Robin America EK13 Service Manual Download Page 3

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CONTENTS

Section Title

Page

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04

2. PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06

3. FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . . 10

5. DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5-1 PREPARATIONS AND PRECAUTIONS .

. . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 DISASSEMBLY PROCEDURE .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

5-4 REASSEMBLY PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8. IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

9. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

10. ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

11. OIL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

12. AUTOMATIC DECOMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 55

13. CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

14. RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

15. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

16. STANDARD REPAIR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

16-1 STANDARD DIMENSIONS AND LIMITS OF USE .

. . . . . . . . . . . . . . . . .

16-2 SERVICE DATA (The following are only for your reference.)

. . . . . . . . . .

16-3 AIR GAP AND CLEARANCE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16-4 TIGHTENING TORQUE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17. MAINTENANCE AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Summary of Contents for EK13

Page 1: ...EK13 EK1 7 EK20 EK28 EK30 ...

Page 2: ...2 ...

Page 3: ...ASSEMBLY PROCEDURE 32 6 ENGINE OIL 50 7 MAGNETO 51 8 IGNITION SYSTEM 52 9 WIRING DIAGRAM 53 10 ELECTRIC STARTER 53 11 OIL SENSOR 54 12 AUTOMATIC DECOMPRESSION SYSTEM 55 13 CARBURETOR 56 14 RECOIL STARTER 59 15 TROUBLESHOOTING 62 16 STANDARD REPAIR TABLES 66 16 1 STANDARD DIMENSIONS AND LIMITS OF USE 66 16 2 SERVICE DATA The following are only for your reference 75 16 3 AIR GAP AND CLEARANCE 75 16 ...

Page 4: ...ve Arrangement Overhead Valve Cooling System Forced air cooling system Lubrication System Splash lubrication system Lubricant Automobile engine oil Grade SE or higher SG SH or SJ in recommended SAE 10W 30 Under ordinary atmospheric temperatures SAE 5W 30 In cold areas Capacity of Lubricant L 0 55 0 6 Carburetor Horizontal draft Float type Fuel Automobile unleaded gasoline Fuel Consumption Rate g k...

Page 5: ...iewed from the P T O shaft side Valve Arrangement Overhead Valve Cooling System Forced air cooling system Lubrication System Splash lubrication system Lubricant Automobile engine oil Grade SE or higher SG SH or SJ in recommended SAE 10W 30 Under ordinary atmospheric temperatures SAE 5W 30 In cold areas Capacity of Lubricant L 0 6 1 1 Carburetor Horizontal draft Float type Fuel Automobile unleaded ...

Page 6: ...th 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 certain equipment it is recommended that the continuous output required from the equipment to be kept below this conti...

Page 7: ...ontinuous Rated HP Continuous Rated HP Continuous Rated HP Continuous Rated HP TORQUE TORQUE TORQUE TORQUE OUTPUT OUTPUT OUTPUT OUTPUT REVOLUT REVOLUTION REVOLUTION REVOLUTION REVOLUTION r p m r p m r p m r p m r p m MAXIMUM TORQUE Continuous Rated HP OUTPUT TORQUE ...

Page 8: ...nd realized fuel efficient EK13 17 20 28 Lens shape combustion chamber napier ring for second ring and optimum setting of the carburetor resulted in fuel efficient and less oil consumption EK30 3 2 USER FRIENDLY Remarkably silent among same range of engines Suitable clearance in between rocker arm and rocker shaft in addition cylinder head cover with double metal sheets enables less valve noise EK...

Page 9: ...t required in low to medium engine speed for agriculture work It shows quick response tough and strong in operation 3 6 EASY INSTALLATION ON AGRICULTURE MACHINE Low center of gravity light weight and compact design 30 degrees inclined cylinder makes the model lower height and low center of gravity then achieving light weight and compactness The inclined cylinder makes installing engine easier for ...

Page 10: ...g cover is aluminum die casting which is mounted on the output shaft side of the crank case Remove the main bearing cover to inspect inside of the engine Oil gauges fillers are on both sides of the cover for easy maintenance 4 3 CRANKSHAFT The crankshaft is forged carbon steel to have tough metal structure and the crank pin is induction hardened The output side of the shaft has a crankshaft gear a...

Page 11: ...ke valve is located on flywheel side of the cylinder head Hard alloy valve seats are 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 aluminum die casting with a pent roof combustion chamber construction EK13 17 20 28 The intake and exhaust po...

Page 12: ...rankcase Lubrication oil is splashed onto those parts in the case by the oil splasher on the connecting rod 4 12 IGNITION SYSTEM The ignition system is a transistor controlled magneto system which consists of a flywheel and an ignition coil with a built in transistor mounted on the crankcase This ignition system has latest automatic ignition timing control for easy start 4 13 CARBURETOR The engine...

Page 13: ...h rotates at the same speed as the crankshaft to effectively reduce vibration EK17 UP 4 16 DECOMPRESSION SYSTEM The automatic decompression system is mounted on the camshaft It opens the exhaust valve before the compression top thereby releasing the compression pressure and reducing the force required to pull the recoil starter During engine operation the decompression system is overpowered by cen...

Page 14: ...14 4 17 DIMENSIONS B Type D Type ...

Page 15: ...125 116 143 7 229 244 275 5 8 335 358 420 437 9 26 32 10 48 5 56 4 63 7 11 56 64 12 38 49 46 5 13 40 50 50 52 2 14 50 60 15 80 96 16 14 25 14 5 17 5 13 18 182 219 5 19 162 195 5 20 10 12 21 66 90 5 22 114 5 66 122 4 66 154 2 90 5 23 18 20 25 24 5 7 25 5 7 26 2 9 hole 2 11 hole 27 2 9 hole X 14 slotted hole 2 11 hole X 24 slotted hole The number is subject to change without notice mm ...

Page 16: ...16 4 18 SECTIONAL VIEW OF THE ENGINE 1 EK13 17 20 28 Governor spring Rocker cover Balancer shaft Piston Rocker arm Cross flow port Center plug placement pent roof combustion chamber 2 EK30 ...

Page 17: ...s This will make reassembly easier 3 To prevent parts from being mislaid keep each group provisionally assembled after removing the parts from the engine 4 Handle the disassembled parts with the utmost care Clean them with cleaning oil if necessary 5 Use suitable tools with correct way when disassembling and reassembling the engine 5 2 SPECIAL TOOLS Tool name Purpose Commercially available product...

Page 18: ...x 12mm located on both sides of the case Take care not to lose the gaskets To discharge oil quickly remove the oil gauge M22 14 mm spanner 2 Drain the fuel Shut OFF the fuel strainer Remove the fuel strainer cup Open the strainer to drain fuel from fuel tank Drain fuel from the carburetor drain or screwdriver Drain plug Oil gauge ...

Page 19: ...ead Take care not to lose the gasket Take care not to cut your hand with the muffler gasket 12 mm box spanner 10 mm box spanner or spanner 5 Fuel tank 1 Remove the fuel tank mounting nuts or and bolts from the crankcase 2 Disconnect fuel hose from the fuel tank to strainer side 3 Remove the fuel tank from the crankcase 10 or 12 mm box spanner 10 or 12 mm spanner M8 X 18L M8 X 18L M8 X 16L M8 X 16L...

Page 20: ...acket from the cylinder head Release the bolt 10 mm box spanner M6 x 14 mm 1 pc 7 Governor system 1 Loosen the bolt and remove the governor lever from the governor shaft There is no need to remove the bolt 2 Remove the governor spring 3 Remove the governor rod and the rod spring from the carburetor 10 or 12 mm box spanner or spanner M8 X 35L With washer M6 X 14L M8 Nut M8 Nut Speed control lever B...

Page 21: ...r Carburetor Insulator Remove the air cleaner while pulling the breather pipe away from the rocker cover or cleaner base Remove the air cleaner with carburetor together from the cylinder head M6 bolt with washer 2 pcs Remove the insulator 10 mm box spanner Element Cover Cover Element Element Oil pan Dumper Dual type Oil bath type ...

Page 22: ...cs 11 Recoil starter Remove the recoil starter from the blower housing 10 mm box spanner M6 x 14 mm 4 pcs 12 Blower housing Remove the blower housing from the crankcase 10 mm box spanner M6 x 12 mm 3 pcs 13 Cylinder baffle Remove the cylinder baffle 1 and 2 10 mm box spanner M6 x 12 mm 3 pcs CYLINDER BAFFLE 2 CYLINDER BAFFLE 1 Stop switch Blower housing Recoil starter ...

Page 23: ... other object between the flywheel blades which is a synthetic resin otherwise the risk of damaging the blades might be occurred 2 Knock the wrench with a hammer in a counter clockwise direction EK13 17 mm box spanner or socket wrench M12 nut EK 17 20 28 and 30 19 mm box spanner or socket wrench M14 nut 16 Flywheel Remove the flywheel from the crankshaft Leave the nut temporarily to prevent the fl...

Page 24: ...ion 1 Disconnect the grounding cable from battery 2 Disconnect the wire leading from the key switch ST terminal to the magnetic switch 3 Disconnect the wire that connects the positive terminal of the battery to the magnetic switch 4 Remove the electric starter Remove the Baffle 1 from the crankcase 12 mm box spanner M8 nuts 12 mm box spanner M8 x 12 mm 1 pc ...

Page 25: ...p in this step also an engine which has both of the charge coil and the oil sensor However please make sure do not damaged cut off the oil sensor wire after disassembly procedure Remove the charge coil 10 mm box spanner M6 x 10 mm 1 pc M6 2 to 4 pcs 19 Spark plug Remove the spark plug from the cylinder head 21 mm plug wrench M6 X 12L Flange bolt M6 X 25L Flange bolt ...

Page 26: ... cover 10 mm box spanner M6 x 12mm 4 pcs 21 Rocker arm Remove the rocker arm 10 mm box spanner 10 mm spanner hexagon wrench EK13 17 20 EK28 EK30 Remove the pin rocker arm and the rocker arm from the cylinder head at the compression top dead center Loosen nut pivot bolt and then remove the pivot bolt with rocker arm Hexagon wrench 5mm 10 mm spanner ...

Page 27: ...head gasket from the cylinder head Take care not to lose the dowel pin box spanner 12 mm or 14 mm EK13 17 20 M8 EK28 30 M10 23 Intake and exhaust valves 1 Remove the cotter from the spring retainer 2 Remove the intake valve and the exhaust valve EK13 17 20 28 EK30 Retainer lock Spring retainer Valve spring Oil seal Intake valve Exhaust valve ...

Page 28: ...nge bolts of main bearing cover from the crankcase Remove the main bearing cover while tapping gently around the cover using a plastic hammer or similar tool See Fig Be careful not to damage the oil gauge or oil seal or not to lose the knock pins 10 or 12 mm box spanner EK13 M8 EK17 20 28 30 M8 ...

Page 29: ...remove Remarks and procedures Fasteners 25 Camshaft and tappets Remove camshaft Be careful not to damage camshaft and tappets 26 Balancer Position piston at top dead center and remove balancer Tappets Camshaft Balancer ...

Page 30: ...nnecting rod and remove the piston from the upper part of the cylinder EK13 17 20 30 10mm box spanner EK28 12 mm box spanner 28 Piston and piston rings 1 Remove the piston clips 2 pcs Take out the piston pin and then remove the piston from the connecting rod small end taking care not to damage the connecting rod small end 2 Remove the piston rings from the piston by spreading them at the gap Take ...

Page 31: ... then remove the crankshaft from the crankcase by tapping its magneto side end with a plastic hammer taking care not to damage the oil seal Plastic hammer 30 MODEL WITH OIL SENSOR TYPE Oil sensor 1 Remove the clamp Model without charge coil type 2 Remove the oil sensor from the crankcase Woodruff key Keep gear as it is remove gear only in case of replacing it ...

Page 32: ...hen reassembling the engine apply oil to all moving parts 8 Check clearances and end plays and adjust if necessary 9 When mounting any major part during reassembly of the engine rotate it with your hand to check for any jamming or abnormal noise 5 4 2 ASSEMBLY STEPS AND PRECAUTIONS 1 OIL SENSOR a Mount the oil sensor and fix the wire with the clamp Tightening torque 8 0 10 0 N m 80 100 kgf cm 5 8 ...

Page 33: ...to slide it over the piston NOTE Be careful not to twist the rings too much as they may be damaged Install the oil ring first followed by the top ring When installing the piston ring make sure that the 1R or 2R mark is face up BARREL TAPER UNDER CUT COMBINATION RING BARREL TAPER COMBINATION RING EK13 17 20 28 EK30 ...

Page 34: ...s apart from each other before assembly a Install the piston and connecting rod assembly into the cylinder by holding the piston rings with the ring guide with the MAG mark on the connecting rod on the flywheel side If you do not have a ring guide hold the piston rings with the fingers and tap the upper part of the piston with a piece of wood b Rotate the crankshaft down to the bottom dead center ...

Page 35: ...s of camshaft Align the timing mark on crankshaft gear with the timing mark on camshaft and install camshaft in the crankcase 8 ADJUST CRANKSHAFT AND CAMSHAFT END PLAY Adjust end play to the specified values using the proper spacer The proper spacer may be determined following manner CAUTION Incorrect timing of the gears will cause malfunction of the engine and may results in damage due to interfe...

Page 36: ...45 T 0 50 T 0 55 T 0 60 T 0 20 T 0 25 T 0 30 T 0 35 T 0 40 T 0 45 T 0 50 T 0 55 T 0 60 T 0 20 T 0 40 T 0 60 T 0 50 T 0 60 T 0 70 T 0 80 T 0 90 T 1 00 T 1 20 T 0 50 T 0 70 T 0 90 10 CAMSHAFT END PLAY For type B a Measure the depth A2 From the mating surface to the inner race of the ball bearing b Measure the height B2 From the mating surface to the cam gear inner boss A2 0 35 B2 SIDE CLEARANCE mm S...

Page 37: ...cers chosen at procedure 1 on crankshaft and camshaft Use an oil seal guide when installing the main bearing cover to avoid damaging the oil seal lip Tap the cover into place with a soft hammer NOTE Oil the bolt threads first and then tighten the flange bolts Model Tightening torque Bolt box wrench EK13 10 140 N m 100 140 kgf cm M6X1 0X33L 10mm EK17 20 28 30 22 30 N m 220 300 kgf cm M8X1 0X40L 12m...

Page 38: ...6 and 77 NOTE 2 Carefully scrape off any carbon deposits on the combustion chamber Apply oil to the valve stems before mounting the intake and exhaust valves Insert the valves in the cylinder head and place it on a level workbench Next mount the valve springs the spring retainers and collets valves Mount the stem seal on the intake valve guide Valve spring compressor Retainer lock Spring retainer ...

Page 39: ...nder head bolt EK13 17 20 M8X1 25X60L 2pc M8X1 25X85L 2pcs EK28 M10X1 5X66L 2pcs M10X1 5X100L 2pcs EK30 M10X1 5X66L 2pcs M10X1 5X86L 2pcs Tightening torque Model 1 st step 2 nd step Final Step EK13 17 20 9 8 N m 100 kgf cm 19 6 N m 200 kgf cm 24 5 35 3 N m 250 360 kgf cm EK28 30 9 8 N m 100 kgf cm 19 6 N m 200 kgf cm 41 2 50 0 N m 420 510 kgf cm EK13 17 20 EK30 ...

Page 40: ...pply oil to rocker arms and assemble them to cylinder head using pivot and nut b Adjustment method EK13 17 20 28 Loosen the nut on the adjustment screw and turn the screw to adjust the valve clearance When the valve clearance is correct tighten the nut EK30 Loosen the nut under the rocker arm and turn the bolt pivot to adjust the clearance between rocker arm and valve stem end Tighten the nut on r...

Page 41: ...5 0 7 0 N m 50 70 kgf cm 16 FLYWHEEL COOLING BLOWER and STARTING PULLEY NOTE When mounting the flywheel be sure to wipe off any oil on the tapered part of the crankshaft and flywheel a Mount the woodruff key on the crankshaft b Mount the charge coil and clamp option Tightening torque 6 0 8 0 N m 60 80 kgf cm EK13 17 20 28 EK30 Woodruff key M6 X 25L 4pcs M6 X 12L 1pcs Mount the key to use copper ha...

Page 42: ...rting pulley to the crankshaft f Tighten crankshaft nut with locking pliers adopted as shown in the illustration 17 IGNITION COIL Insert the high tension cord and primary wire from the ignition coil into the notch of the crank case so that not to pinch the cord When mounting the ignition coil insert a thickness gauge between the ignition coil and the flywheel to check the air gap Model EK13 17 20 ...

Page 43: ...ighten flange bolts M6 12 mm flange bolt 3 pcs c Install recoil starter to blower housing M6 8 mm flange bolt 4 pcs d Mount the stop switch to the blower housing M4 12 mm screw and washer 2 pcs e Mount the bracket UN front cover to the blower housing M6 12 mm flange bolt 2 pcs f Attach the muffler bracket to the cylinder head Temporarily fit the flange bolt M8 1 25 16L flange bolt 1 pc Tightening ...

Page 44: ...nstall insulator and gasket and then mount to cylinder head Insert the breather pipe into the rocker cover and then mount the air cleaner base The following are positions to insert for each type of element a Urethane element type and dual element type b Oil bath M6 flange bolt 2 pcs Bolt with washer M6 X 134L 1pc M6 X 147L 1pc Bolt with washer M6 X 80L 2pcs ...

Page 45: ...ver with the governor spring e Governor system adjustment method The governor unit is a centrifugal flyweight type and is installed on the governor gear Since it automatically adjusts the throttle valve of the carburetor by means of a link mechanism it is possible to maintain a constant engine speed even with load variations Turn the speed control lever to the full speed position making sure that ...

Page 46: ...b Connect the fuel pipe to the fuel strainer and the carburetor Mount the fuel strainer to the speed control bracket M6 12 mm Bolt 1 pc 22 MUFFLER a Mount the muffler and the gasket on the cylinder head NOTE Be sure to remove any tape or cloth used to cover the exhaust port when the engine was disassembled Gasket for EK28 30 it is not necessary to care about its direction Tightening torque M8 18 0...

Page 47: ...47 EK13 17 20 EK28 EK30 Mount the muffler Mount the muffler cover M8X16L M8X12L M8 Nut with SP washer 2pcs M6X8L 4pcs M8 Nut 2 pcs M8 12 mm Bolt ...

Page 48: ... Drain the dirty oil from the oil pan and wash it in kerosene Then fill the new engine oil up to the specified oil level Oil capacity in the Oil Bath oil pan mL EK13 17 20 50 EK28 30 105 24 EXTERNAL INSPECTION Reassembly is completed Check that the wiring is correct and that there are no loose nuts and bolts or any other faults visible on the outside of the engine Cover Paper element NOTE Instead ...

Page 49: ...eing 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 the engine operating speed Model Step EK13 EK17 EK20 EK28 EK30 Engine Speed r p m Time Step 1 No L...

Page 50: ... Engineers 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 of appropriate viscosity and grade according to the prevailing conditions Care must be taken when using multi grade engine oil because the oil consumption rate tends to increase wh...

Page 51: ...ension cable for any damage or short circuiting 2 Check the sparking Take the spark plug out of the cylinder head connect the spark plug with the plug cap and ground it on the cylinder head or any other metallic part of the engine The gap between the electrodes of the spark plug should be between 0 6 mm and 0 7 mm Rotate the engine by pulling the recoil starter and check the spark plug gap for spa...

Page 52: ... side of the ignition coil and the base current I1 flows to the power transistor Tr1 Current I1 turns the power transistor Tr1 ON and the electric current I2 flows 2 When flywheel reached the ignition timing timing control circuit transmit signal to turn on Tr2 and Tr1 turn off at the same time at the particular moment current in primary coil cut off abruptly then high voltage is generated in seco...

Page 53: ...53 9 WIRING DIAGRAM 9 1 MODEL WITHOUT ELECTRIC STARTER 10 ELECTRIC STARTER Ignition coil Flywheel Magneto Spark plug Stop switch ...

Page 54: ...54 11 OIL SENSOR Not available ...

Page 55: ... the flyweight is pulled by spring and lifts up the decompression pin Then tappet exhaust which in turn opens up the exhaust valve slightly to release the compression accordingly recoil pulling force become lighter When the cranking speed reaches specified r p m flyweight move to outer against spring force because the centrifugal force applied to the flyweight and the decompression pin coming down...

Page 56: ...vel 13 2 2 SLOW SYSTEM The slow system supplies fuel to the engine during idling and low speed operation Fuel is initially metered by the main jet and then metered once again by the slow jet The fuel air mixture is fed to the engine through the pilot outlet and the bypass During idling fuel is fed to the engine mainly through the pilot outlet 13 2 3 MAIN SYSTEM The main system feeds fuel to the en...

Page 57: ... air passages and fuel passages or by variations in the fuel level To get the best possible performance from the carburetor ensure that the each passages are kept clean so that air and fuel can flow freely through them The procedures for overhauling the carburetor are described below 13 3 1 THROTTLE SYSTEM 1 When the throttle stop screw is removed the spring can be taken out 2 Remove the Phillips ...

Page 58: ...gine malfunction 5 The tightening torque of the bolt is 9 N m 90 kgf cm 6 5 ft lb Be sure not to forget to mount the washer 13 3 5 FLOAT SYSTEM 1 Take out the float pin and then remove the float and the needle valve Since the needle valve is linked to the float take care when assemble Do not use drill or similar objects for cleaning the jets as these are likely to damage the orifices which in turn...

Page 59: ...l firmly with your left hand and untie the tentative knot with your right hand Continue to hold the case and the reel with your left hand and hold the reel center with your right hand then loosen both hands alternately to allow the reel gradually to turn to the arrow direction until the spring is completely released Do this carefully to avoid dangers caused by spring back Disassembly is completed ...

Page 60: ... the spring is hooked Mount the ratchet into the reel Mount the ratchet guide assembly taking care not to move the ratchet Tighten the set screw Hold the ratchet guide gently by your hand to prevent it from rotating and then tighten the set screw Tightening torque M6 5 5 N m 55 kgf cm 4 0 ft lb Tension the reel spring 1 Grip the case and turn the reel 6 times counterclockwise 2 Fix the reel so tha...

Page 61: ...vent it from springing out of the housing unit Wear protective gloves when doing this b Hook the inner end of the spring onto the projection on the starter case Refer to the assembly procedure for more details 2 About lubrication Lubricate the rotating and frictional parts and the spring with grease heat resistant grease recommended or engine oil when the starter is disassembled and prior to long ...

Page 62: ...d a high back pressure due to a long exhaust pipe Problem and possible cause Remedy 1 Spark plug Improper spark plug gap Insulation defect Carbon deposits Adjust the gap Replace Clean 2 Ignition coil Insulation defect or discontinuity Poor contact or broken wire Replace Repair or replace 1 Ignition system problems 3 Improper air gap between ignition coil and flywheel Adjust 1 No fuel in fuel tank ...

Page 63: ...gasoline or water in gasoline Replace 1 Air cleaner clogged Clean or replace Poor output 4 Low air intake volume 2 Throttle valve malfunction Repair or replace 1 Cooling air flow obstructed at inlet or cylinder baffle portion Clean 2 Poor quality engine oil Replace 3 Lean fuel air mixture Check and adjust carburetor 4 Excessive back pressure of exhaust system Check and clean or replace Overheat 1 ...

Page 64: ...system 3 Choke does not open fully Repair or replace 1 Low compression Check and repair High fuel consumption 2 Engine core components 2 Overcooling Check and adjust load and or engine speed 1 Loose ignition system wiring Inspect and tighten 1 Ignition system problems 2 Improper or faulty spark plug Clean or replace 1 Lean or rich fuel air mixture Clean adjust or replace carburetor 2 Carburetor co...

Page 65: ...65 15 2 ELECTRIC STARTER ...

Page 66: ...t contact width Intake and Exhaust STD EK13 17 20 1 1 1 4 mm EK28 30 1 0 1 3 mm Contact rate to those valve seat 85 and more a Scrape the valve seat face by valve seat cutter 45 degree slightly b Put ink marker on valve face and fit it on the seat face then check contact position c Scrape the face by valve seat cutter 15 degree d Scrape the face again by the cutter 45 degree slightly and recheck c...

Page 67: ...D1 D2 Model STD Limit EK13 17 20 9 975 9 900 9 95 EK28 Intake Exhaust 12 000 12 018 12 05 EK13 is nothing Rocker arm pin outer diameter mm D1 D2 Model STD Limit EK13 17 20 9 960 9 970 9 9 EK28 Intake Exhaust 11 973 11 984 11 9 EK30 is nothing Rocker arm inner diameter for pin mm Model STD Limit EK13 17 20 10 000 10 015 10 05 EK28 Intake Exhaust 12 000 12 018 12 05 EK30 is nothing D1 D2 D2 D1 ...

Page 68: ...79 265 79 365 EK30 80 250 80 265 80 365 Model Second re boring 0 50 Limit EK13 61 500 61 515 61 615 EK17 67 500 67 515 67 615 EK20 72 500 72 515 72 615 EK28 79 500 79 515 79 615 EK30 80 500 80 515 80 615 Roundness after re boring Less than 0 01 mm Cylindricity after re boring Less than 0 015 mm 3 PISTON Outer diameter at skirt in thrust direction mm Model STD Limit EK13 60 965 60 980 60 865 EK17 6...

Page 69: ...30 0 02 0 06 0 10 Piston pin hole mm Model STD Limit EK13 13 003 12 995 13 035 EK17 EK20 15 003 14 995 15 035 EK28 18 002 17 994 18 035 EK30 18 008 18 000 18 035 Piston pin outer diameter mm Model STD Limit EK13 13 000 13 005 12 960 EK17 EK20 15 000 15 005 14 960 EK28 EK30 18 000 18 005 17 960 Model Oversize 0 50 Limit EK13 61 465 61 480 61 365 EK17 67 465 67 480 67 365 EK20 72 465 72 480 72 365 E...

Page 70: ...g 0 2 0 4 0 9 2nd ring 0 2 0 4 0 9 Oil ring 0 2 0 7 0 9 b EK30 STD Limit Top ring 0 10 0 25 0 7 2nd ring 0 08 0 28 0 7 Oil ring 0 1 0 6 0 8 4 CONNECTING ROD Small end inner diameter mm Model STD Limit EK13 13 015 13 025 13 080 EK17 EK20 15 015 15 025 15 080 EK28 EK30 18 015 18 025 18 080 Clearance between small end and piston pin mm Model STD Limit EK13 EK17 EK20 EK28 EK30 0 01 0 003 0 12 ...

Page 71: ... 20 11 N m EK28 26 N m EK30 17 N m Clearance between large end and crank pin mm Model STD Limit EK13 EK17 EK20 0 015 0 040 1 1 EK28 EK30 0 020 0 045 1 1 Large end side clearance mm Model STD Limit EK13 EK17 EK20 EK28 EK30 0 4 1 1 1 3 5 CRANKSHAFT Crank pin outer diameter mm Model STD Limit EK13 25 475 25 485 25 37 EK17 EK20 29 975 29 985 29 87 EK28 EK30 33 470 33 480 33 37 ...

Page 72: ... 32 680 Journal outside dia mm D type STD Model D1 D2 Limit EK13 13 966 13 984 13 95 EK17 EK20 14 966 14 984 14 95 EK28 EK30 17 966 17 984 17 95 B type STD Limit Model D1 D2 D1 D2 EK13 13 966 13 984 19 980 19 993 13 95 19 95 EK17 EK20 14 966 14 984 24 980 24 993 14 95 24 95 EK28 EK30 17 966 17 984 29 980 29 993 17 95 29 95 7 VALVE Valve stem outside dia mm Model STD Limit EK13 17 20 5 442 5 460 5 ...

Page 73: ... Intake 0 045 0 072 0 1 EK13 17 20 0 040 0 072 0 1 EK28 30 Exhaust 0 040 0 075 0 1 Valve clearance in cold state mm Model STD Limit EK13 0 15 0 20 0 25 EK17 0 10 0 15 0 25 EK20 0 12 0 17 0 25 EK28 EK30 0 07 0 12 0 25 8 TAPPET Stem outside dia mm Model STD Limit EK13 EK17 EK20 EK28 EK30 7 960 7 975 7 93 ...

Page 74: ...t EK13 EK17 EK20 EK28 EK30 0 035 0 075 0 1 9 VALVE SPRING FREE LENGTH mm Model STD Limit EK13 EK17 EK20 31 8 32 3 31 5 EK28 EK30 36 5 37 0 36 2 B Limit 1 5 10 VALVE SEAT ANGLE INTAKE AND EXHAUST Valve cutter angle a Valve contact width b Model STD Limit EK13 EK17 EK20 a 90 b 1 1 1 4 2 0 EK28 EK30 a 90 b 1 1 1 3 2 0 More than 85 ...

Page 75: ...ve Capacity L 0 25 0 26 0 26 0 55 0 55 Lubricant Consumption mL Hr 5 5 5 5 7 Oil consumption has been measured under following condition Good break in operation has been finished Oil 10W 30 Grade SE Load Continuous load 3600 rpm 16 3 AIR GAP AND CLEARANCE ITEM Clearance mm EK13 EK17 EK20 EK28 EK30 Valve clearance Intake Exhaust 0 15 0 20 0 10 0 15 0 12 0 17 0 07 0 12 0 07 0 12 Air gap Ignition and...

Page 76: ...ad EK28 27 270 24 30 240 300 oil the screw thread Connecting rod EK30 17 170 16 19 160 190 oil the screw thread EK13 40 400 30 50 300 500 EK17 20 67 670 60 75 600 750 Flywheel EK28 30 76 760 70 85 700 850 Rocker cover head cover 6 60 5 7 50 70 EK13 12 120 10 14 100 140 Main bearing cover Crankcase cover EK17 20 28 30 26 260 22 30 220 300 M10 12 125 10 15 100 150 M12 25 250 20 30 200 300 Drain plug...

Page 77: ... accidents 4 Running the engine with insufficient oil can result in serious problems including engine seizure 5 A clogged air cleaner can cause power loss and malfunction 17 2 INSPECTION AND MAINTENANCE AFTER THE FIRST 20 HOURS MAINTENACE ITEMS REASON REMARKS 1 Change the crankcase oil 1 Sludge is deposited during running in 17 3 INSPECTION AND MAINTENANCE EVERY 100 HOURS EVERY 10 DAYS MAINTENACE ...

Page 78: ...malfunction 2 Faulty piston rings can cause low output power and engine malfunction 3 To prevent fuel leakage and attendant dangers 17 8 SPARK ARRESTER AND TAIL SCREEN OPTION Check and clean the spark arrester and the tail screen which are mounted on the tail of the exhaust muffler every 100 hours Clogged the spark arrester or the tail screen can cause prevents the flow of exhaust gas reduces engi...

Page 79: ...n the cylinder bore inject oil through the spark plug hole pull the recoil starter knob gently 2 or 3 times and then put back the spark plug 4 Pull the recoil starter knob until the resistance is heavy Leave it in that position 5 Clean the exterior of the engine with an oiled cloth Place a plastic cover or similar over the engine and store the engine in a dry place ...

Page 80: ...80 ISSUE EMD ES7820 December 2014 ...

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