Subaru EX35 Service Manual
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Subaru EX35 Service Manual

Gasoline engine aircooled 4 cycle
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  • Page 2: Table Of Contents

    3. FEATURES (EX35, 40 series) ........

  • Page 3: Specifications

    1. SPECIFICATIONS Model EX35D EX40D Air-Cooled, 4-Cycle, Slant Single-Cylinder, Type Horizontal P.T.O. Shaft, OHC Gasoline Engine 89 × 65 (3.50 × 2.56) Bore & Stroke mm (in.) 404 (24.65) Piston Displacement ml (cu.in.) Compression Ratio 5.5(7.5)/3000 6.3(8.5)/3000 Continuous Output kW(HP)/r.p.m. 6.3(8.5)/3600 7.0(9.5)/3600 7.4(10.0)/3600...

  • Page 4: Performance

    2. PERFORMANCE 2-1 MAXIMUM OUTPUT The Maximum output is the output of an engine with its throttle valve fully opened and considering that all the moving parts are properly broken in. A new engine may not produce full maximum output while its moving parts are still not broken-in. NOTE : Power curves shown in the following charts are made in conformity with SAE internal combustion engine standard test code J1349.
  • Page 5 2-4 PERFORMANCE CURVES EX35D MAXIMUM TORQUE MAXIMUM HORSEPOWER CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE REVOLUTION r.p.m. - 3 -...
  • Page 6 EX40D MAXIMUM TORQUE MAXIMUM HORSEPOWER CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE REVOLUTION r.p.m. - 4 -...

  • Page 7: Features (Ex35, 40 Series)

    3. FEATURES (EX35, 40 series) 3-1 HIGH OUTPUT Thanks to the adoption of a cam profile exclusively for intake and exhaust and the optimization of the shape of the intake/exhaust port and the shape of the combustion chamber, the top-of-the-class-level maximum output is achieved.

  • Page 8: General Description Of Engine Components

    4. GENERAL DESCRIPTION OF ENGINE COMPONENTS 4-1 CYLINDER AND CRANKCASE The cylinder and crankcase are aluminum die-casting as a single piece. A special cast iron cylinder liner is molded into the aluminum die-casting. The crankcase has a mounting surface on the output shaft side to which the main bearing cover is attached.
  • Page 9 4-5 PISTON RINGS The piston rings are made of special cast iron. The profile of the top ring is a tapered face. The oil ring is designed for better sealing and less oil consumption, in combination with 3 pieces. TAPER RING THREE-PIECE RING...

  • Page 10: Lubrication System

    * Model EX35 and 40 has a smooth advanced IGNITION COIL ignition timing system to improve starting performance. (For further details, refer to page Fig.4-11...
  • Page 11 4-14 CARBURETOR The engine is equipped with a horizontal draft carburetor. The carburetor setting is calibrated after careful testing for optimum all-round performance (including starting, acceleration, fuel consumption, output power characteristics). Special attention is also paid to the general-purpose use of the engine. Fig.4-12 (For further information, refer to page 54, section “13.
  • Page 12 4-18 SECTIONAL VIEW OF THE ENGINE Cross sectional view – across the shaft FUEL TANK TANK CAP BLOWER HOUSING GOVERNOR LEVER COOLING BLOWER GOVERNOR GEAR RECOIL STARTER HANDLE CRANKSHAFT STARTING PULLEY RECOIL STARTER CONNECTING ROD FLYWHEEL RECOIL BRACKET BOLT MAIN BEARING COVER CHARGE COIL OIL SENSOR (RECOIL BRACKET)
  • Page 13 Cross sectional view – along the shaft GOVERNOR SHAFT CHAIN GUIDE MUFFLER COVER EXHAUST PISTON PIN GOVERNOR LEVER FUEL TANK MUFFLER VALVE TAIL SCREEN or DEFLECTOR (OPTION) GOVERNOR GEAR SPARK ARRESTER (OPTION) MAGNETIC SWITCH ROCKER STOP CAMSHAFT SWITCH INTAKE VALVE PISTON STARTING MOTOR...

  • Page 14: Disassembly And Reassembly

    5. DISASSEMBLY AND REASSEMBLY 5-1 PREPARATIONS AND PRECAUTIONS (1) When disassembling the engine, memorize the location of each part so that you can reassemble the engine correctly. If necessary, attach identification tags with the required assembly information to the parts. (2) Store groups of parts in separate boxes.

  • Page 15: Disassembly Procedure

    5-3 DISASSEMBLY PROCEDURE Step Parts to remove Remarks and procedures Fasteners Drain the engine oill Remove a drain plug (M14 x 12mm) located on both 14 mm spanner sides of the case. Take care not to lose the gaskets. * To discharge oil quickly, remove the oil guage(M22). Drain the fuel Shut (OFF) the fuel strainer.
  • Page 16 Step Parts to remove Remarks and procedures Fasteners Air cleaner cover Remove the air cleaner cover and element. - screwdriver Air cleaner Remove the air cleaner while pulling the breather pipe 10 mm box spanner away from the rocker cover. M6 nut : 2 pcs.
  • Page 17 Step Parts to remove Remarks and procedures Fasteners Muffler and Muffler cover (1) Remove the muffler cover from the muffler. 12 mm box spanner (2) Remove the muffler from the cylinder head. Take 10 mm box spanner or care not to lose the gasket. spanner * Take care not to cut your hand with the muffler M6 x 8 mm : 4 pcs.
  • Page 18 Step Parts to remove Remarks and procedures Fasteners Stop switch Disconnect the wire and remove the stop switch from + screwdriver the blower housing. M4 x 12 mm : 2 pcs. Recoil starter Remove the recoil starter from the blower housing. 10 mm box spanner M6 x 14 mm : 4 pcs.
  • Page 19 Step Parts to remove Remarks and procedures Fasteners Speed control lever and Remove the speed control lever and bracket from the 10 mm box spanner Bracket cylinder head. M6 x 12 mm : 1 pc. Release the bolt temporarily. Slide to dismount the speed control lever and bracket from the cylinder head and the choke lever of the carburetor.
  • Page 20 Step Parts to remove Remarks and procedures Fasteners Ignition coil Remove the spark plug cap from the spark plug and 10 mm box spanner remove the ignition coil from the crankcase. M6 x 25 mm ： 2 pcs. Starting pulley Remove the starting pulley and cooling Blower from the 24 mm box spanner or Cooling Blower...
  • Page 21 Step Parts to remove Remarks and procedures Fasteners [MODEL WITH ELECTRIC STARTER TYPE] Control box, (1) Disconnect the grounding cable from battery. Diode rectifier, (2) Disconnect the wire leading from the key Magnetic switch switch“ST” terminal to the magnetic switch. Electric starter (option) (3) Disconnect the wire that connects the positive 12 mm box spanner...
  • Page 22 Step Parts to remove Remarks and procedures Fasteners [MODEL WITH CHARGE COIL TYPE] Wire clamp Disconnect the wire clamp. 10 mm box spanner M6 x 10 mm : 1 pc. NOTE: Disconnect the wire clamp in this step, also an engine which has both of the charge coil and the oil sensor.
  • Page 23 Step Parts to remove Remarks and procedures Fasteners Rocker cover (1) Remove the rocker cover from the cylinder head. 10 mm box spanner (2) Remove the gasket (rocker cover). M6 x 12mm : 4 pcs. Rocker arm Remove the pin (rocker arm) and the rocker arm from the cylinder head at the compression top dead center.
  • Page 24 Step Parts to remove Remarks and procedures Fasteners Main bearing cover Remove the flange bolts of main bearing cover from 12 mm box spanner the crankcase. M8 x 38mm : 8 pcs. Remove the main bearing cover while tapping gently around the cover using a plastic hammer or similar tool.
  • Page 25 Step Parts to remove Remarks and procedures Fasteners Tensioner, Camshaft (1) Remove the tensioner. (See Fig. 5-20) M10 box spanner or Do not lose the pin (tensioner). spanner (2) Remove the retaining bolt of pin (camshaft) from M6 x 12mm : 1 pc. the cylinder head.
  • Page 26 Step Parts to remove Remarks and procedures Fasteners Cylinder head, (1) Remove the cylinder head from the crankcase. 12 mm box spanner Chain guide (2) Remove the cylinder head gasket from the cylinder head. M10 × 75mm : 4 pcs. Take care not to lose the dowel pin.
  • Page 27 Step Parts to remove Remarks and procedures Fasteners Connecting rod and piston (1) Scrape off any carbon from the cylinder and the 12 mm box spanner piston head, then remove the connecting rod bolt. M8 x 40mm : 2 pcs. (2) Remove the connecting rod cap.
  • Page 28 Step Parts to remove Remarks and procedures Fasteners Crankshaft (1) Remove the woodruff key (for the flywheel magneto). (2) Remove the crankshaft from the crankcase Plastic hammer by tapping its magneto side end with a plastic hammer, taking care not to damage the oil seal. (See Fig.

  • Page 29: Reassembly Procedure

    5-4 REASSEMBLY PROCEDURE 5-4-1 NOTES ON REASSEMBLY (1) Clean the each parts carefully, taking special care with the piston, cylinder, crankshaft, connecting rod and bearings. (2) Scrape off any carbon deposits on the cylinder head and the piston head. Be particularly careful when removing carbon from the piston ring grooves.
  • Page 30 (3) PISTON AND PISTON RINGS OPEN ENDS OF PISTON RING (a) Install each piston ring in the correct groove of the piston by widening it enough to slide it over the piston. NOTE: Be careful not to twist the rings too much, as they may be damaged.
  • Page 31 (4) PISTON AND CONNECTING ROD The piston is attached to the connecting rod by the piston pin. When assembling the piston and connecting rod, make sure to align the mark on the piston head with the ‘MAG’ mark on the connecting When assembling the rod.
  • Page 32 (b) Rotate the crankshaft down to the bottom dead center and lightly tap the piston head until the large end of the connecting rod touches the crank pin. (c) To mount the connecting rod, line up the matching marks and fit the clinch portions firmly together. ALIGNMENT ALIGNMENT MARKS...
  • Page 33 (7) CHAIN GUIDE Mount the chain guide to the crankcase. CHAIN GUIDE Models EX35, 40 mounting positions Fig.5-40 Fig.5-41 (8) CYLINDER HEAD Tightening Torque step step Cylinder head bolts Remarks 29.0 - 31.0 N ・ m (290 - 310 kgf ・ cm) Re-use M10 ×...
  • Page 34 (9) SETTING THE TIMING CHAIN Number of oval steel link : 112 CHAIN GUIDE FITTING POSITION MARK PLATE The mark plate does not have a camshaft side or crankshaft sprocket side. TIMING MARK ROLL PIN TIMING MARK CAMSHAFT SPROCKET CRANKSHAFT SPROCKET MARK PLATE Fig.5-43 (10) MOUNTING THE CAMSHAFT ON THE CYLINDER HEAD...
  • Page 35 (11) MOUNTING THE TENSIONER (TENSIONER) SPRING PIN (TENSIONER) (TENSIONER) TENSIONER Fig.5-45 Fig.5-46 (12) BALANCER SHAFT TIMING MARK BALANCER GEAR CRANKSHAFT GEAR Fig.5-47 - 33 -...
  • Page 36 (13) MAIN BEARING COVER Apply oil to the bearing and the oil seal lip when mounting the main bearing cover. Also apply sealant (Three Bond “1215”) to the surface of the crankcase. To avoid damaging the oil seal lip, wrap the crankshaft key-way portion with polyvinyl tape before mounting the main bearing cover.
  • Page 37 (14) Pass the pin (rocker arm) through the rocker arm and mount them on the cylinder head. ROCKER ARM (EXHAUST VALVE SIDE) NOTE 1: Conduct this job at the compression (ROCKER ARM) top dead center. (The position of two punch marks on cam sprocket is in parallel with the cylinder head surface at a time.) Punch marks...
  • Page 38 (16) ROCKER COVER Replace the gasket with a new one, and mount SPARK PLUG GASKET the rocker cover. (ROCKER COVER) M6 × 12 mm flange bolt : 4 pcs. Tightening torque 5.0 - 7.0 N ・ m (50 - 70 kgf ・ cm) (3.6 - 5.1 ft ・...
  • Page 39 (19) FLYWHEEL, COOLING BLOWER COOLING BLOWER and STARTING PULLEY NOTE: When mounting the flywheel, be sure to wipe off any oil on the tapered portion of the crankshaft and flywheel. a) Mount the flywheel on the crankshaft. b) Install cooling blower and starting pulley to STARTING PULLEY the crankshaft.
  • Page 40 (21) CARBURATOR (a) Replace the gasket of insulator with a new one and mount the insulator on the cylinder head intake side. (b) Mount the carburetor. (22) GOVERNOR LEVER (See Fig.5-58, 59) (a) Pass the governor rod through the rod spring, then connect to the throttle lever of the carburetor. (b) Attach the governor rod and rod spring to the governor lever, then mount the governor lever on the governor shaft.
  • Page 41 The dimensions of the governor spring are different each other according to the Hz. The governor spring for the standard engine is same as that for the engine to be connected to the 60Hz generator. EX35 and 40 / 60Hz (STD) color : silver EX35 and 40 / 50Hz...
  • Page 42 (24) AIR CLEANER BASE ⓐ ⓑ M6 flange nut : 2 pcs. M6 × 16 mm flange bolt : 1 pc. M6 FLANGE NUT : 2 pcs. M6 x 16 FLANGE BOLT : 1 pc. AIR CLEANER BASE GASKET BREATHER PIPE Fig.5-60 (25) SPEED CONTROL LEVER and BRACKET Tighten the bolt which is temporarily fit.
  • Page 43 (26) BAFFLE2, RECOIL BRACKET, BLOWER HOUSING, RECOIL STARTER and STOP SWITCH (1) Set the ignition coil cord to the notch of the insulator, and then mount the baffle 2 to the crankcase. (M6×12 mm bolt : 3 pcs.) (2) Mount the recoil bracket to the crankcase stud bolts. (M6 Nut : 4 pcs.) (3) Mount the stop switch to the blower housing.
  • Page 44 (28) FUEL TANK and FUEL STRAINER FUEL TANK (1) Mount the fuel tank to the crankcase, and connect the fuel pipe to the fuel tank and the fuel strainer. Hold the fuel pipe with the clamp on the brower housing, and then M6 x 12 tighten the bolts and nuts for the fuel tank.
  • Page 45 (32) FILLING WITH ENGINE OIL Use the automobile engine oil of API service class SE or higher grade. The amount of oil, refer to the table below. Model Model EX35 EX40 Engine oil volume 1.2L (maximum) - 43 -...
  • Page 46 While the engine is being tested, check for oil leaks. Make final carburetor adjustment and regulate the engine operating speed. Step Model EX35 Model EX40 Engine Speed Time...

  • Page 47: Engine Oil

    6. ENGINE OIL Using engine oil of the correct grade and viscosity greatly lengthens engine life and improves performance. Too much or too little oil can also result in serious problems, including engine seizure. 6-1 CLASSIFICATION BY OIL GRADE API (American Petroleum Institute) Classifi...

  • Page 48: Magneto

    7. MAGNETO 7-1 MAGNETO The Robin Engine uses a T.I.C. type breakerless magneto ignition system. (1) T.I.C. (TRANSISTOR IGNITER CIRCUIT) has the ignition coil outside the flywheel, which is the standard specification. A charge coil system is available as an option. (The flywheel is a specialized piece of equipment.) As for the lighting coil, the ignition coil is outside the flywheel and a lighting coil is inside.

  • Page 49: Ignition System

    8. IGNITION SYSTEM The ignition system is a pointless flywheel magneto with automatic advancing characteristic. Being different from the breaker point type ignition system, this system is completely free from such troubles as starting-up failure due to dirty, burnt or corroded point surface. 8-1 IGNITION COIL INTERNAL CIRCUIT LowSpeed Ignition...

  • Page 50: Wiring Diagram

    9. WIRING DIAGRAM 9-1 MODEL WITHOUT ELECTRIC STARTER Spark plug Black Ignition coil (with built-in transistor) Flywheel Fig.9-1 9-2 MODEL WITH ELECTRIC STARTER Spark plug Black Ignition coil Key switch Magneto Charge coil Diode rectifier Battery (12V-24AH or larger) LA108 LA408 Key switch 066-00003-30...
  • Page 51 9-3 MODEL WITH OIL SENSOR Black Orange Orange Stop switch, Oil sensor LED, Oil sensor Black control unit Body LA106 earth LA104 Black To stop switch Spark plug Oil sensor as option Fig.9-3 - 49 -...
  • Page 52 10-3 COMPONENT PARTS - Magnetic and shift type - MAGNETIC SWITCH LEVER PINION AY ARMATURE AY YOKE AY SPRING (BRUSH) BRUSH FRONT COVER CASE METAL BRUSH HOLDER REAR COVER FRONT METAL THROUGH BOLT (2 pcs.) PINION STOPPER SET Fig.10-3 - 51 -...
  • Page 53 10. ELECTRIC STARTER 10-1 SPECIFICATIONS Model EX35, 40 Model STARTING MOTOR AY PINION GEAR M8×1.25 Manufacturer DENSO Voltage （V） Power （kW） Weight （kg） MOUNTING FACE 150.2 53.8 (204) Fig.10-1 10-2 OPERATING PRINCIPLES The battery is connected to the 8 mm diameter terminal of the magnetic switch.

  • Page 54: Oil Sensor

    11. OIL SENSOR 11-1 SPECIFICATIONS Float type Type (with lead switch incorporated) Resistance 100 M ohms or over (at FULL oil level) OIL SENSOR Operating -30 to +180 degree Celsius Temperature Fig.11-1 11-2 CONSTRUCTION AND OPERATION The oil sensor is composed of the float, permanent magnet incorporated into the float and the oil sensor.

  • Page 55: Automatic Decompression System

    12. AUTOMATIC DECOMPRESSION SYSTEM 12-1 FUNCTIONS AND CONSTRUCTION EX series engines employ an automatic decompression system as a standard feature. This enables easy starting of the engine, with lighter recoil pull. The automatic decompression system releases the compression of the engine by lifting up the exhaust valve at cranking speed.

  • Page 56: Carburetor

    13. CARBURETOR 13-1 SPECIFICATIONS EX35 EX40 A/C Type URETHANE DUAL URETHANE DUAL Main Jet Slow Jet Venturi Bore (mm) 13-2 FUNCTIONS AND CONSTRUCTION 13-2-1 FLOAT SYSTEM The float chamber is located below the carburetor body. Through the operation of the float and the needle valve, the float chamber maintains a constant fuel level while the engine is working.

  • Page 57: Fuel System Outline

    FUEL SYSTEM OUTLINE PILOT OUTLET Fuel and air Flow Fuel and air Flow for Main system for Slow system FUEL FUEL BYPASS FLOAT CHAMBER CHOKE BORE FLOAT CHAMBER CHOKE BORE MAIN JET MAIN AIR BLEED SLOW JET SLOW AIR BLEED MAIN NOZZLE SLOW PORT BENTURE...
  • Page 58 13-3 DISASSEMBLY AND REASSEMBLY Mechanical failures aside, most carburetor malfunctions occur when the fuel/air ratio of the mixture is not correct. This is usually caused by clogged jets, air passages and fuel passages, or by variations in the fuel level. To get the best possible performance from the carburetor, ensure that the each passages are kept clean so that air and fuel can flow freely through them.
  • Page 59 The procedures for overhauling the carburetor are described below. (Refer to Fig. 13-2.) 13-3-1 THROTTLE SYSTEM (1) When the throttle stop screw is removed, the spring can be taken out. (2) Remove the phillips screw and the throttle valve , then take out the throttle shaft and seal as dust proof.

  • Page 60: Recoil Starter

    14. RECOIL STARTER 14-1 RECOIL STARTER Tools required: Screwdriver, pliers and protective glasses CAUTION Put on the protective glasses prior to start disassembly. 14-1-1 DISASSEMBLY PROCEDURE (1) Release the reel spring power -1 Hold the starter knob and pull out the starter rope.
  • Page 61 (2) Remove the components. (Fig. 14-2) SET SCREW -1 Grip the case and loosen the set screw. RATCHET -2 Take out the set screw, the ratchet guide, the GUIDE friction spring and the ratchet in that order. FRICTION SPRING (3) Remove the reel. (Fig. 14-2) RATCHET -1 Hold down the reel gently to keep it from RETURN...
  • Page 62 (2) Mount the components -1 Mount the ratchet into the reel. (Fig. 14-5) THE RATCHET SHOULD BE IN THE CLOSED POSITION Fig.14-5 -2 Mount the ratchet guide assembly, taking Set screw care not to move the ratchet. (Fig.14-6) Ratchet guide Friction spring Ratchet guide sub-assembly Fig.14-6...
  • Page 63 (5) Install the rope NOTE: This procedure requires 2 people. -1 Pass the rope end through the rope guide and the rope hole of the reel and pull through Approx. 20mm approximately 20 cm out of the reel. (Fig. 14-7) -2 Tie a knot in the rope end .
  • Page 64 14-1-3 CHECKING THE RECOIL STARTER AFTER REASSEMBLY (1) Pull the starter knob about 2-3 times. (a) If the starter knob is too heavy to pull, check that each parts have been assembled as specified. (b) If the ratchet does not work, check for missing parts such as the friction spring. (2) Pull out the starter knob as far as it will go.

  • Page 65: Installation

    15. INSTALLATION Installation has a decisive influence on engine life, ease of maintenance and inspection, frequency of inspection and repair, running costs and other related aspects. Before installing the engine, be sure to plan the installation with care, taking the points below into account. 15-1 INSTALLING When installing the engine, pay special attention to the position of installation, the method for coupling with working equipment, and the foundations and supports for the engine.

  • Page 66: Power Transmission To Drive Machines

    Washer applicable component parts. PTO shaft Fig.15-1 ■ Metric keyway-type crankshaft EX35/40 Washer; Use the washer (material; SS41P) with the 6.0 or over Washer Thickness thickness described below; ROBIN genuine part 020-01002-20, Washer Thickness;...
  • Page 67 Key Location When using the belt pulley with the extended boss on both side as shown in the illustration, put the spacer so that the key stays in the keyway portion of the crankshaft. Proper Improper Key should be within this portion. Spacer Fig.15-2 Belt Pulley Installation...

  • Page 68: Troubleshooting

    16.TROUBLESHOOTING If the engine shows any sign of malfunction, the cause should be determined immediately and appropriate countermeasures should be taken to prevent the problem from worsening. This section describes certain known problems, their possible causes and appropriate countermeasures. Note, however, that the list of problems presented here is not all.
  • Page 69 Problem and possible cause Remedy 1. Insufficient compression 1) Loosen spark plug Retighten; replace gasket 2) Leakage from cylinder head gasket Retighten; replace gasket 3) Piston ring seizure or wear Replace 4) Piston or cylinder wear Repair or replace 5) Incorrect valve and seat contact Repair or replace 6) Valve stem seizure Repair or replace...
  • Page 70 Problem and possible cause Remedy 1. Oil leakage 1) Loose oil drain plug Tighten 2) Faulty oil drain gasket Replace 3) Loose main bearing cover bolts Tighten 4) Faulty main bearing cover gasket Replace Replace 5) Crankshaft oil seal (front, rear) defect 2.
  • Page 71 16-2 ELECTRIC STARTER Engine does not start Check battery charged Charge or replace the battery. state and battery terminal Does the Does the Repair connection or connection or corrosion crank run? starter run? corrosion of battery terminals. for any abnormality. Key switch Connected state Check/repair wiring to the...
  • Page 72 Problem and check item Description Remedy 1. Checking of Check S terminal and B (1) When no voltage is applied to the S terminal continuity of wiring terminal for deformation, and B terminal, check continuity of the looseness, rusting, or dust terminals and key switch and repair or KEY SWITCH sticking.

  • Page 73: Ignition Coil

    Problem and check item Description Remedy Check engaged Motor idles and engine does not (1) Remove and check the starter. state of pinion run. Check or replace the pinion clutch and ring gear. if necessary. (2) Check battery charged state and battery terminal connection or corrosion for any abnormality.

  • Page 74: Standard Repair Tables

    17. STANDARD REPAIR TABLES “STD” in the following table is the parts dimension from the brand new engine or the spare parts. Whereas, “Limit” shows the maximum allowance for the parts to be used on the engine. If the measurement exceeds beyond the “Limit”, the part needs to be replaced and/or repaired. 17-1 STANDARD DIMENSIONS AND LIMITS OF USE Unit: mm (in.) ITEM...
  • Page 75 Unit: mm (in.) ITEM Limit CYLINDER * Inner diameter To be rebored when the 89.000 - 89.022 difference between max. Standard (3.5039 - 3.5040) and min. of diameter reached to 0.1 (0.004). 89.250 - 89.272 First reboring Ditto (3.5138 - 3.5147) 89.500 - 89.522 Second reboring Ditto...
  • Page 76 Unit: mm (in.) ITEM Limit PISTON * Ring groove side clearance 0.050 - 0.090 0.15 (0.0020 - 0.0035) (0.0059) Oil ring 0.030 - 0.125 (three-piece) (0.0012 - 0.0049) * Piston pin hole 20.989 - 21.022 21.045 (0.8263 - 0.8276) (0.82854) * Piston pin outer diameter 20.992 - 21.000 20.960...
  • Page 77 Unit: mm (in.) ITEM Limit CONNECTING ROD * Large end inner diameter 38.000 - 38.016 38.1 (1.4961 - 1.4967) (1.5000) * Clearance between large end and crank pin 0.030 - 0.060 (0.0012 - 0.0024) (0.0079) * Small end inner diameter 21.010 - 21.023 21.08 (0.8272 - 0.8277)
  • Page 78 Unit: mm (in.) ITEM Limit CAMSHAFT 35.658 - 35.758 35.61 * Cam peak height (intake and exhaust) Intake (1.4039 - 1.4078) (1.4020) Cam peak EXHAUST height INTAKE 39.408 - 39.508 39.36 Exhaust (1.5515 - 1.5554) (1.5496) Cam inner diameter 10.0 - 10.036 10.05 (0.3937 - 0.3951) (0.3957)

  • Page 79: Service Data (The Following Are Only For Your Reference.)

    (0.0276 - 0.0394) (0.0787) CHAIN LENGTH 160N (16kgf.) 346.20 349.0 (13.6299) (13.7402) 17-2 SERVICE DATA (The following are only for your reference.) EX35 EX40 Compression pressure (kg/cm / 500 rpm) Fuel consumption Continuous load / 3600 rpm (L/Hr) Capacity Lubricant Effi...

  • Page 80: Tightening Torque

    17-3 TIGHTENING TORQUE Tightening Torque ITEM N ・ m kgf ・ cm ft ・ lb Re-use 29.0 - 31.0 290 - 310 21.0 - 22.4 When replace to new M10×75 flange bolt Cylinder head bolts cylinder head and 37.0 - 39.0 370 - 390 26.7 - 28.2 flange bolts...

  • Page 81: Maintenance And Storage

    18.MAINTENANCE AND STORAGE The maintenance jobs described below apply to correct use of the engine under normal conditions. The maintenance intervals mentioned in this section are not a guarantee that no maintenance is required during those intervals. For example, when the engine is used in dusty conditions, the air cleaner should be cleaned every day, rather than every 100 hours.
  • Page 82 18-5 INSPECTION AND MAINTENANCE EVERY 300 HOURS MAINTENACE ITEMS REASON / REMARKS (1) Inspect the intake and exhaust valve clearance. (1) Incorrect clearance can cause low power output Adjust if necessary. and engine malfunction. 18-6 INSPECTION AND MAINTENANCE EVERY 500 TO 600 HOURS (EVERY 6 MONTHS) MAINTENACE ITEMS REASON / REMARKS (1) Remove the cylinder head and remove any carbon.

  • Page 83: Engine Storage

    18-9 ENGINE STORAGE (1) Carry out the maintenance jobs described in step 18-1 above. (2) Drain fuel from the fuel tank and carburetor float chamber. (3) To prevent rust in the cylinder bore, inject oil through the spark plug hole, pull the recoil starter knob gently 2 or 3 times and then put back the spark plug.
  • Page 84 ISSUE EMD-ES2461...

This manual is also suitable for:

Ex40

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