Subaru Robin EX30 Engine Service Repair Workshop Manual

SERVICE MANUAL EX30 ENGINES Model PUB-ES2268 Rev. 10/06

CONTENTS Section Title Page 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3. FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4. GENERAL DESCRIPTION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . . . 5 5. DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5-1 PREPARATIONS AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5-3 DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 5-4 REASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 7. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 8. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 9. ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 10. OIL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 11. AUTOMATIC DECOMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 12. CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 13. RECOIL STARTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 14. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 15. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 16. STANDARD REPAIR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 16-1 STANDARD DIMENSIONS AND LIMITS OF USE . . . . . . . . . . . . . . . . . . . . 67 16-2 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 17. MAINTENANCE AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

- 1 - 1. SPECIFICATIONS MODEL EX30D Type Air-cooled, 4-cycle single cylinder, overhead camshaft, gasoline engine Displacement mL (cc) 287 Direction of Rotation Counterclockwise, as Viewed from P.T.O. Shaft side Lubricant Automotive detergent oil (API/ SE or higher grade, SAE/ 10W-30 etc.) Oil Capacity Liter 1.0 Fuel Automotive Gasoline (Unleaded) Spark Plug NGK BR-6HS Starting System Recoil starter /Electric starter Dry Weight kg 21 Dimensions (L x W x H) mm 415 x 424 x 319 Valve Clearance (Intake and Exhaust) 0.12 mm (0.0047 in.) Note : Adjust the valve clearance while the engine is cold. Emissions Durability Period (California only) 500 hours +0.03 0 +0.0012 0

- 2 - 2-1 MAXIMUM OUTPUT The Maximum output is the output of an engine with its throttle valve fully opened and considering that all the moving parts are properly broken in. A new engine may not produce full maximum output while its moving parts are still not broken-in. NOTE : Power curves shown in the following charts are made in conformity with SAE internal combustion engine standard test code J1349. 2-2 CONTINUOUS RATED OUTPUT The continuous rated output is the output of an engine at optimum governed speed which is most favorable from the view point of engin's life and fuel consumption. When the engine is installed on a certain equipment, it is recommended that the continuous output required from the equipment to be kept below this continuous rated output. 2-3 MAXIMUM TORQUE The maximum torque is the torque at the output shaft when the engine is producing maximum output at a speciﬁc r.p.m.. 2. PERFORMANCE

- 3 - 2-4 PERFORMANCE CURVES 2000 2400 2800 3200 3600 4000 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 kW 17.0 18.0 19.0 20.0 [HP] r.p.m. REVOLUTION TORQUE OUTPUT 0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 1.7 1.8 1.9 2.0 RECOMMENDED HORSEPOWER RANGE MAXIMUM HORSEPOWER MAXIMUM TORQUE CONTINUOUS RATED HP

- 4 - 3-1 EXTREMELY EASY START - NO KICK-BACK Reliable Starting and Less Pulling Force are achieved by: - Sophisticated Mechanical Compression Release System as well as newly designed Combustion Chamber. - EX engines start instantly even at minus (-) 10°C, without any perceptible kick-back. 3-2 EXTREMELY EASY MAINTENANCE Extreme ease of maintenance is realized by: - Only with ordinary tools, routine maintenance, assembly and disassembly can be performed. 3-3 EXTREMELY ADVANCED TECHNOLOGY Extreme reliability and durability are achieved by: - Heavy Duty Chain Driven OHC System Oval type case-hardened steel links enhance performance and resist stretching, which result in extended maintenance free operation. - Completely New Main Bearing Cover's Design Flush-mounted main bearing cover with lower moment of deformation significantly increases reliability and engine life. - Superior Cooling and Lubrication System Heat reduction is achieved by more efficient, larger and more numerous cooling fins on crankcase, cylinder and mounting base, as well as by outstanding oil delivery system. - Large Ball Bearings on both ends of crankshaft for maximum stability under demanding loads. - Cast Iron Cylinder Liner resists wear 3-4 EXTREME POWER AND PERFORMANCE Extremely Higher Power and Lower Fuel Consumption are realized by: - High speed and homogeneous combustion achieved by sophisticated Pentroof Combustion Chamber which includes Intake and Exhaust Valves located at optimum angle. - Straight Intake Port with minimal air flow resistance. Environmentally friendly EX engines comply with EPA Phase 2 and CARB Tier II Emission Regulations in the USA. Extreme application compatibility With four versatile models, existing slant-cylinder engines can be easily replaced. 3. FEATURES

- 5 - 4-1 CYLINDER AND CRANKCASE The cylinder and crankcase are aluminum die-casting as a single piece. A special cast iron cylinder liner is molded into the aluminum die-casting. The crankcase has a mounting surface on the output shaft side to which the main bearing cover is attached. The cylinder is inclined to the right at an angle of 25 degrees from the horizontal as viewed from the output shaft side. 4-2 MAIN BEARING COVER The main bearing cover is an aluminum die-casting, which is mounted on the output shaft side of the crankcase. By removing the main bearing cover, the inside of the engine can be inspected with ease. Pilots and bosses are machined into the cover to facilitate the direct coupling of the engine with machines such as generators and pumps. There is an oil ﬁlling port, with oil gauge, on either side of the cover. 4-3 CRANKSHAFT The crankshaft is made of spheroidal graphite cast iron, and the crank pin is high-frequency induction- hardened. The crank sprocket used to drive the chain and the gear used to drive the governor gear are pressed into the output end of the shaft. 4-4 CONNECTING ROD AND PISTON The connecting rod is a specially heat-treated aluminum alloy die-casting. Its large and small ends function as bearings. A splasher built into the connecting rod lubricates by splashing engine oil. The piston is an aluminum alloy casting with grooves for mounting two compression rings and one oil ring. 4. GENERAL DESCRIPTION OF ENGINE COMPONENTS

- 6 - 4-5 PISTON RINGS The piston rings are made of special cast iron. The profile of the top ring is a barrel face or tapered face, and that of the second ring is a tapered face. There are 2 types of oil ring depending on the engine specification. As those are interchangeable, the cutter ring with coil expander type can be selected as the spare part. TOP RING OIL RING 1 2 BARREL THREE-PIECE CONSTRUCTION 1 2 4-6 CAMSHAFT The camshaft and the sprocket are made of special sintered alloy. They are constructed as a single piece. The camshaft is provided with intake and exhaust cam, and the decompression release lever is mounted on the sprocket shaft end side. 4-7 VALVE ARRANGEMENT This engine has a chain-driven overhead cam and overhead valve construction, with a single cam performing both intake and exhaust operations. 4-8 CYLINDER HEAD The cylinder head is an aluminum die-casting with a pent roof combustion chamber construction. The intake and exhaust ports are arranged in a cross direction to improve combustion efficiency. DECOMPRESSION RELEASE LEVER EXHAUST VALVE INTAKE VALVE

- 7 - 4-9 GOVERNOR SYSTEM This engine is equipped with a centrifugal flyweight type governor that makes it possible to operate the engine at a constant speed, even with load variations. (The governor flyweights are mounted on a governor gear.) GOVERNOR GEAR 4-10 COOLING SYSTEM The engine uses a forced air-cooling system in which a cooling fan (which also works as a flywheel) forces cooling air into the cylinder and the cylinder head. Baffles are provided to guide the flow of the cooling air. 4-11 LUBRICATION SYSTEM The rotating parts, sliding parts and valves of the engine are lubricated with oil in the crankcase. The oil is splashed onto the parts by the oil splasher on the connecting rod. 4-12 TIMING CHAIN Timing chain system is adopted and designed for lubricating for the upper portion of cylinder head. The timing chain is engaged between the sprocket portion of integrated camshaft in the cylinder head and the crankshaft gear sprocket. The sprocket teeth in particular shape are adopted to enhance the durability and to realize low noise level. 4-13 IGNITION SYSTEM The ignition system is a transistor controlled magneto system with the ignition timing set at 23 degrees before the top dead center. The magneto consists of a flywheel and ignition coil. The flywheel (which also works as a fan) is directly mounted on the crankshaft and the ignition coil is directly mounted on the crankcase. ※ Model EX30 has a smooth advanced ignition timing system to improve starting performance. (For further details, refer to page 43, section "7. MAGNETO") OIL SPLASHER TIMING CHAIN FLYWHEEL IGNITION COIL

Subaru Robin EX30 Engine Service Repair Workshop Manual

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