Robin FL-H7500 Service Manual Download

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Summary of Contents for FL-H7500

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Page 2: ...3 ENGINE DISASSEMBLY 4 ENGINE REASSEMBLY 5 CARBURETOR DISASSEMBLY AND REASSEMBLY 6 STARTER DISASSEMBLY AND REASSEMBLY MALFUNCTION AND REPAIRE CHECK AND RECONDITIONING CRITERIA FOR RECONDITIONING NOTI...

Page 3: ...rced Lubrication 20 4 720 cfm 14 1 498 cfm Joystick Lever with rubber grip Trigger Lever Cruise Control Lever One Flexible Pipe One Swivel Pipe One Blower Pipe One Blower Nozzle Two Shoulder Strap Hos...

Page 4: ...OF PARTS DESIGNATION OF PARTS DESIGNATION OF PARTS 8 Choke Lever 9 Starter Handle 10 Fuel Tank 11 Fuel Tank Cap 12 Muffler 13 Shoulder Strap 14 Air Inlet Net 15 Plug Cover 22 Blower Pipe 16 Spark Plu...

Page 5: ...any loss and wrong reassembly of screw bolts and nuts try to assemble each group of disassemble parts temporarily 5 Handle disassembled parts carefully and clean them with wash oil 6 After removing g...

Page 6: ...the CONTOROL CABLE 4X16mm 5 M5 25mm 1 2 Remove the THROTTLE LEVER 2 from the LEVER 2 ASSY M6 14mm 1 7 CASE AIR CLEANER P11 1 Remove the CASE AIR CLEANER M5 16mm 4 1 Remove the PLATE SEPARETOR Be sure...

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Page 10: ...Instructions 3 COVER AIR CLEANER KNOB BOLT ELEMENT DUCT HOSE CLAMP 1 Remove the COVER AIR CLEANER by looseninig KNOB BOLTS 2 Remove the DUCT by looseninig HODE CLAMPS KNOB BOLT COVER AIR CLEANER ELEME...

Page 11: ...the COVER ENGINE NOTICE Be careful not to loose the GUARD OIL or COVER PLUG 5 TANK FUEL 1 Remove the fuel tube NOTICE The fuel will spout if the fuel tube is removed with the fuel tank filled with fue...

Page 12: ...SE AIR CLEANER 2 Disconnect the two tubes connected to the air cleaner 1 2 SCREW M5 16 W SW 4PCS ROCKER COVER AIR CLEANER AIR CLEANER CYLINDER PLATE SEPARETOR PLATE CHECK VALVE CHECK VALVE CHECK VALVE...

Page 13: ...ME 1 Remove the FRAME 9 CASE 1 VOLUTE DAMPER 2 ELBOW O RING 1 Remove the CASE 1 VOLUTE N O TICE Be careful not to loose the nuts ELBOW NUT M5 BLACK DAMPER 2 TAPPING SCREW 5 16 9PCS SCREW M5 65 W SW 2P...

Page 14: ...art name Disassembling Instructions 10 IMPELLER 1 Remove the IMPELLER 11 ENGINE CASE 2 VOLUTE 1 Remove the ENGINE SOCKET HEAD BOLT M6 30 W SW 6PCS BASE CASE 2 VOLUTE IMPELLER SOCKET HEAD BOLT M6 40 W...

Page 15: ...rt name Disassembling Instructions 6 1 LEVER CASE 1 LEVER CASE 2 LEVER ASSY 1 Remove the CASE 1 LEVER and CASE 2 LEVER ASSY TAPPING SCREW 4 16 5PCS CASE 2 LEVER ASSY NUT M5 1PCS SCREW M5 25 1PCS CASE...

Page 16: ...Disassembling Instructions 6 1 LEVER CASE 2 LEVER ASSY LEVER 2 THROTTLE 2 Remove the LEVER 2 THROTTLE from the CASE 2 LEVER ASSY LEVER 2 THROTTLE SELF ROCK NUT M6 1PCS SOCKET HEAD BOLT M6 14 1PCS WAS...

Page 17: ...INE 0 0 COVER ENGINE 10 1 0 CASE 2 VOLUTE 0 0 STARTER 15 1 5 ENGINE 0 0 CASE 2 LEVER 5 0 5 LEVER 2 THROTTLE 0 0 CASE 1 LEVER 3 0 3 CASE 2 LEVER 0 0 1 Check if the LEVER 2 THROTTLE can be smoothly move...

Page 18: ...MUFFLER on the CASE 2 VOLUTE rib with the number a as shown in the photograph 2 IMPELLER SOCKET HEAD BOLT M6 30 W SW 6PCS Tightening torque 80 20 0 BASE 1 2 CASE 2 VOLUTE IMPELLER SOCKET HEAD BOLT M6...

Page 19: ...nner top groove of the ELBOW Apply silicon or grease over the ring before fitting it NUT M5 BLACK SCREW M5 65 W SW 2PCS Tightening torque 20 10 5 DAMPER 2 SCREW M5 40 1PCS Tightening torque 20 Tighten...

Page 20: ...e FRAME by screwing the SCREW RIVETS CUSHION RIVET ROCK 6PCS SCREW M5 16 W SW MEC 2PCS Tightening torque 25 15 0 FRANGE NUT M6 2 Tightening torque 25 15 0 SCREW RIVETS NET Upside NET Tighten the SCREW...

Page 21: ...bes correctly as shown in the photographs below Apply silicon or oil over the inserting part of the tubes before installing them if necessary 8 CASE AIR CLEANER CASE VOLUTE SCREW M5 16 W SW 4PCS Tight...

Page 22: ...in the groove of the CASE 2 VOLUTE The CONTROL CABLE should be under the high tension code 3 Connect the WIRES from the LEVER and the ones of the COIL and hold the CONTROL CABLE and connected wire usi...

Page 23: ...ER ENGINE with the TAPPING SCREW 11 COVER ENGINE GUARD OIL STARTER COVER PLUG 1 Fix the COVER PLUG in advance to the COVER ENGINE 2 The GASKET CARBURETOR should be positioned on the part with number b...

Page 24: ...bolt should be 15kgf cm 3 Be careful that the DUCT fitted in is not covered with the COVER AIR CLEANER KNOB BOLT COVER AIR CLEANER ELEMENT DUCT HOSE CLAMP HOSE CLAMP Fit in the hose clamp with the bol...

Page 25: ...re in the groove of the CASE 1 LEVER 3 Fit the end fitting of the control inner cable in the hole c of the LEVER 1 THROTTLE Fit the TORSION SPRING over the cylindrical hollow column e and fit the LEVE...

Page 26: ...d in according to no 13 1 and CASE 1 LEVER fitted in according to no 13 2 together TAPPING SCREW 4 16 5PCS Tightening torque 5 8kgf cm CASE 2 LEVER SCREW M5 25 1PCS Used to tighten the lever on the SW...

Page 27: ...clamp screw and nut 3 Fit the FLEXIBLE PIPE in the ELBOW on the blower and tighten the HOSE CLAMP 100 4 Insert the BLOWER PIPE into the SWIVEL PIPE and turn the BLOWER PIPE clockwise to tighten it In...

Page 28: ...ning length of the BAND through the BUCKLE Tighten the BUCKLE by pushing it towards the HANGER in the direction of the arrow shown in the drawing while pulling on the BAND in the opposite direction 2...

Page 29: ...emove the ROCKER ARM 1 Remove the RETAINER SPRING Support the VALVE from the inner side of the CYLINDER HEAD push RETAINER SPRING and slide it 2 Remove the VALVE 3 Remove the SPRING VALVE RETAINER PLA...

Page 30: ...Remove the tube from the CYLINDER SCREW SCREW M5 M5 25W SW 2PCS 25W SW 2PCS SCREW SCREW M5 M5 14W SW 1PCS 14W SW 1PCS 1 1 PULLEY PULLEY 1 Remove the PULLEY 1 Remove the PULLEY 29 29 PULLEY M10 width a...

Page 31: ...AD BOLT M6 M6 70 3PCS 70 3PCS 5 5 PLUG SPARK PLUG SPARK 1 Remove the PLUG SPARK 1 Remove the PLUG SPARK PLUG SPARK PLUG SPARK 30 30 6 6 ROCKER COVER ROCKER COVER 1 Remove the ROCKER COVER and GASKET R...

Page 32: ...R COVER CAMGEAR CAM LIFTER CAM LIFTER CAMGEAR CAMGEAR 1 Remove the 1 Remove the COVER CAMGEAR COVER CAMGEAR 2 Remove the 2 Remove the PUSH ROD PUSH ROD 3 Remove the 3 Remove the CAM LIFTER CAM LIFTER...

Page 33: ...d remove the VALVES the RETAINER SPRINGS and remove the VALVES IN IN EX EX Slide the Slide the SPRING down SPRING down Slide the Slide the RETAINER SPRING RETAINER SPRING Remove the ROCKER SHAFT by hi...

Page 34: ...LEAD VALVE and RETAINER PLATE 1 Remove the LEAD VALVE and RETAINER PLATE 2 Remove the CASE OIL 2 Remove the CASE OIL 9 9 33 33 BOLT BOLT M8 M8 12 1PCS 12 1PCS SCREW SCREW M5 M5 25 W SW 5PCS 25 W SW 5P...

Page 35: ...ns 10 10 FLYWHEEL FLYWHEEL COIL COIL 1 Remove the COIL 1 Remove the COIL 2 Remove the FLYWHEEL 2 Remove the FLYWHEEL 34 34 SOCKET HEAD BOLT SOCKET HEAD BOLT M4 M4 20 W SW 2PCS 20 W SW 2PCS FRANGE NUT...

Page 36: ...the screwdriver remove the CRANKCASE by prying it off with the screwdriver see the figure below see the figure below 2 2 Pull the CRANKSHAFT out of the CYLINDER Pull the CRANKSHAFT out of the CYLINDE...

Page 37: ...e PISTON RINGS and OIL RING 3 Remove the PISTON RINGS and OIL RING CRANKSHAFT CRANKSHAFT PISTON PISTON PISTON RINGS PISTON RINGS OIL RING OIL RING OTHERS OTHERS Be careful not to damage the OIL SEAL B...

Page 38: ...engine oil over the rotating portions and sliding surfaces Check and adjust the clearance Check and adjust the clearance After reassembling each of the rotatable main parts rotate by hand to test it f...

Page 39: ...e direction OND RING in the opposite direction SECOND RING SECOND RING White mark right White mark right Fit in the PISTON with Fit in the PISTON with its its I mark I mark directed as directed as sho...

Page 40: ...and slide RETAINER SPRING while pushing spring RETAINER SPRING while pushing spring Slide the Slide the SPRING down SPRING down 4 4 CYLINDER CYLINDER 1 Install the two CHECK VALVES on the CYLINDER 1...

Page 41: ...TON into the CYLINDER 2 Insert the CRANKSHAFT PISTON into the CYLINDER 3 Apply the silicon system liquid gasket equally over the shaded area of 3 Apply the silicon system liquid gasket equally over th...

Page 42: ...the COIL and WIRES in the CRANKASE 4 Fit the COIL and WIRES in the CRANKASE See the figure below Air gap 0 3mm See the figure below Air gap 0 3mm Be careful not Be careful not t o l o o s e t h e t o...

Page 43: ...EAD VALVE with the Attach LEAD VALVE with the cut out facing to OIL cut out facing to OIL FILLER HOLE FILLER HOLE 8 8 Cut out Cut out BOLT BOLT M8 M8 12 1PCS 12 1PCS Tightening torque Tightening torqu...

Page 44: ...name Assembling Instructions Assembling Instructions GASKET CYLINDER HEAD GASKET CYLINDER HEAD Finally tighten again the BOLT that was Finally tighten again the BOLT that was tightened first tightene...

Page 45: ...ROD is put into the spherical grooves 2 Make sure that the PUSH ROD is put into the spherical grooves of the CAM LIFTER and ROCKER ARM adjust bolt of the CAM LIFTER and ROCKER ARM adjust bolt 3 Attac...

Page 46: ...0 20 20 kgf cm kgf cm 12 12 ROCKER COVER ROCKER COVER 1 Attach the ROCKER COVER and 1 Attach the ROCKER COVER and GASKET ROCKER COVER GASKET ROCKER COVER NOTICE NOTICE The breather should be The breat...

Page 47: ...TUBE 3PCS TUBE 3PCS 1 Attach the INSULATOR and GASKET INSULATOR 1 Attach the INSULATOR and GASKET INSULATOR 2 Fit the TUBES in the CYLINDER using the PIPE JOINT T 2 Fit the TUBES in the CYLINDER using...

Page 48: ...tach the CAP OIL NOTICE NOTICE Be careful not to fail to place the PACK Be careful not to fail to place the PACK ING or fill the tank with oil ING or fill the tank with oil 47 47 Part name Part name A...

Page 49: ...position The float chamber is provided with a diaphragm and covered by a cover Negative pressure in the air intake passage causes the diaphragm to swell upward and thereby pushing up the hinge to open...

Page 50: ...he INLET VALVE and the OUTLET VALVE should be flat and not bent The DIAPHRAGM ASSY should be free of any hardening damage or bend After cleaning the PUMP BODY ASSY test it for deformation of the METER...

Page 51: ...L to the direction of the arrow until it stops by controlling the rotation of the REEL with your thumb Remove the parts as shown in Fig 6 2 Remove the REEL slowly by turning it back and forth gently i...

Page 52: ...ARTER CASE wind the STARTER ROPE around the REEL three turns in the direction of the arrow shown in Fig 6 5 draw out the third turn of the STARTER ROPE from the REEL ct out and fit the REEL completely...

Page 53: ...not over stressed If the SPIRAL SPRING comes away with a sound and the STARTER ROPE will not be moved back reassemble the RECOIL STARTER from the beginning Other notice When the SPIRAL SPRING fly out...

Page 54: ...Correct the causes of bad fuel flow Replace faulty parts with new ones if necessary Is the gasoline fresh Yes Gasoline stored in a bad way goes bad quickly Old gasoline should be replaced with new on...

Page 55: ...he PISTON RING for marked abrasion Marked abrasion needs replacing the PISTON RING with a new one See disassemble reassemble Is the CAP OIL tightened Yes Tighten the CAP OIL Was the engine oil spilled...

Page 56: ...new one Required reconditioning The point at which a part of the engine is thought that it does not function any more without being repaired because of its wear breakage and or decreased function Usag...

Page 57: ...Oil 1 0 1 0 2 0 0 06 0 06 Vernier calipers Replacement PIN hole 12 0 03 0 03 Replacement Gap between PISTON and CYLINDER 6 1 14 1mm higher from bottom 0 1 0 1 At skirt bottom in piston thrust directio...

Page 58: ...lift 4 3 Vernier calipers CAMGEAR replacement Intake exhaust valve Valve clearance in the cold 0 15 0 08 0 4 Thickness gage Adjustment External diameter of rocker shaft 5 Micrometer Replacement Diame...

Page 59: ...ing the spilled oil causes oil spots because the spilled oil is absorbed from the cooling air intakes and scattered Drained oil should be properly dealt with according to the law Do not discard squeez...

Page 60: ...and care after initial 20 hour use Check and care Reason 1 Oil change To remove the oil that has initially got dirty Check and care after every 50 hour use Check and care Reason 1 Oil change 2 Fuel fi...

Page 61: ...drains out The container should have a capacity of at least 220 ml to be able to catch all of the oil Loosen the oil drain bolt 2 to let the oil drain out Be careful not to allow oil to get on the fue...

Page 62: ...ove the COVER ENGINE 2 TANK FUEL 1 Remove the fuel tube Notice The fuel will spout if the fuel tube is removed with the TANK FUEL filled with fuel 2 Remove the TANK FUEL SCREW M6 12 W SW 2PCS TANK FUE...

Page 63: ...ation is completed 3 Even if the two counter marks and the CRANKCASE come in a horizontal position where this happens before the EXHAUST VALVE moves to a large degree or the INTAKE VALVE moves when ro...

Page 64: ...EMENT is a dry type and should not get wet Never wash with water 4 Replace the ELEMENT with a new one if it is damaged or very dirty Part No 6676500201 ELEMENT AIR CLEANER 5 Wipe off any oil that has...

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Robin FL-H7500, Service Manual

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