Robin America EY20 Service Manual

SERVICEMANUALEY15-3, EY20-3ENGINESModelsPUB-ES1609Rev. 12/01

- 7 -4-4 CONNECTING ROD AND PISTONThe connecting rod is forged of aluminum alloy,and its large and small ends fanction as bearings.The large end has a

- 8 -4-7 CYLINDER HEADThe cylinder head is an aluminum die-casting, andforms a Ricardo type combustion chamber withsquish area for high combustion eff

- 9 -4-11 IGNITION SYSTEMThe ignition system is a transistor controlled mag-neto system which consists of a flywheel and anignition coil with a built-

- 10 -Fig. 4-134-14 SECTIONAL VIEW OF ENGINEFuel TankCylinder HeadSpark Plug CapSpark PlugPiston PinRecoil StarterPistonCrankshaftFlywheelBlower Housi

- 11 -Fig. 4-14Stop SwitchConnecting RodCrankcaseOil ScraperAir CleanerIntake andExhaust ValveCarburetorTappetCamshaftSpeedControl LeverMuffler

- 12 -.oNtraPlooTesUelbacilppAledoMepahS70-30059-722gnirpSevlaVreniateRgnitnuomroFgnirpSevlaVdnareniateRkcoLreniateR41,31,01YE02,81,51YE72,52,32YE82YE

- 13 -5-3 DISASSEMBLY PROCEDURESpetSevomerotstraPserudecorPskrameRlooT1gulPniarD)1(.lioenigneniarDfosedishtobnosgulpniarDtloB21x41M.esacknarcehtottonl

- 14 -Fig. 5-4petSevomerotstraPserudecorPskrameRlooT3gnisuoHrewolB)1(gnisuohrewolbehtevomeRehtdnaesacknarcehtmorf.daehrednilyc.scp2:tlobegnalF21x6M.sc

- 15 -Fig. 5-6petSevomerotstraPserudecorPskrameRlooT8reveLronrevoGevitalerehtdnastrap)1()2(evomerdnatlobehtnesooLehtmorfrevelronrevogeht.tfahsronrevog

- 16 -Fig. 5-7petSevomerotstraPserudecorPskrameRlooT01lioCnoitingI)1(gulpkrapsehtevomeR,gulpkrapsehtmorfpacnoitingiehtevomerdna.esacknarcehtmorflioc.s

© Copyright 2001 Robin America, Inc.940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212e-mail: [email protected] • w

- 17 -Fig. 5-9petSevomerotstraPserudecorPskrameRlooT31gulPkrapS)1(gulpkrapsehtevomeR.daehrednilycehtmorfrennapsxoBmm1241daeHrednilyC)1()2(dnatlobmm8eh

- 18 -petSevomerotstraPserudecorPskrameRlooT71tfahsmaC)1(morftfahsmacehtevomeR.esacknarcehtsteppatehttneverpoT,gnigamadrognillafmorfehtotesacknarcehtt

- 19 -petSevomerotstraPserudecorPskrameRlooT91doRgnitcennoCnotsiPdna)1()2()3(rehtodnanobracffoeparcSreppuehtmorfstisopedngierof,notsipdnarednilycehtfo

- 20 -5-4-2 PISTON AND PISTON RINGS1) If no ring expander is available, install the ringby placing the open end over the first land ofthe piston, and

- 21 -3-51YE3-02YEgniRpoTlerraBecaFrepaTdnalevebrennlgniRdnoceStuCrednUrepaTgniRliOgniRrettuCrednapxElioChtiw2) Reassemble the piston and connecting r

- 22 -5-4-4 TAPPET AND CAMSHAFTInsert the tappets into the crankcase holes first,and then mount the camshaft.NOTE : Align the timing mark on the root

- 23 -NOTE: Fig 5-24 shows one of the methods mea-suring the crankshaft side clearance between themachined face of the crankcase and shims. As apaper

- 24 -5-4-7 TAPEET ADJUSTMENTLower the tappet all the way down, push the valve, and insert a thickness gauge between the valve andtappet stem to measu

- 25 -1520"15" mark "20" mark5-4-8 CYLINDER HEADRemove carbon from the cylinder head, particularly its combustion chamber, and cle

- 26 -5-4-10 IGNITION COIL, FLYWHEEL AND STARTER PLLEYFit the flywheel on to the crankshaft.Also, fasten the starter pulley together with the flywheel

CONTENTSSection Title Page1. SPEC

- 27 -Table. 3petSdaoLdeepSenignEemiT1petS daoLoNmpr005,2.nim012petS daoLoNmpr000,3.nim013petS daoLoNmpr006,3.nim014petS3-51YE)PH53.1(Wk0.1mpr006,3.ni

- 28 -6. GOVERNER ADJUSTMENTModels EY15-3 and EY20-3 employ a centrifugal fly-weight type governor. The governor is mounted onthe governor gear and th

- 29 -*Dimensions of the governor spring for the engine to be connected to the generator:The dimensions of the governor spring to be used are differen

- 30 -7. CARBURETOR7-1 OPERATION AND CONSTRUCTION (See Fig.7-1)7-1-1 FLOAT SYSTEMThe float chamber is located just below the carburetor body, and the

- 31 -7-1-2 SLOW SYSTEMThe pilot system feeds the fuel to the engine during idling and low-speed operation.The fuel is fed through the main jet (M.J)

- 32 -CAUTION :When cleaning the jets, use neither a drill nor a wire (because of possible damage of theorifice which will adversely affect fuel flow)

- 33 -Fig. 8-18. MAGNETO8-1 FEATURESIgnition system of the model EY15-3 and EY20-3 is a maintenance-free electronic pointless magnetosystem.The electr

- 34 -8-3 MAGNETO TROUBLESHOOTINGWhen the engine does not start or starts with difficulty, or when its operation is unstable, the followingchecks will

- 35 -9. OIL LEVEL SENSOR (OPTION)9-1 FUNCTIONWhen the oil level sensor detects the insufficient level of engine oil, it halts engine for warning andp

- 36 -Fig. 10-1Fig. 10-210. RECOIL STARTER10-1 RECOIL STARTER (STEEL)Tools to be prepared: Driver, Pinchers (Pliers) and Protective GlassesWARNINGBefo

- 1 -1. SPECIFICATIONSSpecifications are subject to change without notice.LEDOMD3-51YED3-02YEepyT,rednilyC-elgniS,elcyC-4,delooC-riAenignEenilosaG,evl

- 37 --2: Hold up the reel gradually and slowly andremove it from the case.-3: If the spring in the reel likes to jump out,redo the steps of (3)-1 and

- 38 -Fig. 10-5Fig. 10-6Fig. 10-7Fig. 10-8Set screwRatchet guideFriction SpringAbout 200mm from the reelLATCHET GUIDE SUB-ASSEMBLY-2: Holding the latc

- 39 -10-1-3 CHECK AFTER REASSEMBLY(1) Pull the starter knob a few times to check if :A. The starter knob is too heavy to pull, check that each part h

- 40 -Fig. 10-10Fig. 10-1110-2 RECOIL STARTER (SYNTHETIC RESINS)Tools to be prepared: Driver, Pinchers (Pliers) and Protective GlassesWARNINGBefore s

- 41 -Fig. 10-12Boss of realFig. 10-13Fig. 10-14Ratchet holeWithin this areaRatchetClawReceivingarea ofthe ReelInner endof springHook of Case-2: Hold

- 42 -(4) Wind the spiral spring.-1: Hold the case tightly and rotate the reelcounterclockwise until it stops. (It stopswhen it is wound approx. 6 tur

- 43 -10-2-3 CHECK AFTER REASSEMBLY(1) Pull the starter knob a few times to check if :A. The starter knob is too heavy to pull, check that each part h

- 44 -11. INSTALLATIONEngine life, ease of maintenance and inspection, frequency of checks and repairs, and operating costare all depend on the way in

- 45 -11-5 POWER TRANSMISSION TO DRIVEN MACHINES11-5-1 BELT DRIVETake the following notes into consideration.* V-belts are preferable to flat belts.*

- 46 -13.TROUBLESHOOTING13-1 STARTING DIFFICULTIESIf a sign of malfunction is found on the engine it is necessary to find out the cause immediately an

- 2 -2. PERFORMANCE2-1 MAXIMUM OUTPUTThe maximum output is the output of an engine with its throttle valve fully opened and considering that allthe mo

- 47 -13-2. INSUFFICIENT OUTPUT13-3. OVERHEATnonemonehPsesuacelbissoPydemeRgnitaehrevO)1noitropelffabrednilycrotelnitadetcurtsbowolfriagnilooCnaelClio

- 48 -13-4. ROUGH IDLING13-5. HIGH ENGINE OIL CONSUMPTIONnonemonehPsesuacelbissoPydemeR1egakaelliOgulpniardnesooL)1nethgiTdegamadteksaggulpniarD)2ecal

- 49 -13-6. HIGH FUEL CONSUMPTION13-7. DETONATIONnonemonehPsesuacelbissoPydemeR1metsysleuFdeggolcrenaclcriA)1 ecalperrpnaerC)2rebmahctaolfnilevelleufh

- 50 -METI3-02YE,3-51YEDTStimiLDAEHREDNILYCssentalF*NAHTSSEL1.0)400.0(51.0)600.0(htdiwtcatnoctaesevlaV*.XE.NI5.1-2.1)1950.0-2740.0(5.2)890.0(.aidedisn

- 51 -METI3-51YE3-02YEDTStimiLDTStimiLREDNILYC.aidedisnI*.gniroberretfassenidnuoR*.gniroberretfayticirdnilyC*DTS910.36-0.36)1184.2-3084.2(derobereboTe

- 52 -METI3-51YE3-02YEDTStimiLDTStimiLNOTSIPecnaraelcedisevoorggniR*elohnipnotsiP*.aidedistuonipnotsiP*dnanotsipneewtebecnaraelC*trikstarednilyc.aerap

- 53 -METI3-51YE3-02YEDTStimiLDTStimiLDORGNITCENNOC.aidedisnidneegraL*dneegraldorneewtebecnaraelC*nipknarcdna.aidedisni.aidedisnidnellamS*llamsneewteb

- 54 -METI3-51YE3-02YEDTStimiLDTStimiLTFAHSMAC).XEdna.NI(thgiehmaC*.aidedistuolanruoJ*epyt"D"50.52-58.42)689.0-879.0(7.42)279.0(9.82-7.82)83

- 55 -Unit : mm (in)METI3-51YE3-02YEDTStimiLDTStimiLTEPPAT.aidedistuometS*.aidedisniediuG*metsneewtebecnaraelC*ediugdna789.6-879.6)1572.0-7472.0(878.6

- 56 -14-2 TORQUE SPECIFICATIONS14-3 OIL GRADE CHARTMETIeuqroTgninethgiTm.Nmc-gkbl-tfstlobdaehrednilyC62-22062-0228.81-9.51stlobpacdorgnitcennoC3-51YE

- 3 -2-4 PERFORMANCE CURVESMAXIMUM TORQUE(kgf.m) N.mTORQUE(HP) kWMAXIMUMHORSEPOWEROUTPUTCONTINUOUSRATED HPRECOMMENDEDHORSEPOWER RANGEREVOLUTIO

- 57 -15. MAINTENANCE AND STORAGEThe following maintenance jobs apply when the engine is operated correctly under normal conditions.The indicated main

- 58 -15-4 EVERY 100-200 HRS. (MONTHLY) MAINTENANCE15-5 EVERY 500-600 HRS. MAINTENANCE15-6 EVERY 1000 HRS. (YEARLY) MAINTENANCE15-7 ENGINE STORAGE(1)

PRINTED IN THE USA

- 4 -EY20-3DTORQUE3MAXIMUMHORSEPOWERCONTINUOUSRATED HPRECOMMENDEDHORSEPOWER RANGEREVOLUTION2 0 0 03 0 0 04 0 0 000112234534OUTPUT(HP) kW(kgf.m)

- 5 -3. FEATURES (compared with former model)1. Re-designed outlookThinner recoil starter, newly designed air cleaner and muffler are adopted.Also, in

- 6 -4. GENERAL DESCRIPTION OF ENGINE COMPONENTS4-1 CYLINDER AND CRANKCASEThe cylinder and crankcase are single piece alu-minum die-casting.The cylind