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Cobra Y145V Service Manual

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MODEL: Y145V
COBRA ENGINE
SERVICE MANUAL
Cobra Garden Machinery
Henton and Chattell Ltd., London Road, Nottingham NG2 3HW UK
www.cobragarden.co.uk

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Summary of Contents for Cobra Y145V

  • Page 1 MODEL: Y145V COBRA ENGINE SERVICE MANUAL Cobra Garden Machinery Henton and Chattell Ltd., London Road, Nottingham NG2 3HW UK www.cobragarden.co.uk...

  • Page 2: Table Of Contents

    CONTENT CONTENT 1. INTRODUCTION.......................1 1-1 Parts Description......................1 1-2 Specifications......................2 1-3 Service Limit....................... 2 2. DIMENSION AND TORQUE....................4 2-1 Dimension........................4 2-2 The Position Of Installing Hole...................5 2-3 PTO Installing Drawing....................5 2-4 Torque Value.......................6 2-5 Standard Torque Value....................7 3.
  • Page 3 CONTENT 4-2-2 Special Tools....................21 4-3 Dismounting Chart....................22 4-4 Gasoline Engine......................23 4-4-1Recoil starter / fan cover................. 23 4-4-2 Muffler......................26 4-4-3 Fuel Tank....................... 27 4-4-4 Air Cleaner.....................28 4-4-5 Governor......................30 4-4-6 Carburetor...................... 32 4-4-7 Flywheel......................37 4-4-8 Cylinder Head / Valve..................41 4-4-9 Crankshaft / Piston..................

  • Page 4: Introduction

    1. INTRODUCTION INTRODUCTION Parts Description...

  • Page 5: Specifications

    1. INTRODUCTION Specifications MODEL Y145V ITEM L×W×H(not including crankshaft 415×345×280(mm) output terminal) 9.5Kg Dry Weight Engine Type Single Cylinder Horizontal,4-Stroke, OHV Displacement 144.3cc 65mm×43.5mm Bore × Stroke Theoretical Maximum Power 2.6kW/3,600r/min 2.0Kw /2800r/min Recommended Using Power Maximum Torque 7N· m /2,800r/min 410g/kW·...
  • Page 6 1. INTRODUCTION 12.007-12.022 Small End I.D 12.050 22.020-22.033 22.060 Big End I.D Connecting Rod 0.14-0.16 Big End Clearance 0.20 0.01-0.03 Small End Clearance 0.08 22.10 Crankshaft Crankshaft Pin O.D 22.17-22.18 Valve Clearance 0.10±0.02 0.15±0.02 Stem O.D 5.465-5.480 5.315 5.465-5.480 5.315 Guide I.D IN/EX 5.500-5.512...

  • Page 7: Dimension And Torque

    2. DIMENSION AND TORQUE DIMENSION AND TORQUE Dimension...

  • Page 8: The Position Of Installing Hole

    2. DIMENSION AND TORQUE The Position Of Installing Hole 2-3 PTO Installing Drawing Q161 Shaft...

  • Page 9: Torque Value

    2. DIMENSION AND TORQUE Torque Value ITEMS FASTENERS TORQUE VALUE (N· m ) Connection-Rod Bolt M5×26 10±0.5 Governor Gear Bolt M6×12 11±1 11±1 Crankcase Cover Bolt M6×30 Spark Plug M14-1.25 18±2 Cylinder Head Bolt M8×45 26±2 Rotation Shaft Locked Nut M6 ×...

  • Page 10: Standard Torque Value

    2. DIMENSION AND TORQUE Standard Torque Value FASTENERS SPECIFICATION TORQUE VALUE(N·m) 5mm Bolt, Nut 4.5-6 6mm Bolt, Nut 8-12 8mm Bolt, Nut 18-25 10mm Bolt, Nut 29-34 12mm Bolt, Nut 49-59 4mm Screw 1.5-2.6 5mm Screw 3.5-5 Bolt, Nut 6mm Screw 7-11 5mm Flange Bolt 3.6-6.9...

  • Page 11: Maintenance

    3. MAINTENANCE MAINTENANCE Maintenance Schedule FREQUENCY EVERY 6 EACH FIRST MONTH EACH SEASON EACH YEAR MONTH OR 100 TIME OR 20 HRS OR 50 HRS OR 300 HRS ITEM Oil Level √ Check Engine Oil Replace √ √ Check √ Air Cleaner Clean Replace √...
  • Page 12 3. MAINTENANCE When the temperature in your area is in the frame of the above chart, you can use other viscosity of engine oil. OIL DIPSTICK SEALING RING (Don’t Refuse) OIL UPPER LIMIT OIL LOWER LIMIT OIL HOLE CHECK METHOD 1.

  • Page 13: Air Cleaner

    3. MAINTENANCE Air Cleaner Wash the engine each 50 hrs (or 3 months). (Wash more frequently in dust area) Remove the air cleaner cover and take the element out.  Change the damaged element.  Clean the element before reusing. ...

  • Page 14: Wash The Strainer

    3. MAINTENANCE Wash The Strainer Don’t smoke or use fire near the flammable solvent. FUEL TANK a) Fill the fuel into the container b) Remove the fuel tube, screw the strainer bolt off. c) Check the strainer for damage and clean the strainer.

  • Page 15: Valve Clearance Adjustment

    3. MAINTENANCE e) To avoid cross-threading, first, screw in spark plug by hand, then tighten with a spark plug wrench to compress the gasket. If a new spark plug is used, more twist 1/2 turns after compressing the gasket. g) If reinstalling the used spark plug, just more twist 1/8-1/4 turns. Spark plug torque value：18±2N·...
  • Page 16 3. MAINTENANCE After the cylinder head cover is removed, engine oilmay flow. Be sure to wipe up any flowed oil. b) Pull the starting rope lightly and set the piston at top dead center of the compression stroke (Insert a feeler gauge between the rocker arm and valve to measure the valve clearance).

  • Page 17: Governor

    3. MAINTENANCE Clearance too big: Intake and exhaust valve opening delay will shorten the intake and exhaust time, lower the opening height of the valve and change normal distributing phase to result in power lowering from the intake lack and exhaust uncompleted. Furthermore, also make vale train parts knock increasing and wearing quickly.

  • Page 18: Disassembling And Servicing

    4. DISASSEMBLING AND SERVICING DISASSEMBLING AND SERVICING Troubleshooting 4-1-1 Starting Difficult TROUBLE CAUSE REMEDY There is no enough fuel in fuel tank and Fill fuel, open fuel cock. fuel cock is closed. Air vent in the fuel filler cap is clogged Dredge air vent.
  • Page 19 4. DISASSEMBLING AND SERVICING TROUBLE CAUSE REMEDY Piston ring is worn to or even over its Replace wear limit Piston ring is broken. Replace Piston ring is sticking. Clear up carbon fouling. Spark plug is not installed tighten or Tighten with a gasket in. without a gasket.

  • Page 20: Power Lack

    4. DISASSEMBLING AND SERVICING Turn the fuel cock to “OFF” position, and drain the gasoline of the carburetor.  Remove the spark plug and spark plug cap  Pull the recoil starter grip to drain the gas in the cylinder. ...

  • Page 21: Speed Unstable

    4. DISASSEMBLING AND SERVICING 4-1-3 Speed Unstable TROUBLE CAUSE REMEDY Piston, cylinder or piston ring is worn excessively. Replace the worn Piston pin and piston pin hole are worn excessively. Replace piston or piston pin Knocking Sound Tie rod small head is worn excessively. Replace tie rod Roller bearing for crankshaft main shaft is worn.

  • Page 22: Gasoline Engine Is Overheat

    4. DISASSEMBLING AND SERVICING 4-1-5 Gasoline Engine Is Overheat TROUBLE CAUSE REMEDY Oil insufficient in the gasoline Refill engine oil Exhaust pipe blocked up Clean exhaust pipe Shroud leaking Repair damaged part Cooling fins blocked by foreign matter Clear cooling fins Connection rod deformation to make piston and cylinder Replace connection rod bushing side wear...

  • Page 23: Preparation Of Servicing

    4. DISASSEMBLING AND SERVICING Preparation Of Servicing 4-2-1 Safety Precautions Indicate a possibility of invalid warranty and personal or equipment damage if instructions are not followed. Please pay special attention to the following: 1. Strictly set the engine according to the regulated power on the nameplate. Do not overload, overrun the engine or run it with low load and at low speed in a long time.

  • Page 24: Special Tools

    4. DISASSEMBLING AND SERVICING 4-2-2 Special Tools TOOL NAME APPLICATION NOTE Float lever gauge Carburetor float level inspection 1. Valve guide driver Valve guide removal, installation. 2. Retainer assembler Assembling ball bearing 3. Assembler handle Installing handle and bearing 4. Inner retainer assembler Assembling ball bearing and time.

  • Page 25: Dismounting Chart

    4. DISASSEMBLING AND SERVICING Dismounting Chart ENGINE CARBURETOR FLYWHEEL AIR CLEANER SHROUD RECOIL STARTER MUFFLER ENGINE HOUSING...

  • Page 26: Gasoline Engine

    4. DISASSEMBLING AND SERVICING Gasoline Engine 4-4-1Recoil starter / fan cover Removal：...
  • Page 27 4. DISASSEMBLING AND SERVICING Wear gloves and eye protection during disassembly, and take care not to allow the return spring to come out. Installation Instruction ① Pass the recoil starter rope through the rope in the recoil starter pulley and make a figure-eight knot at the rope end. Check the rope foe wearing and broken before reassembling, then, install it.
  • Page 28 4. DISASSEMBLING AND SERVICING ⑥ Pass the recoil starter rope through the recoil starter case and recoil starter grip, and make a figure-eight knot at the rope end. ⑦ Pull the recoil starter rope lightly to check the drive cam for function.

  • Page 29: Muffler

    4. DISASSEMBLING AND SERVICING 4-4-2 Muffler Removal / Installation Disassemble the muffler as shown on the figure. The muffler can produce carbon deposits in the long time operation and seriously trouble the exhaust system. To get the best performance, the muffler must be periodically removed the carbon deposits.

  • Page 31: Fuel Tank

    4. DISASSEMBLING AND SERVICING 4-4-3 Fuel Tank a) Removal / Installation The fuel tank does not require general maintenance, but, sometimes the dusts and vapor will trouble the fuel system, so that, periodically washing it with lubrication oil and gasoline is required.
  • Page 32 4. DISASSEMBLING AND SERVICING Remove the fuel tube, screw the fuel strainer bolt off and remove the fuel tank.  Clean the fuel tank and dry it thoroughly.  After Cleaning, install the strainer on the fuel tank and connect the fuel tube. ...

  • Page 33: Air Cleaner

    4. DISASSEMBLING AND SERVICING NOTICE Check for damage of the air cleaner and install.  AIR CLEANER Note the installation direction, view from the air  GASKET cleaner side. Before installing the breather tube, check for  deterioration or damage. Replace if necessary. Pay attention to connect the beveled end smaller to the air cleaner case and other end to the engine.
  • Page 34 4. DISASSEMBLING AND SERVICING 4-4-5 Governor Removal / Installation...

  • Page 35: Governor

    4. DISASSEMBLING AND SERVICING THROTTLE VALVE RETURN SPRING (Hook the left end hook into the hole of the Throttle valve shaft projection . ) GOVERNOR LEVER (Insert the left end into vertical hole of the throttle valve) SPRING SPRING CHOKE LEVER BOLT M6×12 GOVERNOR RASSY...
  • Page 36 4. DISASSEMBLING AND SERVICING 4-4-6 Carburetor At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Output power will decrease, and fuel consumption will increase. Engine performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw.

  • Page 37: Carburetor

    4. DISASSEMBLING AND SERVICING THROTTLE VALVE THROTTLE SHAFT CHOKE SHAFT INSULATOR CHOKE GASKET (Don’t Reuse) CARBURETOR INSULATOR AIR CLEANER CARBURETOR CARBURETOR GASKET Gasket (Don’T (Don’T Reuse) Reuse) Wash the carburetor in the clean place, first, clean the outside surface, and wash the inside the parts with special carburetor detergent or industrial gasoline.
  • Page 38 4. DISASSEMBLING AND SERVICING a) Carburetor disassembly： PILOT JET STOP THROTTLE SCREW O-RING PILOT SCREW CARBURETOR (Clean With Compressed Before Installation) FLOAT PIN FLOAT VALVE MAIN NOZZLE MAIN JET FLOAT （ After installation, check for operation by lightly pushing with a finger） FLOAT CHAMBER GASKET DRAIN BOLT...
  • Page 39 4. DISASSEMBLING AND SERVICING Check the float valve, float seat and float spring for wear.  FLOAT VALVE FLOAT VALVE WORN NORMAL Clean with compressed air before installation.  MAIN JET Clean with compressed air before installation.  MAIN NOZZLE O-RING Clean with compressed air before ...
  • Page 40 4. DISASSEMBLING AND SERVICING b) After washing the carburetor, reset the pilot screw PILOT SCREW BROKEN back. Only repairing the carburetor can disassemble it.If the pilot screw is broken, replace with new one. Disassemble the broken pilot screw from the ...

  • Page 41: Flywheel

    4. DISASSEMBLING AND SERVICING 4-4-7 Flywheel ①Removal： a) Holding the flywheel with a commercially WHEEL PULLER available strap wrench, remove the nut (Commercial Available) （M14）. b) Disassemble the starter cut and impeller. FLYWHEEL c) Remove with a commercially available flywheel puller. Do not hit the flywheel with a hammer.
  • Page 42 4. DISASSEMBLING AND SERVICING FLYWHEEL (CAST IRON) IMPELLER START HOLE HOLE d) Apply light coat of the oil to the threads and surface of the nut, and install the nut loosely. Torque：52N.m...
  • Page 43 4. DISASSEMBLING AND SERVICING ③Ignition coil STARTI IMPELLER FLYWHEEL BOLT(M6×25) IGNITION COIL HIGH VOLTAGE IGNITION LINE (Check The Insulator For SPARK PLUG CAP Damage, If Damaged, Please Replace It) a) Remove the fuel tank, air cleaner, IGNITION COIL carburetor and recoil starter assy. b) Measure the clearance between the FLY WHEEL CLEARANCE...
  • Page 44 4. DISASSEMBLING AND SERVICING Check the ignition coil （primary side） Measure the resistance of the primary coil by attaching one ohmmeter lead to the ignition coil’s primary terminal while touching the other tester lead to the iron core Primary side resistance value：1.1-1.3Ω （Secondary side）...

  • Page 45: Cylinder Head / Valve

    4. DISASSEMBLING AND SERVICING 4-4-8 Cylinder Head / Valve Removal / Installation ① Remove the muffler ② Remove the air cleaner ③ Remove the recoil starter and shroud ④ Remove the carburetor and insulator...
  • Page 46 4. DISASSEMBLING AND SERVICING CYLINDER HEAD Installation ： Before installation, remove any carbon deposits from the combustion chamber and PIN（10×14） inspect the valve seats. Measure the cylinder compression after reassembly. GASKET BOLT（Ｍ８×45） Loosen and tighten the bolts crisscross SPARK pattern in 2 or 3 steps. PLUG CYLINDER HEAD COVER...
  • Page 47 4. DISASSEMBLING AND SERVICING INTAKE VALVE Reassembly:...
  • Page 48 4. DISASSEMBLING AND SERVICING ⑤ Install the head cover gasket aligning the projection of the head cover gasket with the projection of the cylinder head. ⑥ Valve spring retainer Push down on the valve spring and move the retainer to the side so that valve stem slips through the side hole.
  • Page 49 4. DISASSEMBLING AND SERVICING ② Valve spring free length Measure the free length of the valve Springs. If out of the standard or service limit. Please replace the spring. Standard Service limit 33.5mm 32mm ③ Valve guide Inspect： a) Inspect the valve guide for smooth, scratch and damaged in the inner surface, and matching between the valve guide and cylinder cover for fastness.
  • Page 50 4. DISASSEMBLING AND SERVICING VALVE GUIDE CLIP careful avoid DRIVER damaging cylinder head when driving out the VALVE GUIDE valve guides. INSTALLATION HEIGHT 11MM c) Install the new valve guides from the valve spring side of the cylinder head. Exhaust side: Drive the exhaust valve guide until the clip ...
  • Page 51 4. DISASSEMBLING AND SERVICING the guide may have been bent during installation. Replace the valve guide if it is bent or damaged. Check the valve stem-to-guide clearance. g) The valve stem-to-guide clearance： The vale guide bore detract the valve stem outside diameter to get the clearance between the valve guide and valve stem.
  • Page 52 4. DISASSEMBLING AND SERVICING Use the 32°-45°cutters to narrow and adjust the valve seat so that it contacts the middle of the valve face. The 32°cutter removes material from the top edge (contact too high). d) The 45°cutter removes material from the bottom edge (contact too low). Be sure that the width of the finished valve seat is within specification.

  • Page 53: Crankshaft / Piston

    4. DISASSEMBLING AND SERVICING 4-4-9 Crankshaft / Piston CRANKSHAFT Reassembly： Push in firmly until contact is made with the rearing surface. Be careful not to damage the oil seal.
  • Page 54 4. DISASSEMBLING AND SERVICING ①Disassembly： a) Piston 120° MARKER Install with the maker mark  facing upward as shown. Do not interchange the top ring and the second ring (top ring with SECOND chrome plated). “▽”MARK OIL RING After assembly, check for ...
  • Page 55 4. DISASSEMBLING AND SERVICING c)Oil seal：  Apply oil to the circumference of  a oil seal. Driver Handle Drive the oil seal in the cylinder  RETAINER barrel using following tool. ASSEMBLE OIL SEAL 25×40×7 Tools： Driver handle Retainer assembler Apply the lubrication oil on, after reassembling.
  • Page 56 4. DISASSEMBLING AND SERVICING Clean the carbon deposit Clean the deposit round the piston top and cylinder neck before checking, first soak the carbon deposit with kerosene, and then clean with meter scraper or metal brush. a) Piston skirt O.D Measure the piston skirt O.D with outside micrometer, if out of the service limit, replace it.
  • Page 57 4. DISASSEMBLING AND SERVICING Standard Service Limit 0.015-0.050mm 0.12mm d) Piston ring side clearance Check with placing each ring into each-self groove. The piston ring should be freely turned without loosening and sticking. Then measure with inserting feeler into clearance of the ring and upper and lower face.
  • Page 58 4. DISASSEMBLING AND SERVICING Standard Service Limit 12.007-12.022mm 12.052mm b) Check big end diameter If out of the standard or exceed service limit, replace the connecting rod. Standard Service Limit 22.220-22.233mm 22.250mm c) Connecting rod big end oil clearance  Wipe oil off the crank pin and connecting rod bearing BOLT mating surface.
  • Page 59 4. DISASSEMBLING AND SERVICING ⑤Camshaft check The camshaft is main driving part of the train valve mechanism, which control the intake and exhaust valves opening and closing. Feature: The shaft is equipped with cam and journal which can control intake and exhaust. When operating, camshaft operating face and lifter will be badly rubbed from periodically impacting and easily be damaged.
  • Page 60 4. DISASSEMBLING AND SERVICING ⑥Timing gear a）Check timing gear for engagement clearance with aligning two side mark on the gear. Bolt（M8×45） Oil Seal（25×40×7） Crankcase Cover GASKET (DON’T REUSE IT) GASKET （ 25.4 GOVERNOR ×34×1） WASHER （6.5×12×1） IN INNER SIDE) WITH AFTER SSEMBLING GOVERNOR.
  • Page 61 4. DISASSEMBLING AND SERVICING Timing gear will be damaged in gear worn, gear face peeling off, and gear teeth broken. The engagement clearance is bigger due to gear wearing, the noise is bigger. If the timing gear is damaged, please replace with new one. Please replace the gear with a new set to ensure the engaging face completely engage in.

  • Page 62: Electric Diagrams

    4. DISASSEMBLING AND SERVICING 4-5 Electric Diagrams...

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