Subaru Automobile Parts EX40 User Manual

PARTS  
MANUAL  
Models  
EX40  
ENGINES  
PUB-EP6516  
Rev. 04/14  
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HOW TO USE THIS MANUAL  
Robin engines are identied by MODEL, SPECIFICATION, and CODE NUMBER. For each  
model there may be many different versions called specications. Each specication will be  
unique in some way. The difference may only be the paint color or it may have a different type  
of PTO or some other signicant difference.  
In order the identify the correct service part number, it is important to conrm the specica-  
tion and code numbers for your engine. The specication and code number together are  
know as the PRODUCT NUMBER.  
All Robin 4 cycle engines have a Product Number label similar to the label illustrated below.  
The Product Number Label has a 15 digit alphanumeric string that consists of the  
SPECIFICATION (SPEC) number (11 digits) and the CODE number (4 digits). Please  
note the illustration below:  
E X 4 0 0  
X X X X  
SPEC NO. (11 digits)  
CODE NO. (4 digits)  
PRODUCT NO. (15 digits)  
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MANUAL LAYOUT  
1
4
3
2
1
3
9
6
7
2
5
4
8
1. SECTION NAME  
Parts are broadly classied according to their functions.  
Refer to the Group Index (table of contents) for respective section name.  
2. FIG. No.  
The FIG. number indexes the reference and part numbers to the illustration. Figure numbers  
that vary only in the tens place (i.e..: 700 and 710) are in a group of the same section  
(i.e..:Electrical Device Group).  
3. REF. No .  
The Reference number identies the part illustration with the corresponding part number in the  
part list.  
4. SUBASSEMBLY  
SUBASSEMBLY parts of part assembly are listed below the assembly part. The subassembly  
part reference number is indicated by the number led by "-" such as "-1", "-2".  
5. PART NUMBER  
6. DESCRIPTION  
7. QTY.  
It is the number assigned for sales unit. Use the PART No. when making an order.  
It is designation of the part.  
Quantity of each part used for each product.  
8. REMARKS  
This gives a distinctive feature and/or a supplementary comment for the type, the specication,  
and the part concerned. It also shows part number(s) interchangeable for the part.  
9. FROM-TO  
This section shows the CODE No. to indicate the history of progress in which improved parts  
have been introduced in the product. The FROM-TO CODE No. helps to identify PART No.  
being employed in the product concerned. See the examples below:  
-
2101-  
- 2100  
The part is used in the product irrespective of CODE No.  
The part is used in the products with CODE No. of 2101 and after this number.  
The part is used in the products with CODE No. of 2100 and before this number.  
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GROUP INDEX  
Group Name  
Page  
CRANKCASE GROUP............................................................................... 6  
CRANKSHAFT GROUP............................................................................. 8  
INTAKE and EXHAUST GROUP.............................................................. 10  
GOVERNOR GROUP .............................................................................. 14  
COOLING and STARTING GROUP......................................................... 16  
FUEL, LUBRICANT GROUP.................................................................... 18  
CARBURETOR GROUP .......................................................................... 20  
ELECTRIC DEVICE GROUP .................................................................. 22  
ACCESSORY GROUP............................................................................. 24  
INDEX OF DESCRIPTION SYMBOLS  
SYMBOL  
DESCRIPTION  
SYMBOL  
DESCRIPTION  
AY...........................ASSEMBLY  
CP...........................COMPLETE  
EX...........................EXPORT (from Japan)  
FIG..........................FIGURE  
P=...........................PITCH (in mm)  
P.T.O. (PTO) ...........POWER TAKE OFF  
REF.........................REFERENCE  
R.H. (RH)................RIGHT HAND SIDE  
RR. .........................REAR  
FR...........................FRONT  
" ..............................INCH  
INCL. ......................INCLUDE  
~L............................LITER  
L= ...........................LENGTH (in. mm)  
L.H. (LH).................LEFT-HAND SIDE  
MECH.....................MECHANICAL  
NO (NON)...............NONE  
STD. .......................STANDARD  
SW..........................SWITCH  
T= ...........................THICKNESS (in mm)  
UN ..........................UNIT  
U.S..........................UNDER SIZE  
~V...........................VOLTAGE  
~W..........................WATT  
OPT.........................OPTIONAL  
O.S. ........................OVER SIZE  
W/ ...........................WITH  
W/O ........................WITHOUT  
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SECTION 1  
CRANKCASE GROUP  
FIG. 100  
610  
70  
20  
28  
27  
26  
60  
620  
690  
680  
710  
631  
630  
250  
10  
260  
280  
75  
30  
210  
270  
50  
230  
40  
240  
220  
45  
700  
90  
300  
80  
EX40  
- 6 -  
08-09  
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SECTION 1  
CRANKCASE GROUP  
Ref. Part Number Description  
Qty Remarks  
To-From  
Fig.  
10  
20  
26  
27  
28  
30  
40  
45  
50  
60  
70  
75  
80  
90  
20B-10102-11 Crankcase Cp  
20B-14202-03 Valve Guide  
132-07AA0-50 Seal, intake valve  
056-51000-50 Clip  
263-35341-03 Retainer Plate  
044-03500-90 Oil Seal  
060-03502-40 Ball Bearing  
X60-01500-11 Ball Bearing  
277-15011-03 Pipe Knock  
010-50603-51 Stud, intake  
010-50802-90 Stud, exhaust  
044-00800-10 Oil Seal  
1
2
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
4
2
1
1
2
4
1
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
100  
040-11400-30 Plug  
021-11400-20 Gasket  
210 20B-11002-11 Main Bearing Cover Cp  
220 044-03500-90 Oil Seal  
230 060-03502-40 Ball Bearing  
240 X60-01500-11 Ball Bearing  
250 20B-45003-01 Governor Gear Cp  
260 277-41901-03 Governor Sleeve  
270 279-63601-30 Oil Gauge Ay  
224-63601-03 Oil Gauge  
8157-  
-8156  
280 021-32000-50 Gasket  
300 011-00803-40 Flange Bolt  
610 20B-13001-01 Cylinder Head Cp  
620 20B-15001-03 Gasket, cylinder head  
630 011-01000-40 Flange Bolt  
631 001-04083-50 Flange Bolt  
680 20B-15501-01 Rocker Cover Cp  
690 20B-16001-03 Gasket, rocker cover  
700 031-00600-20 Dowel Pin  
710 011-00600-20 Flange Bolt  
960 20B-99001-07 Gasket Set  
EX40  
- 7 -  
08-09  
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SECTION 2  
CRANKSHAFT GROUP  
FIG. 200  
310  
320  
360  
370  
350  
380  
70  
10  
390  
EX40  
- 8 -  
08-09  
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SECTION 2  
CRANKSHAFT GROUP  
Ref. Part Number Description  
Qty Remarks  
To-From  
Fig.  
10  
20B-20901-01 Crankshaft Cp  
20B-21201-01 Crankshaft Cp  
20B-21001-01 Crankshaft Cp  
005-32054-01 Woodruff Key  
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1" Key  
7/8" Taper  
1" Pump  
200  
200  
200  
200  
200  
200  
200  
200  
200  
200  
200  
200  
200  
200  
200  
70  
310 20B-22501-00 Connecting Rod Ay  
320 001-05084-00 Connecting Rod Bolt  
350 263-23301-33 Piston Pin  
360 20B-23401-H3 Piston  
360 20B-23403-H3 Piston  
360 20B-23404-H3 Piston  
370 20B-23501-07 Piston Ring Set  
370 20B-23502-07 Piston Ring Set  
370 20B-23503-07 Piston Ring Set  
380 056-52100-20 Clip  
Std  
Oversize 0.25mm  
Oversize 0.50mm  
Std  
Oversize 0.25mm  
Oversize 0.50mm  
390 20B-24101-03 Balancer Shaft  
EX40  
- 9 -  
08-09  
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SECTION 3  
INTAKE and EXHAUST GROUP  
FIG. 300  
310  
320  
350  
365  
361  
315  
225  
340  
241  
231  
317  
80  
370  
210  
240  
90  
230  
290  
60  
220  
70  
95  
170  
25  
150  
27  
160  
34  
37 35  
38  
163  
166  
10  
EX4
08-09  
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SECTION 3  
INTAKE and EXHAUST GROUP  
Ref. Part Number  
Description  
Qty Remarks  
To-From  
Fig.  
10 20B-31601-01  
25 20B-35101-03  
27 024-00700-20  
34 005-19041-00  
35 277-36401-03  
37 20B-36501-03  
38 277-38702-03  
60 246-33611-03  
70 246-33711-13  
80 20B-33401-H3  
90 20B-33501-H3  
95 246-35501-03  
150 20B-35601-H1  
160 277-36911-03  
163 277-37101-03  
166 277-36902-03  
170 277-36913-13  
200 20B-35001-01  
210 003-13060-00  
220 20B-36101-00  
225 20B-36102-10  
230 014-90500-20  
231 014-90500-20  
240 017-00500-30  
241 017-00500-30  
290 011-00600-20  
310 20B-30101-J2  
315 20B-37001-01  
317 015-00400-60  
320 20B-34201-11  
340 20B-35201-03  
350 980-20082-80  
361 011-00600-10  
365 011-00803-20  
370 267-37601-01  
Camshaft Cp  
Pin, camshaft  
O ring  
Pin, spring  
Release lever  
Clip  
Return Spring  
Valve Spring  
Spring Retainer  
Intake Valve  
Exhaust Valve  
Collet Valve  
Timing Chain  
Tentioner  
Spring, tentioner  
Pin, tentioner  
Chain Guide  
Pin, rocker  
1
1
1
2
1
1
1
2
2
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
2
5
1
1
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
Clip  
Rocker Arm Ay, intake  
Rocker Arm Ay, exhaust  
Adjust Screw  
Adjust Screw  
Nut  
Nut  
Flange Bolt  
Muffler  
Deflector Cp  
Tapping Screw  
Muffler Cover Cp  
Gasket, muffler  
Flange Nut  
Flange Bolt  
Flange Bolt  
Spark Arrestor  
EX40  
- 11 -  
04-14  
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SECTION 3  
INTAKE and EXHAUST GROUP  
FIG. 310A  
250  
520  
270  
220  
260  
EX40  
- 12 -  
08-09  
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SECTION 3  
INTAKE and EXHAUST GROUP  
Ref. Part Number  
Description  
Q1ty Remarks  
To-From Fig.  
510 20B-32611-H0  
510 20B-32651-H0  
200 20B-32630-H8  
220 20B-32720-H8  
250 20B-32640-H8  
250 20B-32641-H8  
254 20B-32680-H8  
260 20B-32850-H8  
270 20B-32650-H8  
280 X85-11001-80  
290 002-38060-00  
295 001-04061-60  
520 20B-32610-H7  
Air Cleaner Ay  
Air Cleaner Ay  
Cleaner Body  
Gasket, packing  
Cover  
Cover  
Clip1  
Cap  
Bolt  
Rubber Pipe, breather  
Flange Nut  
Flange Bolt  
Element  
1
1
1
1
1
1
2
1
1
1
2
1
1
Dual  
310A  
310B  
310A  
310A&B  
310A  
310B  
310B  
310A  
310A  
310A  
310A  
310A  
310A&B  
EX40  
- 13 -  
04-14  
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SECTION 4  
GOVERNOR GROUP  
FIG. 400  
450  
340  
345  
80  
40  
310  
311  
30  
10  
355  
480  
70  
60  
360  
485  
50  
370  
90  
435  
396  
490  
395  
436  
20  
50  
EX40  
- 14 -  
08-09  
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SECTION 4  
GOVERNOR GROUP  
Ref. Part Number Description  
Qty Remarks  
To-From  
Fig.  
10  
20  
30  
40  
50  
60  
70  
80  
90  
20B-42301-03 Governor Lever  
20B-42201-13 Governor Shaft  
20B-42701-01 Governor Rod  
20B-42801-13 Rod Spring  
003-13060-00 Clip  
001-14062-50 Bolt and Washer  
018-60600-20 Nut  
20B-42503-13 Governor Spring  
003-11080-00 Washer  
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
400  
310 20B-43301-01 Speed Control Lever Cp  
20B-43351-03 Speed Control Lever  
311  
340 227-43501-13 Stop Plate  
345 227-45002-03 Spring Washer  
355 021-70600-30 Friction Washer  
360 004-31061-80 Screw, panhead  
370 002-27060-00 Nut  
Std  
Generator  
011-60400-30 Bolt, swivel  
395 277-43902-03 Clamp  
396 013-10500-30 Screw and Washer  
435 20B-46001-11 Speed Control Bracket Cp  
436 20B-35903-03 Gasket 3  
450 002-35060-00 Self Lock Nut  
480 267-45101-03 Return Spring  
485 011-00600-20 Flange Bolt  
EX40  
- 15 -  
08-09  
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SECTION 5  
COOLING and STARTING GROUP  
220  
FIG. 500  
707  
705  
20  
706  
210  
80  
40  
18  
60  
16  
10  
15  
17  
61  
81  
EX40  
- 16 -  
08-09  
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SECTION 5  
COOLING and STARTING GROUP  
Ref. Part Number Description  
490 277-96107-03 Label, hi-low  
Qty Remarks  
1
To-From  
Fig.  
400  
10  
15  
16  
17  
18  
20  
40  
60  
61  
80  
81  
20B-51201-H1 Blower Housing  
20B-55101-02 Recoil Bracket Un  
010-00804-40 Bolt  
1
1
2
2
4
1
5
1
1
1
3
4
1
1
500  
500  
500  
500  
500  
500  
500  
500  
500  
500  
500  
500  
500  
500  
010-00804-50 Bolt  
002-38060-00 Flange Nut  
073-20054-70 Label, trademark  
001-04061-60 Flange Bolt  
001-65081-20 Bolt  
20B-52702-H1 Bafe 2, head  
279-52711-11  
Bafe 1, case  
011-00600-20 Flange Bolt  
220 013-00602-81 Bolt and Washer Ay  
705 KU3-11077-01 Float C/U Cp11  
706 20B-73102-01 Wire 2 Cp  
EX40  
- 17 -  
08-09  
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SECTION 5  
COOLING and STARTING GROUP  
FIG. 520  
-11  
-8  
-2  
-10  
-9  
-3  
-7  
-6  
-5  
-1  
-4  
210  
EX40  
- 18 -  
08-09  
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SECTION 5  
COOLING and STARTING GROUP  
Ref. Part Number Description  
Qty Remarks  
To-From  
Fig.  
210 20B-50301-00 Recoil Starter Ay  
1
1
1
1
1
1
2
1
1
2
1
1
520  
520  
520  
520  
520  
520  
520  
520  
520  
520  
520  
520  
-1  
-2  
-3  
-4  
-5  
-6  
-7  
-8  
20B-50145-08 Starter Pulley  
261-50100-08 Starter Knob  
20B-50110-08 Starter Rope  
20B-50101-08 Set Screw  
161-50150-08 Ratchet Guide  
227-50135-08 Return Spring  
227-50131-08 Friction Spring  
277-50155-08 Spiral Spring  
161-50125-08 Ratchet  
-9  
-10  
-11  
20B-50120-08 Reel  
20B-50150-08 Starter Case  
EX40  
- 19 -  
08-09  
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SECTION 6  
FUEL, LUBRICATION GROUP  
EX40  
- 20 -  
08-09  
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SECTION 6  
FUEL, LUBRICATION GROUP  
Ref. Part Number Description  
707 004-36041-20 Screw and Washer Ay  
Qty Remarks  
2
To-From  
Fig.  
500  
10  
20  
23  
30  
40  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
63  
20B-60102-01 Fuel Tank Cp  
073-20051-81 Label, warning  
20B-95101-03 Label, model  
X43-04401-61 Fuel Tank Cap Cp  
X64-13600-10 Fuel Filter  
X64-20122-00 Fuel Strainer Ay  
267-62604-11 Fuel Pipe Cp  
X85-10614-91 Rubber Pipe  
X56-11100-60 Hose Clamp  
056-11200-40 Hose Clamp  
20B-62601-01 Fuel Pipe Cp  
085-10620-90 Rubber Pipe  
056-11000-30 Hose Clamp  
011-00600-20 Flange Bolt  
056-81200-10 Clamp  
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
1
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
600  
fuel tank strainer  
fuel pipe, strainer  
fuel pipe, tank  
strainer, carb  
fuel pipe  
002-38080-00 Flange Nut  
011-00802-50 Flange Bolt  
540 20B-32901-J1 Insulator Cp  
550 20B-35901-H3 Gasket 1, insulator  
EX40  
- 21 -  
08-09  
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SECTION 6  
FUEL, LUBRICATION GROUP  
FIG. 610  
EX40  
- 22 -  
08-09  
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SECTION 6  
FUEL, LUBRICATION GROUP  
Ref. Part Number Description  
560 20B-35902-H3 Gasket 2, insulator  
Qty Remarks  
1
To-From  
Fig.  
600  
210 20B-62301-00 Carburetor Ay  
1
Std  
640  
EX40  
- 23 -  
08-09  
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SECTION 7  
ELECT
FIG. 700  
785  
780  
16  
15  
10  
12  
20  
35  
30  
100  
11  
50  
385  
110  
384  
740  
700  
EX40  
- 24 -  
08-09  
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SECTION 7  
ELECTRIC DEVICE GROUP  
Ref. Part Number Description  
20B-62302-00 Carburetor Ay  
Qty Remarks  
To-From  
Fig.  
640  
1
Generator  
10  
20B-79230-H1 Flywheel Cp  
20B-79241-H1 Flywheel Cp  
20B-79430-H1 Ignition Coil  
20B-79301-H1 Charge Coil  
20B-54101-H3 Cooling Blower  
018-01800-10 Flange Nut  
20B-71002-03 Ring Gear  
001-14062-50 Bolt and Washer Ay  
004-35062-00 Screw and Washer Ay  
20B-73101-01 Wire 1  
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
1
1
1
Std  
15 Watt  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
700  
11  
12  
15  
16  
20  
30  
35  
50  
15 Watt  
100 065-01401-50 Spark Plug  
110 065-50003-11 Spark Plug Cap  
384 056-60002-50 Clamp  
385 011-00600-10 Flange Bolt  
700 279-76301-51 Oil Sensor  
733 277-75801-03 Shield Plate  
740 013-00602-60 Bolt and Washer  
770 20B-75501-03 Wire Clamp  
775 015-20600-50 Tapping Bolt  
780 214-79006-01 Clamp Cp  
785 011-00600-10 Flange Bolt  
stop wire  
clamp  
EX40  
- 25 -  
08-09  
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SECTION 7  
ELECTRIC DEVICE GROUP - ELECTRIC STARTER  
FIG. 710  
120  
13  
19  
20  
12  
18  
6
4
3
5
17  
10  
2
11  
15  
14  
1
9
8
16  
7
EX40  
- 26 -  
08-09  
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SECTION 7  
ELECTRIC DEVICE GROUP - ELECTRIC STARTER  
Ref. Part Number Description  
Qty Remarks  
To-From  
Fig.  
120 279-70502-00 Starting Motor Ay  
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
710  
-1  
-2  
209-70550-08 Yoke Cp  
209-70551-08 Brush  
-3  
-4  
-5  
-6  
-7  
-8  
-9  
209-70545-08 Brush Spring  
209-70530-08 Brush Holder  
209-70552-08 Insulator  
209-70554-08 Armature Ay  
209-70521-08 Over Running Clutch Cp  
279-70550-08 Housing Cp  
209-70511-08 Bush  
-10  
-11  
-12  
-13  
-14  
-15  
-16  
-17  
-18  
-19  
-20  
209-70505-18 Frame Cp  
209-70510-08 Bush  
209-70525-08 Lever  
279-70515-18 Magnet Switch Cp  
234-70555-08 Pinion Stopper  
209-70557-18 Snap Ring  
209-70558-08 Through Bolt  
949-29970-02 Nut  
209-70560-08 Nut  
107-70652-08 Spring Washer  
211-70584-08 Nut  
EX40  
- 27 -  
08-09  
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SECTION 7  
ELECTRIC DEVICE GROUP - CONTROL BOX  
FIG. 720  
200  
210  
388  
386  
190  
130  
55  
220  
385  
131  
335  
260  
385  
230  
387  
240  
EX40  
- 28 -  
08-09  
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SECTION 7  
ELECTRIC DEVICE GROUP - CONTROL BOX  
Ref. Part Number Description  
Qty Remarks  
To-From  
Fig.  
720  
720  
720  
720  
720  
720  
720  
720  
720  
720  
720  
720  
720  
720  
720  
720  
720  
55  
277-73105-01 Wire 5  
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
3
2
130  
131  
190  
200  
210  
220  
-1  
214-79007-01 Bolt, starter  
003-10080-00 Washer  
073-20044-80 Label, battery  
20B-75101-01 Control Box Cp  
073-20044-70 Label, starter switch  
066-00003-30 Switch Ay  
066-00099-80 Key  
230  
240  
260  
335  
385  
385  
386  
387  
388  
277-71401-01 Diode Rectier Cp  
044-35061-00 Screw and Washer Ay  
277-73103-11 Wire 3 Cp  
277-73104-01 Wire 4 Cp  
056-30000-60 Wire Band  
20B-76511-01 Bracket Cp, SEL  
056-60002-50 Clamp, sel  
011-00600-20 Flange Bolt  
013-50600-10 Bolt and Washer Ay  
EX40  
- 29 -  
08-09  
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SECTION 9  
ACCESSORY GROUP  
FIG. 900  
EX40  
- 30 -  
08-09  
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SECTION 9  
ACCESSORY GROUP  
Ref. Part Number Description  
Qty Remarks  
To-From  
Fig.  
10  
224-90303-00 Accessory Tool Kit  
1
900  
EX40  
- 31 -  
08-09  
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