Subaru Robin EX13, EX17, EX21, EX27, SP170, SP210, EX21 Engine Service Repair Workshop Manual

SERVICE MANUAL EX13,17,21,27 SP170,SP210 EX21 Electronic Fuel Injection ENGINES Models PUB-ES1934 Rev. 08/09

CONTENTS Section Title Page 1. SPECIFICATIONS ...................................................................................................... 1 2. PERFORMANCE ...................................................................................................... 2 3. FEATURES ............................................................................................................... 7 4. GENERAL DESCRIPTION OF ENGINE COMPONENTS ........................................ 8 5. DISASSEMBLY AND REASSEMBLY .................................................................... 14 5-1 PREPARATIONS AND PRECAUTIONS ............................................................ 14 5-2 SPECIAL TOOLS .............................................................................................. 14 5-3 DISASSEMBLY PROCEDURE .......................................................................... 15 5-4 REASSEMBLY PROCEDURE ........................................................................... 29 6. ENGINE OIL ........................................................................................................... 47 7. MAGNETO .............................................................................................................. 48 8. WIRING DIAGRAM ................................................................................................. 51 9. ELECTRIC STARTER ............................................................................................. 53 10. OIL SENSOR .......................................................................................................... 55 11. AUTOMATIC DECOMPRESSION SYSTEM ........................................................... 56 12. CARBURETOR ....................................................................................................... 57 13. RECOIL STARTER ................................................................................................. 61 14. INSTALLATION ...................................................................................................... 66 15. TROUBLESHOOTING ............................................................................................ 68 16. STANDARD REPAIR TABLES ............................................................................... 74 15-1 STANDARD DIMENSIONS AND LIMITS OF USE ........................................... 74 15-2 TIGHTENING TORQUE .................................................................................... 80 17. MAINTENANCE AND STORAGE .......................................................................... 81

- 1 - 1. SPECIFICATIONS ＊ Specifications are subject to change without notice. Model EX13D EX17D EX21D EX27D Type Air-Cooled, 4-Cycle, Slant Single-Cylinder, Horizontal P.T.O. Shaft, OHC Gasoline Engine Bore & Stroke mm (in.) 58 x 48 (2.28 x 1.89) 67 x 48 (2.64 x 1.89) 67 x 60 (2.64 x 2.36) 75 x 60 (2.95 x 2.36) Piston Displacement ml (cu.in.) 126 (7.69) 169 (10.31) 211 (12.87) 265 (16.17) Compression Ratio 8.5 8.3 Continuous Output kW(HP)/r.p.m. 1.9(2.6)/3000 2.2(3.0)/3600 2.6(3.5)/3000 2.9(4.0)/3600 3.2(4.4)/3000 3.7(5.0)/3600 4.4(6.0)/3000 5.1(7.0)/3600 Maximum Output kW(HP)/r.p.m. 3.2(4.3)/4000 4.2(5.7)/4000 5.1(7.0)/4000 6.6(9.0)/4000 Maximum Torque N ・ m / r.p.m. (kgf ・ m / r.p.m.) (ft ・ lb. / r.p.m.) 8.1/2500 (0.83/2500) (6.01/2500) 11.3/2500 (1.15/2500) (8.34/2500 13.9/2500 (1.41/2500) (10.26/2500 18.6/2500 (1.9/2500) (13.74/2500 Direction of Rotation Counterclockwise as viewed from the P.T.O. shaft side Valve Arrangement Overhead cam system Cooling System Forced air cooling system Lubrication System Splash lubrication system Lubricant Automobile engine oil ; Grade SE or higher (SG,SH or SJ in recomended) SAE 10W-30-----Under ordinary atmospheric temperatures SAE 5W-30-------In cold areas Capacity of Lubricant L 0.6 1.0 Carburetor Horizontal draft, Float type Fuel Automobile unleaded gasoline Fuel Consumption Rate g/kW ・ h (g/HP ・ h) 367 (270) at continuous rated output Fuel Supply System Gravity type Fuel Tank Capacity L 2.7 3.6 6.1 Ignition System Transistorized magneto Spark Plug NGK BR-6HS (CHAMPION RL86C) Charging Capacity (Option) V-A ------------- 12-1A, 3A, 16.7A (Option) Starting System Recoil starter Recoil starter / Electric starter (Option) Governor System Centrifugal flyweight system Dry Weight kg (lb.) 14 (30.87) 15 (33.08) 16 (35.28) 21 (46.31) Dimensions (L x W x H) mm (in.) 297 x 341 x 318 (11.7x13.4x12.5) 304 x 354 x 335 (12.0x13.9x13.2) 311 x 366 x 335 (12.2x14.4x13.2) 351 x 420 x 410 (13.8x16.5x16.1)

- 2 - 2. PERFORMANCE 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..

- 3 - 2000 2400 2800 3200 3600 4000 0 0 0.5 1.0 1.0 1.5 2.0 2.0 2.5 3.0 3.0 3.5 4.0 7.0 8.0 9.0 4.0 5.0 kW [HP] r.p.m. REVOLUTION MAXIMUM TORQUE TORQUE MAXIMUM HORSEPOWER OUTPUT CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE 0.7 0.8 0.9 2-4 PERFORMANCE CURVES EX13D

- 4 - 2000 2400 2800 3200 3600 4000 0 0 0.5 1.0 1.0 1.5 2.0 2.0 2.5 3.0 3.0 3.5 4.0 4.5 12.0 11.0 10.0 9.0 4.0 5.0 6.0 kW [HP] MAXIMUM TORQUE MAXIMUM HORSEPOWER r.p.m. REVOLUTION TORQUE OUTPUT CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE 1.2 1.1 1.0 0.9 EX17D

- 5 - 2000 2400 2800 3200 3600 4000 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 5.0 0 1.0 2.0 3.0 4.0 7.0 6.0 5.0 5.5 4.5 12.0 13.0 14.0 15.0 kW [PS] MAXIMUM TORQUE MAXIMUM HORSEPOWER r.p.m. REVOLUTION TORQUE OUTPUT CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE 1.2 1.3 1.4 1.5 EX21D

- 6 - 2000 2400 2800 3200 3600 4000 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 5.0 0 1.0 2.0 3.0 4.0 9.0 8.0 7.0 6.0 5.0 6.5 6.0 5.5 4.5 15.0 16.0 17.0 18.0 19.0 7.0 kW [HP] MAXIMUM TORQUE MAXIMUM HORSEPOWER r.p.m. REVOLUTION TORQUE OUTPUT CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE 1.5 1.6 1.7 1.8 1.9 EX27D

- 7 - 3. FEATURES 3-1 EXTREMELY SILENT - SOFT TONE QUALITY EX engines are 2dBA quieter and softer in tone than other engines in the same class. This quiet and soft tone is achieved by: - A reduction in mechanical noise realized by employing sophisticated OHC system. - Employment of an optimized capacity Rigid Muffler. 3-2 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. 3-3 EXTREMELY EASY MAINTENANCE Extreme ease of maintenance is realized by: - High Parts Commonality simplifies maintenance & lowers repair cost due to fewer parts for service. More than 90% of component parts are in common between more than two models, in such as Muffler, Intake and Exhaust Valves, Valve Springs, etc. Furthermore, more than 50% of component parts are in common among EX13, EX17 and EX21, in such as Chain Guide, Air Cleaner, Ignition Coil, etc. - Only with ordinary tools, routine maintenance, assembly and disassembly can be performed. 3-4 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 3-5 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.

Subaru Robin EX13, EX17, EX21, EX27, SP170, SP210, EX21 Engine Service Repair Workshop Manual

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