Robin America EY44-2 User manual

ROBIN AMERICA, INC.
ROBIN
TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST
ROBIN
EY 08
EY15
EY15V
EY20
EY20V
EY23
EY28
EY35
EY40
EY45V
EY2 1
EY44
EY18-3
EY25
EY27
EH11
EH12
EH15
EH17
EH21
EH25
EH3 0
EH30V
EH34
EH34V
EH43V
EC13V
DY 23
DY27
DY30
DY35
DY4 1
WISCONSIN ROBIN
SIDE VALVE
W 1-080
WI-145
W1-145V
W1-185
W1-185V
W1-230
W1-280
Wl-340
W1-390
W 1 -450V
EY21W
EY44W
EY 18-3W
EY25W
EY27W
v
WO1-115
wo1-120
WO1-150
WO1-170
wo1-210
WO1-250
WO 1 -300
WOI-3oov
WO1-340
WO1-340V
WO1-43OV
TWO CYCLE
WT1-125V
DIESEL
WRD 1-230
WRD 1-270
WRD1-300
WRD1-350
WRD1-410

CONTENTS
Section Title Page
1 . SPECIFICATIONS ............................................ 1
2 . PERFORMANCE ............................................ 2
2.1
. Maximumoutput ....................................... 2
2.2
. ContinuousRated Output ................................. 2
2.3 . MaximumTorque and Fuel ConsumptionRatio at Max . Output ........ 2
3 . FEATURES ............................................... 3
4 . GENERALDESCRIPTION of ENGINECONSTRUCTION ............... 4
4.1
.
4.2 .
4.3 .
4.4 .
4.5 .
4.6 .
4.7 .
4.8 .
4.9 .
4.10 .
4.11 .
4.12 .
4-1 3 .
4- 14 .
4.15 .
4- 1 6 .
Sectional View of Engine .................................. 4
Crankcase ........................................... 6
MainBearingCover ..................................... 6
Crankshaft ........................................... 6
ConnectingRod and Piston ................................ 6
Camshaft ........................................... 6
Cylinder and Cylinder Head ............................... 6
ValveArrangement ..................................... 6
Balancer ............................................. 6
Governor ............................................. 7
Cooling ............................................. 7
Lubrication ........................................... 7
Ignition ............................................. 7
Carburetor ........................................... 7
Air Cleaner ........................................... 7
Selenium Rectifier ...................................... 7
5.lNSTALLATlON ............................................ 8
5.1 . Mounting ............................................ 8
5.2 . Ventilation ........................................... 8
5.3. Exhaust Gas Evacuation .................................. 8
5.4
. FuelSystem .......................................... 8
5.5 . PowerTransmission to DrivenMachines ....................... 8
5.6 . Wiring .............................................. 9
6 . DISASSEMBLY and REASSEMBLY .............................. 10
81 . PreparationsandSuggestions ............................... 10
6-2 . SpecialTools ......................................... 10
6-3 . DisassemblyandReassemblyProcedures ....................... 11

7 . MAGNETO ............................................... 18
7.1
. Magneto ............................................. 18
7.2
. Breaker PointAdjustment ................................. 18
7.3
. TimingAdjustment ..................................... 18
7.4
. MagnetoService Instructions ............................... 19
8 . GOVERNOR ADJUSTMENT ................................... 21
9.CARBURETOR ............................................. 22
9.1 . Operationand Construction ................................ 22
9.2 . DisassemblyandReassembly ................................. 23
9.3 . Adjustment .......................................... 23
10 . RUN-INOPERATION OF ENGINE after REASSEMBLY ............... 25
11 . TROUBLESHOOTING ....................................... 26
11.1 . StartingDifficultes ...................................... 26
11.2 . EngineMisses ......................................... 27
11.3
. EngineStops .......................................... 27
11.4 . EngineOverheats ...................................... 27
11.5 . EngineKnocks ........................................ 28
11
.6 . EngineBackfiresThroughCarburetor ......................... 28
12 . CHECKS and CORRECTIONS .................................. 29
13 . MAINTENANCE and STORING ................................. 35
13.1
. Daily ChecksandMaintenance .............................. 35
13.2
. Every20HoursChecksandMaintenance ....................... 35
13.4
. Every 100-200 Hours (Monthly)ChecksandMaintenance ........... 35
13.5
. Every 500-600 Hours(Semianual)ChecksandMaintenance .......... 36
13.6 . Every1000Hours (Yearly)ChecksandMaintenance ............... 36
13.7 . Preparation for LongAbeyance ............................. 36
13.3 . Every 50 Hours (10days)ChecksandMaintenance ................ 35

1.
SPEC1
FICATIONS
-1-

2. PERFORMANCE
2-1MAXIMUMOUTPUT
The maximum output of an engineis such standard power as developed by that engine, after its initial run-in period witha1
themovingpartsproperlyworn-in,whenoperatingwiththefullyopenthrottle valve. Therefore,itfollowsthat
a nev
enginemaynotdevelopthismaximumoutputinthebeginning,becausemovingpartsarenot in aproperly
w0rn-h
condition.
2-2 CONTINUOUSRATEDOUTPUT
The continuous rated output of an engine is suchpowerasdevelopedbythatenginewhenrunningatanoptimum speec
most favorable from the point
of view of engine life and fuel consumption ratio. Therefore, it follows that when designing i
driving systemforanymechanism,withamodel EY33-2 or EY44-2 engine, as a primemover,thecontinuouspowe
requirement
of that mechanism must be kept below the continuous rated output specified.
2-3MAXIMUMTORQUEANDFUEL CONSUMPTION RATIOATMAX.OUTPUT
The maximum torque of an engine is that driving torque of the driving shaft at which the engine is driving an external load
while the engine is developing its max. output. The fuel consumption ratio at max. output
is that fuel consumption ratio o
an engine while that engineis running at the max. output.
PERFORMANCECURVE
Model EY33-2
I
( )for B type
RECOMMENDED OPERATING SPEED RANG
a
7
HP
5
I
MAX. TORQUE
125112 5
-I
1.7(3.4)
124)12
--
~
1.6(3.2)
ft"b (23J11.5-- I
kg-rn
1.5 (3.0)
320
300
280
g/
2000 2500 30003500
(1OOO) 112501 115001 11750)
rpm -
P.h
-2-

3. FEATURES
1. A compact,lightweight,andhighlydurable4cycleaircooledEYserieswithhighoutput,embodyingingeniousdesign
and advanced machining techniques.
2. Simpleconstruction,goodappearance,pluseasystart-up.
3. Smoothspeedcontrolfunctions of governorguaranteesstableoperationundervariousloadconditionsoverawide
range
of applications.
4. Economicaladvantagewithminimizedfuelconsumption.
5. Since power can be taken in any direction simply by pulling the belt, and the feed and drain oil work can also be done
easily in two directions
of engine, the engineis easily coupled with operating machines.
6. The use of dynamic balancer reduces vibrations to such an extantas in a two-cylinder engine.
PERFORMANCE CURVE
Model EY44-2
( )for B type
RECOMMENDED OPERATINGSPE
11
10
HP 9
0
7
6
(33) 16.5
(32) 16
(31) 15.5
tt-lb
(1000)
2000 2500
(1250)
3000
(1500)
rpm-
3500
(1750)
2.3(4.6)
2.2(4.4)
kg-m
2.1(4.2)
-J-

/-
FLYWHEEL(COOLI~G FAN) I
LIGHTING COIL
\
CRANKCASE
-4 -

SEl
-5-

4-2 CRANKCASE
The crankcase is made of aluminum die-cast and separable ondriving shaft side with main bearing cover assembled.
Provided on blower side are two ballbearings, each supporting the crankshaft and camshaft.
4-3 MAINBEARING COVER
The aluminum die-castmainbearingcover on the drivingshaftsideallowseasyaccess to the engine interior for inspection
simply by removing it. The’fange and boss permit direct coupling of operating machines such as generators, pumps, etc.
The oil inlets which
also serve as oil gauges can be mounted ondriving shaft side of Models EY33-2B and EY44-2B.
The force-fit balancer shaft and balancer holder mounting boss assure easy mounting of the balancer mechanism.
44 CRANKSHAFT
The crankshaft is machined from carbon steel forging with an induction hardened crank pin. The breaker cam is provided on
blower side, while crankshaft gear and balancer gear are force-fiton driving side.
4-5 CONNECTING ROD and PISTON
The connecting rod is machined from aluminum alloy forging, and forged alloyitself serves as bearing metal at both ends.
(Model EY44-2 employs aluminum metal on thelarge end.)
An
oil scraper is provided onthe large endforthepurpose ofsplashinglubricatingoil.Thepiston is machinedfron
aluminum alloy casting and provided with grooves for two compression rings, one oil rings, and one skirt ring.
The
EY44-2 piston has an offset structure at the piston pin center so as to reduce striking sound of piston.
4-6 CAMSHAFT
Thecarbonsteelforgingcamshaftincorporatesintegralintakeandexhaustcamsplusaforce-fitcamgear. The B-typ
camshaft
also serves as driving shaft and it is driven at half the crankshaft speed.
4-7 CYLINDER and CYLINDERHEAD
Thecylinder is made of specialcastironandprovidedwithmanyfinsforassuringexcellentcoolingeffects.The cylinda
head is made
of aluminumalloycasting.TheRicardotypecombusionchamberwithasufficientareaassures hil
combusion efficiency. The spark plug
is tilted to facilitate fuel tank mounting.
4-8 VALVEARRANGEMENT
Theexhaust valve is positioned in theupstreamofthecolling air so thatit is intensivelycooled downforimprov
durability
of engine.
4-9 BALANCER
An unbalancedinertiaforceproducedduetocrankshaftandpistonconnectingrodintheverticalandlateraldirection:
balanced bybalancerwhichrotatesat
a ratioof 1: 1 in thedirectionoppositetocrankshaft, so thatvibrationsdue
unbalanced inertia force are reduced.
-6-

4-10GOVERNOR
The centrifugal flyweight type governor assures constant-speed operation at selected speed, irrespective of load fluctuations.
4-11 COOLING
The cooling fan which also serves as a flywheel forcily feeds cooling air to the cylinder head with theaid of cylinder baffles
and head cover.
4-12 LUBRICATION
Therotatingand slidingpartsarelubricatedbyscoopingandsplashingoilincrankcasewith oil scraperattachedto
connecting rod.
4-13 IGNITION
The ignition system is of flywheel magneto type with ignition timing set at 23' before TDC. The magneto is composed of a
flywheel,anignitioncoil,abreaker,andlighting(charging)coil.Theflywheel(servingalso as afan)
is mountedon
crankcase, while the other elementsare directly assembled in crankcase (For details, refer to the MAGNETO section).
4-14CARBURETOR
A horizontaldraftcarburetor is employed.Itssettinghasbeencarefullyafterthoroughteststoachievebeststart-up,
acceleration, fuel consumption, output, and other performance. For other details,see the CARBURETOR section.
4-15AIRCLEANER
An impinge type semi-wet air cleaner catches dust particles in the air by means of felt in dust case. The air is then cleaned
by passing through a filter element.
4-16SELENIUMRECTIFIER
The selenium rectifier serves to rectify the AC current generated by AC charging coil of magneto into DC current to charge
battery when a starting motoris combined.
-7-

5. INSTALLATION
Sincetheinstallationmethodaffectsthe service life,easeofmaintenance,frequencyofcheckandreapir,andoperating
costs
of engine, the following contents should be carefully examined before installing your engine.
For details, referto the separate “SALES MANUAL”-Engineering Information-.
5-1 MOUNTING
When installing the engine, its mounting position, coupling conditions with operating machines, and anchoring or supporting
methodsmustbecarefullyexamined.Particularlywhendeterminingitsmountingposition,duecareshouldbetakento
assure the convenience of such routines as replenishment and checking
of fuel and oil, checking of spark plug and breaker
points, maintenance
of air cleaner, and oil drainage.
5-2 VENTILATION
The engine must be supplied with .fresh air for cooling and fuel combustion. If engine is operated with a cover or in a small
room,theengineroom is heated, causingvaporlock,deteriorationofoil,increaseof oil consumption,powerreduction,
seizure,
loss of engine life, and thus proper engine operation can be expected no longer.
It is thereforenecessary
to provied a cooling air duct and a baffle plate for the purpose of preventing insufficient circulation
of heated air after cooling engine and or temperature-rise of operating machines.
The temperature
of engine compartment should be kept below4OoC even in mid-summer.
53 EXHAUST GAS EVACUATION
Since the exhaust gas from engineis toxic, it must be exhausted outsideif engine is operated indoors.
As the output power of an engineis considerably influenced by the length of exhaust duct, its diameter must be increased in
proportion to its length.
5-4 FUELSYSTEM
When fuel tank is separated from engine, it must be located so that its bottom surface lies within 5-50cm (2”-20”) above
the fuel joint
of carburetor. If the fuel tank is installed too low, fuel is not fed properly, and if it is too high, the carburetor
may overflow.
For fuel piping, carefully examineit for heat conductivity, diameter, bending, andleakage through fittings
so as to eliminate
air lock and vapor lock.
It is recommended to minimize piping length. The standard ID of fuel pipe is 4-5mm (5,2”-13/64“).
5-5 POWER TRANSMISSION to DRIVEN MACHINES
5-5-1 BELT DRIVE
Be carefulwiththefollowing items.
*Ilse aV-belt rather than a flat belt.
*Set the driving shaft of engine and the driven shaft
of driven machine in paralled with each other.
*Align the driving pulley
of engine and the driven pulley of driven machine correctly with each other.
*Mount the driving pulley as nearer to the engine as possible.
-8-

5-6 WIRING
a JIS CB104 female terminal
-e JIS CA104 male terminal
-@ JIS LA 104 or LA1 08 plateterminal
- """ The dotted partsare not supplied with the engine.
5-6-1 ROPE STARTINGENGINE
MAGNETO
_""""
'.-N
/
BUZZER
(6"- 8W)
SPARKPLUG LAMP
(12V. 15W)
Fig. 5-6-1
5-6-2 ENGINEwithSTARTINGMOTOR
MAGNETO
LA 104
- g -:

6. DISASSEMBLY and REASSEMBLY
6-1 PREPARATIONS and SUGGESTIONS
1) Whendisassemblingengine,carefullynotemountingpositionsandmethodsofrespectivepartsinorder to beable to
reassemble them correctly. Tag parts, if there is a possibility of confusion.
2) Prepare several boxes to keep parts belonging to respective groups together.
3) In order to prevent missing or misplacing, grouprelatedpartstogether,tentativelyassemblingthemimmediatelyafter
disassembling each sub-assembly.
4) Carefully handle parts, and clean them with washing oil after disassembling.
5) Use correct tools in correct ways.
6) Standard tools to be prepared for disassembling.
a) Work Bench
b)
' WashingPan
c) Disassembling
Tools
d) Washing Oil (KeroseneorGasoline),Mobile Oil
e)EmeryPaper,Cloth
7) Drainfueland oil without fail before disassembly.
To drainoil,unscrewtheoildrainpluglocatedonthesideofcrankcaseoncarburetorsidebyturningit
counter-clockwise.
8) Clamp cylinder head, cylinder main bearing cover, connecting rod, spark plug, and flywheel with specified torque when
reassembling them.
9) Replace all the packings and gaskets with new ones when reassembling.
IO) Wash parts with new gasoline or washing oil, and blow them with compressed air before reassembling.
1 1 ) Apply mobile oil to the rotating and sliding parts.
12) Be careful not to contaminate parts with dust during reassembling.
13) Tighten bolls, nuts, and screws to correct torque readings specified. If small screws are tightened too strongly, they may
be broken.
14) After reassembling, turn the moving parts by hand, and check them for signs of abnormal friction, noises, or looseness.
6-2 SPECIALTOOLS
""
.. . ~ "
c " 3
" - ." -. . ""
-
VALVE SPRING COMPRESSOR
Fig. 6-2
-1 0-

Flywheel Puller
I Bolt
209 9901
0 07
001 65085 00
(Y790-350)
Valve Spring Compressor 209 9901
1 07
(Y790-282) I1
Valve Seat Cutter (45”)
1
(H640-118)
Pilot Stem
1
209 9901 2 07
6-3 DISASSEMBLY and REASSEMBLYPROCEDURES
6-3-1 FUEL TANK and TANK BRACKET
1) Disconnect fuel pipe between fuel strainer and carburetor from carburetor.
2) Detach fuel tank from its mounting bracket (8mm nut X 4).
3) Detach bracket and head cover from cylinder head (8mm bolt X 2).
In reassembly;
It is recommended to replace fuel pipe with new one before reassembly.
CAUTION: REPLACE FULEPIPE WITHNEW ONE ONCE EVERY YEAR.
6-3-2 BLOWER HOUSING and CYLINDERBAFFLE
1) Disconnectprimarycoilwirefromstopbuttonwire.
2) Take off mufflercoverandblowerhousingfromcrankcase.andbafflefrom cylinderhead.
-
(6mm bolt X 36mm screw X 4).
3) Removebafflefromcylinderblock.(6mmscrew X 2).
. 6-3-3 AIRCLEANER
1)Remove aircleanercoverandelement.
2) Detach bottom plate of air cleaner from carburetor by loosening two 6mm bolts.
(Also, detach the choke button from the carburetor chocke lever)
3) Disconnectbreatherpipe.
In reassembly;
Put air cleanerelement
in gasolineandsufficientlywashitwhileshakinguntildust is completelyremoved.After
washing, drytheelementthoroughlyandapplymixture
oil (gasolineandmobile oil mixedataratio of 4:1), before
reassembly.
6-3-4 MUFFLER
Remove muffler from cylinder partof crankcase (8mm nut X 2, 8mm bolt X 2).
6-3-5 GOVERNORLEVER and CARBURETOR
1)Detachgovernor lever fromgovernorlevershaft(6mmnut X 1 ).
2) Detachgovernorrodandrodspringfromcarburetor.
3) Removecarburetorfromcylinder par‘t of crankcase (EY33-2: 6mmnut X 2, EY44-2: 8mmnut X 2).
In reassembly:
Referto
“8. GOVERNOR ADJUSTMENT”section.
-1 1-

6-3-6 STARTING PULLEY and FLYWHEEL (magneto)
Remove 3 piecesmountingboltstodetachstarting
pulley from flywheel.
Remove flywheel from crankshaft.
Insertasocketwrench
or boxwrenchintoan 18mm
nut,and give thewrenchasharpblowwithasoft
hammer. Remove nut and spring washer.
AttachflywheelpullertoflywheelasshowninFig.
6-3-1, andturncenterboltclockwiseuntilflywheel
becomes loose enough to be removed.
Disconnecthightensioncable
of ignitioncoilfrom
sparkplug,disconnectcableclipfromcrankcase,and
Fig. 6-3-1
then, remove ignitioncoil from crankcase
(6mm X 25mm screw X 2).
Remove cable clip from lighting coil cable, and detach lighting coil from crankcase (6mm
X 30mm screw x 2).
Remove breaker cover, and then remove contact breaker and condenser from crankcase.
In reassembly
;
Refer to “7-2 BREAKER POINT ADJUSTMENT” and “7-3 TIMING ADJUSTMENT”.
6-3-7 CYLINDERHEAD and SPARKPLUG
1) Detachsparkplugfromcylinderhead.
2)DetachcylinderheadandgasketfromcylinderbylooseninglOmmnut.
In reassembly;
1) Remove carbon from combustion chamber and also remove dirt from the vicinity of cooling fins of cylinder head.
-
Check head face for distortion. Replace cylinder head, if needed.
2)Replacegasketwithnew
one.
3) Clamping torque of cylinderhead is 450-500 kg-cm (32.5-36ft-lbs).
NOTE: Leavespark plug detached temporarily to facilitate engine rotation duringtiming adjustment. When mounting
finally, tighten
it 250-300 kg-cm (18-21.7 ft-lbs).
6-3-8 INTAKE and EXHAUST VALVE
CA 1
Detachinnerandoutertappet cover fromcylinder
block
(6mm bolt x 2).
Detach retainer locks and valves by Lifting valve spring
using
a valvespringretainer.Proceed in thesameway
bothforintake valve andexhaust valve. (Fig. 6-3-2)
Then, removevalve springs and spring retainers.
JTION: DO NOT DAMAGE GASKET SURFACE OF
TAPPET CHAMBER WITH THE COMPRESSOR
TOOL.
Fig. 6-3-2
-1 2-

In reassembly;
1)Cleancarbonandgumdepositsfromthe valves, seats,portsand valve stemholes.
2) Replace valves, if badly burned, pitted or warped.
3) Correctthe valve seatby using 45" seatcutter tool asillustratedin Fig. 6-3-3. Theseatshouldbe finished to
1.2-1 Smm
(.04-.05 inch) in width.
4) Cylinderblockshouldbereplaced if valve stemclearancebecomesexcessive.'Referto Fig. ..-' 4 for
clearance specifications and proper assembly.
5) Aftercorrecting valve seats, lap valves in place untilauniformring will showentirelyaroundtheface of the
valve. Clean valves, andwashblockthoroughwith
a hotsolution of soapandwater. Wipecylinderwalls
with clean lint free rags and light engine oil.
CAUTION: DO NOT ASSEMBLE VALVE SPRINGS ANDSPRINGRETAINERS AFTER ADJUSTING
TAPPET CLEARANCE.
Fig. 6-3-3
VALVE and VALVESTEMHOLECLEARANCE
A - VALVE FACE ANGLE
4 5"
I B - SEAT ANGLE
I
45"
I C - GUIDE INSIDE DIA.
I
8 DIA. +:.036 (::!;::)
I
INTAKE
8 DIA. -0:oss ( :313rr)
-0 030 3168'
D - VALVE STEM DIA. EXHAUST
8 DIA. 1:::;; ( ::fi::)
MAXIMUMALLOWABLE
CLEARANCE BETWEEN
C and D
INTAKE
0.030-0.09 1 (.0012"-.0036")
EXHAUST
0.090-0.146 (.0035"-,0057")
Fig. 6-3-4
-1 3-

6)
ADJUSTING TAPPET CLEARANCE (Fig. 6-3-5)
* Rotatecrankshaftuntiltappet is initslowest
position,hold valve downandinsertfeelergauge
between valve andtappetstem.Theclearancefor
both intake and exhaust, with engine cold.
0.13-0.17mm (0.0051”to 0.0067“)
* If clearance is less thanspecified,slightlygrind valve
stem and measure it again.
* If clearance is largerthanspecified,sink valve seat
to adjust clearance.
* Afterclearanceadjustment,assemble valvesprings
and valve retainers,andsecurethem
in placewith
retainerlocks.Checktappetclearance again for
proper adjustment by turning crankshaft.
6-3-9 CYLINDERBLOCK
Detachcylinderbylooseningone8mmandfivelOmm
nuts.
In reassembly;
Remove from upper surface
of cylinder, carbon deposit
whichotherwisemaydamagepistonwhenpiston
moves.
lnsertadoublingplatebetweenpistonskirtand
crankcase, and set piston to the cylinder center
so that
piston will not move easily. (Fig. 6-3-6).
Stagger the piston ring gaps
90° apart around piston.
Apply
oil to piston ringandcylinder walls sufficiently.
NOTE: Use new cylinder gasket.
5) Check if pistonmovessmoothlyafterreassembly.
Clamping torque of cylinder
is as shown below.
8mm nut 170-190 kgcm
(12.3-1 3.7 ft-lbs.)
lOmmnut350-400kg-cm (25.3-29 ft-lbs.)
6-3-70. MAINBEARING COVER
I) Unscrew 6mmboltlocated just belowcrankshafton
drivingshaftside of mainbearingcoverand
8 pieces
bolts for mounting main bearing cover.
2)Aftersettingcrankshafttotheupperdeadpoint
of
piston,inserta 4mm rodthrough6mmscrew hole to
fix crankshaftasshowninFig.6-3-7.Then,evenlytap
aroundtheperipheryofbearingcoverwithasoft
hammer until cover breaks free from crankcase.
CAUTION: BE CAREFULNOT TO DAMAGE OIL
SEA 1.
Fig. 6-3-5
RING GUIDE
HOLDER
\
. 1; :~ d
Fig. 6-3-6
MAIN BEARING COVER
Fig. 6-3-7
”1 4-

In reassembly;
1)Whenreassemblingmainbearingcover,assemblegovernorlevershaftandgovernorarmbeforereinstallingthem
into crankcase.
NOTE: If replacement of oil sealis required, force-fit new oil seal before reassembly.
2) Whenreassemblingmainbearingcover,apply oil to bearingsurfaces,geartrain,tappets,and oil seallips,andforma
thin film
of oil on main bearing cover face. Mount an oil seal guide onto .crankshaft to prevent damage to oil seal lips.
NOTE: Turncrankshaft to TDC,and lock the balancer driven gear by inserting a 4mm dia. rod thru theplug hole and Into a hole in
the balancer driven gear (Fig
6-38)
3) Check if side clearance of crankshaft is 0"0.2mm, and adjust it using adjusting collar, if needed.
4) Clamping torque of mounting bolts for main bearing cover is 170-1 90 kg-cm (1 2.3-1 3.7 ft-lbs.).
\TJOWCl?.>nOnD*
TIMING MARK CAMSHAFT
Fig. 6-3-9
6-3-1 1 CAMSHAFT and TAPPET
1) To preventtappetsfromfallingoutandbeingdamagedwhencamshaft is removed,turncrankcaseoveronitssideas
shown in
Fig. 6-3-9. Push tappets inward to clear cam lobes, and remove camshaft.
2) Withdrawtappets.
NOTE: Mark them so that they can be reinstalled in the same holes.
In reassembly;
1) Put tappets back
in their corresponding hole first and then mount camshaft.
CAUTION: DON'T FORGET TO MOUNT GOVERNOR SLEEVE ON CAMSHAFT.
2) Timing marks on camshaft gear and crankshaft gear must be matched up. If valve timing is off,
properly or may not run atall.
engine will not func
:tion
NOTE:Mount camshaft so that the marked tooth on crankshaft gear is between the two marked teeth of the camshaft
gear. (Fig.
6-3-9)
6-3-12CONNECTING ROD and PISTON
1) Straighten out the bent tabs of rod lock washer and remove bolts from connecting rod.
2) Remove oil scraper,lockwasherandconnectingrodcapfromcrankshaft.
3) Remove piston from connecting rod by detaching two clips, and then removing piston pin.
4) Removepistonringsfrompiston by wideningopenends.
-1 5-

In reassembly;
PISTON RING (See Fig. 6-3-10)
1) Use aringexpandertool to preventringfrom
becomingdistorted
or brokenwhen installing onto
piston.
Ifanexpandertool
is notavailable,installringsby
placing the open endof the ring on first land
of piston.
Spread ring only far enough
to slip over piston and into
correctgroove,beingcarefulnottodistrictring.
(Fig.
6-3-1 0)
NOTE: With or without expander tool, assemble bottom
ring firstand
work upward, installing top ring last.
2) Assembletwopistonswhilefacingmaker’s mark
toward piston top.
CAUTION:
1. BE CAREFULNOTTOBROKEN THERING.
2. MOUNTSECONDRING WITH SCRAPER EDGE
DOWN OTHERWISE OIL PUMPINGAND
EXCESSIVE
OIL CONSUMPTIONMA Y
RESUL T. Refer to Fig. 6-3- 11 for correctplace-
ment of rings.
PISTON and CONNECTING ROD
Assemble pistonandconnectingrodusingpistonpinwith
clips mounted to both ends
of piston pin.
NOTES:
7. Measure thecfearancebetween cylinder and piston
on thrust surface at skirtbefore assembly.
If worn outseverer thanspecified, replace it.
2. Since the pistonpin center ofpistonfor EY44-2
is offset from the center of piston by about 6 mm,
set pistontothematch
mark scribed at thetop
of piston. In case of Models B and D, set BF and
Fig-
6-3- 10
TOPRING
.SECONDRING
,011 RING
DF marks to the @ mark on the side of connecting rod before reassembly.
ASSEMBLY of CONNECTING ROD
I) Assembleconnectingrod so thatthe @ markonitssidefacesflywheelside.
2) Apply oil to large and small ends of connectingrodandcrankpinsufficiently
3) Assemble theconnectingrodcapmatchingthemarksonconnectingrod.
Fig. 6-3- 11
4) Mount new lockwashersandthemwithoutfail.
CAUTION: ASSEMBLE OIL SCRAPER WITHOUT FAIL, So THATTHE TAB FACESTOWARD FLYWHEEL.
(When engine is operated while tilting it toward the PTO shaft side, assembleoil scraper tab on main bearingcover side.)
-1 6-