ER12 ER12: Service Manual

ER12
SERVICE MANUAL
CONTENTS
Section Title Page
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. GENERAL DESCRIPTION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . . 5
5. DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-1 PREPARATIONS AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-3 DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-4 REASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10. AUTOMATIC DECOMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11. CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12. RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
13. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
14.TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
15. STANDARD REPAIR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
15-1 STANDARD DIMENSIONS AND LIMITS OF USE . . . . . . . . . . . . . . . . . . . 68
15-2 SERVICE DATA (The following are only for your reference.) . . . . . . . . . . . 73
15-3 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
15-4 AIR GAP AND CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
16.MAINTENANCE AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1. SPECIFICATIONS
Model ER12
Air-Cooled, 4-Cycle, Single-Cylinder,
Type
Horizontal P.T.O. Shaft, OHC Gasoline Engine
Bore × Stroke mm (in.) 60 × 43 (2.36 × 1.69)
Piston Displacement ml (cu.in.) 121 (7.38)
Compression Ratio 9.6
Maximum Output kW(HP)/r.p.m. 2.6(3.5)/3600

N・m / r.p.m. 7.3/2400
Maximum Torque (kgf・m / r.p.m.) (0.74/2400)
(ft・lb. / r.p.m.) (5.38/2400)
Direction of Rotation Counterclockwise as viewed from the P.T.O. shaft side
Valve Arrangement Overhead cam system
Cooling System Forced air cooling system
Lubrication System Trochoid Pump, Forced and Splash lubrication system
Automotive detergent oil - SAE; #20, #30 or 10W-30

Lubricant
API service class; SE or higher (SG, SH or SJ is recommended)
Capacity of Lubricant L (U.S. gal.) 0.35 (0.092)
Carburetor Horizontal draft, Float type or Diaphragm type
Fuel Automobile unleaded gasoline
Fuel Supply System Gravity type
Spark Plug NGK CR5HSB
Starting System Recoil starter
Governor Centrifugal flyweight type
Air Cleaner system Semi wet type
Dry Weight kg (lb.) 9.9 (21.78)
264 x 288 x 334 (10.39 x 11.34 x 13.15) : Float type Caburetor

Dimensions (L x W x H) mm (in.)
264 x 288 x 336 (10.39 x 11.34 x 13.23) : Diaphragm type Caburetor
*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 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.
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 engin’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 to be kept below this continuous rated output.
2-3 MAXIMUM TORQUE

The maximum torque is the torque at the output shaft when the engine is producing maximum output at a
specific r.p.m..
- 2-
2-4. PERFORMANCE CURVES
[kgf・m]
N・m 0.9
8.0
0.8
TORQUE
7.0 0.7
MAXIMUM
TORQUE 6.0 0.6
[HP] kW
3.0
4.0
MAXIMUM
HORSEPOWER
3.0
2.0
RECOMMENDED
OUTPUT
HORSEPOWER
RANGE
2.0
1.0
1.0
0 0
2000 3000 4000
REVOLUTION r.p.m.
- 3-
3. FEATURES
3-1. DEVELOPED EXCLUSIVELY FOR RAMMER
The new ER12 has been developed exclusively for rammer, which especially requires the engine for high
durability, high power output and superb mountability among many construction machineries.
3-2. LIGHTWEIGHT AND COMPACT DESIGN

ER12 has realized lightweight and compact design, while achieving high power output of 2.6kW (engine
displacement 120cc) that enables to widely fulfill the operating weight of 60 to 80kg-class rammers, the
lightest-in-class* weight of 9.9kg, and the smallest-in-class* on the length and width.
3-3. DESIGNED TO OFFER SUPERIOR MOUNTABILITY

ER12 has been designed to offer superior mountability, which is valued for rammer engine, by the optimal
center of gravity for right-and-Ieft balance.
3-4. USER'S SAFETY AS WELL AS USER FRIENDLINESS

ER12 offers several new functions as standard equipment, which has been required to rammer engine for
user's safety as well as user friendliness, such as oil sensor that monitors the oil level not only at starting-up
but also during operation, and automatic shutoff device that stops engine when the rammer rolls over or has
no operation with idling.
3-5. EASE OF MAINTENANCE AND ECONOMICAL EFFICIENCY

ER12 has beeh designed in consideration of ease of maintenance and economical efficiency, such as
adopting solid crank case or the newly developed resinous dust-proof air cleaner for realizing ease of
maintenance, realizing longer operational hours without oil-refilling.
* FHI researches
- 4-
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.
And the lib is made for the crankcase room center
cum oil shelter plate, that improvement breather
function and strength up.
And inside of the crankcase has large rib for oil shelter
which to inprove the breather function and stiffness.
4-2 MAIN BEARING COVER

The main bearing cover is an aluminum die-casting
with heavy-duty structure to endure to install on
rammers, which is mounted on the output shaft side of
the crankcase. By removing the main bearing cover,
the inside of the engine can be inspected with ease.
Pilots and bosses are machined into the cover for
direct mounting of the engine onto rammers.
And it have suction pipe, oil pump, oil filter and oil
pressure switch.
4-3 CRANKSHAFT
The crankshaft is forged carbon steel, and the crank
pin is high-frequency inductionhardened.
The crank pulley used to drive the timing belt and the
gear used to drive the governor gear are pressed into
the output end of the shaft.
4-4 CONNECTING ROD AND PISTON

The connecting rod is a specially heat-treated
aluminum alloy die-casting. Its large and small ends
function as bearings. The piston is an aluminum alloy
casting with grooves for mounting one compression
ring and one oil ring.
JCC
- 5-
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.
1
TOP
1 TAPER
RING
2
OIL THREE-PIECE
2 RING CONSTRUCTION
4-6 CAMPULLEY
The campulley is made of special nylon. They are
constructed as a single piece. The campulley is
provided with intake and exhaust cam, and the
decompression release lever is mounted on the
sprocket shaft end side.
4-7 VALVE ARRANGEMENT

EXHAUST VALVE INTAKE VALVE
This engine has a belt-driven overhead cam and
overhead valve construction, with a single cam
performing both intake and exhaust operations.
- 6-
4-8 CYLINDER HEAD
The cylinder head is on aluminum die-casting with a
lens-shaped combustion chamber. The intake and
exhaust ports are arranged in a cross direction to
improve combustion efficiency.
4-9 GOVERNOR SYSTEM

This engine is equipped with a centrifugal flyweight
type governor that makes it possible to operate the
engine at a constant speed, even with load GOVERNOR
GEAR
variations. (The governor flyweights are mounted on
a governor gear.)
4-10 COOLING SYSTEM

The engine uses a forced air-cooling system in which a cooling fan on the frywheel, reduce noise and forces
cooling air into the cylinder and cylinder head.
Baffle is provided to guide the flow of cooling air.
4-11 LUBRICATION SYSTEM

Lubricant (engine oil) is sprayed onto the parts with pressure spray by the trochoid type of oil pump, and
those parts splashes to the parts necessary to be lubricated.
The trochoid pump is driven by the crankshaft. Lubricant is wholly filtered by the oil pump filter plugged in the
under of the main bearing cover.
- 7-
4-12 TIMING BELT
CAMPULLEY
Timing belt system is adopted and designed for

lubricating for the upper portion of cylinder head.
The timing belt is engaged between the campulley in TIMING BELT
the cylinder head and the crankshaft gear.

The pulley and the gear teeth in round shape are DRIVEPULLEY
adopted to enhance the durability and to realize low
noise level.
CRANKSHAFT
4-13 IGNITION SYSTEM

IGNITION COIL
The ignition system is a pointless flywheel magnet by

a digital control. FLYWHEEL
The magneto consists of a flywheel and ignition coil THICKNESS

GAUGE
with CPU (Central Processing Unit.) and CDI
(Capacitor Discharge Ignition.). The flywheel is
directly mounted on the crankshaft and the ignition
FAN
coil is directly mounted on the crankcase.
4-14 CARBURETOR
The engine is equipped with two types of horizontal
draft carburetors, one has a float controlled fuel system
and a fixed main jet, and another is diaphragm type.
The carburetors are calibrated carefully for sure
starting, good acceleration, less fuel consumption and
maximum output.
For details, refer to page 50, section “11-3 FLOAT
CARBURETOR As details of diaphragm type, refer to FLOAT TYPE DIAPHRAGM TYPE
page 53, section “11-4 DIAPHRAGM CARBURETOR”.
- 8-
4-15 AIR CLEANER
AIR CLEANER BASE ELEMENT
The air-cleaner is a heavy-duty type with a dual URETHANE FOAM
element system; the primary one is an urethane foam
(semi-wet) and secondary one is a semi wet type
element.
AIR CLEANER COVER
4-16 DECOMPRESSION SYSTEM

The automatic decompression system is mounted on RETURN SPRING
the campulley. It opens the exhaust valve before the

ROCKER ARM
compression top, thereby alleviating the compression (EXHAUST VALVE SIDE)
pressure and reducing the force required to pull the

recoil starter.
During engine operation, the decompression system
EXHAUST VALVE
is overpowered by centrifugal force and compression
is fully utilized to produce power.
CAMSHAFT
- 9-
4-17 SECTIONAL VIEW OF THE ENGINE
Cross sectional view – across the shaft
CYLINDER HEAD
SPARK PLUG
PISTON
PISTON RING
IGNITION COIL
PISTON PIN
RECOIL STARTER
OIL PRESSURE SWITCH
OIL PUMP
P.T.O. SHAFT
CRANKSHAFT
ADAPTER
FLYWHEEL MAIN BEARING COVER
CRANKCASE PLUG
SER No. (Stamping) SUCTION PIPE
- 10 -
Cross sectional view – along the shaft
ROCKER COVER
ROCKER ARM FLOAT TYPE CARBURETOR
CAMPULLEY INTAKE VALVE CARBURETOR

(DIAPHRAGM TYPE)
EXHAUST VALVE
MUFFLER
AIR CLEANER
PISTON RING
GOVERNOR LEVER
TIMING BELT
STOP SWITCH
CONNECTING ROD
SPEED CONTROL LEVER
OIL GAUGE GOVERNOR GEAR
BREATHER COVER
SER No. (Stamping)

CRANKCASE
CRANKSHAFT
OIL DRAIN PLUG
- 11 -
5. DISASSEMBLY AND REASSEMBLY
5-1 PREPARATIONS AND PRECAUTIONS
1) W
hen 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. This will make reassembly easier.
3) To prevent parts from being mislaid, keep each group provisionally assembled after removing the parts
from the engine.
4) Handle the disassembled parts with the utmost care. Clean them with cleaning oil if necessary.
5) Use the correct tools in the correct way when disassembling and reassembling the engine.
5-2 SPECIAL TOOLS

Tool name Use
Commercially available product Flywheel puller For pulling off the flywheel
For removing and

Commercially available product Piston ring plier installing piston rings
Piston ring
Commercially available product For holding piston rings
compresser
Commercially available product Chain wrench For locking the flywheel
FLYWHEEL PULLER PISTON RING PLIER
PISTON RING COMPRESSER CHAIN WRENCH
- 12 -
5-3 DISASSEMBLY PROCEDURE
Step Parts to remove Remarks and procedures Fasteners
Drain the engine oill Remove a drain plug (M8 x 12mm) located on both 12 mm spanner
sides of the case.
1 Take care not to lose the gaskets.
* To discharge oil quickly, remove the oil gauge(M22).
Air cleaner Remove breather pipe from rocker cover. 10mm box spanner
2 M6 nut:2pcs.
STEP 2
GASKET(INTAKE)
BREATHER PIPE CLEANER BASE CLEANER COVER
M6 SELF LOCK NUT : 2pcs.
ELEMENT
URETHANE FOAM
GASKET
(Rubber )
GASKET
OIL GAUGE (Aluminum ) M8 DRAIN PLUG : 1pc.
STEP 1
- 13 -
Muffler and Muffler cover (1) Remove the muffler cover from the muffler and 10mm box spanner or
gasket(muffler). spanner
3 (2) Remove the muffler from the cylinder head. 13mm box spanner
Take care not to lose the gasket. M6×18mm:3pcs.
* Take care not to cut your hand with muffler gasket. M6 nut:2pcs.
Recoil starter Disconnect wire of stop switch first, then remove recoil 10mm box spanner
starter. M6×20mm:2pcs.
4 M6×14mm:1pc.
RECOIL ASSY
MUFFLER
M6 x 14 GASKET
FLANGE BOLT : 1 pc. (MUFFLER) M6 SELF LOCK NUT : 2pcs.
STEP 3
M6 x 18
FLANGE BOLT : 3 pcs.
M4 SCREW : 2 pcs.
Do Not remove the plug.

STOP SWITCH
MUFFLER COVER
M6 x 20
FLANGE BOLT : 2 pcs.
STEP 4
- 14 -
Carburetor, Insulator Remove the linkage bushing from governor rod. 10mm box spanner or
spanner
(1) Loosen the and remove the governor lever from
M6×20mm:1pc.
the governor shaft. There is no need to remove the
M6 Nut:1pc.
bolt.
(2) Remove the governor spring.
5
(3) Remove the governor rod and the rod spring from
the carburetor.
Remove the carburetor from the cylinder head.
Remove the insulator.
GASKET
(INSULATOR) INSULATOR
BLACK ROD SPRING
GASKET
(CARBURETOR)
BROWN
LINKAGE BUSHING
CARBURETOR
(FLOAT TYPE)
CYLINDER HEAD GOVERNOR ROD
STEP 5
GOVERNOR LEVER
GOVERNOR
SPRING
CYLINDER HEAD
A
GASKET BOLT
(INSULATOR)
NUT
BLACK
INSULATOR 2
GASKET DETAIL A
STEP 5 (CARBURETOR)
BLACK
CARBURETOR GASKET
(DIAPHRAGM TYPE) (CARBURETOR)
BROWN
SELF LOCK NUT
INSULATOR 1
GASKET
(INSULATOR)
BLACK
A
INTAKE PIPE
- 15 -
Speed control lever and Remove the speed control lever and base plate from 10mm box spanner
Base plate the crankcase. (If necessary) M6×10mm:2pcs.
6 14mm box spanner
Pivot bolt:1pc.
STEP 6 SET SCREW (HIGH SPEED)

NUT
BASE PLATE SET SCREW (LOW SPEED)
SPEED CONTROL
LEVER
SWIVEL (NUT) M4 x 0.7
FRICTION WASHER
(NYLON)
PIVOT BOLT
RETURN SPRING
SPACER M6×10 FLANGE BOLT:2pcs.
PIVOT BOLT Tightening torque : 7.0 - 9.0 N•m
(70 - 90 kgf•cm)
(5.1 - 6.5 ft•lb.)
SPEED CONTROL AY
GOVERNOR SPRING
STEP 6
M6×20 BOLT GOVERNOR LEVER M6 NUT
- 16 -
Cylinder baffle Remove the Cylinder baffle. (If necessary) 10 mm box spanner
7 M6 x 10 mm : 3 pcs.
Breather Remove the breather cover and plate. (If necessary) 8 mm box spanner
8 M6 x 20 mm : 4 pcs.
Ignition coil Remove the spark plug cap from the spark plug. 10 mm box spanner
Disconnect wire of oil pressure switch. M6 x 25 mm：2 pcs.
9 Remove the ignition coil from the crankcase.
CYLINDER BAFFLE
STEP 7
M6×10
FLANGE BOLT:3pcs.
M6×20
FLANGE BOLT:4pcs.
BREATHER
PLATE
GASKET BREATHER COVER
(BREATHER PLATE)
GASKET
(BREATHER COVER)
STEP 8
Disconnect the wire
SPARK PLUG
from the portion SPARKPLUG
RUBBER CAP
IGNITION COIL
STEP 9
M6×20 BOLT : 2pcs.
SWITCH
(OIL PRESSURE)
- 17 -
Flywheel Remove the starting pully from the flywheel. 19 mm socket wrench
Fit a box wrench or a socket wrench on the flywheel nut M14 nut : 1pc.
and loosen the nut by knocking the wrench sharply with a
hammer. (See Fig.4-a)
NOTE:
1. Do not insert screwdriver or other object between the
flywheel blades which is a synthetic resin, otherwise
the risk of damaging the blades might be occurred.
10 2. Knock the wrench with a hammer in a counter
clockwise direction.
Remove the flywheel from the crankshaft. Leave the nut Flywheel puller
temporarily to prevent the flywheel from dropping out.
Fit the flywheel puller as shown in Figure4-b and remove
the flywheel from the crankshaft by rotating the bolt
at the center in a clockwise direction.(Knock the center bolt
with a hammer sometimes)
HAMMER
ALUMINUM BAR
Fig.4-a
STEP 10
NUT
PULLER
Fig.4-b - SCREWDRIVER
WOODRUFF KEY
M14 FLANGE NUT : 1pc.
FLYWHEEL
- 18 -
Spark plug Remove the spark plug from the cylinder head. 16mm plug wrench
11
Rocker cover (1) Remove the rocker cover from the cylinder head . 10mm box spanner
(2) Remove the gasket (rocker cover) M6×14mm : 2pcs.
12
Rocker arm Remove the pin (rocker arm)and the rocker arm from Pliers
the cylinder head at the compression top dead center.
13 (See Fig.4-c)
STEP 11 SPARK PLUG
M6×20 FLANGE BOLT : 2pcs.
ROCKER COVER
STEP 12
VIEW A
GASKET
(ROCKER COVER)
ADJUSTMENT SCREW, NUT

Remove the pin the
allow direction
ROCKER ARM
(EXHAUST SIDE)
PIN(ROCKER)
Matching mark
ROCKER ARM
(INTAKE SIDE)
STEP 13
Cylinder head surface
Fig.4-c
- 19 -
Oil pump Remove oil pump cover o-ring outer rotor and inner 8mm box wrench
rotor. M6×12mm:4pcs.
14
MAIN BEARING COVER

STEP 14
OUTER ROTOR
OIL PUMP COVER
M6×12
FLANGE BOLT:4pcs.
INNER ROTOR
O-RING
(SYNTHETIC RUBBER)
- 20 -
Main bearing cover Remove the flange bolts of main bearing cover from 12mm box wrench
the crankcase. M8×55mm:6pcs.
Remove the main bearing cover while tapping gently
around the cover using a plastic hammer or similar
15 tool. (See Fig.4-d)
Be careful not to damage the oil gauge or oil seal or
not to lose the pipe knocks.
SPACER
STEP 15
CRANKCASE
M8×55
FLANGE BOLT : 6pcs. MAIN BEARING COVER
MAIN BEARING COVER
PLASTIC HAMMER
Fig.4-d
- 21 -
Switch (Oil pressure) Remove the oil pressure switch. (If necessary) 24mm spanner
16
Plug and suction pipe Remove the plug and suction pipe from the main M5×12mm:2pcs.
bearing cover. (If necessary)
17
STEP 16
SWITCH
(OIL PRESSURE)
MAIN BEARING COVER
STEP 17
PLUG AY
(OIL FILTER)
SUCTION PIPE
MESH SCREEN
M14
O-RING M5×12 SCREW : 2pcs.

(SYNTHETIC RUBBER)
PLUG AY
VIEW A
- 22 -
Campulley (1) Remove the retaining bolt of pin (campulley) from the 10mm box spanner
cylinder head. M6×8mm:1pc.
(2) Remove the pin (campulley), taking care not to scratch the Pliers
O-ring.
18 (3) Remove the timing belt from the campulley and then take
out the campulley.
(4) Remove the timing belt from the crankshaft.
PIN CYLINDER HEAD

(CAMPULLEY)
O-RING
(SYNTHETIC RUBBER)
M6×8
FLANGE BOLT : 1pc.
TIMING BELT
CRANKCASE
STEP 18
CAMPULLEY
TIMING BELT
CRANKSHAFT
DRIVEPULLEY
- 23 -
Cylinder head (1) Remove the cylinder head from the crankcase. 12mm box spanner
(2) Remove the cylinder head gasket from the cylinder head. M8×98mm:4pcs.
19 Take care not to lose the pipe knock
Intake and exhaust (1) Remove the collet valve from the spring retainer.
valves (If necessary)
20 (2) Remove the intake valve and the exhaust valve.
STEP 19 STEP 20
COLLET VALVE
STEM SEAL
M8×98 (INTAKE ONLY)
FLANGE BOLT:4pcs.
SPRING
RETAINER
VALVE SPRING
GASKET
(HEAD)
CYLINDER HEAD
KNOCK PIN
EXHAUST
VALVE
CRANKCASE
INTAKE
VALVE
- 24 -
Connecting rod and piston (1) Scrape off any carbon from the cylinder and the 8mm box spanner
piston head, then remove the connecting rod bolt. M5×25mm:2pcs.
(2) Remove the connecting rod cap.
21 (3) Rotate the crankshaft until the piston comes to its
top position. Push the connecting rod and remove
the piston from the upper part of the cylinder.
Piston and piston rings (1) Remove the piston clips(2pcs.). Take out the
piston pin and then remove the piston from the
connecting rod small end, taking care not to
damage the connecting rod small end.
22 (2) Remove the piston rings from the piston by
spreading them at the gap. Take special care not
to damage the rings when doing this.
CLIP
PISTON RING
STEP 22 PISTON
PISTON PIN
CONNECTING ROD
STEP 21
CLIP UPPER PART OF

THE CYLINDER
CRANKSHAFT
CONNECTING
ROD CAP
CONNECTING ROD BOLT : 2pcs.
- 25 -
Crankshaft (1) Remove the woodruff key (for the flywheel
magneto).
(2) Remove the crankshaft from the crankcase Plastic hammer
23 by tapping its magneto side end with a plastic
hammer, taking care not to damage the oil seal.
OIL SEAL (PRESS FITTING)
WASHER
STEP 23
E-CLIP
CRANKSHAFT
GOVERNOR SHAFT
WASHER
- 26 -
5-4 REASSEMBLY PROCEDURE
5-4-1 NOTES ON REASSEMBLY
(1) C
lean the each parts carefully, taking special care with the piston, cylinder, crankshaft, connecting rod
and bearings.
(2) S
crape off any carbon deposits on the cylinder head and the piston head. Be particularly careful when
removing carbon from the piston ring grooves.
(3) Inspect the oil seals for any damage to the lip. Replace them if damaged. Apply oil to the lip before
reassembly.
(4) Replace all the gaskets with new ones.
(5) Replace the keys, pins, bolts and nuts with new ones, if necessary.
(6) Tighten nuts and bolts to the specified torque settings.
(7) When reassembling the engine, apply oil to all moving parts.
(8) Check clearances and end plays and adjust, if necessary.
(9) W
hen mounting any major part during reassembly of the engine, rotate it with your hand to check for any
jamming or abnormal noise.
5-4-2 ASSEMBLY STEPS AND PRECAUTIONS

(1) CRANKSHAFT
(a) W
rap the key-way portion of the crankshaft with
polyvinyl tape and insert the crankshaft into the CRANKSHAFT
crankcase, taking care not to damage the oil

seal lip.
(b) Insert the woodruff key (for the flywheel magneto).

NOTE: Do not insert the woodruff key before
inserting the crankshaft into the POLYVINYL TAPE
crankcase.
- 27 -
(2) PISTON AND PISTON RINGS
(a) Install each piston ring in the correct groove of OPEN ENDS OF PISTON RING
the piston by widening it enough to slide it over

the piston.
NOTE: B
e careful not to twist the rings too
much, as they may be damaged. Install
the oil ring first, followed by the top ring.
When installing the piston ring, make
sure that the "R" mark is face up.
1
TOP
1 TAPER
RING
2
OIL THREE-PIECE
2 RING CONSTRUCTION
MARK “R”
- 28 -
(3) 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
When assembling
head with the ‘JCC’ mark on the connecting rod. the piston and
connecting rod,
JCC
NOTE 1: B
efore assembling the connecting rod, make sure to align
the mark on the
apply oil to its small end. piston head with the
“JCC”mark on the
NOTE 2: B
e sure to insert the clips in the two connecting rod.
ends of the piston pin and check the
clips for any play.
(4) CONNECTING ROD

(a) Install the piston and connecting rod assembly
into the cylinder by holding the piston rings PISTON RING GUIDE
AND PISTON RING
with the ring guide, with the ‘JCC’ mark on
the connecting rod on the flywheel side. (If you
do not have a ring guide, hold the piston rings
“JCC” MARK
with the fingers and tap the upper part of the
piston with a piece of wood.) JCC
NOTE 1: Apply oil to the piston rings, the large

end of the connecting rod and FLYWHEEL SIDE
cylinder before installing the
connecting rod into the cylinder.
NOTE 2: The piston ring gaps should be

positioned around the piston at
P.T.O SHAFT SIDE
180-degree intervals.
OIL RING
180°
TOP RING FLYWHEEL SIDE

("JCC" MARK SIDE)
- 29 -
(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) T
o mount the connecting rod, line up the matching
ALIGNMENT
marks and fit the clinch portions firmly together. MARKS
M5×25mm Connecting rod bolt : 2pcs.

(8mm box wrench)
Tightening torque
6.0 - 8.0 N・m
(60 - 80 kgf・cm)
(4.3 - 5.8 ft・lb.)
(d) Check for free movement of the connecting rod Make sure press fitting to contact exactly
between stem seal and Cylinder head.
by turning the crankshaft slowly.
STEM SEAL
CYLINDER
HEAD
(5) INTAKE AND EXHAUST VALVES
Take the following points into account when
mounting the intake and exhaust valves on the VALVE GUIDE
cylinder head.
COLLET VALVE
NOTE 1: Replace the valve with a new one if
it shows signs of wear. STEM SEAL
SPRING (INTAKE ONLY)
RETAINER
NOTE 2: Carefully scrape off any carbon

VALVE SPRING
deposits on the combustion chamber.
Apply oil to the valve stems before
mounting the intake and exhaust
valves. Insert the valves in the CYLINDER
HEAD
cylinder head and place it on a level
workbench. Next, mount the valve
springs, the spring retainers and
collet valves. (Mount the stem seal Apply oil
on the intake valve guide.) Apply oil
EXHAUST VALVE
INTAKE VALVE
- 30 -
(6) CYLINDER HEAD
(a) Inspect and repair any scratches on mounting surface and replace head gasket to new one before installing.
(b) Insert the pipe knocks between crankcase and cylinder head.
Install cylinder head onto cylinder with new head gasket.
Apply oil to the screw thread.
Tighten four flange bolts evenly in three steps by the following tightening torque:
Cylinder head M8×98mm bolt : 4pcs.
Tightening torque
1 st step 2 st step Final step
5.0 N・m 9.8 N・m 20.0 - 24.0 N・m
(50 kgf・cm) (100 kgf・cm) (200 - 240 kgf・cm)
(3.6 ft・lb.) (7.2 ft・lb.) (14.4 - 17.7 ft・lb.)
(7) SETTING THE TIMING BELT

(a) Set the crankshaft to the top dead center.
CAMPULLEY
(b) S
et the timingbelt to the drive pulley on the crankshaft.
(c) Install the campulley to the cylinder head.

Meet the matching mark of campulley and
cylinder head.
(d) Mounting the campulley on the cylinder head. TIMING BELT
Mount the campulley on the cylinder head by

inserting the pin (campulley)through the head. CRANKSHAFT
Fix the bolt to prevent the pin (campulley) from DRIVE

PULLEY
coming out.
M6×8mm flange bolt : 1pc.
Tightening torque
4.0 - 6.0 N・m
(40 - 60 kgf・cm)
(2.9 - 4.3 ft・lb.)
Matching mark
CYLINDER HEAD
PIN(CAMSHAFT)
O-RING
M6 x 8
FLANGE BOLT : 1pc.
- 31 -
(8) ADJUST CRANKSHAFT END PLAY
(1) A
djust end play to 0.2 mm (0.008") using the
proper spacer.
DEPTH GAUGE
The proper spacer may be determined in the
following manner.
1) Measure the height “A” (From the mating

surface to the inner race of the ball bearing.)
2) Measure the depth “B” (From the mating surface

to the drive pulley.)
DRIVE PULLEY CRANKCASE
B – A = SIDE CLEARANCE (mm)
MAIN BEARING COVER
(SIDE CLEARANCE) – 0.2 mm = THICKNESS
OF CRANKSHAFT SHIM (mm)
B – A = SIDE CLEARANCE (in.) BALL BERARING

DRIVE PULLEY CRANKSHAFT
(SIDE CLEARANCE) – 0.008 in. = THICKNESS
OF CRANKSHAFT SHIM (in.)
Following are available spacer shims.
CRANKSHAFT
T = 0.8 mm (0.031 in.)
SPACER T = 1.0 mm (0.039 in.)
SHIMS
T = 1.2 mm (0.047 in.) CRANKCASE
This image slightly differs from the actual engines.
- 32 -
(9) MAIN BEARING COVER
(a) Insert the plug, suction pipe and oil pressure switch.
PLUG SUCTION PIPE OIL PRESSURE SWITCH

0.8 - 1.2 N・m 6.0- 8.0 N・m 8.0 - 10.0 N・m
(8 - 12 kgf・cm) (60 - 80kgf・cm) (80 - 100 kgf・cm)
(0.6 - 0.9 ft・lb.) (4.3 - 5.8 ft・lb.) (5.8 - 7.2 ft・lb.)
(b) Apply oil to the bearing and the oil seal lip when mounting the main bearing cover. Also apply sealant
(Three Bond “1208B”) 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.
NOTE: Turn the lever portion of governor shaft does to the engine base.
Also apply sealant GOVERNOR SHAFT

(Three Bond “1280B”)
to the surface.
MAIN BEARING COVER

SPACER
㻌
ENGINE BASE
Turn the lever portion

GOVERNOR GEAR of governor shaft does
M8×55 FLANGE BOLT:6pcs.
to the engine base.
Tightening torque
24.0 - 26.0 N・m
(240 - 260 kgf・cm)
(17.7 - 18.8 ft・lb.)
- 33 -
(10) OIL PUMP and COVER
(1) Apply oil to inner and outer rotors of oil pump
O-RING
and attach them in position. OIL PUMP COVER (SYNTHETIC RUBBER)
(2) Set O-ring in position. OUTER ROTOR

ALLOW
(3) Install oil pump cover with the allow marking MARKING
upwards.
M6×12mm flange bolt : 4pcs.
Tightening torque
7.0 - 9.0 N・m
(70 - 90 kgf・cm)
(5.1 - 6.5 ft・lb.)
INNER ROTOR
M6×12 FLANGE MAIN BEARING COVER

BOLT : 4pcs.
(11) ROCKER ARM

(a) Conduct this job at the compression top dead center.
The position of two matching marks on campulley is in parallel with the cylinder head surface at a time.
NOTE: M
ake sure that the piston is at the compression top dead center by checking mutual position
between the flywheel and the ignition coil is at the top.
(b) Pass the pin (rocker arm) through the rocker arm and mount them on the cylinder head.
PIN(ROCKER)
CAMPULLEY
Matching mark
SLIT
- 34 -
(12) VALVE CLEARANCE ADJUSTMENT Adjust the valve clearance
insert the thickness gauge to the portions.
Temporarily fit the flywheel.
Rotate the crankshaft up to the compression
top dead center and insert the thickness gauge
between the valve and the adjusting screw of
rocker arm to measure the clearance.
[Adjustment method]
Loosen the nut on the adjustment screw and turn
the screw to adjust the valve clearance. When
the valve clearance is correct, tighten the nut.
Valve clearance (when the engine is cold)

Intake valve side 0.11 - 0.16 mm
Exhaust valve side (0.0043 - 0.0063 in.)
Tightening torque
5.0 - 7.0 N・m
(50 - 70 kgf・cm)
(3.6 - 5.1 ft・lb.)
NOTE: After adjusting the valve clearances, rotate the

crankshaft and check again that the intake and
exhaust valve clearance are correct. APPLY OIL
(13) ROCKER COVER

Replace the gasket with a new one, and mount ROCKER COVER
the rocker cover.

M6 × 20 mm flange bolt : 2 pcs.
GASKET
Tightening torque (ROCKER COVER)
5.0 - 7.0 N・m

(50 - 70 kgf・cm)
(3.6 - 5.1 ft・lb.)
SPARK PLUG
- 35 -
(14) SPARK PLUG
Remove any carbon deposits from the spark plug and inspect the electrode for damage before mounting.
Replace with a new one, if necessary.
Spark plug : NGK CR5HSB (16 mm plug wrench)
0.6 - 0.7 mm
Electrode gap (0.024 - 0.028 in.)
Tightening torque
New spark plug Re-tightening torque
10.0 - 12.0 N・m 23.0 - 27.0 N・m
(100 - 120 kgf・cm) (230 - 270 kgf・cm)
(7.2 - 8.7 ft・lb.) (16.6 - 19.5 ft・lb.)
(15) FLYWHEEL
(1) P
ut the woodruff key in the keyway of
crankshaft. Wipe off oil and grease
thoroughly from the tapered portion of
crankshaft and flywheel center hole.
FLYWHEEL CHAIN WRENCH
(2) Install the flywheel to crankshaft.
Tighten the flywheel nut.
IGNITION COIL
Tightening torque
60.0 - 70.0 N・m
(600 - 700 kgf・cm) FLYWHEEL
(43.4 - 50.6 ft・lb.)
THICKNESS
M14 nut : 1 pc. (19mm box wrench) GAUGE
(16) IGNITION COIL

When mounting the ignition coil, insert a FAN
thickness gauge between the ignition coil

and the flywheel to check the air gap.
0.3 - 0.5 mm
Air gap (0.012 - 0.020 in.) SWITCH SPARK PLUG
(OIL PRESSURE) RUBBER CAP
Tightening torque
7.0 - 9.0 N・m
(70 - 90 kgf・cm)
(5.1 - 6.5 ft・lb.)
M6 × 20 mm bolt and washer : 2 pcs.
Connect wires referring to the wiring diagram. IGNITION COIL
- 36 -
(17) BREATHER
Assemble gasket (breather plate), breather plate, gasket(breather cover) refer to the following.
Tightening torque
7.0 - 9.0 N・m
(70 - 90 kgf・cm)
(5.1 - 6.5 ft・lb.)
BREATHER PLATE
BREATHER COVER
M6×20 FLANGE BOLT:4pcs.
P.T.O.SHAFT P.T.O.SHAFT
SIDE FLYWHEEL SIDE FLYWHEEL
SIDE SIDE
GASKET (BREATHER PLATE) GASKET (BREATHER COVER)
(18) BAFFLE
Mount the cylinder baffle to the crankcase with
the bolts.
M6 × 10 mm bolt : 3 pcs.
- 37 -
(19) SPEED CONTROL
Install the speed control to the top breather BREATHER COVER FLANGE BOLT
cover with the bolts.
SPEED CONTROL AY
SET SCREW (HIGH SPEED)

NUT
BASE PLATE SET SCREW (LOW SPEED)
SPEED CONTROL
LEVER
SWIVEL (NUT) M4 x 0.7
FRICTION WASHER
(NYLON)
PIVOT BOLT
RETURN SPRING
SPACER M6×10 FLANGE BOLT:2pcs.
- 38 -
(20) GOVERNOR LEVER, CARBURATOR
ROD SPRING LINKAGE
(a) Mount the governor lever on the governor BUSHING
shaft. Do not adjust the bolt on the governor

lever yet.
GOVERNOR ROD
(b) Attach the governor rod and rod spring to
the governor lever.
GOVERNOR LEVER
(c) Replace the gasket of insulator with a new
GOVERNOR
one and mount the insulator on the cylinder SPRING
head intake side.
(d) Hook governor rod to the governor lever
and throttle lever of carburator.
mount the carburator to the cylinder head. BOLT AND
WASHER AY
NUT
(e) Hook the linkage bushing to the governor rod.
(21) AIR CLEANER BASE

Insert the breather pipe into the breather cover and air cleaner base then mount the air cleaner base.
M6 salf lock nut:2pcs.
Tightening torque
Float type carburetor Diaphragm type carburetor
7.0 - 9.0 N・m 4.0 - 5.0 N・m
(70 - 90 kgf・cm) (40 - 50 kgf・cm)
(5.1 - 6.5 ft・lb.) (2.9 - 3.6 ft・lb.)
Then install the element and cleaner cover.
GASKET
(INSULATOR)
RUBBER PIPE
GASKET
(CARBURETOR)
AIR CLEANER BASE
INSULATOR 2 M5 SELF LOCK NUT : 2pcs.
GASKET
(CARBURETOR)
ELEMENT
AIR CLEANER COVER

FLOAT TYPE CARBURETOR
- 39 -
GASKET M5 x 70mm BOLT : 2 pcs.
(INSULATOR)
INSULATOR 2
GASKET RUBBER PIPE
(CARBURETOR)
INSULATOR 1 ADAPTER
(INTAKE)
GASKET
(INSULATOR)
AIR CLEANER BASE

GASKET
(CARBURETOR) M5 SELF LOCK NUT : 2pcs.
RUBBER PIPE
ELEMENT
AIR CLEANER COVER
DIAPHRAGM TYPE CARBURETOR
(22) ADJUST GOVERNOR SYSTEM

(1) Turn the speed control lever all the way
GOVERNOR ROD
toward the high speed position.
567
(2) Check that the governor lever is pulled by
GOVERNOR
the governor spring and carburetor throttle 540 ROD SPRING
550
valve is fully open. 565 GOVERNOR GOVERNOR
LEVER
551 SPRING
Normal hooking
(3) Turn the governor shaft clockwise all the position
560 SPEED
way using a screw driver, and tighten lock GOVERNOR CONTROL
SHAFT LEVER
bolt to secure the lever on the shaft.
562
DIAPHRAGM CARBURETOR
- 40 -
(23) RECOIL STARTER
Attach recoil starter to crankcase.
Tighten flange bolts.
M6 x 20 mm flange bolt : 2 pc.

M6 x 14 mm flange bolt : 1 pcs.
Tightening torque
7.0 - 9.0 N・m

(70 - 90 kgf・cm)
(5.1 - 6.5 ft・lb.)
Insert the high tension cord from the ignition

coil into the notch of the blower housing so as
not to pinch the cord.
(24) STOP SWITCH

(1) Install stop switch to blower housing.
(2) Connect wires referring to the wiring diagram.
(25) MUFFLER
(1) Mount the muffler and the gasket on the
cylinder head. M6 x 18 BOLT : 3 pcs.
MUFFLER COVER
Self lock nut : 2 pcs. SELF LOCK NUT : 2 pcs.
Tightening torque
19.0 - 21.0 N・m
(190 - 210 kgf・cm)
(13.7 - 15.2 ft・lb.)
(2) Mount the muffler cover on the muffler.

GASKET
M6 × 18 mm bolt : 3 pcs. MUFFLER (MUFFLER)
Tightening torque
7.0 - 9.0 N・m

(70 - 90 kgf・cm)
(5.1 - 6.5 ft・lb.)
- End of the reassembly -
- 41 -
(26) EXTERNAL INSPECTION
Reassembly is completed. Check that the wiring is correct and that there are no loose nuts and bolts or
any other faults visible on the outside of the engine.
(27) 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.
Engine oil volume

0.35L
(maximum)
(28) BREAK-IN OPERATION

A new engine or an engine that has been completely overhauled by being fitted with a new piston,
rings, valves and connecting rod should be thoroughly RUN-IN before being put back into service.
Good bearing surfaces and running clearances between the various parts can only be established by
operating the engine under reduced speed and loads for a short period of time.
While the engine is being tested, check for oil leaks.
Make final carburetor adjustment and regulate the engine operating speed.
Step Load Engine Speed Time
Step 1 No Load 2500 r.p.m. 10 min.
Step 4 1.3 kW 3600 r.p.m. 30 min.
Step 5 2.6 kW 3600 r.p.m. 30 min.
- 42 -
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)
Classification SA SB SC SD SE SF SG SH SJ
Grades suited for Robin Engine: SE or higher (SG,SH or SJ in recomended)
6-2 CLASSIFICATION BY OIL VISCOSITY

SAE (Society of Automotive Engineers)
5W
10W
20W
Single grade
#20
#30
#40
10W-30
Multigrade
10W-40
Ambient
temperature
Be sure to use automobile engine oil of the viscosity shown in the table above, depending on environmental
air temperature.
When the air temperature falls below –20℃ or rises above 40℃, be sure to choose engine oil of appropriate
viscosity and grade, according to the prevailing conditions.
*Care must be taken when using multi-grade engine oil, because the oil consumption rate tends to increase
when the air temperature is high.
6-3 ADDING AND CHANGING ENGINE OIL

○ Engine oil inspection and filling up . . . Every time you use the engine
(add engine oil up to the designated maximum level)
○ Engine oil change . . . . . . . . . . . . . . . First time . . . . . . . . . . After 20 hours’ use

Thereafter . . . . . . . . . . Every 100 hours’ use
- 43 -
7. LUBRICATION SYSTEM
7-1 OPERATION AND FUNCTION
Forced pressure spray and splash lubrication system are adopted, in combination with trochoid oil pump
and plugged filter. The trochoid type oil pump is driven by crankshaft, and sprays pressurized engine oil
to the crankshaft, connecting rod and inside of crankcase.
The engine oil in the oil pan is fed through the suction pipe, oil pump filter and gallery of main bearing
cover. The engine oil is provided onto the rotating portions such as journal and pin portion of crankshaft,
connecting rod, the cylinder, and piston. The splashed engine oil is provided to supply the cylinder head
valve system by timing belt.
OIL PRESSURE SWITCH
SPRAY
CRANKSHAFT
OIL PUMP
Flow of oil
PLUG UNIT
(OIL FILTER)
CYLINDER HEAD OIL PURESSURE

CAM, VALVES PISTON SWITCH
ROCKER ARMS SPLASH CYLINDER
CRANKSHAFT
CONNECTING ROD NOZZLE
LARGE END (M.B.C)
SPRAY
TIMING BELT
OIL PAN SUCTION PIPE PLUG UNIT(OIL FILTER) OIL PUMP
- 44 -
7-2 OIL SENSOR
The oil sensor system is composed of the oil pressure switch and CPU (Central Processing Unit) inside of
the Ignition coil. In accordance with the oil level which means oil pressure, the pressure switch functions
“ON” and “OFF”. The type of pressure switch is normally closed “ON” type.
Switching pressure: 0.10 through 0.20 kg/cm2 (10 through 20KPa)
While there is no pressure (No oil, or Low level), the diaphragm is pressed by the spring force, resulting
the contact closes “ON”.
When oil pressure increases, the diaphragm is pressed by the oil pressure which is bigger than the spring
force, resulting the contact opens “OFF”.
INSPECTION
Measure resistance between the terminal and the pressure switch body.
“ON” close the contact: 0 ohm (continuity) while engine stopped.
“OFF” open the contact: ∞ (No continuity) during engine running.
The switch structure is complicated, so if its function cannot be recovered even after cleaning, replace the
switch with new one.
Apply sealant (Three Bond 1215) to the thread on the pressure switch when re-assembling.
- 45 -
7-3 BREATHER SYSTEM
The Breather system functions to decrease for inside pressure of crankcase (in the case of four-stroke
engines). The pressure becomes highly more than the outside atmospheric pressure from reasons as
follows; Piston Comes down, Leak of combustion gases from piston rings, Expansion of internal air by
increase of temperature, Steam of lubrication oil.
Breather system prevents for oil leakage from the oil seals of the rotation parts and/or matching surface
of the crankcase and the main bearing cover and so on.
Breather system is consisted of labyrinthine passage structure and leaf valves, and separates the
increased pressure which from lubrication oil and gas * in the crankcase. The oil is returned in the
crankcase and the gas to the air cleaner to reduce the pressure.
(* Blow by gas: Non-combustion gases including the air pollution element which cannot release to
atmosphere. It is returned to the air cleaner and non-combustion gases burn again.)
In rammer engines, a breather system is required complicated structure to separate oil and gas, reason
why heavy vibration of up-and-down movement compared with stationary engines.
Therefore, the ER12 rammer engine is adopted the design which overcame such a difficulty and becomes
the high-performance with compact.
C
GAS to A
AIR CLEANER
B COMBUSTION
OIL SHELTER C
PLATE
A
BREATHER SYSTEM AIR CLEANER
PASSAGE (for separating to oil and gas.)
(I.D.8)
GAS and OIL
OIL SHELTER LEAF VALVE
B PLATE
LEAF VALVE
(OIL)
CRANK CASE BREATHER
SYSTEM
OIL and GAS
OIL to CRANKCASE OIL
PASSAGE (I.D.3)
GAS
- 46 -
8. MAGNETO
8-1 MAGNETO
The SUBARU Engine uses are CDI. CPU magneto ignition system.
(1) C
DI. CPU (CDI : Capacitor Discharge Ignition. CPU : Central Processing Unit.) has the ignition coil
outside the flywheel, which is the standard specification.
(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.
8-2 INSPECTING THE MAGNETO

If the engine does not start, has difficulty starting, or does not run smoothly, check the magneto for defects
according to the following procedure:
(1) Carefully check the high-tension cable for any damage or short circuiting.
(2) Check the sparking.
ake the spark plug out of the cylinder head, connect the spark plug with the plug cap and ground it
①T
on the cylinder head or any other metallic part of the engine.
(The gap between the electrodes of the spark plug should be between 0.6 mm and 0.7 mm).
otate the engine by pulling the recoil starter and check the spark plug gap for sparking. If the spark
②R
plug is sparking, check the intensity of the spark.
(Before checking the spark plug, disconnect the primary wire from the connector.)
ext, disconnect the spark plug from the plug cap and check the end of the high-tension cable for
③N
sparking.
- 47 -
9. WIRING DIAGRAM
WIRING DIAGRAM
Spark plug
Ignition coil
CDI, CPU
Oil pressure
switch Stop switch
(Oil sensor)
Flywheel
CHECK THE IGNITION COIL

③ Round female terminal
② Hgh tenstion code wire ① Flat female terminal
④ Flat male terminal
⑤ Core
CPU
CDI
* Checking table for analogue circuit tester. (Ω) (R±20%)

Apply black ⊖ needle of the circuit tester
Analogue circuit tester
① ② ③ ④ ⑤
① - 46k 40k ∞ 40k-46k
② ∞ - 2k-3k ∞ 2k-3k
Apply red ⊕ needle
③ ∞ 2k-3k - ∞ 0
of the circuit tester
④ ∞ 45k-50k 40k - 35k-40k
⑤ ∞ 2k-3k 0 ∞ -
* Checking table for digital circuit tester. (Ω) (R±20%)

Apply black ⊖ needle of the circuit tester
Digital circuit tester
① ② ③ ④ ⑤
① - ∞ 40k ∞ ∞
② 17M-18M - 0 17M-18M 0
Apply red ⊕ needle
③ 17M-18M 0 - 17M-18M 0
of the circuit tester
④ ∞ ∞ ∞ - ∞
⑤ 17M-18M 0 0 17M-18M -
※ Digital multimeter SANWA PC500.
- 48 -
10. AUTOMATIC DECOMPRESSION SYSTEM
10-1 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. The following is the explanation of the function.
At the end of the compression process, the release lever lifts up the rocker arm (exhaust) which in turn
opens up the exhaust valve slightly to release the compression.
The release lever has a flyweight on its end and another end of the lever is a crescent cam.
When the engine is cranked, the crescent cam projects above the cam profile and lifts up the rocker arm
(exhaust) because the force of the return spring on the weight is larger than the centrifugal force on the
weight.
ROCKER ARM (EXHAUST)
ROCKER ARM RELEASE LEVER

(EXHAUST)
ROCKER ARM
(INTAKE) RELEASE LEVER
CAM
A CAMSHAFT
CRESCENT CAM
DETAIL A
When the cranking speed reaches a specified r.p.m., the crescent cam is retracted under the cam profile
because the centrifugal force applied to the flyweight becomes larger than the force of the return spring on
the weight and thus it is shifted to the position shown in the illustration below.
RELEASE LEVER
ROCKER ARM (EXHAUST)
ROCKER ARM
(EXHAUST)
ROCKER ARM
(INTAKE)
CAM A CAMSHAFT
RELEASE LEVER
CRESCENT CAM
DETAIL A
12-2 INSPECTION
When assembling the release lever, make sure that it works smoothly.
- 49 -
11. CARBURETOR
11-1 SPECIFICATIONS
Float type
A/C Type Single
Main Jet # 66.3
Pilot Jet # 30
Venturi Bore (mm) φ12
11-2 FUNCTIONS AND CONSTRUCTION

11-2-1 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.
The fuel flows from the tank into the float chamber through the needle valve. When the fuel rises to a
specific level, the float rises. When the buoyancy of the float is balanced with the fuel pressure, the
needle valve shuts off the fuel passage, thereby maintaining the fuel at the predetermined level.
11-2-2 SLOW SYSTEM

The slow system supplies fuel to the engine during idling and low-speed operation.
Fuel is initially metered by the main get and then metered once again by the slow jet.
The fuel / air mixture is fed to the engine through the pilot outlet and the bypass.
During idling, fuel is fed to the engine mainly through the pilot outlet.
11-2-3 MAIN SYSTEM

The main system feeds fuel to the engine at medium and high speed operation.
Fuel is metered by the main jet and flows into the main nozzle. Air metered by the main air jet is
mixed with fuel through the bleed holes of the main nozzle. The fuel/air mist is injected into the
Venturi and mixed once again with air from the air cleaner. This fuel/air mixture is now of optimum
concentration and is fed into the combustion chamber of the engine.
11-2-4 CHOKE SYSTEM

The choke system is for easier start of the engine in cold weather conditions.
When the engine is started with a closed choke, the negative pressure applied to the main nozzle
increases. This causes a larger amount of fuel to be drawn into the carburetor, which in turn makes it
easier to start the engine.
- 50 -
11-3 FLOAT TYPE CARBURETOR
11-3-1 OPERATION AND CONSTRUCTION
FLOAT SYSTEM
The float chamber is located below the carburetor
body and, with a float and a needle valve, FUEL
maintains a constant fuel level during engine
operation.
The fuel flows from the fuel tank into the float
chamber through the needle valve. When the fuel
rises to a specific level, the float rises, and when its
buoyancy and fuel pressure are balanced, the
needle valve closes to shut off the fuel, thereby NEEDLE VALVE
keeping the fuel at the predetermined level.
FLOAT
Fig.11-1
PILOT OUTLET PILOT JET

BY-PASS
PILOT AIR JET
MAIN NOZZLE
AIR
INTAKE
CHOKE
FLOAT
MAIN AIR JET
Fig.11-2 MAIN JET
- 51 -
PILOT SYSTEM
The pilot system feeds the fuel to the engine during idling and low-speed operation.
The fuel is fed through the main jet to the pilot jet, where it is metered, and mixed with the air metered by
the pilot air jet. The fuel-air mixture is fed to the engine through the pilot outlet and the bypass. At idling
speed, the fuel is mainly fed from the pilot outlet.
MAIN SYSTEM
The main system feeds the fuel to the engine at medium and high-speed operation. The fuel is metered
by the main jet and fed to the main nozzle. The air metered by the main air jet is mixed with the fuel
through the bleed holes in the main nozzle, and the mixture is atomized out of the main bore. It is mixed
again with the air taken through the air cleaner into an optimum fuel-air mixture, which is supplied to the
engine.
CHOKE
The choke is used for easy starting when the engine is cold. When the starter is operated with a closed
choke, the negative pressure applied to the main nozzle increases and draws more fuel ; thus richening
the mixture and making starting the engine easier.
3
1 8
11-3-2 DISASSEMBLY AND REASSEMBLY 2 7
6
Apart from mechanical failures, most of carburetor 9 5
10 4
troubles are caused by an incorrect mixing ratio, which
11
may arise mainly due to a clogged up air or fuel
12
passage in jets, or fuel level variations. In order to
24
assure proper flow of air and fuel, the carburetor must
be kept clean at all times. The carburetor disassembly
and reassembly procedures are as follows. 16
19
THROTTLE SYSTEM 23
18
(1) Remove the philips screw ① and throttle valve ②, 22
17
and pull out the throttle shaft ③.
21
20
(2) The spring ④ can be taken out by removing the
throttle stop screw ⑤.
15
14
*Be careful not to damage throttle valve rim. 13
Fig.11-3
- 52 -
CHOKE SYSTEM
(1) Remove the philips screws ⑥ and choke valve ⑦, and pull out the choke shaft ⑧.
(2) When reassembling the choke shaft, make sure that the cutout in the choke valve faces the pilot air
jet. Meanwhile. when reassembling set the at the right position.
PILOT SYSTEM
(1) Remove the bolt ⑨ and plate ⑩. And then remove the pilot jet ⑪.
(2) Reassembly
Tighten the pilot jet securely. Otherwise, the fuel may leak, causing engine malfunction.
MAIN SYSTEM
(1) Remove the bolt ⑬ and take out float chamber body ⑮.
(2) Remove the main jet ⑰ and guide holder ⑱ from the body . And then remove the main nozzle ⑲.
(3) Reassembly
a) Fasten the main jet and main nozzle securely to the body. Otherwise, the fuel may become too rich
and cause engine malfunction.
b) The bolt ⑬ tightening torque is 70 kg-cm. Be sure to set the gasket ⑯ and ⑭ for chamber ⑮.
FLOAT SYSTEM
(1) Pull out the float pin ⑳ and remove the float and then remove the clip and needle valve .
If the needle valve needs to be replaced, replace it with rubber needle.
(2) When removing the needle valve and float, gently tap the reverse side of the float pin ⑳ using a rod
more slender than the float pin and remove, since the float pin is pressed into the carburetor body.
CAUTION :
When cleaning the jets, use neither a drill nor a wire (because of possible damage of the
orifice which will adversely affect fuel flow). Be sure to use compressed air to blow them
clean.
- 53 -
11-4 DIAPHRAGM TYPE CARBURETOR
11-4-1 OPERATION AND CONSTRUCTION
1. ENGINE IMPULSE
The alternating action of the positive pressure and negative pressure inside the engine crankcase
operates the fuel pump diaphragm.
2. FUEL PUMP DIAPHRAGM

The fuel pump diaphragm undulates in response to the engine impulse and as a result of that movement
it feeds the fuel through the fuel pump valve.
3. FUEL INLET
The fuel inlet is the opening through which fuel is sucked from the fuel tank.
4. INLET VALVE
The inlet valve opens when the diaphragm is submitted to the action of a negative pressure in response
to the movement of the pump diaphragm and the inlet valve shuts when it is submitted to a positive
pressure.
5. OUTLET VALVE
Oppositely to the inlet valve, the outlet valve shuts when it is submitted to the action of a negative
pressure and opens when submitted to a positive pressure.
6. INLET SCREEN
The inlet screen filters the fuel that is sucked from the fuel tank to the carburetor.
7. INLET NEEDLE VALVE

The inlet needle valve controls the fuel that is fed from the fuel pump to the metering chamber.
8. THROTTLE VALVE
The throttle valve controls the volume of air sucked into the engine, thereby changing the engine speed.
9. AIR VENT HOLE

The air vent hole is open to the atmosphere, with the purpose of allowing smooth operation of the
metering diaphragm.
- 54 -
10. METERING DIAPHRAGM
The metering diaphragm has the function of operating the metering lever, which is pulled up by the
variations in the negative pressure of the engine.
11. METERING LEVER

The metering lever has the function of opening/shutting the inlet needle valve by transmitting the
movements of the metering diaphragm to that valve.
12. METERING LEVER SPRING

The metering lever spring has the function of pushing up the metering lever, thereby shutting the needle
valve when the engine is stopped and when the metering chamber is full of fuel.
13. METERING CHAMBER

The metering chamber is the fuel storage compartment that has the function of supplying fuel to the
nozzle holes and other parts.
14. FIRST IDLE HOLE

The first idle hole is the only fuel supply hole that is available when the engine is idling.
15. SECOND AND THIRD IDLE HOLES

The second and the third idle holes have the function of supplying fuel when the throttle is at an
intermediate opening state between the idling state and the fully open state.
16. IDLE NEEDLE

The idle needle has the function of controlling the fuel when the engine is at idling speeds and when the
throttle is at a low speed position.
17. HIGH SPEED NEEDLE

The high speed needle has the function of controlling the fuel when the engine is operating at high
speed and when the throttle is at a high speed position.
18. MAIN NOZZLE

The main nozzle is the hole through which fuel is ejected when the engine is operating at high speed
and when the throttle is at a high speed position.
- 55 -
19. VENTURI
The venturi has the function of increasing the air flow at the nozzle section, thereby improving the
atomization of the fuel.
20. CHOKE VALVE

The choke valve has the function of shutting the suction of air when the engine is started at cold state,
thereby securing the temporary supply of a rich fuel/air mixture.
11-4-2 DISASSEMBLY PROCEDURE
Before disassembling the carburetor, make sure to ⑲ ①

⑳
wash it with clean gasoline, washing oil and so on. ②
(1) Loosen the pump cover screw ① and remove

③
the screw and the pump cover ②.
④
(2) Remove the pump gasket ③, the diaphragm ⑤

④, the spring ⑤ and the inlet screen ⑥. ⑥
(3) Next, place the carburetor with the primer

pump side up and remove the primer pump
cover screws ⑦ (4 screws).
⑱
⑰
(4) Remove the primer pump cover ⑨, the body
⑯
AY ⑩, diaphragm AY ⑪ and the gasket ⑫. ⑭
⑮
⑬
(5) Loosen the metering lever pin screw ⑬ and
remove the lever ⑭, pin ⑮, spring ⑯, needle ⑫
valve ⑰ and etc. ⑪
(6) Remove the screw ⑲ the choke valve ⑳ the ⑩

choke shaft , be careful loss spring and
⑨
ball .
⑧
(7) Remove the screw and the throttle valve ,
⑦
and then remove the screw AY , the clip
Fig.11-4
and the seal , after that remove the throttle
shaft .
- 56 -
11-4-3 INSPECTION PROCEDURE
(1) Wash the carburetor body with gasoline or the like and blow it with compressed air.
However, make sure not to blow compressed air into the check valve unit of the carburetor equipped
with primer pump.
(2) Check the gaskets for any deformation and/or damage. If a gasket is deformed or damaged, make
sure to replace it with a new one.
(3) Make sure that the pump diaphragm ④ is not damaged and make sure that the inlet valve and outlet
valve are flat and not bent.
(4) Make sure that the metering diaphragm ⑪ is not damaged and that the plate is not bent.
(5) Check the throttle shaft and the choke shaft for smooth operation.
(6) Check the inlet screen ⑥ for sticking of foreign matter. If there is any particle of foreign matter stuck
on the inlet screen, wash it and blow it out with compressed air.
(7) Check the inlet needle valve ⑰ for abnormal wearing. If the inlet needle valve is worn, change it with
a new one.
11-4-4 REASSEMBLY PROCEDURE
(1) Mount the inlet screen ⑥ on the body.
(2) Mount the inlet needle valve ⑰, metering lever spring ⑯, metering lever ⑭ and other related parts.
After mounting these parts, adjust the metering lever ⑭ position at the specified height.
Be particularly careful when carrying out this adjustment, because the metering lever height depends
on the model.
(3) Next, mount the metering gasket ⑫, metering diaphragm ⑪, body AY ⑩, primary pump ⑧ and
cover ⑨ in this order and then tighten the four cover screws ⑦.
(4) Next, mount the pump diaphragm ④, pump gasket ③ and pump cover ② in this order and then
tighten the pump cover screw ①.
Refer to the figure at the Fig. 11-4 for the procedure for mounting the parts of the carburetor.
- 57 -
12. RECOIL STARTER
12-1 RECOIL STARTER
Tools required: Screwdriver, pliers and protective glasses
CAUTION
Put on the protective glasses prior to start disassembly.
12-1-1 DISASSEMBLY PROCEDURE

(1) Release the reel spring power
-1 Hold the starter knob and pull out the starter

rope.
-2 Pull out the rope fully and align the rope knot
in the reel with the rope guide.
-3 Hold the reel down firmly with both thumbs,
taking care not to allow it to spring back.
(Fig. 12-1)
-4 Remove the knot from the reel, untie the knot
and pull the rope out toward the starter knob. Fig.12-1
Note: This procedure requires 2 people.

-5 While controlling the reel with the thumbs,
slowly wind it back as far as it will go.
Fig.12-2
CAUTION
When the rope is pulled out to its full length, the force stored in the spring reaches its
maximum. Be careful not to drop it or release your grip on it suddenly.
- 58 -
(2) Remove the components. (Fig. 12-3)
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. 12-3) RATCHET
-1 Hold down the reel gently to keep it from REEL

escaping from its case and rotate it slowly STARTER
CASE
back and forth by quarter turns until it moves
smoothly.
-2 Lift the reel up little by little and take it out of
the case.
-3 If the spring is about to pop out of the reel,
STARTER
repeat steps (3)-1 and (3)-2. STARTER SHAFT KNOB
(SHAFT HOOK)
CAUTION
Fig.12-3
Since the spring is stored in the reel,
make sure not to drop or shake the reel
after removing it. Place it on a level
surface such as a table.
Disassembly is completed.
CAUTION
Put on the protective glasses prior to start reassembly.
12-1-2 REASSEMBLY PROCEDURE

(1) Put the reel back into the case
GREASE
-1 Apply grease to the surface of the case.
(Fig.12-4)
-2 Adjust the position of the inner end of the
spring in the reel. (Fig. 12-5)
-3 Hold the reel in such a way that the inner end SHAFT HOOK
of the spring hooks onto the shaft hook and Fig.12-4
then place the reel carefully back into the Position where the inner end of the
spring touches to the rib of the bearing.
case.
Fig.12-5
-4 Turn the reel gently counterclockwise to
confirm that the spring is hooked.
- 59 -
(2) Mount the components
-1 Mount the ratchet into the reel. (Fig. 12-6)
THE RATCHET SHOULD BE

IN THE CLOSED POSITION
Fig.12-6
-2 Mount the ratchet guide assembly, taking

Set screw
care not to move the ratchet. (Fig.12-7)
Ratchet
guide
Friction spring
Ratchet guide sub-assembly
Fig.12-7
(3) Tighten the set screw
-1 Hold the ratchet guide gently by your hand to

prevent it from rotating, then tighten the set
screw.
Tightening torque (M6)

5.5 N・m
(55 kgf・cm)
(4.0 ft・lb.)
(4) Tension the reel spring
-1 Grip the case and turn the reel 6 times

counterclockwise.
-2 Fix the reel so that the rope hole in the reel is Fig.12-8
aligned with the rope guide. (Fig. 12-8)
CAUTION
The spring force reaches its maximum value when the reel is wound up.
Be careful not to drop it or release your grip on it suddenly.
- 60 -
(5) Install the rope
NOTE: This procedure requires 2 people.

-1 P
ass the rope end through the rope guide and Approx. 200mm
FROM THE REEL
the rope hole of the reel and pull through
approximately 20 cm out of the reel.
(Fig. 12-9) ROPE GUIDE
-2 Tie a knot in the rope end . (Fig. 12-10)

-3 Put the rope into the reel, taking care that the
rope end does not stick up. (Fig. 12-11) ROPE HOLE
IN REEL
-4 Grasp the rope firmly with one hand at
approximately 50 cm from the rope guide and
Fig.12-9
keep the rope tense, taking care that the rope
is not pulled into the reel.
-5 Release the reel carefully and allow the rope
Approx. 20mm
to be wound back slowly by the force of the
spring until the knob reaches the rope guide.
Assembly is completed.
Fig.12-10
Fig.12-11
* The disassembly and the reassembly are completed, however, carry out the following to check if the
necessary components have surely been assembled.
- 61 -
12-1-3 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.

(a) If the starter rope remains in the rope slot in the reel, the spring may be over-stressed. To fix this, pull
out the starter rope approximately 30 cm, and, controlling the rotation of the reel with your thumb,
allow the starter rope to rewind about 1 or 2 turns.
(b) If the starter rope rewinds slowly or only partially, apply grease or oil to the rotary parts or the friction
surfaces. If this does not help, try winding up the spring 1 or 2 turns, taking care not to over-stress the
spring.
(c) If there is a sound indicating that the spring is off the hook and the starter rope does not be wound
back, reassemble the recoil starter from the beginning.
SPRING
12-1-4 OTHER GUIDES
STARTER
(1) If the spring escapes from the reel during REEL
disassembly
(a) Hook the outer end of the spring onto the gap
in the reel, and rewind the spring, holding the
spring with your fingers so as to prevent it
from springing out of the housing unit.
Hook the outer end of the
(Wear protective gloves when doing this.) spring onto the gap in the reel.
Fig.12-12
(b) Hook the inner end of the spring onto the STARTER SPRING
REEL
projection on the starter case.
*Refer to the assembly procedure for more
details.
(2) About lubrication

APPLY
Lubricate the rotating and frictional parts and the GREASE
spring with grease (heat-resistant grease
recommended) or engine oil when the starter is
disassembled and prior to long term storage.
STARTER CASE
Fig.12-13
- 62 -
13. 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.
13-1 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. Position the engine so that tasks such
as gasoline and oil replenishment and inspection, spark plug inspection, air cleaner maintenance, oil
drainage and so on can be carried out as easily as possible.
13-2 VENTILATION
An engine requires fresh air for cooling and for burning fuel. When an engine is covered with a bonnet or is
operated in an enclosed space, the temperature around the engine rises and this causes such problems as
vapor lock, oil deterioration, increased oil consumption, power loss, engine seizure, and reduced engine life,
making it difficult for the engine to function normally. It is thus necessary to install ducts and dampers to
guide fresh air, so as not to recycle the hot air used to cool the engine and to prevent the working equipment
from heating up.
Be sure to keep the engine room temperature below 50°C all year round and to prevent the accumulation of
hot air in the engine room.
13-3 EXHAUST EQUIPMENT

Exhaust gas is noxious. When operating the engine indoors, make sure that exhaust gases are discharged
outdoors. However, if the exhaust pipe is long, resistance increases and this lowers engine output.
Therefore, the longer the exhaust pipe the larger its inner diameter should be.
Exhaust pipe length: Less than 3 m Pipe inner diameter: 30 mm

Exhaust pipe length: 3 - 5 m Pipe inner diameter: 33 mm
The ideal solution is forced exhaustion (outdoors) by installing a blower on the exhaust pipe.
* Install a safety cover on the exhaust pipe, muffler and other related parts.
13-4 FUEL SYSTEM

If the fuel tank is detached from the engine, the height from the bottom of the fuel tank to the fuel joint of the
carburetor should be between 5 cm and 50 cm.
When using a fuel pump, the bottom of the fuel tank can be up to 20 cm below the carburetor. Position the
fuel tank carefully because, when it is low, fuel is not fed to the carburetor and when it is high, it can cause
an overflow in the carburetor. When piping the fuel, the hose should be as short as possible and attention
should be paid to heat transmission, size, bending, leakage at hose joints and so on. Care should also be
taken to prevent air lock and vapor lock.
- 63 -
13-5 POWER TRANSMISSION TO DRIVE MACHINES
Clutch fitting onto PTO shoulder
For proper clutch fitting onto PTO shoulder, make round chamfer at clutch corner.
Sharp edge of clutch corner strikes PTO shoulder. In this improper condition, bolt will be loosened,
and PTO damaged finally.
Proper Clutch Improper Clutch
Crankshaft (PTO) Crankshaft (PTO)

Round chamfer for
proper fitting
Sharp edge striking
- 64 -
14.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. Generally speaking, since there is the possibility of multiple causes for a
single problem, please use your experience and common sense when deciding on what action to take.
14-1 ENGINE
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.
Problem and possible cause Remedy
1. Ignition system problems 1) Spark plug
・ Improper spark plug gap Adjust the gap
・ Insulation defect Replace
・ Carbon deposits Clean
2) Ignition coil
・Insulation defect or discontinuity Replace
・Poor contact or broken wire Repair or replace
3) Improper air gap between ignition coil and flywheel Adjust
4) Faulty stop switch Repair or replace
5) Faulty oil pressure switch Replace
2. Fuel system problems 1) No fuel in fuel tank Refill
2) Fuel hose clogged or pinched Clean or replace

Starting difficulties
3) Air in fuel lines Check and retighten joints
4) Poor quality gasoline or water in gasoline Replace

5) Carburetor
・Overflow Adjust
・Clogged or damaged Overhaul
・Throttle valve malfunction (does not close fully) Check and adjust
3. Engine core components 1) Insufficient tightening of cylinder head bolts Check and retighten
problems
2) Wearing of piston, piston rings and/or cylinder Repair or replace
3) Improper contact of valve and seat Repair
4) Valve sticking Repair
5) Improper valve clearance Adjust
6) Leakage from intake manifold gasket Retighten; replace gasket
7) Leakage from carburetor gasket Retighten; replace gasket
8) Insufficient tightening of spark plug Retighten
9) Improper timing belt Adjust
- 65 -
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
7) Improper valve clearance Adjust

Poor output
2. Ignition system problems 1) Faulty spark plug Replace
2) Faulty ignition coil Replace
3) Improper air gap between ignition coil and flywheel Adjust
4) Demagnetization (flywheel magneto) Replace
3. Fuel system malfunction 1) Carburetor clogged Overhaul, clean
2) Fuel strainer and/or hose clogged Clean or replace
3) Air in fuel lines Check and retighten joints
4) Poor quality gasoline or water in gasoline Replace
4. Low air intake volume 1) Air cleaner clogged Clean or replace
2) Throttle valve malfunction Repair or replace
1. Engine 1) Cooling air flow obstructed at inlet or cylinder baffle

Clean
portion
2) Poor quality engine oil Replace

Overheat
3) Lean fuel/air mixture Check and adjust carburetor
4) Excessive back pressure of exhaust system Check and clean or replace
5) Overloading Adjust to rated load
1. Carburetor system 1) Low idling speed Adjust
2) Slow system passage clogged Check and clean
Check or replace
3) Hunting after engine stop
O-ring (spacer)
Rough Idling
2. Intake system 1) Air mixing from air intake system joints Check and tighten;
replace gasket
3. Cylinder head 1) Gasket faulty (blow-by) Replace
4. Valve system 1) Improper valve clearance Adjust
2) Leakage from valve seat Repair
3) Excessive clearance between valve stem and guide Replace
5. Ignition system 1) Weak spark Check; adjust or replace plug
- 66 -
1. Oil leakage 1) Loose oil drain plug Tighten
2) Faulty oil drain gasket Replace

Excessive engine oil consumption
3) Loose main bearing cover bolts Tighten
4) Faulty main bearing cover gasket Replace
5) Crankshaft oil seal (front, rear) defect Replace
2. Oil up 1) Faulty piston oil ring Replace
2) Piston ring seizure, wear or poor contact Replace
3) Excessive wear of piston and/or cylinder Replace
4) Faulty stem seal Replace
5) Excessive oil level Adjust oil level
6) Breather defect Repair or replace

High fuel consumption
1. Fuel system 1) Clogged air cleaner Clean or replace
2) Faulty needle valve and/or high fuel level in float chamber Repair or replace
3) Choke does not open fully Repair or replace
2. Engine core components 1) Low compression Check and repair
Check and adjust load

2) Overcooling
and/or engine speed
1. Ignition system problems 1) Loose ignition system wiring Inspect and tighten
2) Improper or faulty spark plug Clean or replace
2. Fuel system problems Clean, adjust or replace

1) Lean or rich fuel/air mixture
carburetor
Abnormal engine noise
2) Carburetor contamination Overhaul or clean
3) Dirty or clogged fuel lines Clean or replace
4) Air mixing from air intake system joints Tighten; replace gasket
3. Cylinder head 1) Carbon deposit in combustion chamber Clean
2) Leakage from cylinder head gasket Replace
4. Valve system problems 1) Improper valve clearance Adjust
2) Valve heat deterioration Replace
3) Worn or broken valve spring Replace
4)Improper valve timing Adjust
- 67 -
15. 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.
15-1 STANDARD DIMENSIONS AND LIMITS OF USE Unit: mm (in.)

ITEM STD Limit
CYLINDER HEAD
* Flatness
0.05 0.1
(0.002) (0.004)
* Intake/exhaust valve seat

contact width
Intake 0.7 - 1.0

-
Exhaust (0.0276 - 0.0394)
* Intake/exhaust valve guide inner diameter
Intake 5.500 - 5.518

-
Exhaust (0.2165 - 0.2172)
* Rocker arm pin outer diameter
D1 D2
Pin outer diameter 5.970 - 5.980 5.9
D1, D2 (0.2350 - 0.2354) (0.232)
* Rocker arm pin support inner diameter
D3 D4
Support inner diameter 6.00 - 6.018 6.05

D3, D4 (0.236 - 0.237) (0.238)
- 68 -
Unit: mm (in.)
ITEM STD Limit

CYLINDER
* Inner diameter
To be rebored when the
60.02 - 60.04 difference between max.
Standard
(2.3630 - 2.3638) and min. of diameter
reached to 0.1 (0.004).
60.27 - 60.29
First reboring Ditto
(2.3728 - 2.3736)
60.52 - 60.54
Second reboring Ditto
(2.3827 - 2.3835)
* Roundness after reboring
* Cylindricity after reboring Less than 0.01

(0.0004)
Less than 0.015

(0.0006)
PISTON
*O
uter diameter at skirt in thrust direction
59.980 - 60.000 59.92

Standard
(2.3614 - 2.3622) (2.3591)
7mm
Oversize 60.230 - 60.250 60.17

+0.25 (2.3713 - 2.3721) (2.3689)
Oversize 60.480 - 60.500 60.42

+0.50 (2.3811 - 2.3819) (2.3787)
- 69 -
Unit: mm (in.)
ITEM STD Limit

PISTON
* Ring groove side clearance
0.035 - 0.080 0.15
Top
(0.0014 - 0.0032) (0.0059)
Oil ring 0.030 - 0.125

-
(three-piece) (0.0012 - 0.0049)
* Piston pin hole
11.991 - 12.009 12.035

(0.4721 - 0.4728) (0.4738)
* Piston pin outer diameter
11.992 - 12.000 11.960

(0.4721 - 0.4724) (0.4709)
* Clearance between piston and cylinder at skirt
0.077 - 0.117 0.25

(0.0030 - 0.0046) (0.0098)
* Piston ring end gap
0.10 - 0.25 1.5

Top
(0.0039 - 0.0098) (0.0591)
Oil ring 0.20 - 0.70 1.5

(three-piece) (0.0079 - 0.0276) (0.0591)
- 70 -
Unit: mm (in.)
ITEM STD Limit

CONNECTING ROD
* Large end inner diameter
24.000 - 24.013 24.1

(0.9449 - 0.9454) (0.9488)
* Clearance between large end and crank pin
0.020 - 0.046 0.2

(0.0008 - 0.0018) (0.0079)
* Small end inner diameter
12.010 - 12.021 12.08

(0.4728 - 0.4733) (0.4756)
* Clearance between small end and piston pin
0.010 - 0.029 0.12

(0.0004 - 0.0011) (0.0047)
* Large end side clearance
0.100 - 0.700 1.0

(0.0039 - 0.0276) (0.0394)
CRANKSHAFT
* Crank pin outer diameter
23.967 - 23.98 23.85

(0.9436 - 0.9441) (0.9390)
* Journal outer diameter

19.988 - 11.997
D1
(0.7869 - 0.4723)
D1 D2
21.988 - 21.997
D2
(0.8657 - 0.8660)
- 71 -
Unit: mm (in.)
ITEM STD Limit

CAMSHAFT
* Cam peak height (intake and exhaust)
20.228 - 20.328 20.201

Cam peak height
(0.7964 - 0.8003) (0.7953)
Cam inner diameter 9.040 - 9.062 9.085

D1,D2 (0.3559 - 0.357) (0.3577)
* Cam sprocket inner diameter

* Pin (cam sprocket) outer diameter
Pin outer diameter 8.953 - 8.975 8.95

D3 D4
D1 D2 D3,D4 (0.3525 - 0.3534) (0.3524)
INTAKE/EXHAUST VALVES
* Valve stem outer diameter
5.440 - 5.455 5.35
Intake
(0.2142 - 0.2148) (0.2106)
5.426 - 5.444 5.35

Exhaust
(0.2136 - 0.2143) (0.2106)
* Clearance between valve stem and valve guide
0.045 - 0.078 0.3

Intake
(0.0018 - 0.0031) (0.0118)
0.056 - 0.092 0.3

Exhaust
(0.0022 - 0.0036) (0.0118)
* Valve clearance (in cold state)
Intake 0.11 - 0.16 0.25

Exhaust (0.0043 - 0.0063) (0.0098)
- 72 -
Unit: mm (in.)
ITEM STD Limit

VALVE SPRING FREE LENGTH
27.4
(1.0787)
VALVE SEAT ANGLE (INTAKE AND EXHAUST)

* Valve cutter angle (a)
* Valve contact width (b)
a: 90°
Intake
b: 0.7 - 1.0 2.0
Exhaust
(0.0276 - 0.0394) (0.0787)
TIMING BELT
Every 500
No Crazing and hours and
Wound If you find any
damaged part.
15-2 SERVICE DATA (The following are only for your reference.)
Compression pressure (kg/cm2 / 500 rpm)
Fuel consumption Continuous load / 3600 rpm (L/Hr)
Capacity (mL) 350
Lubricant
Efficacy (mL) 210
(tilt 15°)
Consumption (mL/Hr)
* Oil consumption has been measured under-following condition :

・ Good break-in operation has been finished.
・ Oil : 10W-30 (Grade SE)
・ Load : Continuous load / 3600 rpm
- 73 -
15-3 TIGHTENING TORQUE
Tightening Torque
Description
N・m kgf・cm ft・lb
Oil drain bolt 11 - 13 110 - 130 8.0 - 9.4
Connectiong rod cap bolts 6-8 60 - 80 4.3 - 5.8
Cylinder head bolts 20 - 24 200 - 240 14.5 - 17.4
Suction pipe bolts 6-8 60 - 80 4.3 - 5.8
Switch (oil pressuer) 8 - 10 80 - 100 5.8 - 7.2
Plug UN (oil filter) 0.8 - 1.2 8 - 12 0.58 - 0.87
Main bearing cover bolts 24 - 26 240 - 260 17.4 - 18.8
Oil pump cover bolts 7-9 70 - 90 5.1 - 6.5
Rocker arm adjust screw nuts 5-7 50 - 70 3.6 - 5.1
Rocker cover bolts 5-7 50 - 70 3.6 - 5.1
New 10 - 12 100 - 120 7.2 - 8.7

Spark plug
Re-use 20 - 23 200 - 230 14.5 - 16.6
Breather cover bolts 7-9 70 - 90 5.1 - 6.5
Flywheel nut 60 - 70 600 - 700 43.4 - 50.6
Ignition coil bolts 7-9 70 - 90 5.1 - 6.5
Pivot bolt (speed control) 7-9 70 - 90 5.1 - 6.5
Flowt type 7-9 70 - 90 5.1 - 6.5

Air cleaner
Diaphragm type 4-5 40 - 50 2.9 - 3.6
Muffler nuts 19 - 21 190 - 210 13.7 - 15.2
Recoil starter bolts 5-7 50 - 70 3.6 - 5.1
15-4 AIR GAP AND CLEARANCE
Clearance
ITEM
mm in.
Valve clearance (Intake, Exhaust) 0.11 - 0.16 0.0043 - 0.0063
Air gap (Ignition coil and flywheel) 0.3 - 0.5 0.012 - 0.020
Electrode gap (Spark plug) 0.6 - 0.7 0.024 - 0.028
- 74 -
16.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.
16-1 DAILY MAINTENANCE (EVERY 8 HOURS OF USE)

MAINTENACE ITEMS REASON / REMARKS
(1) Clean dust from engine. (1) D
ust can impair operation of various parts.
Governor linkage is especially sensitive to dust.
(2) Check for fuel leakage. Tighten or replace parts, (2) Uneconomical and dangerous.
if necessary.
(3) Check all parts are securely fastened. Tighten, (3) Looseness can result in vibration and accidents.
if necessary.
(4) Check oil level and add up to full mark. (4) R unning the engine with insufficient oil can result in
serious problems, including engine seizure.
(5) Check that the air cleaner element is clean. (5) A clogged air cleaner can cause power loss and
Clean or replace, if necessary. malfunction.
16-2 INSPECTION AND MAINTENANCE AFTER THE FIRST 20 HOURS

(1) Change the crankcase oil. (1) Sludge is deposited during running-in.
(2) Clean oil filter. (2) Insufficient oil causes engine failure.
16-3 INSPECTION AND MAINTENANCE EVERY 100 HOURS (EVERY 10 DAYS)

(1) Change the crankcase oil. (1) Contaminated oil quickens wear.
(2) Clean the air cleaner. (2) A clogged air cleaner can cause engine
malfunction.
(3) Inspect the spark plug. Clean with gasoline or (3) A faulty spark plug can cause low power output
polish with sandpaper if dirty. and poor starting performance.
(4) C
lean oil filter (4) Insufficient oil causes engine failure.
16-4 INSPECTION AND MAINTENANCE EVERY 100 TO 200 HOURS (EVERY MONTH)
(1) Clean the fuel strainer and fuel tank. (1) Contaminated fuel can cause engine malfunction.
(2) Change the air cleaner element. (2) A clogged air cleaner can cause engine
malfunction.
(3) Clean and adjust the spark plug electrode. (3) C ause low power output and poor starting
performance.
- 75 -
16-5 INSPECTION AND MAINTENANCE EVERY 300 HOURS
(1) Inspect the intake and exhaust valve clearance. (1) Incorrect clearance can cause low power output
Adjust if necessary. and engine malfunction.
(2) R eplace oil filter. (2) Insufficient oil causes engine failure.
(3) Remove the cylinder head and remove any carbon. (3) Carbon deposits can cause engine malfunction.
(4) Disassemble and clean the carburetor. (4) A faulty carburetor can cause engine malfunction.
(5) Inspect and fitting the intake and exhaust valve (5) Unfitting can cause low power output and engine
and the seats of them. malfunction.
(6) C heck timing belt. (6) It is produced damage and move in timing by
crazing.
16-6 MAINTENANCE EVERY 500 HOURS (ANNUAL MAINTENANCE)

(1) Overhaul the engine. Clean and correct the engine (1) Dirty, misaligned or worn parts can cause low
parts, replacing if necessary. power output and engine malfunction.
(2) Replace the piston rings. (2) Faulty piston rings can cause low output power
and engine malfunction.
(3) Replace the fuel hose. (Every 2 years) (3) To prevent fuel leakage and attendant dangers.
(4) Replace timing belt. (4) It is produced damage and move in timing by
crazing.
16-7 ENGINE STORAGE

(1) Carry out the maintenance jobs described in step 16-1 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.
(4) Pull the recoil starter knob until the resistance is heavy. Leave it in that position.
(5) Clean the exterior of the engine with an oiled cloth. Place a plastic cover or similar over the engine,
and store the engine in a dry place.
- 76 -
ISSUE EMD-ES7259
PRINTED IN JAPAN
September 2011

ER12 ER12: Service Manual

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ER12

Section Title Page

Bore × Stroke mm (in.) 60 × 43 (2.36 × 1.69)

Piston Displacement ml (cu.in.) 121 (7.38)

Compression Ratio 9.6

Maximum Output kW(HP)/r.p.m. 2.6(3.5)/3600

Valve Arrangement Overhead cam system

Cooling System Forced air cooling system

Lubrication System Trochoid Pump, Forced and Splash lubrication system

Automotive detergent oil - SAE; #20, #30 or 10W-30

Capacity of Lubricant L (U.S. gal.) 0.35 (0.092)

Carburetor Horizontal draft, Float type or Diaphragm type

Fuel Automobile unleaded gasoline

Fuel Supply System Gravity type

Spark Plug NGK CR5HSB

Starting System Recoil starter

Governor Centrifugal flyweight type

Air Cleaner system Semi wet type

Dry Weight kg (lb.) 9.9 (21.78)

264 x 288 x 334 (10.39 x 11.34 x 13.15) : Float type Caburetor

*Specifications are subject to change without notice.

2-2 CONTINUOUS RATED OUTPUT

2-3 MAXIMUM TORQUE

3-2. LIGHTWEIGHT AND COMPACT DESIGN

3-3. DESIGNED TO OFFER SUPERIOR MOUNTABILITY

3-4. USER'S SAFETY AS WELL AS USER FRIENDLINESS

3-5. EASE OF MAINTENANCE AND ECONOMICAL EFFICIENCY

4-2 MAIN BEARING COVER

4-4 CONNECTING ROD AND PISTON

4-7 VALVE ARRANGEMENT

4-9 GOVERNOR SYSTEM

4-10 COOLING SYSTEM

4-11 LUBRICATION SYSTEM

Timing belt system is adopted and designed for

the cylinder head and the crankshaft gear.

4-13 IGNITION SYSTEM

The ignition system is a pointless flywheel magnet by

The magneto consists of a flywheel and ignition coil THICKNESS

page 53, section “11-4 DIAPHRAGM CARBURETOR”.

AIR CLEANER COVER

4-16 DECOMPRESSION SYSTEM

the campulley. It opens the exhaust valve before the

pressure and reducing the force required to pull the

Cross sectional view – across the shaft

FLYWHEEL MAIN BEARING COVER

SER No. (Stamping) SUCTION PIPE

CAMPULLEY INTAKE VALVE CARBURETOR

OIL GAUGE GOVERNOR GEAR

SER No. (Stamping)

5-2 SPECIAL TOOLS

For removing and

Commercially available product Chain wrench For locking the flywheel

FLYWHEEL PULLER PISTON RING PLIER

PISTON RING COMPRESSER CHAIN WRENCH

Step Parts to remove Remarks and procedures Fasteners

BREATHER PIPE CLEANER BASE CLEANER COVER

M6 SELF LOCK NUT : 2pcs.

Do Not remove the plug.

5-4-2 ASSEMBLY STEPS AND PRECAUTIONS

(b) Insert the woodruff key (for the flywheel magneto).

NOTE 1: Apply oil to the piston rings, the large

NOTE 2: The piston ring gaps should be

NOTE 2: Carefully scrape off any carbon

(c) Install the campulley to the cylinder head.

(d) Mounting the campulley on the cylinder head. TIMING BELT

1) Measure the height “A” (From the mating

2) Measure the depth “B” (From the mating surface

B – A = SIDE CLEARANCE (in.) BALL BERARING

NOTE: After adjusting the valve clearances, rotate the