Subaru EH09-2D Service Manual Download Page 8

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– 6 –

Step

Parts to remove

Remarks and procedures

Fasteners

Ignition coil

Remove ignition coil from crankcase.

M6 x 25 : 2 pcs.
10 mm box spanner

Flywheel

(1) Remove the starter pulley from flywheel.

Place socket wrench on flywheel fastening
nut and strike tip of the lever with hammer.

(2) Remove the cooling blower.
(3) Tap on flywheel end of crankshaft using

aluminum bar to remove flywheel.

(4) Remove the key from crankshaft.

M14 nut, springwasher : 1 pc.
M6 x 12 : 4 pcs.
19 mm socket wrench
10 mm box spanner

Spark plug

Remove spark plug from cylinder head.

19 mm plug wrench

SPARK PLUG

SPARK PLUG CAP

FLYWHEEL CP

COOLING BLOWER

WOODRUFF KEY

STARTING PULLEY

M6 x 12 FLANGE
BOLT : 4 pcs.

M14 SPRING WASHER : 1 pc.

M14 NUT : 1 pc.

M6 x 25 BOLT AND
WASHER AY : 2 pcs.

IGNITION COIL CP

STEP 11

STEP 13

STEP 12

ALUMINUM BAR

FLYWHEEL

P.T.O. shaft side

Summary of Contents for EH09-2D

Page 1: ...2121 2005 06...

Page 2: ...TING 36 4 SERVICE DATA 4 1 CLEARANCE DATA AND LIMITS 39 4 2 TORQUE SPECIFICATIONS 44 4 3 OIL GRADE CHART 44 The specifications and information included in this manual were in effect at the time of pri...

Page 3: ...y type Flywheel magneto solid state NGK BMR4A CHAMPION RCJ14 Recoil starter Centrifugal flyweight type Semi wet type 9 9 21 8 249 x 299 x 380 9 8 x 11 8 x 15 0 MODEL Type Continuous Output Maximum Out...

Page 4: ...ower housing Be careful of pulling direction of starter rope M6 x 8 3 pcs 10 mm box spanner 3 Blower housing Disconnect wire of stop switch first then remove blower housing from crankcase M8 x 16 3 pc...

Page 5: ...tank bracket Fuel tank bracket 2 1 Remove the fuel tank bracket from the cylinder head and fuel tank bracket 2 2 Remove the fuel tank bracket 2 M6 flange nut 4 pcs M6 x 12 2 pcs M8 flange nut 1 pc M8...

Page 6: ...Step Parts to remove Remarks and procedures Fasteners 7 Muffler and cylinder baffle Remove spark plug cap first from spark plug muffler and cylinder baffle Be careful not to lose muffler gasket M8 bo...

Page 7: ...cyclone air cleaner 2 Remove carburetor carefully unhooking governor rod and rod spring from governor lever 10 Speed control lever and base plate M6 x 8 2 pcs M6 x 14 1 pc 10 mm box spanner For cyclon...

Page 8: ...3 Tap on flywheel end of crankshaft using aluminum bar to remove flywheel 4 Remove the key from crankshaft M14 nut springwasher 1 pc M6 x 12 4 pcs 19 mm socket wrench 10 mm box spanner 13 Spark plug R...

Page 9: ...sket from crankcase 2 Remove push rods from cylinder M8 x 60 1 pcs M8 x 55 1 pcs M8 x 55x 25 1 pc M8 x 55x 12 5 1 pc Washer 1 pc 10 12 13 mm box spanner box wrench PUSH ROD PIPE KNOCK ROCKER COVER GAS...

Page 10: ...pcs 10 mm box spanner 17 Main bearing cover Be careful not to damage the oil seal Use a soft hammer and evenly tap around outer surface of cover M6 x 28 8 pcs soft hammer 10 mm box spanner MAIN BEARI...

Page 11: ...and procedures Fasteners 18 Camshaft and tappets Lay carnkcase on the flywheel side push tappets up into the block and remove camshaft Be careful not to damage camshaft and tappets CAMSHAFT TAPPET ST...

Page 12: ...ll carbon deposits that might interfere with removal of piston from upper end of cylinder M5 x 25 2 pcs 8 mm box spanner Piston and piston pin 1 Remove clips and piston pin to remove connecting rod fr...

Page 13: ...move Remarks and procedures Fasteners 20 Crankshaft Tap lightly on flywheel end of crankshaft with a soft hammer to remove from crankcase Be careful not to damage oil seal soft hammer CRANKSHAFT STEP...

Page 14: ...etainer and valve spring 2 Remove intake and exhaust valves from cylinder head Clean carbon and gum deposit from the valves valve seats ports and guides Inspect valves valve seats and guides 10 mm spa...

Page 15: ...over Case Rocker Cover Breather Plate Cylinder Head Main Bearing Cover Tightening torque 8 10 N m 80 100 kgf cm 5 7 7 2 ft lb Tightening torque 19 21 N m 190 210 kgf cm 13 7 15 2 ft lb Tightening torq...

Page 16: ...14 CRANKSHAFT PISTON Crankshaft Piston Connecting Rod Piston Ring Set Tightening torque 6 8 N m 60 80 kgf cm 4 3 5 7 ft lb Tightening torque 45 50 N m 450 500 kgf cm 32 5 36 2 ft lb...

Page 17: ...Intake Chamber Muffler Tightening torque 7 9 N m 70 90 kgf cm 5 0 6 5 ft lb Tightening torque 17 19 N m 170 190 kgf cm 12 3 13 7 ft lb Tightening torque 8 5 10 5 N m 85 105 kgf cm 6 1 7 5 ft lb Valve...

Page 18: ...16 GOVERNOR SPEED CONTROL Governor Shaft Base Plate Governor Lever Speed Control AY Tightening torque 7 9 N m 70 90 kgf cm 5 0 6 5 ft lb...

Page 19: ...17 COOLING STARTING Cylinder Baffle Blower Housing Cooling Blower Recoil Starter Tightening torque 9 11 N m 90 110 kgf cm 6 5 8 0 ft lb...

Page 20: ...mmended Spark Plug BMR4A NGK Electrode Gap 0 6 to 0 7 mm Tightening torque Retightening New spark plug 23 25 N m 230 250 kgf cm 16 6 18 1 ft lb 12 15 N m 120 150 kgf cm 8 7 10 9 ft lb Tightening torqu...

Page 21: ...nd nuts to specification refer to the TORQUE SPECIFICATIONS See page 44 7 Apply oil to rotating and sliding portions 8 Check and adjust clearances and end plays where specified in this manual 9 When m...

Page 22: ...nly far enough to slip over piston and into correct groove Use care not to distort ring Install top and second ring with punched mark beside the gap face upward OPEN ENDS OF PISTON RING 3 2 1 3 2 1 MA...

Page 23: ...Install piston and connecting rod assembly into cylinder Use a piston ring compressor to hold piston rings The MA mark of the connecting rod is to face the flywheel side of the engine when assembled M...

Page 24: ...5 mm connecting rod bolt 2 pcs 3 Check for free movement of connecting rod by turning crankshaft slowly M A MA MARK SPLASHER LEFT SIDE 2 3 6 TAPPETS AND CAMSHAFT 1 Oil the tappets and install them Pus...

Page 25: ...determined in the following manner 1 Measure the height A From the mating surface to the inner race of the ball bearing 2 Measure the depth B From the mating surface to the crank gear B A SIDE CLEARA...

Page 26: ...Use an oil seal guide when installing the main bearing cover to avoid damaging the oil seal Tap the cover into place with a soft hammer M6 x 28 mm Flange bolt 8 pcs MAIN BEARING COVER CP M6 x 28 FLAN...

Page 27: ...alve guides out and press new guides in Refer to SERVICE DATA for clearance specifications After replacing valves and guides lap valves in place until a uniform ring shows around the face of the valve...

Page 28: ...60 sus BOLT 1 pc WASHER 1 pc GASKET ROCKER COVER PIPE KNOCK 2 3 9 ROCKER ARMS AND PUSH RODS 1 Insert push rods into crankcase Put push rod tip in the hollow of tappet top An oil return slot is located...

Page 29: ...Tighten the nut on rocker arm 3 Install rocker cover and gasket M6 x 30 x 10 mm bolt 4 pcs FLYWHEEL ALIGNMENT MARKS THICKNESS GAUGE ROCKER ARM BOLT PIVOT NUT Note Temporally fit the flywheel in positi...

Page 30: ...120 150 kgf cm 8 7 10 9 ft lb Note Attach cooling blower to flywheel with three projections on flywheel adjusted to three holes on cooling blower 2 3 12 FLYWHEEL MAGNETO 1 Put the woodruff key in the...

Page 31: ...x 25 mm bolt and washer 2 pcs THICKNESS GAUGE IGNITION COIL 2 3 14 BREATHER Install breather plate breather cover gasket in position M6 x 12 mm flange bolt 2 pcs Connect breather pipe after installin...

Page 32: ...5 Install insulator and gaskets for carburetor to cylinder head 6 Install carburetor to cylinder head hooking governor rod to governor lever and throttle lever of carburetor Hook rod spring over gove...

Page 33: ...ghten lock bolt to secure the lever on the shaft M6 x 25 mm bolt and washer 1 pc 2 3 16 AIR CLEANER 1 Install the air cleaner gasket and the cleaner base and tighten them M6 flange nut 2 pcs 2 Install...

Page 34: ...p 1 temporarily fitting 1 Attach gasket with the crows faced inside of muffler 2 Temporarily attach cylinder baffle and muffler onto cylinder head 3 Fit grommet holding ignition code and stop switch w...

Page 35: ...lts and nuts for cylinder baffle and muffler securely M6 x 8 mm flange bolt 1 pc cylinder buffle M8 nut 1 pc cylinder buffle 2 Install recoil starter to blower housing M6 x 8 mm flange bolt 3 pcs Note...

Page 36: ...L TANK BRACKET 2 3 22 FUEL TANK BRACKET 2 Attach washer t 1 2 in position and then install fuel bracket 2 M8 flange nut 1 pc 2 3 23 FUEL TANK BRACKET Set fuel tank bracket onto rocker cover installing...

Page 37: ...speed side Engine speed is varied by the equipment so adjust the speed to the specified one indicated on the equipment Low speed side Adjust the engine speed to 1 400 rpm by the carburetor idle screw...

Page 38: ...rk plug Improper spark plug gap Insulation defect Carbon deposits 2 Ignition coil Insulation defect or discontinuity Poor contact or broken wire Adjust the gap Replace Clean Replace Repair or replace...

Page 39: ...eel magneto Replace Replace Replace Adjust 4 Poor quality gasoline or water in gasoline 1 Carburetor clogged 2 Fuel strainer and or hose clogged 3 Air in fuel lines Replace Overhaul clean Clean or rep...

Page 40: ...ose main bearing cover bolts Tighten 4 Faulty main bearing cover gasket Replace 5 Crankshaft oil seal front rear defect Repair or replace 2 Piston ring seizure wear or poor contact Replace 3 Excessive...

Page 41: ...ISTON Piston size At skirt in thrust direction 2nd o s 51 38 2 0228 51 47 51 49 2 0264 2 0272 1st o s 51 13 2 0123 51 22 51 24 2 0165 2 0173 LESS THAN 0 01 0 004 Roundiness after reboring LESS THAN 0...

Page 42: ...035 0 4327 0 4344 0 25 0 010 0 010 0 049 0 0004 0 0019 1 5 0 0591 Top 0 15 0 35 0 006 0 014 2nd 0 35 0 55 0 014 0 022 PISTON Ring groove side clearance 10 960 0 4315 10 992 11 000 0 4328 0 4331 Cleara...

Page 43: ...CONNECTING ROD Big end inside dia 0 12 0 0047 0 010 0 029 0 0004 0 0011 Clearance between small end and piston pin Big end side clearance D1 D2 19 988 19 997 0 7869 0 7873 20 85 0 821 20 967 20 980 0...

Page 44: ...ht IN and EX 5 35 0 2106 5 426 5 444 0 2136 0 2143 5 35 0 2106 5 440 5 455 0 2142 0 2148 IN EX 0 3 0 012 0 056 0 092 0 0022 0 0036 0 3 0 012 0 045 0 078 0 0018 0 0031 Clearance between valve stem dia...

Page 45: ...5 0 055 0 0010 0 0022 TAPPET Stem outside dia 26 7 1 05 VALVE SPRING FREE LENGTH a 90 b 0 8 1 1 0 031 0 043 2 0 0 079 Guide inside dia VALVE SEAT ANGLE IN and EX Valve cutter angle a Valve contact wid...

Page 46: ...5 7 450 500 32 5 36 2 45 50 8 5 10 5 85 105 6 1 7 6 17 19 170 190 12 3 13 7 8 10 80 100 5 7 7 2 12 15 120 150 8 7 10 9 230 250 23 25 16 6 18 1 ITEMS 4 3 OIL GRADE CHART Use oil classified as SE or hi...

Page 47: ...2121 2005 06...

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