Subaru Robin Power Products R1200 service manual Assembly Procedure

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9-4 ASSEMBLY PROCEDURE

n Precautions in assembly

(1)Thoroughly clean each part. When cleaning, take special care with the piston, cylinder, crankshaft, connecting rod, and each bearing.

(2)Be sure to completely scrape off th carbon deposits on the cylinder head and piston head. Also, thoroughly remove carbon deposits from each piston ring groove.

(3)Check whether the lip of each oil seal is damaged or not, and if damaged, replace it with a new one. Also, while assembling, apply lubricating oil to the lip of each seal.

(4)Replace the gaskets and other similar items with new ones.

(5)Check the keys, pins, bolts, nuts etc., and replace them, if necessary, with new ones.

(6)Apply torque, according to the specified rate, to those sections where the torque is rated.

(7)Apply lubricating oil to rotating and sliding parts when they are assembled.

(8)Check the clearance of each part prior to assembly and adjust them if necessary.

(9)When each of the main components have been assembled, turn each one by hand and check for smoothness of rotation and unusual noise.

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Contents Rozh -J &ii Foreword Contents Assembly Specifications ItemsPower Factor AC OutputOutput Max Rated 800 W Frequency 50 Hz Voltage 110 Output MaxFrequency 60 Hz Voltage 12ov DC Output Under no load is approximately from 18V up toFeatures Component Identification CHOKE-RUN-STOPFunction of Each Component L-5 4CONNECTING ROD and Piston Main Bearing CoverCrankshaft CamshaftAIR Cleaner Carburetor‘CC Description of Main OperationsVoltage Regulation Under Load Fis Output Waveform Current @ Curr&t @ Operational Limits of the Generator Load Electric Battery Capacity Wire Length Measuring Procedures II ’ Mj 1 mIPage To Measure Insulation Resist Control Panel Functional Check of Each Component L aOne section, replace with Assy 83 AVR Windings, or peripheral temperature Resistance Cleaning of Slip RingValue El 10.7J-z At rated rpm Exciting coilDisassembly and Assembly Precautions Tools DriverPrecautions Nection Description SequenceI Part to remove j IFront cover Description I2 Remove the front coverBy unscrewing three M5 x 8 screwsDescription Precautions Part to Sequencej remOveBe careful not to Damage the fuel PipeLpanner Part to Sequence, removeSpanner Remove $Ez End cover Description Precautions @ Driver Remove the connector Assembling, beThat 1wiring Part toRemOve ’Rear ‘bracket Description See Fig. g-3-10Pull away the stator cover SequenceI Rpearfito~~ Description’ plastic hammer Siw‘ Part to / Sequencej remove ’ JFront Ibracket Description Necessary Precautions13 m/m box Spanner RemOve DescriptionPrecautions Necessary Tools Blower i 1 1housing I10 m/m box spannerNecessary Precautions . tools @ Driver Precautions Bolt has only to be loosened One M6 x 12 boltBrace nuts 112m/m box ’spanner 10 m/m box jspanner ’Governor Remove the governor lever j Lever26 i &cocci*n Remove the starting pullyIgnition coil from Crank case by takingPull out the intake valve and the exhaust valve Notch Spanner 1spring retainer’sFront and hook ’ the minus driver RetainerCamshaft Description ISequenceI Part toCrankcase Tappets to distin Guish them from one Be careful not to open the joint too wide, or it will break Remove the crankshaft Be careful not toAssembly Procedure WTolerances of new installed parts Connecting rod is joined to the piston with the piston pin Piston and Piston RingConnecting ROD Tappets and CamshaftIntake Valve and Exhaust Valve WV&e h valve guide clearance =53Tappet Adjustment Breather Plate and Tappet Cover Cylinder HeadIgnition COIL, Exciting COIL, Flywheel and Starting Pulley Ignition PlugGovernor Lever Speed Control Nut Muffler and Muffler CoverHead Cover and Blower Housing 1’7 Recoil StartorFront Bracket Rear Bracket and Stator Brash Holder Bracket Cover Page Fuel Pipe Connection Front Cover and Element CoverConnection of Coupler and Plug Secure the side cover with four M 5 x 8 screws Carburetor Schematic Diagram of the Fuel System By-Pass Choke Disassembly and Assembly of Carburetor 184 Safety Precautions Troubleshooting Starting failur Cock is closed Pzlzq L1Ill IISymptoms AIgnition coil ’ \ r?J Hanging posi- tion is not normal Abration 7Symptoms 0Governor system III Seat Case Case there Abnormal Operation Is too much Pour Lubri Been changed Replace Periodically 1Symptoms Voltemeter Stator sub-coil Symptoms LNo DC voltage is output Voltag,eistoo high QParts LSymptoms Symptoms Voltage Is abnormally low Parts For Adjustment Criteria TableUel con Limit Items Adjustment Criteira Description Tools Wiring Diagram LT-TwMaintenance Checks and Maintenance for Every 200 Hours Every Month Page Page Issue EMD-GS0095

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