASKET OIL DRAIN PLUG ON BOTH SIDE OIL FILLER CAP OIL LEVEL GAUGE ...

Page 20: ...ANER BASE HOSE CLAMP M6 FLANGE BOLT BREATHER PIPE HOSE CLAMP Step Parts to remove Remarks and procedures Fasteners 5 Air cleaner cover and elements Remove cleaner cover and cleaner element 6 Air cleaner base Remove breather pipe from 1 cylinder head M6 x 12 Flange bolt 3 pcs ...

Page 21: ...h control box M6 x 18 Flange bolt 2 pcs M6 x 14 Flange bolt 6 pcs 8 Chock control lever and link 1 Remove the choke knob 2 Remove the choke contol link M6 bolt 1 pc CONTROL BOX CHOKE CONTROL ROD RETURN SPRING WAVED WASHER LINK PIVOT CHOKE CONTROL LINK CHOKE KNOB CLAMP M5 TAPPING SCREW BLOWER HOUSING M6 FLANGE BOLT M6 FLANGE BOLT STEP 7 STEP 8 ...

Page 22: ... M8 FLANGE BOLT CARBURETOR GASKET carburetor Step Parts to remove Remarks and procedures Fasteners 9 Carburetor At first remove fuel pipe Take out carburetor along with governor rod and rod spring M8 x 80 Flange bolt 2 pcs ...

Page 23: ...ction washer 6 Speed control lever M6 x 12 bolt and washer 3 pcs M6 self lock nut 1 pc 11 Speed control bracket unit M6 x 12 Flange bolt 2 pcs 12 Starting motor At first remove wiring M8 x 65 Flange bolt 2 pcs STOP PLATE SPRING WASHER SPEED CONTROL LEVER M6 FLANGE BOLT M8 FLANGE BOLT M6 SELF LOCK NUT FRICTION WASHER FRICTION WASHER BRACKET UNIT speed control STEP 11 STEP 10 STEP 12 GOVERNOR SPRING...

Page 24: ...HER ASSY TO KEY SWITCH IGNITION COIL PLUG TERMINAL SPARK PLUG CAP M6 BOLT AND WASHER ASSY Step Parts to remove Remarks and procedures Fasteners 13 Fuel pump Remove pluse pipe at first Remove fuel pump ASSY and detach bracket M6 x 12 Flange bolt 2 pcs M6 x 12 Flange bolt 2 pcs 14 Ignition coil 1 Take out plug cap 2 Remove ignition coil 3 Cut out stop wire fixing bands 4 Disconnect stop wires from i...

Page 25: ...RE CP GASKET INTAKE MANIFOLD M8 FLANGE NUT GASKET STEP 15 M8 FLANGE NUT 22 Step Parts to remove Remarks and procedures Fasteners 15 Intake manifold M8 flange nut 4 pcs 16 Regulator and Wire CP Disconnect wire connector from regulator and then remove regulator from 1 cylinder baffle M6 x 12 Flange bolt 2 pcs ...

Page 26: ...Remarks and procedures Fasteners 17 Cylinder baffles 1 2 3 4 M6 x 12 flange bolt 8 pcs M6 FLANGE BOLT M6 FLANGE BOLT M6 FLANGE BOLT CYLINDER BAFFLE 2 CYLINDER BAFFLE 4 CYLINDER BAFFLE 1 CYLINDER BAFFLE 3 M6 FLANGE BOLT STEP 17 ...

Page 27: ...ts to remove Remarks and procedures Fasteners 18 Cooling fan Remove cooling fan from flywheel M6 x 16 bolt washer 4 pcs 20 Charge coil M5 x 20 bolt washer 4 pcs 15A coil M5 x 25 bolt washer 4 pcs 30A coil 19 Flywheel Untighten flywheel nut and leave it to avoid the flywheel fell out Take out flywheel by means of flywheel puller M18 Flange nut 1 pc ...

Page 28: ...opping engine NGK BPR4EY 22 Oil cooler EH72 1 Disconnect oil hoses with clamps detached 2 Remove oil cooler 3 Remove bracket unit M6 x 12 Flange bolt 4 pcs A A OIL COOLER HOUSE CLAMP HOUSE CLAMP OIL HOUSE 1 OIL HOUSE 2 HOUSE CLAMP BRACKET UNIT M6 FLANGE BOLT M6 FLANGE BOLT STEP 22 STEP 21 STEP 21 SPARK PLUG SPARK PLUG ...

Page 29: ... faced to 1 or 2 on each cylinder head Put the marking of original position onto each push rod rocker arm and valve for reassembly M10 x 65 Flange bolt 8 pcs STEP 23 STEP 23 STEP 24 STEP 24 M6 FLANGE BOLT ROCKER COVER ROCKER COVER HOOK PIVOT NUT PUSH ROD ROCKER ARM BOLT PIVOT GASKET rocker cover M10 FLANGE BOLT GUIDE PLATE CYLINDER HEAD 2 GASKET 2 M6 FLANGE BOLT ROCKER ARM PIVOT NUT PUSH ROD GUIDE...

Page 30: ...THER COVER M6 FLANGE BOLT INTAKE VALVE EXHAUST VALVE SPRING RETAINER VALVE SPRING COLLET VALVE COLLET VALVE SPRING RETAINER STEP 25 Step Parts to remove Remarks and procedures Fasteners 25 Intake exhaust valves Breather cover Breather plate Take out collet valves with spring retainer depressed by hand Take out valve springs M6 x 14 Flange bolt 2 pcs ...

Page 31: ...ARING COVER M8 FLANGE BOLT STEP 26 THRUST BEARING Step Parts to remove Remarks and procedures Fasteners 26 Main bearing cover Take out key from PTO shaft Wrap PTO shaft with polyvinyl tape not to damage oil seal by key groove edge Tapping with plastic hummer take out main bearing cover M8 x 45 Flange bolt 10 pcs ...

Page 32: ...CAMSHAFT Step Parts to remove Remarks and procedures Fasteners 27 Camshaft tappet Mate the markings both on crankshaft gear and camshaft gear and then take out camshaft Put the marking of original position onto each tappet for reassembly ...

Page 33: ...connecting rod 4 Remove piston rings from piston Put the marking of original position onto each piston ring clip piston pin connecting rod and cap for reassembly M8 Connecting rod bolt 4 pcs 29 Crankshaft 1 Remove key from crankshaft 2 Take out crankshaft from crankcase KEY STEP 28 STEP 28 STEP 29 PISTON PISTON PISTON RING SET CLIP CONNECTING ROD PISTON PIN CLIP CONNECTING ROD CAP M8 CONNECTING RO...

Page 34: ...ure spring is jumped out 5 Take out snap pin and pull out governor shaft Make sure not to loose washer 6 Remove oil pump cover outer rotor inner rotor and o ring M6 x 28 Flange bolt 3 pcs 10 32 x 11 1 pc M14 x 12 M6 x 14 Flange bolt 4 pcs STEP 30 STEEL BALL OIL PUMP FILTER SPRING relief valve GASKET aluminum PLUG oil relief 10 32 FLANGE BOLT Inch GOVERNOR LEVER SHAFT WASHER SNAP PIN M6 FLANGE BOLT...

Page 35: ...8 Check and adjust clearances and end plays where specified in this manual 9 When there are many bolts fasten opposing bolts Do not fasten bolts in a circular order In other words after tightening one place go to the opposite side and tighten this place next 5 4 2 Pre assembly A CRANKCASE 1 Fix oil pump filter in position 2 Insert ball and spring into the oil relief valve hole and tighten plug to ...

Page 36: ...spring and valve stem Place cylinder head on flat table and install washer valve spring valve and spring retainer 4 Install rocker arm NOTE Clean valves and wash cylinder head thoroughly Remove carbon and gum deposits from the valves seats ports and guides Inspect valves valve seats and valve guides Replace valves that are badly burned pitted or warped Valve guides should be replaced when valve st...

Page 37: ...cure piston pin in position TOP RING SECOND RING OIL RING 1 2 3 BARREL TAPER COMBINATION RING 1 2 3 MAIN BEARING COVER GOVERNOR SLEEEVE GOVERNOR GEAR GOVERNOR GEAR SHAFT WASHER THRUST BEARING PISTON CLIP PISTONRING SET PISTON PIN CLIP CONNECTING ROD CONNECTING ROD CAP M8 CONNECTING ROD BOLT D MAIN BEARING COVER and GOVERNOR GEAR 1 Insert washer into governor gear shaft 2 Insert governor gear along...

Page 38: ...ning torque 22 0 27 0 N m 225 275 kgf cm 16 3 19 8 ft lb CONNECTING ROD PISTON RING COMPRESSOR MARK 1 1 SECOND RING OIL RING TOP RING ALIGNMENT MARKS NOTE Apply enough oil to bearing portion of crankcase For smooth fitting of crankshaft assemble oil pump related parts later For easy installation put crankcase on box or wood blocks NOTE The 1 mark of the connecting rod for 1 cylinder and 2 mark for...

Page 39: ...g mark on both crankshaft gear and camshaft alined CRANKSHAFT GEAR CAMSHAFT GEAR TIMING MARK 4 Adjust side clearance Measure end play of crankshaft and camshaft Adjust end play to 0 using the proper spacer SPACER mm A 0 48 B 1 2 HEIGHT GAUGE CRANKSHAFT READING READING CRANKCASE SPACER A B CRANKCASE MAIN BEARING COVER 0 48 mm CRANKSHAFT GEAR THICKNESS WITH GASKET TIGHTENED CAUTION Incorrect alineme...

Page 40: ...kets in position onto 1 and 2 cylinder head surfaces 3 Install 1 and 2 cylinder heads Tighten bolts evenly in steps to the specified torque M10 x 65 Flange bolt 4 pcs Tightening torque 41 0 49 0 N m 400 500 kgf cm 30 2 36 1 ft lb NOTE Before installing main bearing cover be sure to check the installation of governor lever shaft and oil pump filter in the crankcase in position Tap cover with a soft...

Page 41: ...ng screw to adjust the clearance between rocker arm and valve stem end and then tighten lock nut to the specified torque 3 Adjust valve clearance of 2 cylinder side in the same manner 4 Rotate crankshaft several times and be sure to check valve clearance again Adjust valve clearance if necessary Lock nut Pivot bolt Tightening torque 6 8 8 8 N m 70 90 kgf cm 5 0 6 5 ft lb THICKNESS GAUGE 1 MARK 1 1...

Page 42: ...around electrode and clean or replace with new one as necessary Spark plug NGK BPR4EY Tightening torque New plug 13 CHARGE COIL Install charge coil with the wiring located at 2 o clock position M5 x 20 bolt washer 4 pcs 15A coil M5 x 25 bolt washer 4 pcs 30A coil Tightening torque 2 9 3 9 N m 30 40 kgf cm 2 2 2 9 ft lb CHARGE COIL ELECTRIC STARTER PULLING M8 FLANGE BOLT 2 pcs NOTE Never tighten th...

Page 43: ... head 2 Install intake manifold M8 flange nut 4 pcs M6 FLANGE BOLT REGULATOR CYLINDER BAFFLE 1 18 REGULATOR Install regurator onto cylinder baffle 1 Install regulator onto cylinder baffle 1 with the terminal of earth wire white commonly fixed on the right hand side Connect charge coil wire connector to regulator Connect wire green to magnetic switch M6 x 18 Flange bolt 2 pcs Tightening torque 16 6...

Page 44: ...6 BOLT and WASHER 4 pcs 21 COOLING FAN Attach cooling fan onto flywheel M6 x 16 bolt washer 4 pcs Connect wiring from key switch to the primary terminal of ignition coil Tightening torque 6 8 8 8 N m 70 90 kgf cm 5 1 6 5 ft lb TO IGNITION COIL 1 TO IGNITION COIL 2 TO KEY SWITCH WIRE CP M6 x 30 bolt washer 4 pcs Ignition coil air gap 0 3 0 5 mm 0 012 0 020 in Tightening torque 6 8 8 8 N m 70 90 kgf...

Page 45: ...rol lever GOVERNOR LEVER GOVERNOR SHAFT ROD SPRING GOVERNOR ROD THROTTLE LEVER 24 GOVERNOR LEVER Attach governor rod and rod spring between governor lever and carburetor throttle lever and insert the governor lever to governor lever shaft Tighten locking bolt temporarily M8 FLANGEBOLT CARBURETOR GASKET carburetor 22 CARBURETOR Set gasket onto intake manifold and install carburetor M8 x 80 Flange b...

Page 46: ...buretor chock lever and chock control lever b 5 4 3 2 1 a GOVERNOR GEAR GOVERNOR SPRING ADJUSTING SCREW SPEED CONTROL LEVER GOVERNOR LEVER CARBURETOR GOVERNOR ROD ROD SPRING FULL OPEN FULL CLOSE LOCK NUT HIGH SPEED LOW SPEED A B STOP PLATE SPRING WASHER SPEED CONTROL LEVER M6 FLANGE BOLT M6 SELF LOCK NUT FRICTION WASHER FRICTION WASHER BRACKET UNIT speed control 50Hz 60Hz A 3 b A 2 b A 3 b A 2 b A...

Page 47: ...ING Front M6 x 14 Flange bolt 4 pcs BLOWER HOUSING Side M6 x 18 Flange bolt 2 pcs M6 x 14 Flange bolt 2 pcs GOVERNOR LEVER GOVERNOR SHAFT Tightening torque 2 9 4 9 N m 30 50 kgf cm 2 2 3 6 ft lb Tightening torque 3 9 5 9 N m 40 60 kgf cm 2 9 4 3 ft lb 26 ADJUST GOVERNOR SYSTEM Governor system is centrifugal flyweight type Governor weight is installed into governor gear driven by crankshaft Governo...

Page 48: ...NER and BREATHER PIPE 1 Connect breather pipe to air cleaner base 2 Fit air cleaner base onto carburetor M6 x 12 Flange bolt 3 pcs 3 Connect breather pipe to 1 cylinder head 4 Set air cleaner element along with urethane foam onto base 5 Install air cleaner cover with knob FUEL PUMP AIR CLEANER BASE Tightening torque 6 8 8 8 N m 70 90 kgf cm 5 0 6 5 ft lb Tightening torque 6 8 8 8 N m 70 90 kgf cm ...

Page 49: ...URE SWITCH OIL PRESSURE SWITCH O RING OIL FILTER OIL FILTER 3 4 TURNS 3 4 TURNS 31 OIL FILTER Apply oil to O ring and install oil filter by tighte ning about 3 4 turns after attaching crankcase surface Tightening torque 9 9 14 7 N m 100 150 kgf cm 16 3 19 8 ft lb EH63 64 65 EH72 EH63 64 65 EH72 NOTE Not to tighten excessively NOTE Start engine after assembling and check for no oil leakage from oil...

Page 50: ...stall Muffler cover onto Muffler M6 Flange bolt 6 pcs 34 FINAL CHECK Be sure to check loosen bolts and nuts and also electric wiring connections A M6 FLANGE BOLT A MUFFLER BLACKET MUFFLER COVER M6 FLANGE BOLT M8 BOLT WASHER M6 FLANGE BOLT GASKET MUFFLER M8 SUS FLANGE NUT Tightening torque 16 6 18 6 N m 170 190 kgf cm 12 3 13 7 ft lb Tightening torque 16 6 18 6 N m 170 190 kgf cm 12 3 13 7 ft lb Ti...

Page 51: ...being fitted with a new piston rings valves and connecting rod should be thoroughly RUN IN before being put back into service Good bearing surfaces and running clearances between the various parts can only be established by operating the engine under reduced speed and loads for a short period of time While the engine is being tested check for oil leaks Make final carburetor adjustment and regulate...

Page 52: ...y by crankshaft and delivers pressurized engine oil to the journal and pin portions of crankshaft camshaft etc The engine oil in the oil pan is fed through the oil pump filter into oil pump and the engine oil pressure is adjusted by the relief valve after discharging from oil pump Through the oil cooler and cartridge type oil filter the engine oil is provided onto the rotating portions such as jou...

Page 53: ... end Cam Tappet Rocker arm Valve stem Oil relief valve Oil cooler Oil pump Oil pump filter Oil pan Element Oil puressure switch 2 1 1 Oil relief Valve opening pressure 3 8 kg cm2 373KPa 2 Oil pressure switch Normally close type Contact pressure 1 0kg cm2 98KPa OIL PUMP OIL PUMP FILTER CRANKSHAFT OIL FILTER OIL COOLER RELIEF VALVE OIL PRESSURE SWITCH CAMSHAFT EH72 ...

Page 54: ...e oil inspection and filling up Every time you use the engine add engine oil up to the designated maximum level Engine oil change First time After 20 hours use Thereafter Every 100 hours use Be sure to use automobile engine oil of the viscosity shown in the table above depending on environmental air temperature When the air temperature falls below 20 or rises above 40 be sure to choose engine oil ...

Page 55: ...uel goes into pump chamber frown suction chamber Fuel discharge process The vacuum pressure of crankcase inside is decreased in accordance with the piston moving downwards to the bottom dead center The vacuum pressure of the pulse chamber is also decreased and the diaphragm moved back by means of the return spring force The fuel in the pump chamber is pressed by the diaphragm and delivered to the ...

Page 56: ...T VALVE SEAT CHECK VALVE SPRING OUTLET CHECK VALVE MAIN JET SLOW JET IDEL SCREW BACUUM CUSHION JET DIAPHRAGM SPRING PUMP DIAPHRAGM LEAK JET IDEL PORT BACUUM PORT FUEL FUEL AIR MIXTURE FLOAT MIXTURE AIR AIR VENT HOLE CHOKE VALVE PILOT AIR JET MAIN AIR JET NEEDLE VALVE FUEL INLET PIPE FUEL MAIN NOZZLE THROTTLE VALVE BY PASS PILOT OUTLET TAMPER CAP EMULSION TUBE FUEL CUT VALVE MAIN JET PILOT JET FUEL...

Page 57: ...in with the air taken through the air cleaner into an optimum fuel air mixture which is supplied to the engine CHOKE The choke is used for easy start when engine is cold When the starter is operated with a choke valve fully closed the negative pressure applied to the main nozzle increases and draws much fuel accordingly thus easily start up the engine ACCELERATOR PUMP SYSTEM EH72 only When the thr...

Page 58: ...6 SHAFT ASSY choke 7 CHOKE VALVE 8 VALVE float 9 FLOAT ASSY 10 FLOAT PIN 11 MAIN JET 12 SOLENOID VALVE ASS Y 13 JET slow 14 NEEDLE idle adjust 15 THROTTLE SHAFT ASS Y 16 THROTTLE VALVE 17 EXPANSION PLUG 18 PLUG 19 O RING 20 PLUG anti tamper 19 3 4 5 6 7 2 12 11 13 18 17 20 9 8 10 14 16 15 1 EH63 64 65 ...

Page 59: ...t screw 22 SCREW throttle adjust 23 NEEDLE idle adjust 24 THROTTLE SHAFT ASS Y 25 FILTER throttle shaft 26 COLLAR 27 THROTTLE VALVE 28 VALVE SET SCREW 29 O RING 30 PLUG ANTI TAMPER 31 SCREW and WASHER ASS Y 32 SPRING 33 DIAPHRAGM ASS Y 34 COVER ASS Y 35 BODY ASS Y 36 U RING 37 HOLDER 38 SCREW and WASHER ASS Y 39 SCREW body set 40 PIPE connector 41 PIPE connector 42 SPACER 43 SCREW holder set 44 CL...

Page 60: ...transistor Current I1 turns the power transistor ON and the electric current I2 flows 2 At lower engine revolution when the flywheel reached the ignition point the low speed ignition timing control circuit operates to run the base current I3 to turn the signal transistor A ON allowing the current I1 to bypass as current I4 At this moment the power transistor turns OFF and the current I2 is abruptl...

Page 61: ...RAM Connect key switch magnetic switch and battery with wirings of proper gauge as shown by the dotted lines in the wiring diagram OIL WARNING LAMP OIL PRESSURE SWITCH BATTERY 12V SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG IGNITION COIL 2 OFF RUN START OFF RUN START CARBURETOR IGNITION COIL 1 CHARGE COIL REGURATOR ELECTRIC STARTER Key switch Option parts RED BLACK GRAY GREEN BLACK WHITE RED OIL W...

Page 62: ...the spline of armature shaft The pinion gear is engaged with ring gear and flywheel and crankshaft are rotated STARTING MOTOR ELECTRIC STARTER S S M M M M M KEY SWITCH MAGNETIC SWITCH BATTERY COMPONENT PARTS 1 STARTING MOTOR ASS Y 2 ARMATURE ASS Y 3 THRUST WASHER KIT 4 PINION STOPPER SET 5 YOKE ASS Y 6 REAR COVER ASS Y 7 STARTER METAL 8 BRUSH HOLDER ASS Y 9 BRUSH 10 BRUSH SET 11 BRUSH SPRING 12 PI...

Page 63: ...ecker 1 1 Spark plug cap 2 2 To spark plug or Engine body earth Start cranking in the same way as starting the engine and inspect whether spark is greater than the rated value In case of no spark or sparking performance a is less than 6 mm 0 236 in Clean the spark plug Adjust the electrode gap Replace the spark plug Check the ignition coil next page Engine body a 1 Associated cable Ignition cable ...

Page 64: ...tly differs from the rated value Ω 20 when 20 C 1 2 CHARGE COIL Measure the resistance between the wires 1 1 and 2 2 Replace the charge coil if the actual resistance value differs from the rated value Ω 20 when 20 C Measure the resistance between the wires and core 1 2 Ignition coil air gap 0 3 0 5 mm 0 012 0 020 in Resistance 8 16 kΩ Core High tension cable Secondary 0 5 Ω Stop wire Primary 1 2 R...

Page 65: ...hen engine is stopped 0 Ω continuity When engine is running no continuity D B C A REGULATOR Measure the resistance between the wires Rated resistance value Ω 20 when 20 C SOLENOID for Fuel Cut Off of Carburetor Measure the resistance between the cable and body body earth Ω 10 when 20 C Replace the regulator if the actual resistance value differs from the rated value As the solenoid is a constant p...

Page 66: ...auses Remedy 1 Electric starter does not operate 1 Poor connection of key switch wiring Check repair or replace 2 Wiring discontinuity between key switch and starter motor Replace 3 Wiring discontinuity between battery and starter motor Replace 4 Improper battery low capacity or dicharged battery Charge or replace battery 5 Poor connection of battery terminal Check clean or replace 6 Starter magne...

Page 67: ... Refill 2 Fuel pump clogged Clean 3 Fuel hose clogged or pinched Clean or replace 4 Air mixing into fuel lines Check and adjust connecting portion 5 Improper gasoline or water infiltration Replace 6 Carburetor Overflow Clogged or damaged Improper operation of throttle valve Adjust Disassembly and clean Check and adjust 7 Poor connection of fuel cut valve wiring Check and repair 4 Engine core compo...

Page 68: ...tion Replace 3 Fuel system malfunction 1 Carburetor clogged Disassembly and clean 2 Improper fuel pump operation Disassembly and clean 3 Fuel strainer or fuel hose clogged Clean or replace 4 Air mixing into fuel lines Check and adjust connecting portion 5 Improper gasoline or water infiltration Replace 4 Low intake air volume 1 Air cleaner clogged Clean or replace 2 Throttle valve faulty Repair or...

Page 69: ...Replace 5 Ignition system 1 Weak ignition spark Check and replace spark plug 9 5 ROUGH IDLING 9 6 HIGH ENGINE OIL CONSUMPTION Phenomenon Possible causes Remedy 1 Oil leakage 1 Loosen drain plug Tighten 2 Drain plug gasket damaged Replace 3 Incorrect oil filter fitting Repair 4 Loosen main bearing cover bolts Tighten 5 Main bearing cover gasket damaged Replace 6 Crankshaft oil seal damaged Replace ...

Page 70: ...ection of ignition system wirings Check and connect properly 2 Improper or damaged spark plug Clean or replace 2 Fuel system malfunction 1 Lean or rich air fuel mixture Clean adjust or replace 2 Carburetor damaged Disassembly and clean 3 Fuel lines clogged or damaged Clean or replace 4 Air mixing from connecting portion of air intake system Connect properly or replace gasket 3 Cylinder head 1 Carb...

Page 71: ... ignition system wirings Check and connect properly 2 Fuel system 1 Lean or rich air fuel mixture Disassembly and repair 2 Carburetor clogged Disassembly and repair 3 Improper idling adjustment of carburetor Adjust 4 Improper gasoline or water infiltration Replace 3 Engine core componets 1 Valve heat deterioration or improper valve adjustment Adjust or replace 2 Valve spring deterioration Replace ...

Page 72: ...on of he hot air used for engine cooling and temperature rise of the machine Keep the engine room temperature below 50 C even in the hottest period of the year 10 3 EXHAUST GAS DISCHARGE Exhaust gas is noxious When operating the engine indoors be sure to discharge the exhaust gas outdoors If a long exhaust pipe is used in such a case the internal resistance increases causing loss of engine power T...

Page 73: ...he measurement exceeds beyond the Limit the part needs to be replaced and or repaired 11 1 STANDARD DIMENSIONS AND SERVICE LIMITS STD CYLINDER HEAD Flatness Valve guide inside dia Valve seat contact width Unit mm in ITEM Limit 0 05 or less 0 002 or less IN EX IN EX EH63 EH64 EH65 EH72 EH63 EH64 EH65 EH72 EH63 EH64 EH65 EH72 0 1 0 004 0 7 1 0 0 028 0 039 2 0 0 079 6 035 6 053 0 2376 0 2383 6 15 0 2...

Page 74: ...8 EH63 EH64 EH65 EH72 1st reboring 80 500 80 519 3 169 3 170 84 500 84 522 3 3268 3 3276 EH63 EH64 EH65 EH72 2nd reboring 0 01 0 0004 EH63 EH64 EH65 EH72 STD 79 968 79 988 3 148 3 149 83 980 84 000 3 3063 3 3071 EH63 EH64 EH65 EH72 80 218 80 238 3 158 3 159 84 230 84 250 3 3161 3 3169 EH63 EH64 EH65 EH72 1st o s 80 468 80 488 3 168 3 169 84 480 84 500 3 3260 3 3268 79 878 3 145 83 890 3 3028 80 12...

Page 75: ... 0 0098 0 25 0 0098 EH63 EH64 EH65 EH72 EH63 EH64 EH65 EH72 0 15 0 006 0 03 0 07 0 0012 0 0028 2nd EH63 EH64 EH65 EH72 0 15 0 006 0 057 0 175 0 0022 0 0069 Oil ring EH63 EH64 EH65 EH72 0 15 0 006 0 2 0 4 0 0079 0 0157 Top 2nd EH63 EH64 EH65 EH72 1 5 0 0591 0 2 0 7 0 0079 0 0276 Oil ring EH63 EH64 EH65 EH72 1 5 0 0591 20 989 21 002 0 8263 0 8269 21 035 0 8281 Piston ring end gap 20 991 21 000 0 826...

Page 76: ... 8277 EH63 EH64 EH65 EH72 21 080 0 8299 Clearance between small end and piston pin 0 010 0 032 0 0004 0 0013 EH63 EH64 EH65 EH72 0 12 0 0047 Big end side clearance 0 1 0 4 0 0039 0 0127 EH63 EH64 EH65 EH72 1 0 0 0394 Journal dia D1 44 984 45 000 1 77102 1 77165 D2 44 986 44 997 1 77110 1 77154 EH63 EH64 EH65 EH72 CRANKSHAFT Crankpin outside dia 38 956 38 970 1 5337 1 5343 EH63 EH64 EH65 EH72 38 90...

Page 77: ... 20 1 385 5 970 5 985 0 2350 0 2356 5 85 0 2303 19 967 19 980 0 7861 0 7866 EH63 EH64 EH65 EH72 EH63 EH64 EH65 EH72 19 950 0 7854 5 970 5 985 0 2350 0 2356 5 85 0 2303 IN EX EH63 EH64 EH65 EH72 EH63 EH64 EH65 EH72 EH63 EH64 EH65 EH72 0 050 0 083 0 00197 0 00327 0 30 0 0118 0 050 0 083 0 00197 0 00327 0 30 0 0118 IN EH63 EH64 EH65 EH72 0 07 0 13 0 003 0 005 IN EX cold EX STD Unit mm in ITEM Limit D...

Page 78: ...3 EH64 EH65 EH72 8 954 8 979 0 3525 0 3535 8 924 0 3513 Tappet guide clearance 0 021 0 061 0 000827 0 002402 0 15 0 0059 Guide inside dia 9 00 9 015 0 3543 0 3549 9 08 0 3575 EH63 EH64 EH65 EH72 EH63 EH64 EH65 EH72 EH63 EH64 EH65 EH72 VALVE SPRING FREE LENGTH 39 5 1 5551 STD Unit mm in ITEM Limit 1 Above values are rough standard They will be changed by the engine condition and the environment 2 O...

Page 79: ... 8 70 90 5 0 6 5 Intake manifold bolts 16 6 18 6 170 190 12 3 13 7 Main bearing cover bolts 22 5 27 5 230 280 16 5 20 2 Oil filter 9 9 14 7 100 150 7 3 10 8 Oil pressure switch 5 9 9 8 60 100 4 3 7 2 Oil relief plug 14 7 24 5 150 250 10 8 18 0 Rocker arm Lock nut 6 8 8 8 70 90 5 0 6 5 Pivot bolt 16 6 18 6 170 190 12 3 13 7 Rocker cover 6 8 8 8 70 90 5 0 6 5 Spark plug New one 11 7 14 7 120 150 8 6...

Page 80: ...Spark plug 7 Magneto 8 Fuel hoses clamps and sealing gaskets The following maintenance schedule is based on the normal engine operation Should the engine be operated in extremely dusty condition or in heavier loading condition the maintenance interval must be shortened depending on the contamination of oil clogging of filter elements wear of parts and so on MAINTENANCE ITEMS REMARKS 1 Clean away d...

Page 81: ...e Service Manual or consult your nearest service dealer Note 3 More frequent oil changing oil filter replacement and air cleaner service on replacement may be necessary depending on operating conditions This would include dusty environment high ambient temperature heavy engine loading Periodic Maintenance Schedule table Check and refill engine oil Change engine oil Note 1 Initial 20 hours Replace ...

Page 82: ...and the spark arrester will be very hot Allow the muffler to cool before cleaning the spark arrester How to remove the spark arrester 1 Remove the flange bolts from the muffler cover and remove the muffler cover 2 Remove the special screw from the spark arrester and remove the spark arrester from the muffler SPARK ARRESTER SCREEN MUFFLER MUFFLER COVER Clean the spark arrester screen Use a brush to...

Page 83: ...To prevent rust in the cylinder bore apply oil through the spark plug hole and turn the crankshaft several turns by hand Reinstall the plug 4 Turn the crankshaft by hand and leave it where the resistance is the heaviest 5 Clean outside of the engine with oiled cloth 6 Put a plastic cover or the like over the engine and store the engine in dry place ...

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