SERVICE

MANUAL
Model

EH025/EH035
ENGINE

PUB-ES1740
Rev. 05/03

940 Lively Blvd. Wood Dale, IL 60191 Phone: 630-350-8200 Fax: 630-350-8212
e-mail: sales@robinamerica.com www.robinamerica.com

Copyright 2003 Robin America, Inc.

CONTENTS
Section

Title

Page

1. SPECIFICATIONS ....................................................................................................... 1
2. PERFORMANCE ........................................................................................................ 2
2-1
2-2
2-3
2-4

MAXIMUM OUTPUT ........................................................................................................

CONTINUOUS RATED OUTPUT ....................................................................................
MAXIMUM TORQUE AND FUEL CONSUMPTION WITH MAXIMUM OUTPUT .............
PERFORMANCE CURVES .............................................................................................

2
2
2
3

3. FEATURES .................................................................................................................. 5
3-1 THE SMALLEST AND LIGHTEST 4-STROKE ENGINE IN THE MARKET ..................... 5
3-2 4-STROKE ENGINE ALLOWING OPERATION IN THE TILTED POSITION,
REQUIRED IN BRUSH CUTTING WORK AND OTHER SIMILAR APPLICATIONS ...................... 5

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS .......................................... 8

4-1 CYLINDER BLOCK AND CRANKCASE .......................................................................... 8
4-2 CRANKSHAFT AND CONNECTING ROD ...................................................................... 8
4-3 PISTON ............................................................................................................................ 8
4-4 PISTON RINGS ............................................................................................................... 9
4-5 CAM GEAR ...................................................................................................................... 9
4-6 COOLING SYSTEM ......................................................................................................... 9
4-7 LUBRICATION SYSTEM ................................................................................................. 9
4-8 IGNITION SYSTEM ....................................................................................................... 10
4-9 CARBURETOR .............................................................................................................. 10
4-10 AIR CLEANER ............................................................................................................. 10
4-11 DECOMPRESSION SYSTEM ....................................................................................... 11
4-12 SECTIONAL VIEW OF ENGINE .................................................................................. 12

5. DISASSEMBLY AND REASSEMBLY ....................................................................... 14

5-1
5-2
5-3
5-4

PREPARATIONS AND SUGGESTIONS ........................................................................

SPECIAL TOOLS ...........................................................................................................
DISASSEMBLY PROCEDURES ....................................................................................
REASSEMBLY PROCEDURES .....................................................................................

14
14
14
26

6. MAGNETO ................................................................................................................ 41
6-1 FLYWHEEL MAGNETO ................................................................................................. 41
6-2 IGNITION OF MAGNETO .............................................................................................. 41

7. AUTOMATIC DECOMPRESSION SYSTEM ............................................................. 42

7-1 FUNCTION AND MECHANISM ..................................................................................... 42
7-2 INSPECTION ................................................................................................................. 42

Section

Title

Page

8. CARBURETOR ........................................................................................................ 43
8-1 OPERATION AND CONSTRUCTION ............................................................................43
8-2 DISASSEMBLY AND REASSEMBLY.............................................................................44

9. RECOIL STARTER .................................................................................................. 47

9-1
9-2
9-3
9-4

HOW TO DISASSEMBLE ..............................................................................................47

HOW TO REASSEMBLE ...............................................................................................49
CHECK AFTER REASSEMBLE ....................................................................................50
OTHER GUIDES ............................................................................................................50

10. TROUBLESHOOTING ........................................................................................... 51

10-1
10-2
10-3
10-4
10-5
10-6

STARTING DIFFICULTIES ..........................................................................................51

ENGINE MISFIRES .....................................................................................................52
ENGINE STOPS ..........................................................................................................52
ENGINE OVERHEATS ................................................................................................53
ENGINE KNOCKS .......................................................................................................53
ENGINE BACKFIRES THROUGH CARBURETOR .....................................................53

11. INSTALLATION ..................................................................................................... 54

11-1
11-2
11-3
11-4

INSTALLING .................................................................................................................54
VENTILATION ..............................................................................................................54
EXHAUST GAS DISCHARGE .....................................................................................54
POWER TRANSMISSION TO DRIVEN MACHINES ...................................................54

12. SERVICE DATA ...................................................................................................... 55

12-1 CLEARANCE DATA AND LIMITS ................................................................................55
12-2 TORQUE SPECIFICATIONS .......................................................................................58
12-3 OIL GRADE CHART ....................................................................................................59

13. MAINTENANCE AND STORAGE .......................................................................... 60

13-1
13-2
13-3
13-4
13-5

DAILY MAINTENANCE ................................................................................................60

INITIAL 20 HRS. MAINTENANCE ...............................................................................60
EVERY 50 HRS. (10 DAYS) MAINTENANCE .............................................................60
EVERY 100-200 HRS. (MONTHLY) MAINTENANCE ................................................. 61
ENGINE STORAGE .....................................................................................................61

1. SPECIFICATIONS
MODEL

EH025

EH035

Air-Cooled, 4-Cycle, Single-Cylinder,

Horizontal P.T.O. Shaft, Gasoline Engine

Type
Bore x Stroke

34 x 27 mm (1.34 x 1.06 in.)

39 x 28 mm (1.54 x 1.10 in.)

Piston Displacement

24.5 cm3 (1.49 cu.in.)

33.5 cm3 (2.04 cu.in.)

Compression Ratio

8.3

8.6

Continuous

0.55 kW (0.75 HP) /7000 r.p.m.

0.81 kW (1.10 HP) /7000 r.p.m.

Max.

0.81 kW (1.10 HP) /7000 r.p.m.

1.18 kW (1.60 HP) /7000 r.p.m.

1.18 N m (0.12 kgfm) /5000 r.p.m.

1.76 Nm (0.18 kgf m) /5000 r.p.m.

Output
Max. Torque
Direction of Rotation

Counterclockwise As Viewed From P.T.O. Shaft Side

Cooling system

Forced Air Cooling

Valve Arrangement

Overhead Valve

Lubrication
Lubricant
Capacity of Lubricant

Forced Lubrication
Automotive Oil SAE #20, #30 or 10W-30 ; Class SF or higher
0.08 liters (0.021 U.S. gal.)

Carburetor

0.10 liters (0.026 U.S. gal.)

Diaphragm Type

Fuel

Automotive Unleaded Gasoline

408 g/kW h (300 g/HPh)

340 g/kWh (250 g/HPh)

Fuel Consumption Ratio

At Continuous Rated Output
Fuel Feed System
Fuel Tank Capacity

Diaphragm Pump
0.5 liters (0.13 U.S. gal.)

Ignition System

Flywheel Magneto (Solid State)

Spark Plug

NGK CMR6A (M10 x 1.0)

Starting System

Recoil Starter

Air Cleaner
Dry Weight
Dimensions (L x W x H)

0.65 liters (0.17 U.S. gal.)

Semi-Wet Type
2.8 kg (6.17 lb.)

3.5 kg (7.72 lb.)

170 mm x 213 mm x 225 mm

(6.69 in. x 8.39 in. x 8.86 in.)

191 mm x 234 mm x 246 mm

(7.52 in. x 9.21 in. x 9.69 in.)

Specifications are subject to change without notice.

- 1-

2. PERFORMANCE
2-1 MAXIMUM OUTPUT
The maximum output is the output of an engine with its throttle valve fully opened under the condition that
all the moving parts are properly broken in after the initial break-in period. A new engine may not produce
full maximum output while its moving parts are still not broken-in.

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 engine'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 should be kept
below this continuous rated output.

2-3 MAXIMUM TORQUE AND FUEL CONSUMPTION WITH MAXIMUM OUTPUT

The maximum torque is the torque at the output shaft when the engine is producing maximum output at
certain revolution. The fuel consumption rate is the amount of fuel in grams consumed per horsepowerhour when the engine is working at continuous rated output.

- 2-

2-4 PERFORMANCE CURVES

(Nm)
1.2

(kg-m)
0.12

(kW)

1.0

0.10

1.0

0.8

0.08

0.6

0.06

MAXIMUM TORQUE

(PS)

1.2
0.8

PO

OUTPUT

ER

E
RS

1.0

0.8

TORQUE

EH025

HO

CONTINUOUS RATED
HORSEPOWER

U
XIM

MA

0.6

0.6
0.4

RECOMMENDED
HORSEPOWER RANGE

0.2

(g/kWh) (g/PSh)
450
600

CLUTCH
CHARACTERISTICS

0.2

400
0

500

350

400

300
250

CLUTCH MEET
4000 - 4400 r.p.m.

300
4000

5000

6000

Revolution

7000
(r.p.m.)

- 3-

8000

FUEL CONSUMPTION RATE

0.4

EH035

(PS)
1.6

(kW)
1.2

ER

(Nm)
1.8

(kg-m)

1.6

0.16

1.4

0.14

1.2

0.12

0.18
TORQUE

MAXIMUM TORQUE

1.4

P
SE

1.0

UM

CONTINUOUS RATED
HORSEPOWER

IM

AX

1.2

0.8
1.0

0.8

RECOMMENDED
HORSEPOWER RANGE

0.6

(g/kWh) (g/PSh)
450
600

0.6
0.4

400
0.4
0.2

500

350

400

300
250

CLUTCH MEET
4000 - 4400 r.p.m.

300
4000

5000

6000

Revolution

7000
(r.p.m.)

- 4-

8000

FUEL CONSUMPTION RATE

OUTPUT

HO

3. FEATURES
3-1 THE SMALLEST AND LIGHTEST 4-STROKE ENGINE IN THE MARKET
1) Small-sized lubricant oil tank, thanks to the Robin original lubrication system.
2) Compact construction because of the optimum design, not taking any bore-up into consideration.
3) Shorter shaft length at the output side (magneto side), by arranging the cam gear unit at the opposite
side of the magneto.
4) Light weight construction, because of the resin made came gear, rocker cover and other parts.(EH025)
And because of the resin made came gear, other parts.(EH035)
5) Parts of the valve driving system with thoroughgoing light weight construction

3-2 4-STROKE ENGINE ALLOWING OPERATION IN THE TILTED POSITION, REQUIRED IN

BRUSH CUTTING WORK AND OTHER SIMILAR APPLICATIONS
1) Robin's original lubricating system
Small-sized lubrication system with high reliability, that makes it possible to operate the engine in tilted
position.
Basic system
Oil flow
Blow-by air (including fresh air) and oil mist

Fig. 3-1

- 5-

(a) Since Robin lubricating system makes use of the pressure fluctuations in the crankcase, a lead valve
is arranged at the lower part of the crankcase. By utilizing the negative pressure that occurs during
the piston rising stroke, lubricant oil is supplied from the oil tube (located inside the oil tank, that is
separated from the crankcase) to the crankcase, through the oil passage of the crankshaft which has
rotary valve that opens and shuts with an appropriate timing.
(b) At the same time, fresh air and blow-by air containing oil mist coming from the rocker arm compartment are sucked through the two assist holes that open at the piston top dead center.
(c) The supplied oil is diffused by the crank arm and other parts, thereby transforming in mist.
That diffused oil mist is compressed during the piston lowering stroke, and an appropriate quantity of
the compressed oil mist is pumped to the cam gear compartment and to the rocker arm compartment
through the lead valve, and oil pasage. Thus, it lubricates the various parts of the engine. The remaining oil mist returns to the oil tank via bypass hole.
(d) The oil tank has two pressure relief holes located at its left and right sides which are connected to the
assist hole of the cylinder unit. These pressure relief holes have the function to keep the pressure of
the oil tank constant.
(e) Oil inside the rocker arm compartment is sucked back to the crankcase by the strong negative pressure inside the crankcase, through the two return paths located at the left and right sides.
(f) The blow-by gas and a small amount of oil mist flow from the rocker arm compartment to the oil
separator inside the air cleaner, through the breather pipe. Then separated into blow-by gas and oil
mist.
(g) The separated oil mist returns into the crankcase, passing through the assist hole of the cylinder.

Engine operation in tilted positions

(a) When the engine is tilted carburetor side down.
The return path at the carburetor side inside
the rocker arm compartment comes to the
lower position. Then, the stagnant oil is sucked
back to the crankcase. At that time, the check
valve of the pressure relief hole prevents oil
from flowing back, because the carburetor side
pressure relief hole, located inside the oil tank,
is in the oil.

Fig. 3-2

- 6-

(b) When the engine is tilted muffler side down.

In the same way as that of the carburetor side
down, the return path in the rocker arm compartment and the pressure relief hole operate
and return the stagnant oil into the crankcase.

(c) Engine tilted back and forth

The breather hole located inside the rocker arm
compartment is arranged approximately at the
center of the rocker arm compartment, so as
to prevent stagnant lubricant oil from being
gushed out at either back or forth inclined position. The stagnant oil is sucked back into the
crankcase through the return path.
Fig. 3-3

(d) Upside down position

Basically, it is presumed that the engine is not
used (is not required to operate) continuously
in the upside down position, and only the practical tilted positions are taken into consideration
as priorities. Measures are adopted, however,
so that the engine can be run for a short time
in upside down positions during the work and/
or during idling.
The oil return passage tube at the muffler side
is extended up to the rocker arm cover in order to suck the oil that stagnates in the rocker
arm compartment while the engine is in the
upside down position. At that time, the pressure relief hole located inside the oil tank is
closed by the check ball, so as to prevent oil
from back flowing from the oil tank.
Fig. 3-4

Lubrication inside the cylinder is carried out with a sufficient volume of oil, irrespective of the position of
the engine, and there is no risk of engine seizure, wear and other similar problems caused by improper
lubrication. The oil volume supplied into the cam gear compartment and into the rocker arm compartment is limited to an appropriate amount, to minimize the oil consumption.

- 7-

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS

4-1 CYLINDER BLOCK AND CRANKCASE
The cylinder block and crankcase are aluminum
die-castings split in upper and lower parts.
The cylinder block and the cylinder head are a
single piece. The valve seats are molded and the
valve guides (intake valves and exhaust valves)
and the valve stem seal (intake side only) are
press fitted. The cylinder bore is finished with hard
chromium plating.

Fig. 4-1

4-2 CRANKSHAFT AND CONNECTING ROD

The crankshaft is made of malleable cast iron, and
the entire crank pin surface is hardened by cementation.

CONNECTING ROD

The crank gear is press fitted at the opposite side

to the P.T.O..

CRANKSHAFT

The connecting rod is a carbon steel casting, and

needle roller bearings are press fitted in the large
and small ends.

Fig. 4-2

4-3 PISTON
The piston is made of high silicon alminun, and
measures are taken to improve its wearing resistance.

PISTON

Fig. 4-3

- 8-

4-4 PISTON RINGS

The piston rings are made of special cast iron. The top ring is a barrel face type, the second ring is a
tapered one, and the oil ring consists of three pieces, so as to reduce the oil consumption.

TOP
RING

SECOND
RING

TAPER

OIL RING

THREE-PIECE
ASSEMBLY

BARREL

Fig. 4-4

4-5 CAM GEAR

The cam gear consists of the combination of the
cam and the gear. The cam is a sintered component, widely used in this kind of application. The
gear is made of synthetic resin to reduce both
weight and gear noise.

Fig. 4-5

4-6 COOLING SYSTEM

This engine adopts the forced air-cooled system, where cooling air is sent to the cylinder block by an
even-pitched cooling fan that works as a flywheel as well. This cooling air is guided properly to the
cylinder block by the baffle plate.

4-7 LUBRICATION SYSTEM

The rotary parts and the sliding parts of the engine are lubricated by lubricant oil, which is forcibly supplied by utilizing the pressure generated by the up-down movement of the piston. Moreover, the oil
compartment is provided separately in order to prevent lubricant oil from flowing directly into the cylinder.

- 9-

4-8 IGNITION SYSTEM

The ignition system is a TIC flywheel magneto
type. The ignition timing is 25 degrees before the
top dead center.
The magneto consists of the flywheel and the ignition coil. The flywheel (that works as a cooling
fan as well) is mounted on the crankshaft and the
ignition coil is mounted directly on the cylinder
block.

Fig. 4-6

4-9 CARBURETOR
This engine adopts a diaphragm type carburetor.
The carburetor is calibrated carefully for easy starting, good acceleration, low fuel consumption and
sufficient output.

Fig. 4-7

4-10 AIR CLEANER

EH025

The air cleaner element is urethane foam (semiwet type).

This air cleaner has a compartment that separates
blow-by gas from lubricant oil.

ELEMENT

PLATE

AIR CLEANER COVER

FIXING BOLT

EH035

ELEMENT

PLATE
AIR CLEANER COVER
FIXING BOLT

Fig. 4-8

- 10 -

4-11 DECOMPRESSION SYSTEM

The decompression equipment is installed inside
the gear of the cam-gear unit. The decompression equipment opens the intake valve before the
compression top to relieve the compression pressure for easy start.

CAMLIFTER

WEIGHT

CRESCENT CAM

Fig. 4-9

- 11 -

4-12 SECTIONAL VIEW OF ENGINE

INTAKE VALVE

EXHAUST VALVE

BREATHER PIPE
MUFFLER COVER

CARBURETOR

AIR
CLEANER
MUFFLER

CONNECTING
ROD

CHECK BALL

RETURN
PIPE

OIL GAUGE

Fig. 4-10

- 12 -

ROCKER ARM
SPARK PLUG
PUSH ROD

PISTON
PISTON RING

IGNITION COIL

PISTON PIN

FLYWHEEL
CAM GEAR

RECOIL
STARTER

OIL TUBE

FUEL TANK

Fig. 4-11

- 13 -

5. DISASSEMBLY AND REASSEMBLY

5-1 PREPARATIONS AND SUGGESTIONS
1) When disassembling the engine, memorize the locations of individual parts so that they can be
reassembled correctly. If you are uncertain of identifying some parts, it is suggested attach tags to
them.
2) Have boxes ready to keep disassembled parts by group.
3) To prevent losing and misplacing, temporarily assemble each group of disassembled parts.
4) Carefully handle disassembled parts, and clean them with washing oil if necessary.
5) Use the correct tools in the correct way.

5-2 SPECIAL TOOLS (EH025 ONLY)

Tool No.

Tool

Use

560-90020-00

Flywheel puller

For pulling off the flywheel

Fig. 5-1

5-3 DISASSEMBLY PROCEDURES

Step

Parts to remove
Engine oil drain

Remarks and procedures

Remove the oil gauge.

Plug cover, plug cap, stop switch 1) Remove plug cover from engine
cover.
Remove
the plug cap.
2)
3) Disconnect lead wire of stop
switch from ignition coil
(Except Stop switch : EH035)
*Hold lead wire with plier and pull
it out straight.
Engine cover

Fasteners

Remove engine cover from blower

housing and recoil.

- 14 -

M5x8 mm: 1 pce.

(EH035)

M5x12 mm: 2 pcs.

(EH025)
M4x16 mm: 2 pcs.
(EH025)
M5x12 mm: 3 pcs.
(EH035)

OIL GAUGE

Fig. 5-3

Fig. 5-2

LEAD WIRE

Fig. 5-4

EH025

STOP SWITCH

PLUG COVER

EH035

M5 x 8 SCREW : 1 pce.

PLUG COVER

STEP 1

STEP 1
M5 x 12 SCREW AND
WASHER AY : 1 pce.
ENGINE COVER

M5 SCREW AND
WASHER : 2 pcs.

M4 SCREW AND
WASHER : 2 pcs.

ENGINE COVER

M5 x 12 SCREW AND
WASHER AY : 2 pcs.

Fig. 5-5

Fig. 5-6

- 15 -

Step

Parts to remove
Air cleaner, insulator, insulator
carburetor

Remarks and procedures

1) Remove air cleaner cover and air
cleaner element.
2) Remove fuel tube from carburetor,
and then remove breather pipe and
return pipe from cylinder.
It is convenient to use a small-sized
screwdriver to remove tubes.
3) Remove air cleaner plate.
The air cleaner plate is fastened
together with the carburetor.
4) Remove insulator and insulator
carburetor.

*Breather unit of the air cleaner (plate 1) Remove the plate separator.
Make sure of removing the plate
separator, check valve)
separator by holding its edge.
When holds the square pipe, there is
risk of damaging the pipe.
2) Remove the check valve plate
(fastened together with the check
valve) with a small-sized screwdriver.
It is recommendable to pry the hook
of the check valve plate with a screwdriver to remove the plate.
*Disassemble the breather unit
only if necessary.
3) Remove the check valve (1).

- 16 -

Fasteners
M5 x 14 mm ; 1 pc.

M5 x 68 mm; 2 pcs.

M5 x 18 mm ; 2pcs.
M5 x 12 mm ; 1pce.

EH025
CHOKE PLATE

CHOKE LEVER

PLATE
M5 x 40
SCREW : 2 pcs.

AIR CLEANER CARBURETOR

PLATE
O-RING

ELEMENT
AIR CLEANER
COVER

SPACER
BREATHER PIPE

CHECK
VALVE (1)

CHECK
VALVE

Fig. 5-8

O-RING
CHECK VALVE
PLATE

M5 x 14 SCREW
AND WASHER
: 1 pce.
PLATE,
SEPARATOR

GASKET,
SEPARATOR

STEP 2
INSULATOR,
CARBURETOR

GASKET,
CARBURETOR

RETURN PIPE

RETURN
PIPE

GASKET,
INSULATOR

INSULATOR

Fig. 5-9

M5 x 18
SCREW AND
WASHER : 2 pcs.
M5 x 12 SCREW
AND WASHER : 1 pce.

Fig. 5-7

GASKET,
INSULATOR
INSULATOR

EH035

INSULATOR,
CARBURETOR

STEP 2

GASKET,
CARBURETOR

CHOKE PLATE
CHOKE LEVER
PLATE
CARBURETOR

M5 x 40
SCREW : 2 pcs.

O-RING
M5 x 18 SCREW AND WASHER : 2 pcs.

AIR CLEANER
COVER

M5 x 12 SCREW AND WASHER : 1 pce.

AIR CLEANER
PLATE

RETURN PIPE

ELEMENT
M5 x 14 SCREW
AND WASHER
: 1 pce.

CHECK VALVE (1)

O-RING
CHECK VALVE PLATE

PLATE,
SEPARATOR

CHECK VALVE
GASKET, SEPARETOR

Fig. 5-10

Fig. 5-11

- 17 -

Step

Parts to remove

Remarks and procedures

Fasteners

Remove the muffler cover from the

muffler.
The muffler and the muffler cover are
fastened together with two M5 x 40 mm
socket head bolts.

M5 x 5mm; 1 pc.
M5 x 40mm
socket head bolt ;
2 pcs.

Recoil starter

Remove recoil starter from crankcase.

M4 x16mm; 2 pcs.
(EH025)
M5 x14mm; 4 pcs.
(EH035)

Fuel tank

Remove fuel tank from housing blower.

Pulley

Remove the pulley from the crankshaft. Utilize the hole of the pulley, and
remove the pulley by tapping it with a
metallic rod and a hammer. (The thread
is clockwise).

Muffler and Muffler cover

M5 SOKET HEAD
BOLT : 2 pcs.

M5 SCREW : 1 pc.

HOLE OF THE PULLEY

Fig. 5-12

MUFFLER
COVER
MUFFLER

STEP 3

MUFFLER
GASKET

EH025

EH035

PULLEY

RECOIL
STARTER

RECOIL
STARTER

FUEL
TANK
PULLEY

M4 SCREW AND
WASHER : 2 pcs.

Fig. 5-13

- 18 -

M5 SCREW AND
WASHER : 4 pcs.

Step

Parts to remove
Blower housing

Remarks and procedures

Remove blower housing from cylinder
and crankcase

4
Clutch

EH025

Remove the clutch from the flywheel.

BLOWER HOUSING

M5 SCREW AND
WASHER : 3 pcs.

M6 BOLT,
CLUTCH : 2 pcs.

STEP 4

SPRING

EH035
M5 SOCKET
HEAD BOLT : 4 pcs.

CLUTCH

M8 BOLT,
CLUTCH : 2 pcs.

STEP 4
SPRING

BLOWER HOUSING

CLUTCH

Fig. 5-14

- 19 -

Fasteners
M5 x18mm; 3 pcs.
(EH025)
M5 x16mm; 4 pcs.
(EH035)
M6 x23mm; 2 pcs.
(EH025)
M8 x23.5mm; 2 pcs.
(EH035)

Step

Parts to remove
Flywheel

Remarks and procedures

Fasteners

1) Remove flywheel from crankshaft.

*Use the flywheel puller as shown
in the Figure, and remove the flywheel by rotating the center shaft
clockwise.

5
Ignition coil

Remove ignition coil from cylinder

block.

Spark plug

Remove the spark plug from the cylinder block

M4 x 20 mm ;
2 pcs.

SPARK PLUG

STEP 5

IGNITION COIL

M4 SCREW AND
WASHER : 2 pcs.
FLYWHEEL

Fig. 5-15

Fig. 5-16

- 20 -

M6 BOLT AND
WASHER : 1 pce.

Step

Parts to remove

Remarks and procedures

Oil case

1) Remove oil case from crankcase.

2) Remove the oil case from the
recoil side of the crankcase, by
tapping the oil case with a plastic
or wooden hammer.

Oil tube and Retainer plate

1) Pull out the oil tube, by holding its

base. It is recommendable to pry
the oil tube with a small-sized
screwdriver.
2) Remove retainer plate from crankcase. When removing the retainer
plate, take care not to lose the
lead valve.

Fasteners
M5 x18 mm;
4 pcs.

M4 x10 mm; 1 pc.

OIL TUBE

Fig. 5-17

LEAD VALVE

RETAINER PLATE

GASKET, CASE

M4 SOCKET HEAD
BOLT : 1 pce.

OIL TUBE

OIL WEIGHT

STEP 6
Fig. 5-18

OIL CASE

M5 SCREW AND
WASHER : 4 pcs.

- 21 -

Step

Parts to remove

Remarks and procedures

Fasteners

Rocker cover

Remove rocker cover from cylinder

block.

M5 x 16mm ; 3 pcs.
(EH025)
M5 x 16mm ; 4 pcs.
(EH035)

Cam gear cover

Remove cam gear cover from cylinder

block.

M5 x 14mm ; 3 pcs.

Cam lifter, Cam gear and

Push rod

1) Position the cam peak portion

down, then remove the cam lifter
shaft, and remove the cam lifter.
2) Remove the cam gear shaft, and
remove the cam gear.
3) Remove the push rod.

Rocker arm

Remove the rocker arm shaft, then remove the rocker arm. Hold the rocker
arm shaft, that can be seen between
the intake and exhaust rocker arm,
with pincers, then remove the shaft.

ROCKER ARM
M5 SCREW AND
WASHER : 3 pcs.

ADJUSTING SCREW

ROCKER COVER
PUSH ROD

STEP 7
GASKET,
CAMGEAR COVER

GASKET,
ROCKER COVER

CAMGEAR COVER

ROCKER SHAFT
CAMLIFTER
SHAFT
M5 SCREW AND
WASHER : 3 pcs.

CAMLIFTER

CAMGEAR
CAMGEAR SHAFT

Fig. 5-20
Fig. 5-19

- 22 -

Step

Parts to remove

Remarks and procedures

Fasteners

Crankcase

Remove the crankcase from the

cylinder block by tapping it with a
plastic or wooden hammer from the
recoil side. Take care not to lose the
check balls (2 pcs.) that are held by
the washer of the screw.

Crankshaft

Remove crankshaft from cylinder

block. When removing the crankshaft
from the cylinder block, take care not
to damage the oil seal.

M5 x 14mm ; 8 pcs.
(EH025)
M5 x 16mm ; 4 pcs.
(EH035)
M5 x 33mm ; 4 pcs.
(EH035)

Fig. 5-21
CYLINDER BLOCK

STEP 8

CRANKSHAFT

CRANKCASE

Fig. 5-22
M5 SOCKET HEAD
BOLT : 8 pcs.

- 23 -

Step
9

Parts to remove
Valve, Valve spring and
Spring retainer

Remarks and procedures

Hold the valve from the inner side of the
cylinder, then push the spring retainer
and remove it by sliding.

SPRING RETAINER

VALVE SPRING

SPACER

STEP 9

INTAKE VALVE

EXHAUST VALVE

Fig. 5-23
Fig. 5-24

- 24 -

Fasteners

Step

Parts to remove

Remarks and procedures

Piston and Piston ring

Fasteners

1) Remove the two piston clips, take

out the piston pin, and then
remove the piston from the small
end of the connecting rod.
When removing the piston, take
care to prevent dust from getting in
the bearing at the connecting rod
small end.
2) To remove the two piston rings
and the oil ring, open wide the
open end of the rings and remove
them from the piston.
Take care not to widen the open
end of the rings too much, or the
rings may break.

10

PISTON RING

CLIP

PISTON PIN
PISTON
CLIP

STEP 10

CRANKSHAFT

Fig. 5-25

- 25 -

5-4 REASSEMBLY PROCEDURES

PRECAUTIONS FOR REASSEMBLY

1) Clean parts thoroughly before reassembly.

Pay most attention to cleanliness of piston, cylinder, crankshaft, connecting rod and bearings.
2) Scrape off all carbon deposits from cylinder head, piston top and piston ring grooves.
3) Check lip of oil seals. Replace oil seal if the lip is damaged. Apply oil to the lip before reassembly.
4) Replace all the gaskets with new ones.
5) Replace keys, pins, bolts, nuts, etc., if necessary.
6) Torque bolts and nuts to specification referring to the "TORQUE SPECIFICATIONS".
7) Apply oil to rotating and sliding portions.
8) Check and adjust clearances and end plays where specified in this manual.
9) Check resistance and/or noise by rotating parts by hand, when reassemble main parts.

5-4-1 CYLINDER BLOCK, VALVE SPRING AND SPRING RETAINER

(1) Before reassemble, apply 4 cycle engine oil
(10W-30) to cylinder inner surface, piston slide
face and valve guide holes.
(2) Install valve spring and spring retainer as
shown in Fig. 5-26. Push spring retainer down
until valve stem comes through the hole of
spring retainer, then slide the spring retainer.

1.INSERT THE
VALVE SPRING

SPRING RETAINER

VALVE SPRING

2.SLIDE THE
SPRING RETAINER

SPRING
RETAINER
VALVE
SPRING
SPACER

Fig. 5-26

SPACER MOUNTING
POSITION
INTAKE VALVE

Fig. 5-27

- 26 -

EXHAUST VALVE

5-4-2 CONNECTING ROD, PISTON AND PISTON RINGS

Install the piston on the connecting rod
(1) After installing the piston rings, apply 4-cycle engine oil to the rings.
NOTE ;
Install the top ring and the second ring with their open ends displaced by 180 degrees. When installing a
new ring, place the white mark at the right-hand side, and when reassembling a used one, install it with
the contact face down.

TOP
RING

SECOND
RING

TAPER

OIL RING

THREE-PIECE
ASSEMBLY

BARREL

Fig. 5-28
WHITE MARK
PISTON RING
CLIP

PISTON PIN
PISTON

CLIP

CRANKSHAFT

APPLY GREASE
ON THE INNER FACE

Fig. 5-29

- 27 -

5-4-3 CYLINDER BLOCK AND CRANKCASE

Installing cylinder block and crankcase
Make sure that the liquid packing (Three Bond 1216) is evenly applied on the crankcase before installing
the cylinder block.
Tightening torque of the hexagonal socket head bolts (8 pce.) of the lower part of the crankcase :
Tightening torque : 4.5 - 6.5 Nm
(45 - 65 kgfcm)
(3.3 - 4.7 ftlb.)
M5 SOCKET HEAD
BOLT : 8 pcs.

CYLINDER
BLOCK

CRANKCASE
LOWER PART

Fig. 5-30

Tightening order

3
7

LIQUID PACKING
(THREE BOND 1216)
DO NOT APPLY LIQUID
PACKING IN EXCESS

Fig. 5-31
CRANKCASE

M5 SOCKET HEAD
BOLT : 8 pcs.

M5 x 33 SOCKET
HEAD BOLT : 4 pcs.
M5 x 16 SOCKET
HEAD BOLT : 4 pcs.

Fig. 5-32

- 28 -

Fig. 5-33

5-4-4 OIL CASE

Install the lead valve with the cutout facing to the
oil filling port.
Retainer plate M4 x 10 mm hexagonal socket head
bolt (1 pc.)
Oil case M5 x 18 mm screw, and washer (4 pcs.)

OIL CASE

Tightening torque
M4 BOLT

M5 SCREW

3 - 4 Nm
(30 - 40 kgfcm)
(2.2 - 2.9 ftlb.)

4 - 5.5 Nm
(40 - 55 kgfcm)
(2.9 - 4.0 ftlb.)

M5 SCREW AND
WASHER : 4 pcs.

OIL WEIGHT
M4 SOCKET HEAD
BOLT : 1 pce.
OIL TUBE
RETAINER PLATE

GASKET, CASE

LEAD VALVE

CUTOUT

CRANKCASE
LOWER PART

Fig. 5-34

- 29 -

*ASSEMBLE
SEPARATELY

5-4-5 FLYWHEEL
Installing the flywheel
Degrease the crankshaft and the tapered portion
of the flywheel perfectly when installing them.
Align the flywheel key with the crankshaft key
groove.
Flywheel tightening bolt M6 x 16 mm, with spring
washer :
Tightening torque : 9 - 12 Nm
(90 - 120 kgfcm)
(6.5 - 8.8 ftlb.)
Fig. 5-35

FLYWHEEL

M6 BOLT AND
WASHER : 1 pc.

Fig. 5-36

5-4-6 IGNITION COIL

PLUG CAP

Installing the ignition coil (Air gap adjustment)

Air gap : 0.3 mm

THICKNESS GAUGE

Ignition coil tightening torque

M4 x 20 mm, with washer and spring washer
(2 pcs.)
NOTE :
Measure the air gap between the flywheel magnet and the ignition coil.
Tightening torque : 2 - 4 Nm
(20 - 40 kgfcm)
(1.4 - 2.9 ftlb.)

IGNITION
COIL

FLYWHEEL

Fig. 5-37

- 30 -

5-4-7 BLOWER HOUSING

M5 SCREW AND
WASHER : 3 pcs.

Installing the blower housing.

BLOWER HOUSING

Blower housing tightening torque

M5 x 18 mm Screw : 3 pcs. (EH025)
M5 x 16 mm Socket hesd bolt : 4 pcs. (EH035)
Tightening torque : 4 - 5.5 Nm
(40 - 55 kgfcm)
(2.9 - 4.0 ftlb.)

Fig. 5-38

5-4-8 CAM GEAR

Installing the cam gear.
(1) Align the mark punched on the flywheel (key
position groove) with the timing mark on the
ignition coil.

TIMING MARK

Fig. 5-39

(2) Install the cam gear with the cam top facing
down vertically (use the timing mark for
reference).

TIMING MARK
CAMGEAR
SHAFT,
CAMGEAR

Fig. 5-40

Fig. 5-41

- 31 -

5-4-9 PUSH ROD, CAMLIFTER AND ROCKER ARM

Installing the push rod, cam lifter and rocker arm

APPLY A SUFFICIENT AMOUNT OF OIL

(1) Apply sufficient oil in the rocker shaft hole.

Fig. 5-42

(2) Install the cam lifter.

ADJUSTING SCREW

(3) Pass the push rod through the hole of the cylinder block. Align the push rod end with the
cam lifter ball groove.

BALL
GROOVE
PUSH ROD
BALL
GROOVE

CAM LIFTER

Fig. 5-43

(4) Install the rocker arm assembly. Align the push

rod end with the ball groove of the adjusting
screw.

ROCKER
ARM
ADJUSTING
SCREW
PUSH ROD
CAM LIFTER SHAFT

CAM LIFTER

Fig. 5-44

- 32 -

5-4-10 CAMGEAR COVER

Installing the cam gear cover
CAMGEAR COVER

Before installing the cam gear cover, apply oil on

the camgear and the cam lifter sliding surface.
Camgear cover tightening torque M5 x 14 mm
screw (3 pcs.)
Tightening torque : 4 - 5.5 Nm
(40 - 55 kgfcm)
(2.9 - 4.0 ftlb.)

Fig. 5-45

GASKET,
CAMGEAR COVER
CAMGEAR COVER

M5 SCREW AND
WASHER : 3 pcs.

Fig. 5-46

5-4-11 VALVE CLEARANCE ADJUSTMENT

Loosen the nut and adjust the valve clearance by
rotating the adjusting screw with a hexagon bar
wrench. Adjust the valve clearance at the compression top dead center.

THICKNESS GAUGE

After the adjustment, tighten the nut firmly.

Valve clearance : 0.15 mm
(0.0059 in.)
Tightening torque : 5 - 6.5 Nm
(50 - 65 kgfcm)
(3.6 - 4.7 ftlb.)

ADJUSTING SCREW

Fig. 5-47

- 33 -

5-4-12 ROCKER COVER

Before installing the rocker cover, apply oil on the
sliding surfaces of the rocker arm and the valve
stems.

M5 SCREW AND
WASHER : 3 pcs.

ROCKER COVER

Rocker cover tightening torque

M5 x 16 mm screw : 3 pcs. (EH025)

GASKET,
ROCKER COVER

M5 x 16 mm screw : 4 pcs. (EH035)

Tightening torque : 4 - 5.5 Nm
(40 - 55 kgfcm)
(2.9 - 4.0 ftlb.)

Fig. 5-48

5-4-13 PULLEY, FUEL TANK AND RECOIL STARTER

Install the pulley on the crankshaft.
M5 SOCKET HEAD BOLT : 2 pcs.

Pulley tightening torque :

MUFFLER COVER

Tightening torque : 4 - 5.5 Nm

(40 - 55 kgfcm)
(2.9 - 4.0 ftlb.)
Install the tank on the main bearing cover.
M5 SCREW
: 1 pce.

Install the recoil on the crankcase.

PLATE

Recoil tightening torque

MUFFLER

M4 x 16 mm screw : 2 pcs. (lower side) (EH025)

GASKET, MUFFLER

Tightening torque : 1 - 2.5 Nm

(10 - 25 kgfcm)
(0.7 - 1.8 ftlb.)

A
FUEL TANK

PLATE

M5 x 14 mm screw : 4 pcs. (EH035)

Tightening torque : 1 - 2.5 Nm
(10 - 25 kgfcm)
(0.7 - 1.8 ftlb.)

DAMPER

5-4-14 MUFFLER AND MUFFLER GASKET

EH035

EH025

Install the gasket, muffler and muffler cover on

the cylinder head exhaust port.

PULLEY

RECOIL
STARTER

RECOIL
STARTER

M5 x 40 mm socket head bolt (2 pcs.)

M5 x 5 mm screw (1 pc.)
Tightening torque
M5 BOLT

M5 SCREW

7 - 9 Nm
(70 - 90 kgfcm)
(5.1 - 6.5 ftlb.)

3 - 5 Nm
(30 - 50 kgfcm)
(2.2 - 3.6 ftlb.)

PULLEY

M4 SCREW AND
WASHER : 2 pcs.

Fig. 5-49

- 34 -

M5 SCREW AND
WASHER : 4 pcs.

5-4-15 INSULATOR AND INSULATOR CARBURETOR

Cover the insulator on the insulator carburetor and
tighten them together.
M5 x 18 mm screw : 2 pcs. (EH025, EH035)
M5 x 12 mm screw : 1 pc. (EH025, EH035)

EH025
GASKET,
INSULATOR,
INSULATOR
CARBURETOR
INSULATOR

Tightening torque : 4 - 5.5 Nm

(40 - 55 kgfcm)
(2.9 - 4.0 ftlb.)
NOTE :
The end face of the adjustment screw shall be
aligned with the insulator end face (no protrusion).
The angular side of the gasket shall face up.

M5 x12
SCREW AND
WASHER : 1 pc.

M5 x 18 SCREW AND
WASHER : 2 pcs.

EH035
INSULATOR,
CARBURETOR

GASKET,
INSULATOR

INSULATOR

M5 x12 SCREW AND

WASHER : 1 pc.

M5 x 18 SCREW AND
WASHER : 2 pcs.

Fig. 5-50

Alignment

Approx. 2 mm

Fig. 5-51

- 35 -

5-4-16 CARBURETOR AND AIR CLEANER

(a) Assemble the plate, choke plate, air cleaner plate, carburetor, gasket carburetor, spacer, o-ring,
breather pipe and return pipe.
NOTE :
When installing the choke plate, keep the choke lever fully closed. (lever touching the upper stopper).
Apply grease or silicone on the choke plate after installing it.
Air cleaner tightening torque

Air cleaner tightening torque

M5 x 68 mm screw : 2 pcs.

M5 x 14 mm screw : 1 pce.

Tightening torque : 2 - 4 Nm
(20 - 40 kgfcm)
(1.4 - 2.9 ftlb.)

Tightening torque : 0.5 - 1 Nm

(5 - 10 kgfcm)
(0.35 - 0.7 ftlb.)

EH025

EH035
GASKET,
CARBURETOR

CHOKE LEVER
CARBURETOR
CHOKE PLATE
AIR CLEANER
PLATE
PLATE
O-RING
M5 SCREW
: 2 pcs.
AIR CLEANER ELEMENT
COVER

SPACER

GASKET,
CARBURETOR
CHOKE PLATE
CHOKE LEVER
PLATE
CARBURETOR
M5 SCREW
: 2 pcs.
O-RING

AIR CLEANER
COVER

AIR CLEANER
PLATE
BREATHER PIPE

BREATHER PIPE

CHECK
VALVE (1)

M5 SCREW
AND WASHER
: 1 pce.
PLATE,
SEPARATOR

RETURN
PIPE

ELEMENT
RETURN PIPE
CHECK VALVE (1)

M5 SCREW AND
WASHER : 1 pce.

O-RING
CHECK VALVE
PLATE

O-RING
CHECK VALVE
PLATE

PLATE,
SEPARATOR

CHECK VALVE
GASKET, SEPARATOR

CHECK VALVE
GASKET, SEPARATOR

Fig. 5-52

STOPPER (UPPER)

STOPPER (UPPER)

STOPPER
(LOWER)

CHOKE CLOSE

CHOKE OPEN
Fig5-53

- 36 -

STOPPER
(LOWER)

(b) Connect the fuel tank tube to the fuel joint of

the carburetor. (Check the bent of the tube).
(c) Connect the return pipe to the pipe joint at the
center of the cylinder.
(d) Connect the breather pipe to the pipe on the
rocker cover and fasten it with the hose clamp.

BREATHER PIPE
HOSE CLAMP
AIR CLEANER PLATE
UPPER CLAW

RETURN
PIPE

(e) Install the air cleaner cover after hooking it on

the upper claw of the air cleaner plate.
TUBE

TUBE

Fig. 5-54

5-4-17 SPARK PLUG

Installing the spark plug.
Tightening torque : 9 - 13 Nm
(90 - 130 kgfcm)
(6.5 - 9.4 ftlb.)

5-4-18 CLUTCH
Install the clutch with the (EH025),
R(EH035) mark on the clutch shoe at the front
side (facing the assembly worker).

M6 BOLT : 2 pcs. (EH025)

M8 BOLT : 2 pcs. (EH035)

SPRING

Bolt (clutch)
M6 x 23mm : 2 pcs. (EH025)
M8 x 23.5mm : 2 pcs. (EH035)
Tightening torque : 7.5 - 10 Nm
(75 - 100 kgfcm)
(5.4 - 7.2 ftlb.)

CLUTCH

Fig. 5-55

- 37 -

5-4-19 ENGINE COVER, STOP SWITCH AND PLUG COVER

Installing the engine cover, stop switch and plug
cover.
(1) Assemble the stop switch on the engine cover
in advance. Connect the stop switch wire to
the terminal of the switch. (EH025)
(2) Faston terminals (2 places) from the stop
switch. (EH025)
Either Faston terminal can be connected with
the coil terminal. (EH025)
Faston terminals (2 places) of the coil. (EH025)
The cylinder side is the grounding terminal.
(EH025)
Install the engine cover by placing it on the
engine from above, and screw its front side
on the blower housing (two places) and its rear
side on the crankcase (two places). (screw the
rear side together with the recoil).

Fig. 5-56

ENGINE COVER
MUFFLER

NOTE :
When installing the engine cover, make sure that
there is no coil terminal disconnected and no high
voltage cord bent.

THE INSULATOR CARBURETOR

SHALL BE PLACED INSIDE.

Fig. 5-57

- 38 -

(4) Install the plug cover by hooking the lower claw on

the engine cover first and then fitting its upper part.

M5 x 12 mm screw (2 pcs.) (EH025,EH035)

M5 x 8 mm screw (1 pce.) (EH035)

Tightening torque : 1.5 - 3 Nm
(15 - 30 kgfcm)
(1.1 - 2.1 ftlb.)

Tightening torque : 2 - 4 Nm
(20 - 40 kgfcm)
(1.4 - 2.9 ftlb.)
M4 x 16 mm screw (2 pcs.) (EH025)

M5 x 14 mm screw (1 pce.) (EH035)

Tightening torque : 1 - 2 Nm
(10 - 20 kgfcm)
(0.7 - 1.4 ftlb.)

EH025

Tightening torque : 1 - 2 Nm
(10 - 20 kgfcm)
(0.7 - 1.4 ftlb.)

EH035

STOP SWITCH

PLUG COVER

PLUG COVER

ENGINE COVER

M5 x 12 SCREW AND
WASHER : 2 pcs.

M5 x 8 SCREW : 1 pce.

ENGINE COVER

M4 x 16 SCREW AND
WASHER : 2 pcs.

Fig. 5-58

- 39 -

M5 x 12 SCREW AND
WASHER AY : 2 pcs.

M5 x 14 SCREW
AND WASHER

5-4-20 ENGINE OIL, OIL GAUGE

(1) Place the engine horizontally and fill oil from
the oil filling port up to the threaded mouth.
Use Robin genuine oil or engine oil class SF
or higher.
Oil capacity : EH025
EH035

0.08L (80 cc)

0.10L (100 cc)

(2) After filling oil, tighten the oil gauge.

(3) Test run
An engine that has been completely overhauled should be thoroughly RUN-IN, especially when the cylinder, piston rings, valves,
etc., have been changed with new ones.

OIL GAUGE

Fig. 5-59

- End of the reassembly UPPER LIMIT

(MOUTH OF THE OIL
CHARGING PORT)
OIL LEVEL

Fig. 5-60

- 40 -

6. MAGNETO
6-1 FLYWHEEL MAGNETO
The ignition system of the EH025 is the T.I.C. (Transistor, Igniter, Circuit) point less ignition system.

6-2 IGNITION OF MAGNETO

When the engine does not start, has difficulty in starting or does not run correctly, carry out the following
checks for magneto failure.
(1) Check carefully the high voltage wiring for damage and short-circuit.
(2) Check the spark.
1) Remove the spark plug from the cylinder and connect the spark plug with the plug cap and ground
it to the cylinder. (The electrode gap of the spark plug should be 0.7 to 0.8 mm.)
2) Rotate the flywheel by pulling the recoil starter and check the spark and examine the intensity of
the spark.
3) If the plug does not spark, remove the spark plug and the plug cap, place the high voltage wire end
a few millimeters away from the cylinder, pull the recoil starter and check whether the high voltage
wire end sparks.

- 41 -

7. AUTOMATIC DECOMPRESSION SYSTEM

7-1 FUNCTIONS AND MECHANISM
The decompression system is installed on the cam in order to open the intake valve and relieve the
compression pressure at the first half of the engine compression cycle. The flyweight installed inside the
cam gear has an appropriate shape (weight) to have the effect of the centrifugal force, and the end of the
rotary shaft has a crescent cam shape. Since the gravity force on the weight is larger than the centrifugal
force on the weight at the low cam gear revolution when starting, the crescent cam projects the cam
profile and lifts up the follower of the cam lifter, opens the intake valve.

FLYWEIGHT
CAMLIFTER

CRESCENT
CAM

ION
AT
T
RO

Fig. 7-1

When the engine is running, the crescent cam is retracted into the camshaft profile because the centrifugal force applied onto the flyweight becomes larger than the gravity force and the decompression turns
OFF.
FLYWEIGHT
CAMLIFTER

CRESCENT
CAM

N
TIO
TA
O
R

Fig. 7-2

7-2 INSPECTION
(1) When assembling the cam gear assembly, be sure that the spring hook is hooked on the flyweight.
(2) Be sure that the flyweight moves smoothly.
- 42 -

8. CARBURETOR
8-1 OPERATION AND CONSTRUCTION
8-1-1 FUNCTIONS AND CONSTRUCTION OF THE DIAPHRAGM SYSTEM
This engine is equipped with a diaphragm type carburetor.
Since the fuel level is kept constant, irrespective of the tilting angle of the engine, it can be operated at
any position. The float chamber is provided with a diaphragm and is covered with a cover. When negative
pressure is generated in the air intake, the diaphragm bulges up, thereby pushing up the metering lever
and opening the inlet needle valve. When the negative pressure disappears, the spring forces the valve
shut. Therefore, fuel flow rate can be controlled by appropriately determining the diaphragm area and the
spring load.

AIR INTAKE
INLET NEEDLE VALVE
JET

METERING LEVER

DIAPHRAGM
ASSEMBLY
FUEL

Fig. 8-1

- 43 -

FUEL

8-2 DISASSEMBLY AND REASSEMBLY

14
13

3
15

17

18

16

19

20

21

22

12

9
23
10
24
11
25

Fig. 8-2

1. Screw

9. Jet

17. Inlet needle valve

2. Plug

10. Gasket, pump

18. Metering lever

3. Swivel

11. Diaphragm, pump

19. Screw, metering lever pin

4. Washer

12. Spring, pump

20. Metering diaphragm gasket

5. Ring, spring retaining

13. Body assembly, pump

21. Diaphragm assembly, metering

6. Valve assembly, throttle

14. Inlet screen

22. Body assembly air purge

7. Body assembly, carburetor

15. Metering lever spring

23. Primer pump

8. O-ring

16. Metering lever pin

24. Primer pump cover

25. Screw

- 44 -

8-2-1 PRECAUTIONS
(1) Wash the carburetor with clean gasoline before disassembly.
(2) Disassemble and reassemble the carburetor by referring to the exploded view.
(3) Refrain from disassembling the throttle valve assy. (6), pump body assy. (13) and the main body.

8-2-2 DISASSEMBLY AND REASSEMBLE PROCEDURES

(1) Removes the screw (25) and the primer pump cover (24). Remove dust or foreign matter stuck on the
primer pump (23), if any.
(2) Remove the pump body assy. (13) from the main body (Be careful not to lose the spring (15)).
Remove dust or foreign matter caught in the inlet screen (14), if any.
(3) Remove the jet (19) from the main body.
(4) Remove the screw (1) and remove the throttle valve assy. (6) from the main body.
(5) When assembling the carburetor, be sure that the jet (9) and the spring (12) are firmly installed.

8-2-3 PRECAUTIONS FOR INSPECTION

(1) Wash the main body with gasoline and blow it clean with compressed air.
(2) Check the jet for dust stuck on the surface, corrosion, etc. If there is dust stuck on the jet, wash it and
blow it clean with compressed air. If the jet is corroded, replace it with a new one. (NOTE : When
replacing a jet, be sure of using a new one with the same number).
(3) Check the gasket for deformation and damage. If it is deformed or damaged, change with a new one.
(4) The pump (diaphragm) should not be hardened nor damaged.
(5) The inlet valve and the outlet valve should be flat and not bent.
(6) The diaphragm assy. should be free of any hardening, damage or bent.
(7) After assembling the pump body assy.,check it for deformation of the metering lever and metering
spring, height of the metering lever, dust stuck on the inlet screen, valve leakage, etc. To check the
main check valve for correct operation, connect a vinyl or rubber hose to the check valve portion from
the jet side and breathe it with your mouth. If the valve stops when blown and closes when sucked,
the valve is working normally. If there is any abnormality, immerse it in gasoline for approximately 10
minutes and then blow and suck it repeatedly. If the valve can not be fixed even by doing so, replace
it with a new pump body assy.
(NOTE : Refrain from blowing the main check valve with compressed air. When using an air gun,
keep them approximately 30 cm apart of each other when the compressed air has a pressure of 6 kg/
cm2).
(8) Check the primer pump for any hole, damage or abnormal hardening. Be sure that the combination
valve is working normally.

- 45 -

8-2-4 MARKS ON THE CARBURETOR

Marks are stamped as shown in the figure at the
right.
1 Model No.
2 Date of manufacture

Example
1 : 116 ---------- WYL116 (Walbro model No.)
2 : 914
week 14 (May. 29-Apr. 2)

1999

Fig. 8-3

- 46 -

9. RECOIL STARTER
9-1 HOW TO DISASSEMBLE
The recoil starter rarely have problem under normal use. When it fails, however, or when greasing,
disassemble and reassemble it according to the following procedure.
Tools : Screwdriver and pincers (pliers)
(1) Remove the recoil starter from the engine.
(2) Pull out the starter knob, hold the rotary reel
with your thumb as shown in Figure 9-1 when
the reel notch gets aligned with the starter rope
outlet, and pull the starter rope to inside the
recoil starter with a screwdriver.
Hook the starter rope to the notch, and rewind
the reel to the arrow direction until it stops, by
controlling the rotation of the reel with your
thumb.

NOTCH

Fig. 9-1

- 47 -

(3) Remove the parts as shown in Fig. 9-2.

Remove the reel slowly while turning it back and forth gently, otherwise the spiral spring may escase
from the case which may invite danger. (It the spiral spring escapes, put it in the case by following
procedure shown in Fig. 9-6.)
Untie the starter rope knot at the reel end and withdraw it to complete disassembling.

EH025

SWING ARM
REEL
SPIRAL SPRING

SET SCREW

STARTER SHAFT

COLLAR

STARTER KNOB

REEL

EH035

SPIRAL SPRING
SET SCREN

STARTER KNOB

Fig. 9-2

- 48 -

9-2 HOW TO REASSEMBLE

(1) Pass the starter rope through the starter knob
and make an overhand knot as shown in Fig.
9-3. Pass the opposite side of the starter rope
from the starter case to the reel, and make a
knot in the same way, then put the rope end
securely into the rope housing in the reel.
Then, apply a small amount of grease on the
starter shaft and on the spiral spring.

RO
APPmm
10
X.

(2) Check that the spring is securely set in the

reel and form the spring end to have 1 to 2
mm clearance between inner end of the spring
and the reel bush so that the inner end catches
the hook securely as shown in Fig. 9-4. The
shape of spring inner end (approx. 10 cm from
the end) can be adjusted with plier if necessary.

X.
RO
P
AP mm
10

Fig. 9-3

SPIRAL SPRING END

REEL

(3) Prior to installing the reel in the starter case,

wind the starter rope to the reel in the arrow
direction of Figure 9-5, take out the third turn
of the starter rope from the reel notch and then
install the reel securely inside the starter case
so that the spiral spring inner end catches the
hook. Next, hold the starter rope as shown in
Figure 9-5, and rotate the reel 4 to 5 turns in
the arrow direction by utilizing the reel notch.
After winding the reel, hold it securely to prevent it from reverse turn and pull out the starter
knob to stretch the rope tight and then release
the knob slowly. Rassemble the parts in reverse order of disassembling shown in Fig.
9-2. Tighten the setscrew securely.

SPIRAL SPRING
INNER END
HOOK

APPLY
GREASE
REEL BUSH

STARTER SHAFT
1 to 2 mm
REEL

Fig. 9-4

*Be sure to check the following to make sure

that the parts are securely installed.

Fig. 9-5

- 49 -

9-3 CHECK AFTER REASSEMBLE

(1) Pull the starter knob a few times to check if:
A. The starter knob is too heavy to pull, check that each part has been assembled as specified.
B. The ratchet fails to function, check is parts such as friction spring have been missing.
(2) Pull out the starter knob to extend the rope to its extreme to see if:
A. The starter rope still remains in the rope slot of the reel, unwind the rope by 1 to 2 turns as shown
in Fig. 9-1, as the spring may be over-stressed.
B. The starter rope is found weak to recoil or droops in halfway, apply grease or mobile oil to the
rotating part and to the friction parts. If it persists, wind-up the spring by 1 to 2 turns. (In this case,
check that the spring is not over-stressed.)
C. The spring escapes with a sound and the starter rope fails to spring back to its original position,
reassemble the starter from the beginning.

9-4 OTHER GUIDES

(1) When the spring escapes from the reel :
Make a ring having a rather small diameter
than spring housing using a thin wire.
Hook the outer end of the spring onto a part of
the ring and re-wind the spring into the wire
ring as shown in Fig.9-6 then put it into the
housing.
Remove the ring slowly while holding down
the spring to avoid getting out of place.
The ring can easily be removed by prying it
with the tip of a screwdriver.
Refer to Fig.9-4 for which way the spiral spring
must be placed.
(2) When it is lubricated :
Lubricate the starter shaft and spring with a
grease (If possible, heat-resistant type is preferable) or a mobile oil when the starter is being disassembled and prior to long-term storage.
(3) When the swing arm does not move smoothly:
Apply grease (Alevin No. 3) or mobile oil on it.

- 50 -

WIRE RING

SPRING

Fig. 9-6

10. TROUBLESHOOTING
The following three conditions must be fulfilled for satisfactory engine start.
1. The cylinder filled with a proper fuel-air mixture.
2. Good compression in the cylinder.
3. Good spark, properly timed, to ignite the mixture.
The engine cannot be started unless these three conditions are met. There are also other factors which
make engine start difficult, e. g., a heavy load on the engine when it is about to start at low speed, and a
high back pressure due to a long exhaust pipe.
The most common causes of engine troubles are given below :

10-1 STARTING DIFFICULTIES

10-1-1 FUEL SYSTEM
(1) No gasoline in the fuel tank.
(2) The carburetor is not choked sufficiently especially when the engine is cold.
(3) Water, dust or gum in the gasoline interfering the fuel flow to the carburetor.
(4) Inferior grade gasoline or poor quality gasoline not vaporized enough to produce the correct fuel-air
mixture.
(5) If the carburetor overflows, excessive fuel runs into the cylinder when starting the engine, making the
fuel-air mixture too rich to burn. If this happens, remove the spark plug, and turn the starting pulley a
few turns in order to let the rich fuel-air mixture out of the spark plug hole into the atmosphere.
Keep the choke valve open during this operation.
Dry the spark plug well, screw it into place, and try to start again.

10-1-2 COMPRESSION SYSTEM

If starting difficulties and loss of power are not due to the fuel system or ignition system, the following
must be checked for possible lack of compression.
(1) Engine inside is completely dried up because of a long period of storage.
(2) Loose or broken spark plug. This causes a hissing noise made by mixture gas running out of cylinder
in compression stroke during cranking.
(3) Damaged head gasket or loose cylinder head. A similar hissing noise is produced during compression stroke.
(4) Incorrect Valve clearance
If the correct compression is not obtained even after remedying the above, disassemble the engine
and check further as follows :
a) Valve stuck open due to carbon or gum on the valve stem.
b) If the piston rings are stuck on the piston, remove the piston and connecting rod from the engine.
Clean or replace the parts.
- 51 -

10-1-3 IGNITION SYSTEM

Check the followings for lack of spark.
(1) Wires of the ignition coil, spark plug or contact breaker disconnected.
(2) Ignition coil damaged and shorted.
(3) Spark plug cable wet or soaked with oil.
(4) Spark plug dirty or wet.
(5) Spark plug electrode gap incorrect.
(6) Spark plug electrode is connected or bridged.
(7) Incorrect spark timing.

10-2 ENGINE MISFIRES

(1) Incorrect spark plug electrode gap. Adjust it to anywhere between 0.7 and 0.8 mm.
(2) Ignition cable worn and leaking.
(3) Sparks weak.
(4) Ignition wire connections loose.
(5) Water in gasoline.
(6) Insufficient compression.

10-3 ENGINE STOPS

(1) Fuel tank empty. Water, dirt, gum, etc. in gasoline.
(2) Vapor lock, i. e., gasoline evaporating in the fuel lines due to overheat around the engine.
(3) Vapor lock in the fuel lines or carburetor due to the use of too volatile winter gas in the hot season.
(4) Air vent hole in the fuel tank cap plugged.
(5) Bearing parts seized due to lack of oil.
(6) Magneto or ignition coil faulty.

- 52 -

10-4 ENGINE OVERHEATS

(1) Crankcase oil level low. Add oil immediately.
(2) Spark timing incorrect.
(3) Low grade gasoline is used, or engine is overloaded.
(4) Cooling air circulation restricted.
(5) Cooling air path misdirected causes loss of cooling efficiency.
(6) Cylinder head cooling fins clogged up with dirt.
(7) Engine operated in an enclosed space without sufficient cooling air.
(8) Exhaust gas discharge restricted, or carbon deposits in the combustion chamber.
(9) Engine running on low-octane gasoline detonates due to heavy load at low speed.

10-5 ENGINE KNOCKS

(1) Poor quality gasoline.
(2) Engine operating under heavy load at low speed.
(3) Carbon or lead deposits in the cylinder head.
(4) Spark timing incorrect.
(5) Loose connecting rod bearing due to wear.
(6) Loose piston pin due to wear.
(7) Curses of engine overheat.

10-6 ENGINE BACKFIRES THROUGH CARBURETOR

(1) Water or dirt in gasoline, or low-grade gasoline.
(2) Intake valve stuck.
(3) Valves overheated, or hot carbon particles in the combustion chamber.
(4) Engine cold.

- 53 -

11. INSTALLATION
Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost all
depend on the way in which the engine is installed. Review the following instructions carefully for installing the engine.

11-1 INSTALLING
When mounting the engine, carefully examine its position, the method of connecting it to a machine, the
foundation, and the method of supporting the engine.
When determining its mounting position, in particular, make sure that gasoline and oil can easily be
supplied and checked, the spark plug can easily be checked, the air cleaner can easily be serviced, and
that the oil can easily be discharged.

11-2 VENTILATION
Fresh air is necessary for cooling the engine and burning the fuel.
In the case the engine is operated under a hood or in a small room, temperature rise in the engine room
can cause vapor lock, oil deterioration, increased oil consumption, loss of power, piston seizure, shorter
engine life, etc., making it impossible to operate the engine properly. It is necessary, therefore, to provide
a duct or baffle to guide cooling air to the engine to prevent recirculation of the hot air used for engine
cooling, and temperature rise of the machine. Keep the engine room temperature below 50
C even in the
hottest period of the year.

11-3 EXHAUST GAS DISCHARGE

Exhaust gas is noxious. When operating the engine indoors, be sure to discharge the exhaust gas
outdoor. If a long exhaust pipe is used in such a case, the internal resistance increases causing loss of
engine power. Thus pipe inside diameter must be increased in proportion to exhaust pipe length.
Exhaust pipe : Less than 3 m long, pipe inside diameter 30 mm ,
Less than 5 m long, pipe inside diameter 33 mm.

11-4 POWER TRANSMISSION TO DRIVEN MACHINES

11-4-1 BELT DRIVE
Take the following notes into consideration.
* V-belts are preferable to flat belts.
* The driving shaft of the engine must be parallel to the driven shaft of the machine.
* The driving pulley of the engine must be in line with the driven pulley of the machine.
* Install the engine pulley as close to the engine as possible.
* If possible, span the belt horizontally.
* Disengage the load when starting the engine.
If no clutch is used, use a belt tension pulley or the like.

11-4-2 FLEXIBLE COUPLING

When using a flexible coupling, run out and misalignment between the driven shaft and engine shaft
must be minimized. Run out and misalignment tolerance are specified by the coupling manufacturer.
- 54 -

12. SERVICE DATA

12-1 CLEARANCE DATA AND LIMITS
Unit : mm (in)
ITEM

STD

Limit

EH025

3.005 - 3.025
(0.118 - 0.119)

3.1
(0.122)

EH035

3.505 - 3.525
(0.138 - 0.139)

3.6
(0.142)

EH025

34.00 - 34.02
(1.3386 - 1.3394)

34.06
(1.3409)

EH035

39.00 - 39.02
(1.5354 - 1.5362)

39.06
(1.5378)

CYLINDER
* Valve guide inside dia.

* Inside dia.

STD

- 55 -

Unit : mm (in)
ITEM

STD

Limit

EH025

33.959 - 33.980
(1.3370 - 1.3378)

33.940
(1.3362)

EH035

38.959 - 38.980
(1.5338 - 1.5346)

38.940
(1.5331)

0.03 - 0.07
(0.0012 - 0.0028)

0.12
(0.005)

4.5-8.2 mm

PISTON
* Piston size (At skirt in thrust direction)

STD

* Ring groove side clearance

Top

EH025

0.02 - 0.06
(0.0008 - 0.0024)

EH035

0.03 - 0.07
(0.0012 - 0.0028)

2nd

0.12
(0.005)

Oil ring

0.04 - 0.14
(0.0016 - 0.0055)

0.20
(0.008)

EH025

7.996 - 8.005
(0.3148 - 0.3152)

8.03
(0.3161)

EH035

9.996 - 10.005
(0.3935 - 0.3939)

10.03
(0.3949)

EH025

7.994 - 8.000
(0.3147 - 0.3149)

7.988
(0.3145)

EH035

9.994 - 10.000
(0.3935 - 0.3937)

9.988
(0.3932)

0.1-0.25
(0.0039-0.0098)

0.8
(0.0315)

0.1 - 0.25
(0.0039 - 0.0098)

0.8
(0.0315)

0.1 - 0.6
(0.0039 - 0.0236)

0.8
(0.0315)

* Piston pin hole

* Piston pin outside dia.

* Piston ring end gap

EH025

Top
EH035

EH025

2nd
EH035

Oil
ring

EH025
EH035

- 56 -

Unit : mm (in)
ITEM

STD

Limit

23.20 - 23.30
(0.9134 - 0.9173)

22.65
(0.8917)

5.01 - 5.06
(0.1972 - 0.1992)

-----------

EH035

4.99 - 5.00
(0.1965 - 0.1969)

-----------

EH025

2.975 - 2.990
(0.1171 - 0.1177)

2.9
(0.1142)

EH035

3.475 - 3.490
(0.1368 - 0.1374)

3.4
(0.1339)

EH025

2.950 - 2.965
(0.1161 - 0.1167)

2.9
(0.1142)

EH035

3.450 - 3.465
(0.1358 - 0.1364)

3.4
(0.1339)

EH025

0.015 - 0.050
(0.0006 - 0.0020)

EH035

0.017 - 0.050
(0.0007 - 0.0020)

CAMSHAFT
* Cam height (IN. and EX.)
EH025

EH035
D1

* Journal outside dia.

D2

EH025
D1

EH035
EH025

D2

VALVE
* Valve stem outside dia.
IN.

EX.

*Clearance between valve stem dia. and valve

guide.
IN.

EH025

EX.

0.040 - 0.075
(0.0016 - 0.0030)

0.2
(0.0079)

0.2
(0.0079)

EH035

* Valve clearance

IN. / EX.
(cold)

* Valve lift

0.13 - 0.17
(0.0051 - 0.0067)

3.0 - 3.2
(0.1181 - 0.1260)

2.6
(0.1024)

EH025

17.7
(0.6969)

-----------

EH035

21.0
(0.8268)

-----------

IN. / EX.
* Valve spring free length (IN. and EX.)

- 57 -

12-2 TORQUE SPECIFICATIONS

Tightening Torque
ITEMS
N-m

Kg-cm

ft-lb.

Retainer plate (Crankcase)

3-4

30 - 40

2.2 - 2.9

Cylinder block (Crankcase)

4.5 - 6.5

45 - 65

3.3 - 4.7

Oil case (Crankcase)

4 - 5.5

40 - 55

2.9 - 4.0

Cam gear cover

4 - 5.5

40 - 55

2.9 - 4.0

Ignition coil

2-4

20 - 40

1.4 - 2.9

Flywheel

9 - 12

90 - 120

6.5 - 8.8

Clutch

7.5 - 10

75 - 100

5.4 - 7.2

Rocker arm (adjust screw)

5 - 6.5

50 - 65

3.6 - 4.7

Rocker cover

4 - 5.5

40 - 55

2.9 - 4.0

Muffler

7-9

70 - 90

5.1 - 6.5

Muffler cover

3-5

30 - 50

2.2 - 3.6

Insulator carburetor
(insulator&crankcase)

4 - 5.5

40 - 55

2.9 - 4.0

Recoil starter

1 - 2.5

10 - 25

0.7 - 1.8

Blower housing (engine cover)

2-4

20 - 40

1.4 - 2.9

Spark plug

9 - 13

90 - 130

6.5 - 9.4

Cover (air cleaner)

0.5 - 1

5 - 10

0.04 - 0.7

2-4

20 - 40

1.4 - 2.9

4 - 5.5

40 - 55

2.9 - 3.9

1.5 - 3

15 - 30

1.1 - 2.2

Air cleaner plate

Pulley
Plug cover

EH035

- 58 -

12-3 OIL GRADE CHART

Use oil classified SF or higher.
Multi-grade oil tends to increase its consumption at high ambient temperature.
Comparison between oil viscosity and temparature
5W
10W
20W

Single
grade

#20

Specified
Lubricant
Quality

#30
#40

10W-30

Multigrade

10W-40
20W-40
- 20
-4

- 10
14

0
32

- 59 -

10
50

20
68

30
86

40 C
104 F

13. MAINTENANCE AND STORAGE

The following maintenance jobs apply when the engine is operated correctly under normal conditions.
The indicated maintenance intervals are by no means guarantees for maintenance free operations during these intervals.
For example, if the engine is operated in extremely dusty conditions, the air cleaner should be cleaned
every day instead of every 50 hours.

13-1 DAILY MAINTENANCE

MAINTENANCE ITEMS

REMARKS

1) Clean away dust and chaff from engine.

Governor linkage is especially sensitive to dust.

2) Check fuel leakage from fuel system. If any,

retighten fasteners or replace necessary parts.
3) Inspect for loose hardware and retighten if
necessary.

Loose bolts and nuts may come off and result in

breakage of other parts.

4) Check oil level and add up to full mark.

13-2 INITIAL 20 HRS. MAINTENANCE

MAINTENANCE ITEMS
1) Change crankcase oil.

REMARKS
To remove sludge from run-in operation.

13-3 EVERY 50 HRS. (10 DAYS) MAINTENANCE

MAINTENANCE ITEMS
1) Change crankcase oil.

REMARKS
Contaminated oil quickens wear.

2) Clean air cleaner.

3) Check and clean spark plug.

- 60 -

13-4 EVERY 100-200 HRS. (MONTHLY) MAINTENANCE

MAINTENANCE ITEMS

REMARKS

1) Clean fuel filter and fuel tank.

2) Inspect cooling system and remove dirt and chaff.

Remove blower housing and clean up between fins

and housing.

3) Overhaul engine.

Clean and correct parts.

Replace piston rings and other necessary parts.

4) Replace fuel lines once a year.

Avoid hazards caused by fuel leakage.

13-5 ENGINE STORAGE

(1) Perform the above 13-1 and 13-2 maintenance jobs.
(2) Drain fuel from the fuel tank and carburetor.
(3) To prevent rust in the cylinder bore, apply oil through the spark plug hole and turn the crankshaft
several turns by hand. Reinstall the plug.
(4) Turn the starting pulley by hand and leave it where the resistance is the heaviest.
(5) Clean outside of the engine with oiled cloth.
(6) Put a plastic cover or the like over the engine and store the engine in dry place.

- 61 -

PRINTED IN THE USA