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ROBIN
AMERICA, INC.
ROBIN
TO
WISCONSIN
ROBIN
ENGINE
MODEL
CROSS REFERENCE
LIST
ROBIN
EY08
EY15
EY 15V
EY20
EY2OV
EY23
EY28
EY3
5
EY40
-
EY45V
EY2
1
EY44
EY 18-3
EY25
EY27
EH11
EH12
EH15
EH17
EH21
EH25
EH30
EH30V
EH34
EH34V
EH43V
EC13V
DY23
DY27
DY30
DY3
5
DY4 1
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 1-43 OV
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
..............................................
1
2
.
PERFORMANCE
...............................................
2
2-1
Maximum Output
..........................................
2
2-2
Continuous Rated Output
....................................
2
2-3
Maximum Torque and Fuel Consumption Ratio
at
Maximum Output
........
2
3
.
FEATURES
..................................................
3
4
.
GENERAL DESCRIPTION
of
ENGINE CONSTRUCTION
...................
4
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-1 1
4-12
4-13
4-14
Cylinder. Crankcase
........................................
4
Main Bearing Cover
.........................................
4
Crankshaft
..............................................
4
Connecting Rod and Piston
...................................
5
Camshaft
...............................................
5
Valve Arrangement
.........................................
5
Cylinder Head
............................................
6
Governor
...............................................
6
Cooling
.................................................
6
Lubrication
..............................................
6
Ignition
................................................
7
Carburetor
..............................................
7
Air Cleaner
..............................................
7
Sectional View
of
Engine
.....................................
8
5
.
DISASSEMBLY
and
REASSEMBLY
..................................
10
5-
1
Preparation and Suggestion
....................................
10
5-2
Special Tools
.............................................
10
5-3
How
To
Disassemble
........................................
12
5-4
How
To
Reassemble
........................................
16
6
.
MAGNETO
...................................................
24
6-1
Magneto
................................................
24
6-2
Magneto Trouble Shooting
....................................
24
7
.
GOVERNOR ADJUSTMENT
.......................................
25
8
.
CARBURETOR
................................................
26
8-1
Operation and Construction
...................................
26
8-2 Disassembly and Reassembly
..................................
27
Section
Title
Page
9
.
BREAK-IN OPERATION
Of
REASSEMBLED ENGINE
.....................
28
10
.
ROBIN SOLID STATE IGNITION ENGINE (U.T.C.I.)
.....................
29
10-1
Features
................................................
29
10-2
Basic Principle of U.T.C.
I
.....................................
29
I1
.
ROBIN OIL SENSOR SYSTEM (FLOAT
SYSTEM)
.......................
30
11-1
Features
................................................
30
11
-2
Basic Principle
............................................
30
11
-3
Checking Procedures
........................................
32
11
-4
Precautions
..............................................
33
11-5
Wiring
.................................................
33
12
.
TROUBLE SHOOTING
...........................................
34
12-
1
Starting Difficulties
.........................................
34
12-2
Engine Misfires
............................................
35
12-4
Engine Overheat
...........................................
35
12-3
Enginestops
.............................................
35
12-5 Engine Knocks
............................................
36
12-6
Engine Backfires through Carburetor
.............................
36
13
.
INSTALLATION
...............................................
37
13-1
Installing
................................................
37
13-2
Ventilation
..............................................
37
13-3
Exhaust Gas Discharge
.......................................
37
13-4
Power Transmission to Driven Machines
...........................
37
13-5
Wiring
.................................................
38
14
.
CHECKS
and
CORRECTIONS
......................................
39
15
.
TABLE
of
CORRECTION STANDARDS
...............................
40
16
.
MAINTENANCE
and
STORING
.....................................
45
16-1
Daily Checks and Maintenance
.................................
45
16-2
Every
20
Hours Checks and Maintenance
..........................
45
16-3
Every
50
Hours
(IO
days)
Checks and Maintenance
....................
45
16-4
Every
100
.
200
Hours (Monthly) Checks and Maintenance
..............
45
16-5
Every
500
.
600
Hours (Semiannual) Checks and Maintenance
............
46
16-6
Every
1000
Hours (Yearly) Checks and Maintenance
...................
46
16-7
Preparation for Long Abeyance
.................................
46
1.
SPEC1
FICATIOMS
Model
EY08BN EY08D
Air-Cooled, 4-Cycle, Vertical, Single Cylinder Gasoline Engine
Bore
x
Stroke (in)
77.6 cc (4.74 cu. in) Piston Displacement (cu. in)
51
mm
'x
38
mm
(2.01"
x
1.50")
Compression Ratio
6.5
Continuous Rated Output (HP/rpm)
1.0/3000
1.4/3600
1
.O?
1 500
1.4/1800
Max. Output (HP/rpm)
0.72/1600 0.36/3200
Max. Torque (kg-m/rpm)
2.0/2
1
00
2.0/4200
Direction of Rotation
1
Counterclockwise Facing to P.T.O. Shaft
Clockwise Facing to P.T.O. Shaft
Cooling System
I
Forced Air Cooling
~
Lubrication
Splashing Type
Lubricant
Automobile Oil Class
SC
~~
Carburetor
Horizontal Draft, Float Type
~~
Fuel
320
at
continuous rated output operation Fuel Consumption Ratio (gr/Hp-h)
Non-leaded Automobile Gasoline
Fuel Feed
I
Gravity Type
Fuel
Tank
Capacity
I
Approx.
1.5
liter (0.40
U.S.
gal.)
Reduction Ratio
I
-
1
/2
Speed Governor
8.5 kg (18.7 Ibs.)
8 kg (17.6 Ibs.)
Dry Weight (Ibs.)
Recoil Starter
Starting System
-
Lighting Capacity (V-W)
NGK-BM4A (S.T.D.)
Spark Plug
Flywheel Magneto Type (Solid
State
Ignition) Ignition System
Centrifugal Flyweight Type
Length (in)
326
mm
(12.83")
Height
(in)
264
mm
(10.39")
Width (in)
Dimensions
252 mrn (9.92")
-1
-
2.
PERFORMANCE
2-1
MAXIMUM OUTPUT
The maximum output of an engine
is
such standard power as developed by the engine, after its initial break-in
period with all the moving parts properly worn in, when operating with a fully open throttle valve, Therefore,
a new engine may not develop the maximum output in the beginning because the moving parts are not in a
properly worn-in condition.
2-2
CONTINUOUS RATED OUTPUT
The continuous rated output of an engine
is
such power as developed
by
that engine when running continu-
ously at an optimum speed, and most favorable from the viewpoint of engine life and fuel consumption ratio,
with the governor in operation. It is suggested, therefore, that when designing a driving system
for
any mech-
anism, with this engine
as
prime mover, the continuous power requirement
of
that mechanism be kept below
the continuous rated output specified.
2-3
MAXIMUM TORQUE
and
FUEL CONSUMPTION
RATIO
at
MAXIMUM OUTPUT
These mean the maximum torque of the output shaft and fuel consumption ratio at the maxiumum output
of
an
engine.
HP
L
W
0
a
3’
L
0
I
PERFORMANCE
CURVE
MODEL
EY08D
( )
for
BN
type
0.45
0.40
0.35
0.30
2.5
2.0
1.5
1
.o
0.5
2000
3000
4000
(1
000)
(1
500)
(2000)
Revolution
-
r.p.m.
(0.9)
kg-rn
-2-
3.
FEATURES
1.
Compact, lightweight, durable, powerful 4cycle air cooled engine embodying ingenious design techniques
and skilful workmanship.
2.
Simple construction, smart appearance, maximum easiness
of
start owing to automatic decompression
device
3.
Pointless Solid State ignition system is newldy adopted for preventing poor igniting.
4.
Reliable prime mover for varietyof purposes with smooth speed controlrby a governor under varying load
conditions.
5.
Economical because fuel consumption is very low
-3-
4.
GENERAL DESCRIPTION
of
ENGINE CONSTRUCTION
4-1
CYLINDER, CRANKCASE
The cylinder and crankcase are single piece alumi-
num die casting. The cylinder liner, made of special
cast iron, is built into the alminum casting. The
in-
take and exhaust ports are located on one side
of
the cylinder, and are also inserted into the casting.
The crankcase is separable on the output shaft side,
where the main bearing cover
is
attached to it.
(See Fig.
1
.)
Fig.
1
4-2
MAIN
BEARING
COVER
The main bearing cover made
of
aluminum die casting is built onto the output shaft side
of
the crankcase
so
that the inside of the engine can readily be checked by simply removing the cover. It is provided with a flange
and boss for directly mounting machines,
such
as
generators and pumps.
Two oil gauges also serving
as
oil filler caps can be mounted. (See
Fig.
2
and
Fig.
3.)
Oi
I
Ring
for Centering
!ID
Oil
Gauge
Fig.
2
4-3
CRANKSHAFT
The crankshaft is forged of carbon steel, and the
crankpin
is
induction-hardened. It has a crank gear
pressure-fitted on the output end. (See
Fig.
4.)
Fig.
3
~~
Induction Hardening
(Portion of Crankpin)
\
Crank Gear (Pressure-fit)
Fig.
4
-4-
The connecting rod is made of aluminum die casting,
which itself serves as bearings at both the large and
small ends. The large end cap and the oil scraper are
moulded in a unit for splashing the lubricating oil.
The piston is cast
of
aluminum alloy, and has grooves
for receiving two compression rings and one
oil
ring.
(See Fig.
5.)
4-4
CONNECTING ROD
and
PISTON
4-5 CAMSHAFT
In the EY08D engine, the camshaft is integrally built
with a cam gear of special cast iron, and has intake
and exhaust cams. Also the camshaft has aluminum
plain bearings attached to both ends.
(No
ball bear-
ing is used.) (See Fig.
6.)
In the EY08BN engine, the camshaft is forged of car-
bon steel and is provided with a force-fit cam gear.
@
It serves also
as
the driving shaft, being driven at half
the crankshaft speed, and a ball bearing is used at
the P.T.O. shaft side.
4-6
VALVE ARRANGEMENT
The intake valve is located upstream
of
the cooling
air with the result that the carburetor is intensively
cooled. (See Fig.
7.)
Top
Ring
Second Ring
Oil
Ring
Connecting
Rod
Oil
Scraper
\I
L
Fig.
5
:
Fig.
6
Direction
of
Cooling
Wind
Fig.
7
-5-
4-7
CYLINDER HEAD
The cylinder head
is
an aluminum die casting, and
forms a Ricardo type combustion chamber with
ample area for high combustion efficiency.
(See
Fig.
8.)
4-8
GOVERNOR
The governor is a centrifugal flyweight type which
permits constant operation- at the selected speed
against load variations. Govrnor gear is installed on
the bearing cover without fail, and
it
engages with
the cam gear after reassembling. (See Fig.
9.)
I
Fig.
8
Main
Be
!mor
Sleeve
Spacer
Q
-
Governor Gear Complete
Fig.
9
4-9
COOLING
The cooling fan serving also as a flywheel cools the cylinder and the cylinder head by forced air cooling. Cyl-
inder baffles
and
head cover are provided for guiding the cooling air.
4-10
LUBRICATION
The rotating and
sliding
parts are being lubricated
by scooping
and
splashing the
oil
in the crankcase
with the
oil
scraper. (See Fig.
10.)
Fig.
10
-6-
4-11
IGNITION
The ignition system
is
a flywheel magneto type with
ignition timing set at
25"
before TDC. The magneto
is composed
of
a
flywheel and ignition coil. The fly-
wheel serving also as a fan is mounted directly on the
crankshaft, and the ignition coil in the crankcase.
(For further details, refer to Section
on
the Mag-
neto.) (See
Fig.
1 1
.)
4-12 CARBURETOR
A
horizontal draft carburetor is employed. It has
been carefully set after thorough tests to assure satis-
factory start up, acceleration, fuel consumption, out-
put performance, etc.
For construction and order details, refer to the Sec-
tion on Carburetor Construction, Disassembly and
@
Reassembly. (See Fig. 12.)
4-13 AIR CLEANER
The air cleaner
of
the standard
ty
:ngine
is
an
0
b-
long type using
a
sponge element.
(A
cyclone type
semi-wet double element air cleaner is optionally
available.) (See
Fig.
13.)
I
Ignition Coil
Fig.
1
1
Fig.
12
Air Cieaner for
Standard Type
Cyclone Type
(Option)
Fig.
13
-7-
4-14
SECTIONAL
VIEW
of
ENGINE
MODEL
EY08D
-8-
Stop Button
Connecting
Rod
Crankcase
MODEL
EY08D
Air
Cleaner
Carburetor
Intake and
Exhaust Valve
Tappet
Camshaft
Governor
Shaft
-9-
5.
DISASSEMBLY
and
REASSEMBLY
5-1
PREPARATIONS
and
SUGGESTIONS
1)
When disassembling the engine, remember well the locations of individual parts
so
that they can be reas-
sembed correctly.
If
you are uncertain
of
identifying some parts, it
is
suggested that tags be attached
to
them.
2)
Have boxes ready
to
keep disassembed parts by group.
3)
To
prevent missing and misplacing, temporarily assemble each group of disassembed parts.
4)
Carefully handle disassembed parts, and clean them with washing oil.
5)
Use the correct tools
in
the correct way.
5-2
SPECIAL
TOOLS
For
your reference, the following shows special tools of Robin Engine for Disassembly, Measuring and Inspec-
tion Instruments.
Part
No.
2099500407
2309500107
2079500307
2309500207
2059500107
Tool
Flywheel Puller
(with
bolt)
Valve Spring
Retainer
Valve Guide
Puller
Use
For pulling
off
Flywheel
For mounting and
dismounting Valve
Spring Retainer
and Retainer
Lock
For pulling off
Valve guide
Applicalbe
Model
EY08
EY10, 13, 14
EY
15,18,
20
EY23, 25, 27,
EY33
EY35,40,44
EC05.07, 10
EC17,25.37
EY08
EY10,13, 14
EY 15, 18,20
EY23
EY25.27, 33
EY35,40,44
EY08
EY10
EY13,
14
Shape
-10-
Part
No.
2069500107
2279500107
207 95001 07
“20248
Tool
Valve Guide
Puller
Timing Tester
Use
For pulling
off
Valve guide
For
adjusting
timing
Applicalbe
Model
EY18.23
EY 15,ZO
EY25, 27
EY10,
13,
14
EY 15, 18,20
EY25,27,33
EY35,40,44
EC03,04,05
EC07,10,
17
EC25,37
Shape
-
11
-
5-3
HOW
TO
DISASSEMBLE
*Length of the bolt indicates the length from the bolt head bottom surface to the threaded end.
Order
5
I
tern
Fuel tank
Recoil starter
Tank bracket
Head cover
Fan cover
Muffler cover
Muffler
Air cleaner
Procedures
(1)
Close the fuel cock.
(2)
Disconnect the fuel pipe between the fuel
strainer and carburetor at the carburetor
side.
(3) Remove the fuel tank from the tank bracket.
M6
x
14
mm bolt
:
3
pcs.
(1)
Remove the recoil starter.
M6
x
8
mm bolt
:
3
pcs.
(1)
Remove the
tank
bracket, the head cover,
and the fan cover from the crankcase and
the cylinder head.
M6
x
10
rnm
bolt
:
2
pcs.
M6
x
12
bolt
:
1
pce.
M6 nut
:
2
pcs.
(1)
Remove the muffler cover
1
from the
muffler.
M6
x
8
mm bolt
:
2
pcs.
(2)
Remove the muffler from the cylinder
portion
of
the crankcase.
M6
x
28
mrn bolt
:
1
pce.
M6
x
50 mm bolt
:
1
pce.
(1)
Remove the air cleaner cover and the
(2)
Remove the
air
cleaner case from the
element.
carburetor.
M6 nut
:
2
pcs.
(3) Disconnect the breather pipe.
Remarks
Sems bolt
Fastened together
Remove the primary
wire of the stop but-
ton.
Air cleaner is fasten-
ed together with the
carburetor.
Governor Lever
Governor Spring
Lock
Bolt
{--)
,Governor Rod Spring
Governor
Rod
Lever
L
'
High
Speed Set
Screw
Governor
Shaft
Fig.
14
Tool
10
mm box spanner
IO
mm box spanner
10
m
box spanner
Ir
10
mm spanner
10
mm box spanner
x
10
mm
spanner
10
mm box spanner
-
12
-
Order
Itern Procedures
I
Remarks
I
Too
I
6
Governor lever
and the relative
parts
Carburetor
Starting pulley
Flywheel
(1)
Remove the governor Iever from the gover-
M6
x
25 mm bolt
:
1
pce.
nor shaft.
(2) Remove the governor rod and rod spring
(3) Remove the carburetor from the
from the carburetor.
cylinder portion
of
the crankcase.
Just loosen the bolt,
unnecessary to take
out the bolt.
10
mm box spanner
or
10
mm spanner
(1) Remove the starting pulley from the
fly-
Be
careful not to
wheel.
damage the blades
of
M12 nut
:
1
pce.
the flywheel with
a
Fit a box
or
socket wrench over the fly-
wheel nut, and strike it hard with a ham-
driver and a like.
wise with a hammer.
mer to remove the nut and spring washer.
Strlke counterclock-
(See Fig.
15)
17
mm box spanner
or
socket wrench
(1)
Remove the flywheel from the crankshaft.
Fit the flywheel
puller as shown
in
Fig.
16,
turn the
center bolt clock-
wise and pull out
the flywheel.
Fig.
15
Fig.
16
Order
I
tern
Procedures
~ ~~~~~~~~~~~ ~ ~~
9
(1)
Remove the plug terminal from the spark
Ignition coil
plug and remove the ignition coil from the
crankcase.
M6
x
25
mm
bolt
:
2
pcs.
10
(1)
Remove the spark plug from the cylinder
Spark plug
he ad
Remarks
Sems bolt
7
10
mm
box
spanner
I
19 mm box spanner
-
13
-
Order
I
Item
11 Cylinder head
I
l2
I
Intake and
exhaust valve
13
I
Main bearing
cover
Procedures
(1)
Remove the
M6
bolts and remove the cylin-
M6
x
32
mm bolt
:
5
pcs.
M6
x
40
mm bolt
:
2
pcs.
(2)
Remove the cylinder head gasket from the
der head from the crankcase
crankcase.
(1)
Remove the inner and outer tappet covers
M6
x
12
mm bolt
:
2
pcs.
from the crankcase.
(2)
Pull out the intake and exhaust valve.
(3)
Remove the valve spring and the valve
spring retainer.
(1) From the crankcase remove the bolt fasten-
M6
x
25
mm bolt
:
6 pcs.
(2)
Remove the cover, lightly tapping the cover
ing the main bearing cover.
evenly with a plastic hammer.
\
(-)
Driver
\
Fig.
17
Remarks
M6
x
40
mm bolt
is
special bolt.
Put the notch on the
outer circumference
of the spring retainer
on this side.
Hook the medium
size
(-)
driver at the
dent (lower side)
of
the spring retainer
and pull out the
valves, while pulling
the spring retainer
toward you.
(See Fig.
17.)
Sems bolt
Be careful not to
damage the oil seal.
(See Fig.
18.)
Tool
10
mm
box
spanner
The front is this
sidf
(-)
driver
10 mm
box
spanner
Main/Bearing Cover
I
Plastic Hammer
Fig.
18
-
14
-
Procedures
I
Remarks
I
Too
I
(1)
Remove the camshaft from the crankcase. To prevent the tap-
pets from falling or
damaging, place the
crankcase
on
the
side. (See Fig.
19
.)
15
Tappet
~~~ ~~~~ ~~~ ~~
I
(1) Remove the tappets from the crankcase.
Before removing put
a mark of intake or
exhaust
on
each
tappet.
Order
16
17
18
I
tern
Connecting rod
and piston
Piston and
piston pin
Crankshaft
Camshaft
Procedures
(1)
Scrape off carbon and other foreign deposits
from the upper parts of the cylinder and
piston, and then straighten out the bent
tabs of the lock washers
on
the connect-
ing rod, and remove two pieces of the bolt.
(2)
Remove the lock washer and the connecting
rod cap from the crankshaft.
(3)
Turn the crankshaft until the piston is raised
up to the hghest position, push the connect-
ing rod
up,
and
remove the piston out of the
top
of
the cylinder.
(1) Remove the two clips, pull out the piston
pin, and take the piston off from the small
end of the connecting rod.
(2)
Spread the open ends of the piston rings
and remove them from the piston.
(1)
Remove the woodruff key (for the mag-
neto).
(2)
Lightly hammer the magneto end of the
crankshaft, and pull it out of the crank-
case.
-
15
-
Remarks
I
Tool
8
mm
box
spanner
or
8
mm spanner
Pay attention to the
direction
of
the con-
necting rod cap.
Be careful
not
to
damage the inside of
the small end of the
connecting rod.
Be careful not to
break the rings by
spreading too much.
Be careful not to
damage the oil seal.
5-4
HOW
TO
REASSEMBLE
.Precaution in reassembling
Every and each part should be cleaned thoroughly. Especially, pay utmost care and attention to the clean-
liness of the piston, cylinder, crankshaft, connecting rod and bearings.
Scrape completely off carbons from the cylinder head and the upper part of the piston; especially the
carbon adhered in the groove of the piston ring should be carefully and completely taken out.
Carefully check the lip portion of every
oil
seal. If faulty one is found, replace it without any hesitation.
Apply enough oil
to
the lip portion of the oil seal when reassembling.
Replace all the gaskets with new ones.
Replace the key, pin, bolt, nuts, etc. with new one, if necessary.
Whenever tightening torque
is
specified, conform to the specified figures.
Apply oil to the revolutionary parts and friction surfaces, when reassembling.
Check and adjust the clearances of various portions and then reassemble.
When some main portions are assembled in the course of reassembling, turn
or
move the gadgets by hand
and pay attention to the frictional noise and resistance.
*Sequence and precautions in reassembling
5-4-1 GOVERNOR
SHAFT
1)
Insert the governor shaft into the crankcase.
2)
Place the clips
on
the governor shaft.
5-4-2 CRANKSHAFT
1) Inser the crankshaft into the crankcase as shown
.
Note: Be careful not to damage
the
oil
seal
lip.
in Fig.
20.
2)
Put woodruff key (for magneto) in place.
Shaft
Fig.
20
-16-
/
