Robin America DY30 User manual

PARTS
MANUAL
DY30 / DY35
DY41 / DY42
ENGINE
Models
PUB-EP5769A
Rev. 08/00

© Copyright 2000 Robin America, Inc.
940 Lively Blvd.  Wood Dale, IL 60191  Phone: [phone]  ax: 630-350-8212
e-mail: [email protected] • www.robinamerica.com

- 3 - '00-07
HOW TO USE THIS MANUAL
Robin engines are identified by MODEL, SPECIFICATION, and CODE NUMBER. For each
model there may be many different versions called specifications. Each specification will be
unique in some way. The difference may only be the paint color or it may have a different
type of PTO or some other significant difference.
In order the identify the correct service part number, it is important to confirm the specifica-
tion and code numbers for your engine. The specification and code number together are
know as the PRODUCT NUMBER.
All Robin 4 cycle engines have a Product Number label similar to the label illustrated below.
The Product Number Label has a 15 digit alphanumeric string that consists of the
SPECIFICATION (SPEC) number (11 digits) and the CODE number (4 digits). Please
note the illustration below:
PRODUCT NUMBER LABEL LOCATIONS
PRODUCT NUMBER LABEL
X X X X
SPEC NO. (11 digits) CODE NO. (4 digits)
PRODUCT NO. (15 digits)
D Y 4 2 0

MANUAL LAYOUT
- 4 - '00-07
1. SECTIONNAME Parts are broadly classified according to their functions.
Refer to the Group Index (table of contents) for respective section name.
2. FIG. No. The FIG. number indexes the reference and part numbers to the illustration. Figure numbers
that vary only in the tens place (i.e..: 700 and 710) are in a group of the same section
(i.e..:Electrical Device Group).
3. REF. No . The Reference number identifies the part illustration with the corresponding part number in the
part list.
4. SUBASSEMBLY SUBASSEMBLY parts of part assembly are listed below the assembly part. The subassembly
part reference number is indicated by the number led by "-" such as "-1", "-2".
5. PART NUMBER It is the number assigned for sales unit. Use the PART No. when making an order.
6. DESCRIPTION It is designation of the part.
7. QTY. Quantity of each part used for each product.
8. REMARKS This gives a distinctive feature and/or a supplementary comment for the type, the specification,
and the part concerned. It also shows part number(s) interchangeable for the part.
9. FROM-TO This section shows the CODE No. to indicate the history of progress in which improved parts
have been introduced in the product. The FROM-TO CODE No. helps to identify PART No.
being employed in the product concerned. See the examples below:
- The part is used in the product irrespective of CODE No.
2101- The part is used in the products with CODE No. of 2101 and after this number.
- 2100 The part is used in the products with CODE No. of 2100 and before this number.

GROUP INDEX
Group Name Page
CRANKCASE GROUP ............................................................................... 6
CRANKSHAFTGROUP ............................................................................ 12
INTAKEandEXHAUST GROUP ............................................................... 16
GOVERNOR GROUP ............................................................................... 22
COOLING and STARTING GROUP ......................................................... 24
FUEL,LUBRICANTGROUP ..................................................................... 26
ELECTRIC DEVICE GROUP .................................................................... 34
- 5 - '00-07
SYMBOL DESCRIPTION
AY .......................... ASSEMBLY
CP .......................... COMPLETE
EX .......................... EXPORT (from Japan)
FIG......................... FIGURE
FR. ......................... FRONT
" .............................. INCH
INCL.......................INCLUDE
~L ........................... LITER
L= ........................... LENGTH (in. mm)
L.H. (LH) ................LEFT-HAND SIDE
MECH ....................MECHANICAL
NO (NON) .............. NONE
OPT. ....................... OPTIONAL
O.S......................... OVER SIZE
SYMBOL DESCRIPTION
P= ..........................PITCH (in mm)
P.T.O. (PTO) ..........POWER TAKE OFF
REF. .......................REFERENCE
R.H. (RH) ...............RIGHT HAND SIDE
RR. .........................REAR
STD........................ STANDARD
SW .........................SWITCH
T=........................... THICKNESS (in mm)
UN .......................... UNIT
U.S. ........................UNDER SIZE
~V .......................... VOLTAGE
~W .........................WATT
W/ .......................... WITH
W/O........................WITHOUT
INDEX OF DESCRIPTION SYMBOLS

SECTION 1 CRANKCASE GROUP
DY30/DY35 & DY41/DY42 - 6 - '00-07
FIG. 100
186 187
188

SECTION
1
CRANKCASE
GROUP
REF
.
P
ART
P
P
NO.
DESCRIPTION
QTY
.
QTYQTY
REMARKS
FROM-TO
FIG.
10
228-101
1
1-01
CRANKCASE
CP
1
DY30
100
228-101
15-01
CRANKCASE
CP
1
DY30,
Electric
Start
100
10
229-101
1
1-01
CRANKCASE
CP
1
DY35
100
229-101
15-01
CRANKCASE
CP
1
DY35,
Electric
Start
100
10
231-10108-1
1
CRANKCASE
CP
1
DY41
/
DY42
100
231-101
10-01
CRANKCASE
CP
1
DY41
/
DY42,
Electric
Start
100
50
005-26081-80
DOWEL
PIN
4
100
51
228-15003-13
PIPE
KNOCK
1
100
65
001-32083-51
STUD
3
100
134
010-50800-44
STUD
2
Electric
Start
100
135
228-16001-1
1
TENSION
BOL
T
BOL
BOL
12
DY30
/
DY35
100
231-16001-1
1
TENSION
T
T
12
DY41/
100
155
228-16002-21
TENSION
T
T
22
DY30
/
DY35
100
231-16002-1
1
T
T
22
DY41 / DY42
100
165
1
STD.
100
228-15802-03
BEARING
1
0.25mm
undersize
100
228-15803-03
BEARING
1
0.50mm
undersize
100
166
228-15002-03
BEARING
1
100
167
005-19250-60
SPRING
PIN
2
100
185
228-25002-03
SLEEVE,
balancer
1
100
186
228-26001-01
BALANCER
COVER
CP
1
100
187
228-25004-03
GASKET
,
balancer
cover
1
100
188
980-05060-10
BOL
T
BOL
BOL
and
W
ASHER
W
AY
3
100
208
212-15008-13
BLIND
PLUG
1
100
210
228-1
1701-1
1
GEAR
CASE
COVER
CP
1
DY30
/
DY35
100
231-1
1701-01
GEAR
CASE
COVER
1
DY41
/
DY42
100
220
044-02200-50
OIL SEAL
1
100
230
060-03500-40
BALL
BEARING
1
100
267
001-32064-50
STUD
2
100
290
228-15007-03
GASKET
, case cover
1
DY30
/
DY35
100
231-15033-03
1
DY41
/
DY42
100
300
001-13088-50
AY
4
100
310
001-13086-50
AY
4
100
350
228-1
1
CP
1
DY30
/
DY35
100
228-1
1
BEARING
CP
1
DY30
/
DY35,
Electric
Start
100
350
231-1
BEARING
CP
1
DY41
/
DY42
100
231-1
1502-21
BEARING
HOUSING
CP
1
DY41
/
DY42,
Electric
Start
100
351
044-04000-20
OIL SEAL
1
100
352
001-13082-00
BOL
T
BOL
BOL
and
W
ASHER
W
AY
7
100
355
228-15004-03
GASKET
,
T=
0.1
1
Select
one
piece
only
,
DY30/35
100
228-15005-03
GASKET
,
T=
0.2
1
Select
one
piece
only
,
DY30-35
100
228-15006-03
GASKET
,
T=
0.3
1
Select
one
piece
only
,
DY30/35
100
DY30/DY35
&
DY41/DY42
- 7 -
'00-07

SECTION 1 CRANKCASE GROUP
DY30/DY35 & DY41/DY42 - 8 - '00-07
FIG. 100
186 187
188

SECTION 1 CRANKCASE GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG.
355 231-15004-03 GASKET, T= 0.1 1 Select one piece only, DY41/42 100
231-15005-03 GASKET, T= 0.2 1 Select one piece only, DY41/42 100
231-15006-03 GASKET, T= 0.3 1 Select one piece only, DY41/42 100
356 228-15014-03 ORING 1 DY30 / DY35 100
231-15014-03 ORING 1 DY41 / DY42 100
380 041-05000-11 BLIND PLATE 1 100
410 228-11601-03 OIL PAN 1 DY30 / DY35 100
231-11601-03 OIL PAN 1 DY41 / DY42 100
415 228-15034-03 GASKET, oil pan 1 DY30 / DY35 100
415 231-15034-03 GASKET, oil pan 1 DY41 / DY42 From 3774 100
231-15008-03 GASKET, oil pan 1 DY41 / DY42 To3773 100
416 980-05060-10 BOLT and WASHER AY 8 100
DY30/DY35 & DY41/DY42 - 9 - '00-07

SECTION 1 CRANKCASE GROUP
DY30/DY35 & DY41/DY42 - 10 - '00-07
FIG. 110

SECTION 1 CRANKCASE GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG.
20 228-14204-03 VALVE GUIDE 2 110
70 001-37082-01 STUD 4 DY30 / DY35 110
001-37082-01 STUD 4 DY41 / DY42 110
416 980-05060-10 BOLT and WASHER AY 2 110
510 228-12401-12 CYLINDERUN 1 DY30 110
229-12401-12 CYLINDERUN 1 DY35 110
231-12401-02 CYLINDERUN 1 DY41 / DY42 110
520 229-15011-03 ORING 1 110
540 228-15012-13 SPACER, T=0.1 1 Select one piece only, DY30 110
228-15013-13 SPACER, T= 0.2 1 Select one piece only, DY30 110
540 229-15012-13 SPACER, T= 0.1 1 Select one piece only, DY35/41/42 110
229-15013-13 SPACER, T= 0.2 1 Select one piece only, DY35/41/42 110
610 228-13110-31 CYLINDER HEAD CP 1 DY30 110
229-13110-21 CYLINDER HEAD CP 1 DY35/41/42 110
625 024-01300-10 ORING 1 110
635 018-01000-11 FLANGENUT 4 110
636 803011070 WASHER 4 110
645 001-31062-51 STUD 2 110
660 010-50601-50 STUD 2 110
680 228-17053-03 ROCKERCOVER 1 110
690 228-15010-03 GASKET, rocker cover 1 110
710 001-13064-00 BOLT and WASHER AY 3 110
820 228-15303-01 BREATHERPLATECP 1 110
840 228-15009-23 GASKET, breather 1 110
*960 228-99001-07 GASKETSET 1 DY30 / DY35
*960 231-99001-07 GASKETSET 1 DY41 / DY42
DY30/DY35 & DY41/DY42 - 11 - '00-07
*The gasket sets include the following:
Fig. 100 items 290, 355, 356, 415
Fig. 110 items 690, 840
Fig. 300 item 195
Fig. 310 item 340
Fig. 400 item 465
Fig. 600 item 650

SECTION 2 CRANKSHAFT GROUP
FIG. 200
DY30/DY35 & DY41/DY42 - 12 - '00-07
With Balancer

SECTION 2 CRANKSHAFT GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG.
10 228-20202-11 CRANKSHAFTCP 1 DY30 / DY35 200
262-20202-01 CRANKSHAFTCP 1 DY41 / DY42 200
25 060-04000-30 BALLBEARING 1 200
50 017-32600-10 LOCKNUT 1 200
65 020-52600-12 LOCK WASHER 1 200
70 005-30040-81 KEY 1 DY30 / DY35 200
005-30072-01 KEY 1 DY41 / DY42 200
210 228-24301-11 BALANCER CP 1 DY30 / DY35 200
231-24301-11 BALANCER CP 1 DY41 / DY42 200
220 061-01500-10 NEEDLEBEARING 2 200
230 228-24202-03 BALANCER GEAR2 1 DY30 / DY35 200
231-24202-03 BALANCERGEAR2 1 DY41 / DY42 200
235 005-32042-01 WOODRUFF KEY 1 200
260 228-24101-03 BALANCERSHAFT 1 200
265 003-14150-00 SNAP RING, inner 1 200
310 228-22501-10 CONNECTING RODAY 1 DY30 / DY35 200
262-22501-00 CONNECTINGRODAY 1 DY42 200
231-22501-00 CONNECTINGRODAY 1 DY41 200
320 228-23001-13 CONNECTINGRODBOLT 2 DY30 / DY35 200
231-23001-13 CONNECTINGRODBOLT 2 DY41 / DY42 200
350 228-23301-03 PISTONPIN 1 DY30 / DY35 200
350 262-23301-03 PISTONPIN 1 DY42 200
228-23301-03 PISTONPIN 1 DY41 200
360 228-23401-43 PISTON 1 STD., DY30 200
228-23402-43 PISTON 1 0.25mm oversize, DY30 200
228-23403-43 PISTON 1 0.50mm oversize, DY30 200
360 229-23401-63 PISTON 1 STD., DY35 200
229-23402-63 PISTON 1 0.25mm oversize, DY35 200
229-23403-63 PISTON 1 0.50mm oversize, DY35 200
360 262-23401-03 PISTON 1 STD., DY42 200
262-23402-03 PISTON 1 0.25mm oversize, DY42 200
262-23403-03 PISTON 1 0.50mm oversize, DY42 200
360 231-23401-43 PISTON 1 STD., DY41 200
231-23402-43 PISTON 1 0.25mm oversize, DY41 200
231-23403-43 PISTON 1 0.50mm oversize, DY41 200
370 228-23501-07 PISTON RINGSET 1 STD., DY30 200
228-23502-07 PISTONRINGSET 1 0.25mm oversize, DY30 200
228-23503-07 PISTONRINGSET 1 0.50mm oversize, DY30 200
370 229-23501-27 PISTON RINGSET 1 STD., DY35/DY41/DY42 200
229-23502-27 PISTONRINGSET 1 0.25mm oversize, DY35/41/42 200
229-23503-27 PISTONRINGSET 1 0.50mm oversize, DY35/41/42 200
380 056-52100-10 CLIP 2 DY30 / DY35 200
233-25002-03 CLIP 2 DY41 / DY42 200
DY30/DY35 & DY41/DY42 - 13 - '00-07

SECTION 2 CRANKSHAFT GROUP
FIG. 200
DY30/DY35 & DY41/DY42 - 14 - '00-07
With Balancer

SECTION 2 CRANKSHAFT GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG.
395 228-22801-13 LARGEENDBEARING 2 STD. 200
228-22802-13 LARGEEND BEARING 2 0.25mmundersize 200
228-22803-13 LARGEEND BEARING 2 0.50mmundersize 200
500 228-22421-21 FLYWHEEL CP 1 DY30 / DY35 200
262-22401-01 FLYWHEEL CP 1 DY41 / DY42 200
510 228-22420-23 FLYWHEEL 1 DY30 / DY35 200
262-22401-03 FLYWHEEL 1 DY41 / DY42 200
520 228-71001-03 RINGGEAR 1 Electric Start 200
530 243-15011-03 PIPE KNOCK 2 Electric Start 200
540 004-11082-50 SCREW 4 Electric Start 200
640 228-24406-03 DRIVINGSHAFT 1 STD. 1" key, 3/8"-24UNF 200
228-24407-03 DRIVINGSHAFT 1 Generator, SAE Taper 200
228-24408-03 DRIVINGSHAFT 1 Pump, 1" threaded 200
228-24401-03 DRIVINGSHAFT 1 Metric 25mm key, M10 X 1.5 200
228-24402-13 DRIVINGSHAFT 1 Generator, Metric Taper 200
228-24403-03 DRIVINGSHAFT 1 Metric Pump, 25mm threaded 200
670 001-67103-00 BOLT 4 200
730 003-20100-00 SPRINGWASHER 4 200
870 228-17911-23 ADAPTER 3 1 STD. 200
228-17821-03 ADAPTER 1 Generator 200
228-17920-13 ADAPTER4 1 Pump 200
880 001-13086-00 BOLT and WASHER AY 4 200
DY30/DY35 & DY41/DY42 - 15 - '00-07

SECTION 3 INTAKE and EXHAUST GROUP
DY30/DY35 & DY41/DY42 - 16 - '00-07
FIG. 300

SECTION 3 INTAKE and EXHAUST GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG.
10 228-31604-00 CAMSHAFTAY 1 300
20 228-31604-01 CAMSHAFTCP 1 300
30 228-33222-01 CAMSHAFTGEARCP 1 300
35 228-35561-03 RELEASELEVER 1 300
40 005-32042-01 WOODRUFF KEY 1 300
48 023-02000-20 SPACER, T= 0.8 1 Select one piece only 300
023-02000-30 SPACER, T= 1.0 1 Select one piece only 300
023-02000-40 SPACER, T= 1.2 1 Select one piece only 300
50 228-33301-03 TAPPET 2 300
60 228-33601-03 VALVE SPRING 2 300
70 228-33701-03 SPRINGRETAINER 2 300
75 228-33801-03 RETAINERLOCK 4 DY30 / DY35 300
262-33801-03 RETAINERLOCK 4 DY41 / DY42 300
76 020-01500-30 WASHER 2 300
80 228-33401-13 INTAKE VALVE 1 300
85 228-35003-03 VALVE STEM SEAL 1 DY30 / DY35 300
262-35001-03 VALVE STEM SEAL 1 DY41 / DY42 300
90 228-33501-03 EXHAUSTVALVE DY30 / DY35 300
262-33501-03 EXHAUSTVALVE 1 DY41 / DY42 300
170 228-35701-13 TAPPET GUIDE 1 300
180 228-35603-11 PUSH ROD SLEEVE 1 DY30 / DY35 300
231-35603-11 PUSHROD SLEEVE 1 DY41 / DY42 300
181 002-18060-00 NUT 4 300
182 003-20060-00 SPRINGWASHER 4 300
185 228-35801-01 PLATE CP, push rod 2 300
190 024-03200-70 ORING 2 300
195 228-35013-03 GASKET, tappet guide 1 300
200 228-35004-03 ROCKERSHAFT 1 300
210 228-35005-03 PUSHROD 2 DY30 / DY35 300
231-35005-03 PUSHROD 2 DY41 / DY42 300
220 228-36201-01 EXHAUSTROCKERARM CP 1 300
225 228-36301-01 INTAKEROCKER ARM CP 1 300
230 014-90600-80 ADJUSTING SCREW 1 300
231 014-90600-80 ADJUSTING SCREW 1 300
240 017-00600-80 NUT 1 300
241 017-00600-80 NUT 1 300
DY30/DY35 & DY41/DY42 - 17 - '00-07

SECTION 3 INTAKE and EXHAUST GROUP
FIG. 310
DY30/DY35 & DY41/DY42 - 18 - '00-07

SECTION 3 INTAKE and EXHAUST GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG.
310 228-30105-01 MUFFLERCP 1 310
320 228-34201-11 MUFFLERCOVER CP 1 310
340 228-35006-03 GASKET 1 310
350 002-19080-00 NUT 2 310
354 003-20080-00 SPRINGWASHER 2 310
360 011-00600-10 FLANGEBOLT 4 310
DY30/DY35 & DY41/DY42 - 19 - '00-07

SECTION 3 INTAKE and EXHAUST GROUP
FIG. 320
DY30/DY35 & DY41/DY42 - 20 - '00-07
A
B C
380
350
STD. 2-Stage
Flat Pleated
Oil Bath 2- Stage Oval
550