Robin EC03ER User manual

ROBIN AMERICA, INC.
ROBIN TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST
ROBIN
EY08
EY15
EY15V
EY20
EY2OV
EY23
EY28
EY3
5
EY40 -
EY45V
EY2
1
EY44
EY18-3
EY25
EY27
EH11
EH12
EH15
EH17
EH21
EH25
EH30
EH30V
EH34
EH34V
EH43V
EC13V
DY23
DY27
DY30
DY3
5
DY41
WISCONSIN ROBIN
SIDE VALVE
W 1-080
W1-145
W1-145V
W1-185
W1-185V
W1-230
W 1-280
W 1-340
W 1-390
Wl-45OV
EY21W
EY44W
EY18-3W
EY25W
EY27W
OVERHEAD VALVE
WO1-115
wo1-120
WO1-150
WO1-170
wo1-210
WOl-250
WO 1-300
WO1-300V
WO1-340
WO
1 -340V
WO 1-43OV
TWO CYCLE
WT1-125V
DIESEL
WRD 1-230
WRD 1-270
-1-300
WRD1-350
WRD1-410
0
0
0

CONTENTS
Section Title Page
1. SPECIFICATIONS" ""."O"""""•"O"O"C".O"""O"O"".O"""'"•""""""S""""""""""""."."""""".--"".--.-......C... 1
2. PERFORMANCE ..."............".........""..................".......""..".................."..C.". 2
2-1 Maximum output ...... C................................................"....".................. 2
2-2 Continuous rated output ...................................."............."................ 2
2-3 Maximum torque ................................................................................ 2
3. DISASSEMBLY AND REASSEMBLY ......"."....................".."............"..... 3
3-1 Preparations and suggestions ...................................".....".................. 3
3-2 Special tool ....................................................................................... 3
3-3 Disassembly procedures .`..............".......................".. ".................."...... 4
3-4 Reassembly procedures .............."..............".. ".................................... 15
4. RECOIL STARTER ...."....................................""................................... 21
4-1 Disassembly .."....."..............".............."... "............."............................. 21
4-2 Reassembly ."..............."............".................""".."............".................... 22
4-3 Checking procedures after reassembly ............................................. 23
4-4 How to do in troubles "........................"........................."................ 23
5. CARBURETOR .........................."."..................................................... 25
5-1 Diagnosis of troubles ....................................................................... 25
5-2 Remedy for trouble ...................."................."................................... 25
6. MAGNETO .-.........."........-...."....".............."............"""............."."............. 27
6-1 Troubleshooting ......"....."..........................................""....................... 27
6-2 Spark testing "".........................................."......................."... "".......... 27
7. BREAK-IN OPERATION OF REASSEMBLED ENGINE ...................27
8. Troubleshooting ..................."".................• .......................... 27
8-1 Troubleshooting ............". "........................................."....................... 27
8-2 Troubleshooting table" ................"............"........................................ 28
9. CHECKS AND CORRECTIONS ............................................... 30
9-1 Service data ...............".....................................................".........".".... 30
9-2 Table of tightening torque ......................................"...................`.... 34
10. MAINTENANCE AND STORAGE ........................................ 36
10-1 Daily checks and maintenance ......".................................................. 36
10-2 Every 50 hours (10 days) checks and maintenance ....................... 36
10-3 Every 150 hours (monthly) checks and maintenance ...................... 36
10-4 Yearly checks and maintenance ....................................................... 37
10-5 Preparations for long .storage ......".. "........"....................................... 37

1. SPECIFICATIONS.
I I
Model
Type :
Bore X stroke
Pistondisplacement
output
EC03ER
ECO4ER
1
Air-cooled,~2-cycle, inclined single cylinder, lead valve, horizontal P.T.O. shaft.
37 X 32mm (1.46 X 1.26 in)
40.2cm3 (2.45 cu.in.)
34.4cm3
(2.1 0 cain.)
40 X 32mm(1.57 X 1.26 in)
1.2/6000 HP/rpm 1.4/6000 HP/rpm
(0.9/6000 KW/min")
(1.0/6000 KW/mi n- '1
.1.8/7000 HP/rpm 2.0/7000 HP/rpm
(1.3/7000 KW/min") (1.5/7000 KW/min")
Max.torque
0.2/5000 kgf m/rpm
0.23/5000 kgf m/rpm
I (2.0/5000 ft. Ibs/min")
I (2.3/5000 ft. Ibs/min")
Directionofrotation
I Counterclockwise as viewdfrom P.T.O.'shaftside
Coolingsystem
I
Forcedaircooling
Lubrication
I Oilmixedfuel
Lubricant
Horizontal draft, float type Carburetor
2-cycleengineoil
Mixturefuel(Gasoline
20-25 : oil 1)
Fuel
Fuelfeedsystem
I-
Gravitytype
Fuel tankcapacity Approx. 1.1 liter
(0.29 U.S. gal.)
Ignitionsystem
I
Pointlessflywheelmagneto(Solidstateignition)
Spark *.plug
NGK BPM7A
Startingsystem
I
Recoi I starter
Dryweight
3.5 kg (7.7 Ibs)
3.4 kg (7.5 Ibs)
Dimensions L-X W-X H
1 72 X 280 X 250mm (6.77 X 1 1.02 X 9.84 in)
a resubject
to change without
-1-

2. PERFORMANCE
2-1 MAXIMUM OUTPUT
The maximum output of an engine is theoutput power of the engine operatingwiththecarburetor
throttle valve fully open after
it has .been broken in properly.
Therefore,
a brand-new engine or an engine which has not been broken in properlymay not
produce the maximumoutput.
2-2 CONTINUOUS RATED OUTPUT
The operation of the engine atthe continuous ratedoutput is most favorablefromthe view point
of engine life andfuel economy.
It is recommended, therefore, thatthe equipment driven by the engine to be designed torequire
the engine power less thanits continuous ratedoutput.
2-3 MAXIMUM TORQUE
The maximum torqueindicates thetorque at theoutputshaft when the engineis producing
maximum output.
0 EC03ER 0 EC04ER
kgf . rn (N . m)
0.21 (2.06)
0.19 (1.86) t
0.17 (1.67) 3
W
0
F
2
4000 . 5000 6000 7000
REVOLUTION - r . P . m.
4000 5000 6000 7000
REVOLUTION - r .P .m.
kgf * m (N .
0.23 (2.26)
0.21 (2.06)
0.19 (1 36)
f-?
-2-

3. DISASSEMBLY AND REASSEMBLY
3- 1 PREPARATIONS AND SUGGESTIONS
(1) When disassembling an engine , memorizewell the locations of individual parts so thatthey
can be reassembled correctly.
If you are uncertain of identifying some parts, it is suggested
thattagstobeattachedto them.
(2) Have boxes ready to keep disassembled parts by group.
(3) To prevent missing and misplacing small parts such as boltsandnuts, etc., temporarily
assemble
as much as possible in each group or set.
(4) Carefully handle disassembled parts,and clean them with washing oil.
(5) Use correct tools in correct way.
(6) Standard tools required for disassembling and reassembling :
a) Work table
b) Washing pan
c) Disassembling tools
d) Washing oil (kerosene or light oil)
e) Emerypaper,waste'.cloth
(7) Before starting disassembly of the engine, drain fuel.
3-2 SPECIAL TOOL
Tool No.
Use
Tool
560 - 90020 - 00
For pulling off theflywheel and clutch
Clutch puller
"--(NOTE]-
Use tKree (3) M5 X 40mm bolts
withthe puller to remove clutch,
and two (2) M6 X 4Omm bolts to
remove flywheel.
Fig. 1
-3-

3- 3 DISASSEMBLY PROCEDURES
Step
Tool
Remarks Procedures
Part to remove
1
(1) Removespark plugcapfromspark
Spark plug
cap
plug.
~
2 Tank cap
(2) Put a draining pan below fuel tank.
(1) Remove tank cap from fuel tank.
(3) Removefuelpipefromcarburetor.
(4) Drain fuelfrom tank.
~ ~ ~~ ~
TANKCAP *
SPARKPLUGCAP
Fig. 2

(Option)
Procedures
(1) Remove clutchcenter bolt from
crankshaft
M6 x 16mm bolt and washer - *-* lpce.
(2) Remove ki-ee screws fromclutch.
M5 x 8mm screw and washer *e* Spa.
(3) Attachclutch puller to clutch.
(4) Pull outclutch assembly using cluch
,,
puller. (See Fig. 3.)
Fig. .3
~mps screw driver
Clutchpuller
M5 SCREW : 3pcs.
Fig. 4
-5-

Step
Air cleaner
4
Part to remove
5
Carburetor
Procedures
(1) Removecleaner cover with element.
(1) Turn fuel cock off.
(2) Loosen two screws and remove air
cleaner base and carburetor.
M6 x 65mm screw and washer....2 pcs.
Remarks
Tool
Disassemble and
reassemble carburetor
refering
to. page 25,
Phillips screw driver
.'5. CARBURETOR".
rl

-
Step
6
-
Part to remove
Tank bracket
and fuel tank
Procedures
I I
Remarks Tool . I
(1) Remove tank bracket from crankcase.
(2) Removefuel tank,
M5 x 14mm screw and washer---.2pcs.
Phillips screw driver
I I I
Fig. 6
-7-

I SteplPart to remove1Procedures I Remarks I Tool I
7
(1) Remove mount rubbers from crank- Rubber
cushion
and tank bracket.
8 lOmm box wrench
(1) Remove engine base.Engine base
(Option)
M6 x 12mm bolt and washer * - - - 3pcs.
MOUNT RUBBERS
I
M6 BOLT : 3pcs.
fl
Fig. 7
-8-

&=
Step Part to remove
* cover
Procedures
(1) Removemuffler cover frommuffler.
(2) Removemuffler.
M5 x 8mm screw ***a 3pc~:
' M6 bolt and washer - : *-2pcs.
(1) Remove cylinder cover.
M5 X 14mm screw and waSher****2pcs..
M5 X 20mm screw and washer-. 0. lpce.
Remarks
(1) Be careful not to
lose the washer
Tool
Phillips screwdriver
lOmm
box wrench
Phillips scniw driver
.
..
Fig. 8
..
-9-

Step lpartto remove1 Procedures I Remarks I Tool
Stopbutton (1) Disconnect couplers of stopbutton wire.
I.
12 starter
Recoil
(1 1 Remove recoil starter.
M5 X 50mm socket bolt and
washer lpce.
M5 X 22mm socket boltwith
washer
- - - 2pcs.
(1) Disassemble and
4mm
reassemble recoil
starter refering to hexagonwrench
page 21,
"4. RECOIL
STARTER".
M5 SOCKET BOLT : Ppcs.
n
Fig. 9
- 10 -

-
Step
13
-
14
-
Part to remove Procedures
lgnition coil
Flywheel
magneto
(1) Removeignition coil from crankcase.
M5 x 2Omm SCEW **e* 2pcs.
(1) Removeflywheel bolt,
M6 X 16mm bolt, spring washer and
washer
1 pce.
(2) Set clutch puller to flywheel.
(See Fig. 10.1
Turn center boltclockwise to pull out
flywheeL
Remarks I Tool 1
Phillips screw driver
(1) Be careful not to
Clutchpuller
lose washer
sd
spring washer.
(2) Flywheel caq easily
be removedby
striking with a
hammer the head
of center bolt of
clutch puller.
Fig. 11
M5 SCREW : ZPCS. . IGNITION COIL
- 11 -

'art to rernova
Woodruff
key
Insulator
and lead
valve
Procedures
(1) Removewoodruffkey from crank -
shaft. (See Fig. 12.)
(1) Remove insulator and lead valve from
Crankcase.
M5 X 20mm screw and washer- 0. -2pcs.
M5 x 22mm screw and washer- *a -2pcs.
(NOTE1
Leadvalve is unreplaceable.
Replaceleadvalve
in completion from
if necessaly.
~ ~~
M5 X 22mm
SCREW : 2pcs.
I $ WIREBRACKET
Remarks
(1) Use a soft hammer
and aluminum stick.
(2) Be careful not to
lose key.
(3) Be careful not to
damage key and
crankshaft keyway.
Tool
Phillips screw driver
/ LEAD VALVE
M5 X 20mm SCREW : 2pcs.
INSULATOR
v
PACKINGS
Fig. 12
- 12 -
Fig. 13

.*
..
.,
1-
..
step
Tool Remarks Procedures Part to remove'
'.
"1 9mm
(l).Removespark plug. fromcylinder.
'Spark plug
17'
plug wrench
*.
r
..
.L
,
..
18 5mm (1) -Remove cylinder from crankcase.
Cylinder
+-
M6 X 18mm socket bolt *-*a 4pcs.
hexagon wrench
,.
..
..
...
.-
I
PACKING I
CYLINDER
.. .
. "_
- 13"

Step
19
-
-
20
’art to remove
Crank-
Piston and
piston ring
Procedures
(1) Disassemble front and mar crankcases.
M5 x 30mm socket bolt 4pcs.
(1) Remove two clipsfrom both ends of
(2) Remove piston pinfrompiston.
(3) Remove piston from connecting rod.
(4) Remove piston ring frompiston.
piston pin.
[NOTE]
Connecting rod is unreplaceable.
Replaceconnectingrodandcrankshaft
in assembly form
if necessaly.
PISTON RING
e
PISTON
Remarks
(1) Be careful not to
damage
oil sed
(1) Be careful not to
lose clips.
(2) Be careful not to
givedamage to the
piston and
connecting rod
(3) Be careful not to
break piston rings
by spreading, too
much
or twisting
them.
Tool
4mm.
hexagon wrench
Long nosepliers
OIL SEAL
\
PISTON PIN
NEEDLE BEARING
CRANKSHAFT
M5 SOCKET
CRANKCASE(REAR)
I
GASKET
Fig. 15
\
CRANKCASE(FRONT1
OIL SEAL
BOLT
: 4pcs.
f7
- 14 -

3- 4 REASSEMBLY PROCEDURES
0 PRECAUTIONSFORREASSEMBLY
(1) Clean partsthoroughly before reassembly.
(2) Scrape off all carbon deposits fromcylinder head, piston top and piston ring grooves.
(3) Check lips of oilseals.Replaceoil seal if I alipis damaged.
(4) Replace allgaskets with newones.
(6) Torque bolts and.nuts to specification refering.to page 34, “9-2 TABLE OF TIGHTENING
(7) Apply oil torotating andsliding parts.
(8) Check andadjust clearances and end plays where specified inthis manual.
Pay most attentionto cleanliness of piston, cylinder, crankshaft, connecting rod and bearings.
Applyoil to lips before reassembly.
- (5) Replace keys, pins, bolts, nuts, etc., if necessary.
TORQUE”.
3-4-1 PISTON AND PISTONRING
(1) If piston ring expander is unavailable, install piston rings by placing the open ends over the
top land of piston and. spreading thering ends only far enough
to slip them into the correct
ring grooves.
-[NOTES]
1. Pay attention not to break piston ring by twisting.
2. Top ring and second ring are common parts.
3. Set pistonringends to locationpinasshowninFig. 16.
Fig. 16
!
TOP RING AND
SECOND RING
TAPER
- 15 -

(2) Install needle bearing to small end of
connecting rod.
(3) Assemble piston and connecting rod with
piston pin and clips. (See page
14, Fig. 15.)
Setthe "M" markstamped onpistontop to
flywheel side of piston.
Fig. 17
3-4-2 CRANKCASE
(1) Insert magneto end of crankshaftinto front crankcase bearing.
(2) Putgasket on thefitting surfaces of crankcase. (Usenew gasket.)
(3) Insert FTO end of crankshaftintorearcrankcase bearing. (See Fig. 17.)
(4) Tighten four (4) bolts evenly to join rearcrankcase tofront crankcase.
M5 X 30mm socket bolt 0. 4pcs.
TIGHTENINGTORQUE
60 - 80 kgf *cm
590 - 780 N crn
55 - 65 IN-LB
(5) Insert key tocrankshaft.
3-4-3 ENGINE BASE (OPTION)
(1) Install engine base to crankcase.
I
Tightenthree (3) bolts evenly to join engine base to crankcase.
M6 x 12mm bolt and washer *e* 3pcs.
TIGHTENINGTORQUE
80 kgf *cm
590 - 780 N - cm
55 - 65 IN-LB
3-4-4 CYLINDER
(1) Put cylinder gasket on thefitting surface of crankcase. (Usenew gasket.)
(2)Insert piston to cylinder.
(3) Put cylinder to crankcase.
M6 X 18mm socket bolt -0 -0 4pcs.
1080 - 1270 N*cm
n i
,
- 16 -

3-4-5 CYLINDERCOVER
(1) Install cylinder cover to cylinder.
M5 X 14mm screw and washer 2pcs.
M5 X 20mm screw and washer * * * lpce.
I .TIGHTENING TORQUE I
30 - 40 kgf cm
295 - 390 N cm
30 - 35 IN-LB
3-4-6 LEADVALVEAND INSULATOR
(1) Install gasket lead valve, withgasket,insulatorand wire bracket to crankc
M5 X 20mm screw and washer 2pcs.
M5 X 22mm screw and washer 2pcs.
395 - 490 N cm
ase.
r Apply sealant (THREEBOND # 1360) to screws.
I I
3-4-7 CARBURETOR AND AIR CLEANER
(1) Installcarburetorgasketandcarburetor,thenmountair cleaner base.
(2) Set cleaner element to cleaner cover.
(3) Set cleaner cover to cleaner base.(See page 6, Fig. 5.)
M6 X 65mm screw and washer 2pcs.
TIGHTENING TORQUE
40 - 50 kgf cm
395 - 490 N cm
35 - 40 IN-LB
3-4-8 MAGNETO (C.D.I.)
(1) Install woodruffkey to crankshaft.
(2) Install flywheel to crankshaft.
M6 X 16mm bolt, spring washer and washer 1pce.
I TIGHTENING TORQUE I
110 - 130 kgf *cm
1080 - 1270 N-cm
95 - 110 IN-LB
I I
(3) Install ignition coil to crankcase.
M5 X 20mm screw 2pcs.
- 17 -