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PARTS
MANUAL
Models
EX40
ENGINES
PUB-EP6516
Rev. 08/08
HOW TO USE THIS MANUAL
Robin engines are identified by MODEL, SPECIFICATION, and CODE NUMBER. For each
model there may be many different versions called specifications. Each specification 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 significant difference.
In order the identify the correct service part number, it is important to confirm the specifica-
tion and code numbers for your engine. The specification 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)
MANUAL LAYOUT
1
4
3
2
1
3
9
6
7
2
5
4
8
1. SECTION NAME
Parts are broadly classified 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 identifies 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 specification,
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.
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
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 -
08-08
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
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
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
270 224-63601-03 Oil Gauge
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 -
08-08
SECTION 2
CRANKSHAFT GROUP
FIG. 200
310
320
360
370
350
380
70
10
390
EX40
- 8 -
08-08
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 -
08-08
SECTION 3
INTAKE and EXHAUST GROUP
FIG. 300
310
320
350
365
361
315
225
340
241
231
317
80
210
240
90
230
290
60
220
70
95
170
25
150
27
160
34
37 35
38
163
166
10
EX4
08-08
SECTION 3
INTAKE and EXHAUST GROUP
Ref. Part Number Description
Qty Remarks
To-From
Fig.
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
10
25
27
34
35
37
38
60
70
80
90
95
20B-31601-01 Camshaft Cp
20B-35101-03 Pin, camshaft
024-00700-20 O ring
005-19041-00 Pin, spring
277-36401-03 Release lever
20B-36501-03 Clip
277-38702-03 Return Spring
246-33611-03 Valve Spring
246-33711-13 Spring Retainer
20B-33401-H3 Intake Valve
20B-33501-H3 Exhaust Valve
246-35501-03 Collet Valve
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
150 20B-35601-H1 Timing Chain
160 277-36911-03 Tentioner
163 277-37101-03 Spring, tentioner
166 277-36902-03 Pin, tentioner
170 277-36913-13 Chain Guide
200 20B-35001-01 Pin, rocker
210 003-13060-00 Clip
220 20B-36101-00 Rocker Arm Ay, intake
225 20B-36102-10 Rocker Arm Ay, exhaust
230 014-90500-20 Adjust Screw
231 014-90500-20 Adjust Screw
240 017-00500-30 Nut
241 017-00500-30 Nut
290 011-00600-20 Flange Bolt
310 20B-30101-J2 Muffler
315 20B-37001-01 Deflector Cp
317 015-00400-60 Tapping Screw
320 20B-34201-11 Muffler Cover Cp
340 20B-35201-03 Gasket, muffler
350 980-20082-80 Flange Nut
361 011-00600-10 Flange Bolt
365 011-00803-20 Flange Bolt
EX40
- 11 -
08-08
SECTION 3
INTAKE and EXHAUST GROUP
FIG. 310
250
520
270
220
260
EX40
- 12 -
08-08
SECTION 3
INTAKE and EXHAUST GROUP
Ref. Part Number Description
Qty Remarks
To-From
Fig.
510 20B-32611-H0 Air Cleaner Ay
-200 20B-32630-H8 Cleaner Body
-220 20B-32720-H8 Gasket, packing
-250 20B-32640-H8 Cover
-260 20B-32850-H8 Cap
-270 20B-32650-H8 Bolt
280 X85-11001-80 Rubber Pipe, breather
290 002-38060-00 Flange Nut
295 001-04061-60 Flange Bolt
520 20B-32610-H7 Element
1
1
1
1
1
1
1
2
1
1
Dual
315
315
315
315
315
315
315
315
315
315
EX40
- 13 -
08-08
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 -
08-08
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-42501-13 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
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
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
490 277-96107-03 Label, hi-low
EX40
- 15 -
08-08
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 -
08-08
SECTION 5
COOLING and STARTING GROUP
Ref. Part Number Description
Qty Remarks
To-From
Fig.
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
2
500
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 Baffle 2, head
279-52711-11
Baffle 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
707 004-36041-20 Screw and Washer Ay
EX40
- 17 -
08-08
SECTION 5
COOLING and STARTING GROUP
FIG. 520
-11
-8
-2
-10
-9
-3
-7
-6
-5
-1
-4
210
EX40
- 18 -
08-08
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 -
08-08
SECTION 6
FUEL, LUBRICATION GROUP
EX40
- 20 -
08-08
SECTION 6
FUEL, LUBRICATION GROUP
Ref. Part Number Description
Qty Remarks
To-From
Fig.
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
X43-04401-42 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
1
600
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
560 20B-35902-H3 Gasket 2, insulator
EX40
- 21 -
08-08
SECTION 6
FUEL, LUBRICATION GROUP
FIG. 610
EX40
- 22 -
08-08
SECTION 6
FUEL, LUBRICATION GROUP
Ref. Part Number Description
Qty Remarks
To-From
Fig.
210 20B-62301-00 Carburetor Ay
20B-62302-00 Carburetor Ay
1
1
Std
Generator
640
640
EX40
- 23 -
08-08
SECTION 7
ELECT
FIG. 700
785
780
16
15
10
12
20
35
30
100
11
50
385
110
384
740
700
EX40
- 24 -
08-08
SECTION 7
ELECTRIC DEVICE GROUP
Ref. Part Number Description
Qty Remarks
To-From
Fig.
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
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
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 -
08-08
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 -
08-08
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 -
08-08
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 -
08-08
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
Key
230
240
260
335
385
385
386
387
388
277-71401-01 Diode Rectifier 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 -
08-08
SECTION 9
ACCESSORY GROUP
FIG. 900
EX40
- 30 -
08-08
SECTION 9
ACCESSORY GROUP
Ref. Part Number Description
Qty Remarks
To-From
Fig.
10
224-90303-00 Accessory Tool Kit
1
900
EX40
- 31 -
08-08
PRINTED IN THE USA
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