Subaru DY27-2 Engine Parts Manual PDF
en
Summary of Content for Subaru DY27-2 Engine Parts Manual PDF
PUB-EP5754A Rev. 07/00
Copyright 2000 Robin America, Inc. ! e-mail: sales@robinamerica.com www.robinamerica.com
- 3 - '00-07
HOW TO USE THIS MANUAL
Robin engines are identified by MODEL, SPECIFICATION, and CODE NUMBER. For each model there may be many different versions called specifications. Each specification will be unique in some way. The difference may only be the paint color or it may have a different type of PTO or some other significant difference.
In order the identify the correct service part number, it is important to confirm the specifica- tion and code numbers for your engine. The specification and code number together are know as the PRODUCT NUMBER.
All Robin 4 cycle engines have a Product Number label similar to the label illustrated below.
The Product Number Label has a 15 digit alphanumeric string that consists of the SPECIFICATION (SPEC) number (11 digits) and the CODE number (4 digits). Please note the illustration below:
PRODUCT NUMBER LABEL LOCATIONS
PRODUCT NUMBER LABEL
X X X X
SPEC NO. (11 digits) CODE NO. (4 digits)
PRODUCT NO. (15 digits)
D Y 2 3 2
MANUAL LAYOUT
- 4 - '00-07
1. SECTION NAME Parts are broadly classified according to their functions. Refer to the Group Index (table of contents) for respective section name.
2. FIG. No. The FIG. number indexes the reference and part numbers to the illustration. Figure numbers that vary only in the tens place (i.e..: 700 and 710) are in a group of the same section (i.e..:Electrical Device Group).
3. REF. No . The Reference number identifies the part illustration with the corresponding part number in the part list.
4. SUBASSEMBLY SUBASSEMBLY parts of part assembly are listed below the assembly part. The subassembly part reference number is indicated by the number led by "-" such as "-1", "-2".
5. PART NUMBER It is the number assigned for sales unit. Use the PART No. when making an order.
6. DESCRIPTION It is designation of the part.
7. QTY. Quantity of each part used for each product.
8. REMARKS This gives a distinctive feature and/or a supplementary comment for the type, the specification, and the part concerned. It also shows part number(s) interchangeable for the part.
9. FROM-TO This section shows the CODE No. to indicate the history of progress in which improved parts have been introduced in the product. The FROM-TO CODE No. helps to identify PART No. being employed in the product concerned. See the examples below:
- The part is used in the product irrespective of CODE No. 2101- The part is used in the products with CODE No. of 2101 and after this number. - 2100 The part is used in the products with CODE No. of 2100 and before this number.
GROUP INDEX
Group Name Page
CRANKCASE GROUP ............................................................................... 6
CRANKSHAFT GROUP ............................................................................ 10
INTAKE and EXHAUST GROUP ............................................................... 12
GOVERNOR GROUP ............................................................................... 16
COOLING and STARTING GROUP ......................................................... 18
FUEL, LUBRICANT GROUP ..................................................................... 20
ELECTRIC DEVICE GROUP .................................................................... 24
ACCESSORIES GROUP .......................................................................... 28
- 5 - '00-07
SYMBOL DESCRIPTION AY .......................... ASSEMBLY CP .......................... COMPLETE EX .......................... EXPORT (from Japan) FIG. ........................ FIGURE FR. ......................... FRONT " .............................. INCH INCL. ...................... INCLUDE ~L ........................... LITER L= ........................... LENGTH (in. mm) L.H. (LH) ................ LEFT-HAND SIDE MECH .................... MECHANICAL NO (NON) .............. NONE OPT. ....................... OPTIONAL O.S. ........................ OVER SIZE
SYMBOL DESCRIPTION P= .......................... PITCH (in mm) P.T.O. (PTO) .......... POWER TAKE OFF REF. ....................... REFERENCE R.H. (RH) ............... RIGHT HAND SIDE RR. ......................... REAR STD. ....................... STANDARD SW ......................... SWITCH T= ........................... THICKNESS (in mm) UN .......................... UNIT U.S. ........................ UNDER SIZE ~V .......................... VOLTAGE ~W ......................... WATT W/ .......................... WITH W/O ........................ WITHOUT
INDEX OF DESCRIPTION SYMBOLS
SECTION 1 CRANKCASE GROUP
DY23-2 / DY27-2 - 6 - '00-07
FIG. 100
SECTION 1 CRANKCASE GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 10 243-10101-61 CRANKCASE CP 1 DY23-2 100
243-10105-61 CRANKCASE CP 1 DY23-2, Electric Start 100 10 244-10101-61 CRANKCASE CP 1 DY27-2 100
244-10105-61 CRANKCASE CP 1 DY27-2, Electric Start 100 30 044-03000-60 OIL SEAL 1 100 36 044-00800-30 OIL SEAL 1 100 45 060-01700-40 BALL BEARING 1 100 50 005-26081-80 DOWEL PIN 2 100 65 001-37062-21 STUD 3 100 66 031-00500-10 DOWEL PIN 1 100 80 040-11400-30 PLUG 2 100 90 021-11400-20 GASKET 2 100
105 031-00600-10 DOWEL PIN 2 100 135 244-16002-11 TENSION BOLT CP 3 100 155 244-16002-11 TENSION BOLT CP 1 100 205 243-75001-03 GROMMET 1 Electric Start 100 210 244-11009-21 MAIN BEARING COVER CP 1 100 220 044-03000-30 OIL SEAL 1 100 250 243-45011-07 GOVERNOR GEAR SET 1 100 251 220-41601-03 FLYWEIGHT 2 100 252 030-73000-70 PIN 2 100 260 205-41901-03 GOVERNOR SLEEVE 1 100 270 214-63601-13 OIL GAUGE 2 100 280 021-32000-10 GASKET 2 100 290 243-15026-03 GASKET, main bearing cover 1 100 300 001-13083-50 BOLT and WASHER AY 12 100 310 001-13084-00 BOLT and WASHER AY 1 100 320 243-15801-03 MAIN BEARING 1 STD. 100
243-15802-03 MAIN BEARING 1 0.25mm undersize 100 243-15803-03 MAIN BEARING 1 0.50mm undersize 100
361 212-15008-13 BLIND PLUG 1 100
DY23-2 / DY27-2 - 7 - '00-07
SECTION 1 CRANKCASE GROUP
FIG. 110
DY23-2 / DY27-2 - 8 - '00-07
SECTION 1 CRANKCASE GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 20 243-14204-13 VALVE GUIDE 2 110 60 001-37082-01 STUD 2 110
610 243-13001-71 CYLINDER HEAD CP 1 110 620 243-15027-13 GASKET, T= 0.2 1 Select one piece only, DY23-2 110
243-15028-13 GASKET, T= 0.3 1 Select one piece only, DY23-2 110 620 244-15027-13 GASKET, T= 0.2 1 Select one piece only, DY27-2 110
244-15028-13 GASKET, T= 0.3 1 Select one piece only, DY27-2 110 635 018-00900-10 FLANGE NUT 4 110 650 001-39066-00 STUD 1 110 660 010-50601-50 STUD 1 110 680 243-17101-01 ROCKER COVER CP 1 110 690 243-1 5032-13 GASKET, rocker cover 1 110 710 011-00601-70 FLANGE BOLT 4 110 730 243-15030-03 PLUG 1 110
*960 255-99001-07 GASKET SET 1 DY23-2 *960 256-99001-07 GASKET SET 1 DY27-2
DY23-2 / DY27-2 - 9 - '00-07
* The gasket set for the DY23-2 contains the following: Fig. 100 items 90, 280, 290 Fig. 110 items 620, 690 Fig. 310 items 340, 555
* The gasket set for the DY27-2 contains the following: Fig. 100 items 90, 280, 900 Fig. 110 items 620, 690 Fig. 310 items 340, 510-2, 555
SECTION 2 CRANKSHAFT GROUP
DY23-2 / DY27-2 - 10 - '00-07
FIG. 200
430
440
SECTION 2 CRANKSHAFT GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 10 244-20401-11 CRANKSHAFT CP 1 200 25 060-03500-20 BALL BEARING 1 200 50 002-18180-00 NUT 1 200 60 003-20180-00 SPRING WASHER 1 200 70 032-30300-10 WOODRUFF KEY 1 200 85 243-25001-03 THRUST WASHER, T=0.8 1 Select one piece only 200
243-25002-03 THRUST WASHER, T=1.0 1 Select one piece only 200 243-25003-03 THRUST WASHER, T=1.2 1 Select one piece only 200
86 011-00600-10 FLANGE BOLT 2 200 210 243-24301-01 BALANCER CP 1 200 215 023-01700-20 SPACER, T= 0.8 1 Select one piece only 200
023-01700-30 SPACER, T= 1.0 1 Select one piece only 200 023-01700-40 SPACER, T= 1.2 1 Select one piece only 200
310 243-22510-00 CONNECTING ROD AY 1 200 320 243-23002-03 CONNECTING ROD BOLT 2 200 350 243-23301-03 PISTON PIN 1 200 360 243-23401-13 PISTON 1 STD., DY23-2 200
243-23402-13 PISTON 1 0.25mm oversize, DY23-2 200 243-23403-13 PISTON 1 0.50mm oversize, DY23-2 200
360 244-23401-13 PISTON 1 STD., DY27-2 200 244-23402-13 PISTON 1 0.25mm oversize, DY27-2 200 244-23403-13 PISTON 1 0.50mm oversize, DY27-2 200
370 243-23501-27 PISTON RING SET 1 STD., DY23-2 200 243-23502-27 PISTON RING SET 1 0.25mm oversize, DY23-2 200 243-23503-27 PISTON RING SET 1 0.50mm oversize, DY23-2 200
370 244-23501-27 PISTON RING SET 1 STD., DY27-2 200 244-23502-27 PISTON RING SET 1 0.25mm oversize, DY27-2 200 244-23503-27 PISTON RING SET 1 0.50mm oversize, DY27-2 200
380 056-52000-30 CLIP 2 200 395 243-22801-03 LARGE END BEARING 2 STD. 200
243-22802-03 LARGE END BEARING 2 0.25mm undersize 200 243-22803-03 LARGE END BEARING 2 0.50mm undersize 200
430 244-17501-13 ADAPTER 1 200 440 001-13082-50 BOLT and WASHER AY 4 200 500 243-22410-13 FLYWHEEL 1 200
DY23-2 / DY27-2 - 11 - '00-07
SECTION 3 INTAKE and EXHAUST GROUP
FIG. 300
DY23-2 / DY27-2 - 12 - '00-07
SECTION 3 INTAKE and EXHAUST GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 10 255-31703-01 CAMSHAFT CP 1 300 35 243-35503-23 RELEASE LEVER 1 300 36 005-19031-00 SPRING PIN 1 300 38 243-35505-03 RELEASE LEVER 1 300 39 243-35022-03 SHAFT, release 1 300 41 005-26081-80 DOWEL PIN 1 300 45 243-35021-03 SPRING, release 1 300 50 243-33301-03 TAPPET 2 300 60 243-33601-03 VALVE SPRING 2 300 70 243-33701-13 SPRING RETAINER 2 300 75 243-33801-13 RETAINER LOCK 4 300 80 243-33401-23 INTAKE VALVE 1 300 85 237-16008-01 STEM SEAL 1 300 90 243-33501-23 EXHAUST VALVE 1 300
100 023-01900-20 SPACER, T= 0.8 1 Select one piece only 300 023-01900-30 SPACER, T= 1.0 1 Select one piece only 300
200 243-35034-03 ROCKER SHAFT 1 300 210 243-35032-01 PUSH ROD CP 2 300 220 243-36002-01 ROCKER ARM CP 2 300 230 014-90800-21 ADJUSTING SCREW 2 300 240 017-00800-90 NUT 2 300
DY23-2 / DY27-2 - 13 - '00-07
SECTION 3 INTAKE and EXHAUST GROUP
FIG. 310
DY23-2 / DY27-2 - 14 - '00-07
SECTION 3 INTAKE and EXHAUST GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 300 255-30103-00 MUFFLER AY 1 310 310 243-30101-51 MUFFLER CP 1 310 320 243-34201-01 MUFFLER COVER CP 1 310 340 243-35002-03 GASKET, exhaust 1 310 350 002-19080-00 NUT 2 310 360 001-10061-00 BOLT and WASHER AY 4 310 380 243-37002-11 TAIL PIPE CP 1 310 395 015-00400-60 TAPPING SCREW 3 310 500 243-33101-13 INTAKE MANIFOLD 1 310 510 243-32601-00 AIR CLEANER AY 1 310
-2 243-32651-08 PACKING 1 310 -7 243-32650-08 PACKING 1 310
-110 243-32640-08 COVER CP 1 310 -120 243-32620-08 BACK PLATE CP 1 310 -160 243-32660-08 WASHER 1 310 -170 243-32670-08 WING BOLT 1 310 520 243-32600-08 ELEMENT CP 1 310 525 243-32611-08 ELEMENT 1 310 555 243-35503-13 GASKET, intake manifold 1 310 556 001-13083-50 BOLT and WASHER AY 2 310 580 001-13061-20 BOLT and WASHER AY 2 310 584 001-13081-60 BOLT and WASHER AY 1 310 900 243-92302-03 LABEL, air cleaner 1 310
DY23-2 / DY27-2 - 15 - '00-07
SECTION 4 GOVERNOR GROUP
FIG. 400
DY23-2 / DY27-2 - 16 - '00-07
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 10 243-42902-21 CONTROL LINK CP 1 400 20 243-42301-12 GOVERNOR LEVER 1 400 21 002-18080-00 NUT 1 400 22 003-20080-00 SPRING WASHER 1 400 80 243-42503-01 GOVERNOR SPRING CP 1 400
310 243-43301-30 SPEED CONTROL AY 1 400 340 227-43501-13 STOP PLATE 1 400 350 227-45002-03 SPRING WASHER 1 400 360 004-31041-00 SCREW 2 400 380 017-60600-30 SELF LOCK NUT 1 400 390 243-44202-01 WIRE BRACKET 1 CP 1 400 410 243-44210-01 WIRE BRACKET 2 CP 1 400 415 243-46001-03 RETURN SPRING 1 400 490 002-18060-00 NUT 2 400 491 001-66063-00 BOLT 1 400 495 243-45002-03 BOLT 1 400 496 003-10060-00 WASHER 1 400 497 010-00603-70 BOLT 1 400 500 255-40166-01 CONTROL PANEL CP 1 400 501 001-14061-20 BOLT and WASHER AY 2 400 502 001-13081-60 BOLT and WASHER AY 3 400 510 243-92101-03 LABEL, operation 1 400 520 243-92102-03 LABEL, operation 1 400 650 243-45502-00 SMOKE SET AY 1 400 660 002-27100-00 NUT 1 400
SECTION 4 GOVERNOR GROUP
DY23-2 / DY27-2 - 17 - '00-07
SECTION 5 COOLING and STARTING GROUP
FIG. 500
DY23-2 / DY27-2 - 18 - '00-07
SECTION 5 COOLING and STARTING GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 10 243-51201-21 BLOWER HOUSING CP 1 500 40 001-13082-00 BOLT and WASHER AY 2 500 60 243-52601-33 CYLINDER BAFFLE 1 500 80 011-00600-10 FLANGE BOLT 5 500
150 001-13083-00 BOLT and WASHER AY 2 500 210 243-50201-20 RECOIL STARTER AY 1 500
-1 106-50116-08 SPIRAL SPRING 1 500 -2 239-50220-08 REEL CP 1 500 -3 243-50110-08 STARTER ROPE 1 500 -4 236-50101-08 STARTER KNOB 1 500 -5 106-50128-18 RATCHET 2 500 -6 106-50132-08 FRICTION SPRING 1 500 -7 106-50136-18 RETURN SPRING 1 500 -8 106-50144-08 FRICTION PLATE 1 500 -9 106-50185-08 THRUST WASHER 1 500
-10 106-50186-08 CLIP 1 500 -11 243-50145-08 STARTING PULLEY 1 500 215 243-95004-13 LABEL, diesel mark 1 500 230 001-14061-20 BOLT and WASHER AY 3 500
DY23-2 / DY27-2 - 19 - '00-07
SECTION 6 FUEL, LUBRICANT GROUP
FIG. 600
DY23-2 / DY27-2 - 20 - '00-07
SECTION 6 FUEL, LUBRICANT GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 10 243-60102-41 FUEL TANK CP 1 600 16 255-91701-03 LABEL, trademark 1 DY23-2 600
256-91701-03 LABEL, trademark 1 DY27-2 600 20 243-91907-13 LABEL, instruction 1 600 27 073-20039-00 LABEL, warning 1 600 30 043-04300-15 FUEL TANK CAP CP 1 600 40 064-13600-10 FUEL FILTER 1 600 80 085-14500-00 RUBBER PIPE 1 4.5 X 9 X 45 600 81 085-14500-00 RUBBER PIPE 1 4.5 X 9 X 95 600 86 228-65032-13 CHECK VALVE 1 600 88 150-75201-03 CLAMP 1 600 89 001-10061-00 BOLT and WASHER AY 1 600 90 056-10800-10 HOSE CLAMP 5 600 95 056-10800-20 HOSE CLAMP 1 600
100 085-00500-40 VINYL PIPE 1 5 X 8 X 120 600 105 001-13082-00 BOLT and WASHER AY 2 600
DY23-2 / DY27-2 - 21 - '00-07
SECTION 6 FUEL, LUBRICANT GROUP
FIG. 610
DY23-2 / DY27-2 - 22 - '00-07
SECTION 6 FUEL, LUBRICANT GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 250 243-63201-00 NOZZLE AY 1 610
-1 243-63204-08 NOZZLE 1 610 260 228-65004-03 GASKET, nozzle 1 610 265 002-38060-00 FLANGE NUT 4 610 270 243-66001-01 BRACKET CP, nozzle 1 1 610 300 255-63103-00 INJECTION PUMP AY 1 610
-1 243-63131-08 PLUNGER AY 1 610 -2 243-63103-08 DELIVERY VALVE 1 610 -3 243-63104-08 DELIVERY SPRING 1 610 -4 243-63105-08 GASKET 1 610 -5 243-63107-08 O RING 1 610 -6 243-63129-08 O RING 2 610
-21 243-63130-08 SCREW 2 610 305 243-65001-03 GASKET, T= 0.1 1 Select one piece only 610
243-65002-03 GASKET, T= 0.2 1 Select one piece only 610 243-65003-03 GASKET, T= 0.3 1 Select one piece only 610
310 085-10600-00 RUBBER PIPE 1 6 X 12 X 120 610 330 085-10600-00 RUBBER PIPE 1 6 X 12 X 180 610 340 085-14500-00 RUBBER PIPE 1 4.5 X 9 X 90 610 350 085-14500-00 RUBBER PIPE 1 4.5 X 9 X 315 610 355 056-11100-20 HOSE CLAMP 4 610 356 056-10800-10 HOSE CLAMP 4 610 400 243-62101-20 FUEL FILTER AY 1 610
-7 228-62112-08 PACKING 1 610 -8 228-62111-08 PLUG 1 610
420 243-66520-10 T-CONNECTOR AY 1 610 -1 243-66521-08 NUT 1 610 -2 243-66506-08 PACKING 1 610
430 243-63301-21 INJECTION PIPE CP 1 610 600 243-64301-00 OIL FILTER AY 1 610 610 001-14061-60 BOLT and WASHER AY 2 610 620 006-26202-00 O RING 1 610 700 228-63902-03 OIL PUMP, outer 1 610 710 006-26103-30 O RING 1 610 720 243-66020-01 COVER CP, oil pump 1 610 730 004-11061-60 SCREW, countersink 3 610
DY23-2 / DY27-2 - 23 - '00-07
SECTION 7 ELECTRIC DEVICE GROUP
FIG. 700
DY23-2 / DY27-2 - 24 - '00-07
SECTION 7 ELECTRIC DEVICE GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 10 243-70110-41 FLYWHEEL CP 1 700 11 243-70102-21 CHARGE COIL CP 1 700 20 243-71002-13 RING GEAR 1 700 35 004-35062-50 SCREW and WASHER AY 2 700 90 226-75101-03 CLAMP 1 700 92 004-35061-00 SCREW and WASHER AY 1 700
130 001-14083-00 BOLT and WASHER AY 2 700 170 001-13081-60 BOLT and WASHER AY 1 700 200 243-40601-11 CONTROL BOX CP 1 700 210 073-20010-90 LABEL, starter switch 1 700 220 066-00003-30 SWITCH 1 700
-1 066-00099-80 KEY 2 700 230 243-71401-01 DIODE RECTIFER CP 1 700 240 001-10061-00 BOLT and WASHER AY 1 700 261 056-60001-70 CLAMP 2 700 262 001-13081-20 BOLT and WASHER AY 1 700 340 243-73104-11 WIRE 2 CP 1 700
DY23-2 / DY27-2 - 25 - '00-07
SECTION 7 ELECTRIC DEVICE GROUP - STARTER MOTOR
FIG. 710
DY23-2 / DY27-2 - 26 - '00-07
SECTION 7 ELECTRIC DEVICE GROUP - STARTER MOTOR
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 120 255-70502-00 STARTING MOTOR AY 1 710
-1 255-70580-08 YOKE AY 1 710 -2 255-70551-08 BRUSH SET 1 710 -3 228-70516-08 BRUSH SPRING 4 710 -4 255-70531-08 BRUSH HOLDER AY 1 710 -6 255-70561-08 AMATEUR AY 1 710 -7 255-70521-08 PINION AY 1 710 -8 210-70534-08 PINION STOPPER SET 1 710 -9 255-70501-08 GEAR CASE AY 1 710
-10 228-70514-08 BRUSH (-) 2 710 -11 255-70505-08 REAR COVER AY 1 710 -12 210-70542-08 REAR COVER METAL 1 710 -14 243-70525-08 SHIFT LEVER KIT 1 710 -15 255-70515-08 MAGNETIC SWITCH AY 1 710 -17 207-70524-08 THROUGH BOLT 2 710 -25 210-70533-08 THRUST WASHER KIT 1 710 -29 210-70542-08 REAR COVER METAL 1 710 -30 255-70570-08 DUST COVER KIT 1 710 -32 228-70522-08 BOLT 2 710 140 002-28080-00 NUT 1 710 160 003-20080-00 SPRING WASHER 1 710
DY23-2 / DY27-2 - 27 - '00-07
SECTION 8 ACCESSORIES GROUP
FIG. 800
DY23-2 / DY27-2 - 28 - '00-07
40
SECTION 8 ACCESSORIES GROUP
REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG. 10 243-90301-00 TOOL KIT 1 800 30 243-65006-00 OIL FEEDER AY 1 800 40 207-26001-03 KEY 1 800
DY23-2 / DY27-2
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