PARTS MANUAL DY30 / DY35 DY41 / DY42 ENGINE. Models. PUB-EP5769A Rev. 08/00

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1 PARTS MANUAL Models DY30 / DY35 DY41 / DY42 ENGINE PUB-EP5769A Rev. 08/00

2 940 Lively Blvd. Wood Dale, IL Phone: Fax: Copyright 2000 Robin America, Inc.

3 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 specification 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. PRODUCT NUMBER LABEL PRODUCT NUMBER LABEL LOCATIONS 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: D Y X X X X SPEC NO. (11 digits) CODE NO. (4 digits) PRODUCT NO. (15 digits) '00-07

4 MANUAL LAYOUT 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 The part is used in the products with CODE No. of 2101 and after this number The part is used in the products with CODE No. of 2100 and before this number '00-07

5 GROUP INDEX Group Name Page CRANKCASE GROUP... 6 CRANKSHAFT GROUP INTAKE and EXHAUST GROUP GOVERNOR GROUP COOLING and STARTING GROUP FUEL, LUBRICANT GROUP ELECTRIC DEVICE GROUP INDEX OF DESCRIPTION SYMBOLS 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 '00-07

6 SECTION 1 CRANKCASE GROUP FIG DY30/DY35 & DY41/DY '00-07

7 SECTION 1 CRANKCASE GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG CRANKCASE CP 1 DY CRANKCASE CP 1 DY30, Electric Start CRANKCASE CP 1 DY CRANKCASE CP 1 DY35, Electric Start CRANKCASE CP 1 DY41 / DY CRANKCASE CP 1 DY41 / DY42, Electric Start DOWEL PIN PIPE KNOCK STUD STUD 2 Electric Start TENSION BOLT 1 2 DY30 / DY TENSION T 1 2 DY41/ TENSION T 2 2 DY30 / DY T 2 2 DY41 / DY STD BEARING mm undersize BEARING mm undersize BEARING SPRING PIN SLEEVE, balancer BALANCER COVER CP GASKET, balancer cover BOLT and WASHER AY BLIND PLUG GEAR CASE COVER CP 1 DY30 / DY GEAR CASE COVER 1 DY41 / DY OIL SEAL BALL BEARING STUD GASKET, case cover 1 DY30 / DY DY41 / DY AY AY CP 1 DY30 / DY BEARING CP 1 DY30 / DY35, Electric Start BEARING CP 1 DY41 / DY BEARING HOUSING CP 1 DY41 / DY42, Electric Start OIL SEAL BOLT and WASHER AY GASKET, T= Select one piece only, DY30/ GASKET, T= Select one piece only, DY GASKET, T= Select one piece only, DY30/ DY30/DY35 & DY41/DY '00-07

8 SECTION 1 CRANKCASE GROUP FIG DY30/DY35 & DY41/DY '00-07

9 SECTION 1 CRANKCASE GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG GASKET, T= Select one piece only, DY41/ GASKET, T= Select one piece only, DY41/ GASKET, T= Select one piece only, DY41/ O RING 1 DY30 / DY O RING 1 DY41 / DY BLIND PLATE OIL PAN 1 DY30 / DY OIL PAN 1 DY41 / DY GASKET, oil pan 1 DY30 / DY GASKET, oil pan 1 DY41 / DY42 From GASKET, oil pan 1 DY41 / DY42 To BOLT and WASHER AY DY30/DY35 & DY41/DY '00-07

10 SECTION 1 CRANKCASE GROUP FIG. 110 DY30/DY35 & DY41/DY '00-07

11 SECTION 1 CRANKCASE GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG VALVE GUIDE STUD 4 DY30 / DY STUD 4 DY41 / DY BOLT and WASHER AY CYLINDER UN 1 DY CYLINDER UN 1 DY CYLINDER UN 1 DY41 / DY O RING SPACER, T=0.1 1 Select one piece only, DY SPACER, T= Select one piece only, DY SPACER, T= Select one piece only, DY35/41/ SPACER, T= Select one piece only, DY35/41/ CYLINDER HEAD CP 1 DY CYLINDER HEAD CP 1 DY35/41/ O RING FLANGE NUT WASHER STUD STUD ROCKER COVER GASKET, rocker cover BOLT and WASHER AY BREATHER PLATE CP GASKET, breather * GASKET SET 1 DY30 / DY35 * GASKET SET 1 DY41 / DY42 *The gasket sets include the following: Fig. 100 items 290, 355, 356, 415 Fig. 110 items 690, 840 Fig. 300 item 195 Fig. 310 item 340 Fig. 400 item 465 Fig. 600 item 650 DY30/DY35 & DY41/DY '00-07

12 SECTION 2 CRANKSHAFT GROUP FIG. 200 With Balancer DY30/DY35 & DY41/DY '00-07

13 SECTION 2 CRANKSHAFT GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG CRANKSHAFT CP 1 DY30 / DY CRANKSHAFT CP 1 DY41 / DY BALL BEARING LOCK NUT LOCK WASHER KEY 1 DY30 / DY KEY 1 DY41 / DY BALANCER CP 1 DY30 / DY BALANCER CP 1 DY41 / DY NEEDLE BEARING BALANCER GEAR 2 1 DY30 / DY BALANCER GEAR 2 1 DY41 / DY WOODRUFF KEY BALANCER SHAFT SNAP RING, inner CONNECTING ROD AY 1 DY30 / DY CONNECTING ROD AY 1 DY CONNECTING ROD AY 1 DY CONNECTING ROD BOLT 2 DY30 / DY CONNECTING ROD BOLT 2 DY41 / DY PISTON PIN 1 DY30 / DY PISTON PIN 1 DY PISTON PIN 1 DY PISTON 1 STD., DY PISTON mm oversize, DY PISTON mm oversize, DY PISTON 1 STD., DY PISTON mm oversize, DY PISTON mm oversize, DY PISTON 1 STD., DY PISTON mm oversize, DY PISTON mm oversize, DY PISTON 1 STD., DY PISTON mm oversize, DY PISTON mm oversize, DY PISTON RING SET 1 STD., DY PISTON RING SET mm oversize, DY PISTON RING SET mm oversize, DY PISTON RING SET 1 STD., DY35/DY41/DY PISTON RING SET mm oversize, DY35/41/ PISTON RING SET mm oversize, DY35/41/ CLIP 2 DY30 / DY CLIP 2 DY41 / DY DY30/DY35 & DY41/DY '00-07

14 SECTION 2 CRANKSHAFT GROUP FIG. 200 With Balancer DY30/DY35 & DY41/DY '00-07

15 SECTION 2 CRANKSHAFT GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG LARGE END BEARING 2 STD LARGE END BEARING mm undersize LARGE END BEARING mm undersize FLYWHEEL CP 1 DY30 / DY FLYWHEEL CP 1 DY41 / DY FLYWHEEL 1 DY30 / DY FLYWHEEL 1 DY41 / DY RING GEAR 1 Electric Start PIPE KNOCK 2 Electric Start SCREW 4 Electric Start DRIVING SHAFT 1 STD. 1" key, 3/8"-24UNF DRIVING SHAFT 1 Generator, SAE Taper DRIVING SHAFT 1 Pump, 1" threaded DRIVING SHAFT 1 Metric 25mm key, M10 X DRIVING SHAFT 1 Generator, Metric Taper DRIVING SHAFT 1 Metric Pump, 25mm threaded BOLT SPRING WASHER ADAPTER 3 1 STD ADAPTER 1 Generator ADAPTER 4 1 Pump BOLT and WASHER AY DY30/DY35 & DY41/DY '00-07

16 SECTION 3 INTAKE and EXHAUST GROUP FIG. 300 DY30/DY35 & DY41/DY '00-07

17 SECTION 3 INTAKE and EXHAUST GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG CAMSHAFT AY CAMSHAFT CP CAMSHAFT GEAR CP RELEASE LEVER WOODRUFF KEY SPACER, T= Select one piece only SPACER, T= Select one piece only SPACER, T= Select one piece only TAPPET VALVE SPRING SPRING RETAINER RETAINER LOCK 4 DY30 / DY RETAINER LOCK 4 DY41 / DY WASHER INTAKE VALVE VALVE STEM SEAL 1 DY30 / DY VALVE STEM SEAL 1 DY41 / DY EXHAUST VALVE DY30 / DY EXHAUST VALVE 1 DY41 / DY TAPPET GUIDE PUSH ROD SLEEVE 1 DY30 / DY PUSH ROD SLEEVE 1 DY41 / DY NUT SPRING WASHER PLATE CP, push rod O RING GASKET, tappet guide ROCKER SHAFT PUSH ROD 2 DY30 / DY PUSH ROD 2 DY41 / DY EXHAUST ROCKER ARM CP INTAKE ROCKER ARM CP ADJUSTING SCREW ADJUSTING SCREW NUT NUT DY30/DY35 & DY41/DY '00-07

18 SECTION 3 INTAKE and EXHAUST GROUP FIG. 310 DY30/DY35 & DY41/DY '00-07

19 SECTION 3 INTAKE and EXHAUST GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG MUFFLER CP MUFFLER COVER CP GASKET NUT SPRING WASHER FLANGE BOLT DY30/DY35 & DY41/DY '00-07

20 SECTION 3 INTAKE and EXHAUST GROUP FIG. 320 A STD. 2-Stage Flat Pleated B Oil Bath C 2- Stage Oval DY30/DY35 & DY41/DY '00-07

21 SECTION 3 INTAKE and EXHAUST GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG GASKET, muffler NUT SPRING WASHER AIR CLEANER AY 1 STD. 2 - Stage, flat pleated 320A AIR CLEANER AY 1 Oil Bath 320B AIR CLEANER AY 1 2- Stage, oval, DY41/42 only 320C OIL PAN CP 1 320B PACKING 1 320A PACKING 1 320B WING NUT CP 1 320C ELEMENT 1 STD. 2-Stage, flat pleaated 320A ELEMENT 1 Oil Bath 320B ELEMENT 1 2-Stage, oval 320C ELEMENT 1 320B LABEL, air cleaner 1 320A LABEL, air cleaner 1 320B LABEL, air cleaner 1 320C AIR CLEANER CAP 1 320B BOLT and WASHER 1 320B WASHER 1 320B DY30/DY35 & DY41/DY '00-07

22 SECTION 4 GOVERNOR GROUP FIG DY30/DY35 & DY41/DY '00-07

23 SECTION 4 GOVERNOR GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG GOVERNOR LEVER GOVERNOR SHAFT WASHER CLIP STEEL BALL GOVERNOR SPRING GOVERNOR YOKE SCREW and WASHER AY START SPRING GOVERNOR LEVER NUT GOVERNOR PLATE AY OIL PUMP, outer BOLT and WASHER AY GOVERNOR SLEEVE CP CONTROL LINK SPACER O RING SPEED CONTROL 1 CP KNOB WASHER WASHER FRICTION WASHER SCREW ADJUSTING SCREW BLIND PLUG NUT WING NUT WIRE BRACKET 1 CP BOLT NUT SPRING WASHER ADJUSTING SCREW PLUG GASKET, aluminum LOCK PLATE RIVET DY30/DY35 & DY41/DY '00-07

24 SECTION 5 COOLING and STARTING GROUP FIG. 500 DY30/DY35 & DY41/DY '00-07

25 SECTION 5 COOLING and STARTING GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG BLOWER HOUSING 1 DY30 / DY BLOWER HOUSING 1 DY41 / DY BOLT and WASHER AY BOLT and WASHER AY CYLINDER BAFFLE 1 1 DY30 / DY CYLINDER BAFFLE 1 1 DY41 / DY CYLINDER BAFFLE 2 1 DY30 / DY CYLINDER BAFFLE 2 1 DY41 / DY SCREW, panhead NUT FLANGE BOLT KEY STARTING PULLY, compl RECOIL STARTER AY SPIRAL SPRING REEL, compl STARTER ROPE STARTER KNOB RATCHET FRICTION SPRING RETURN SPRING FRICTION PLATE THRUST WASHER CLIP FLANGE BOLT BOLT SPRING WASHER WASHER RECOIL COVER BOLT and WASHER AY DY30/DY35 & DY41/DY '00-07

26 SECTION 6 FUEL, LUBRICANT GROUP FIG. 600 DY30/DY35 & DY41/DY '00-07

27 SECTION 6 FUEL, LUBRICANT GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG FUEL TANK CP LABEL, trademark 1 DY LABEL, trademark 1 DY LABEL, trademark 1 DY LABEL, trademark 1 DY LABEL, instruction FUEL TANK CAP CP FUEL FILTER TANK BAND CP BAND GUIDE PIN CP, tank band BOLT NUT FELT VINYL PIPE TANK BRACKET 1 CP 1 DY30 / DY TANK BRACKET 1 CP 1 DY41 / DY TANK BRACKET 2 CP 1 DY30 / DY TANK BRACKET 2 CP 1 DY41 / DY BOLT and WASHER AY BOLT and WASHER AY BOLT and WASHER AY 1 Electric Start HOSE CLAMP BOLT and WASHER AY WASHER NOZZLE HOLDER AY NOZZLE GASKET, nozzle FLANGE NUT OIL GAUGE CP BRACKET CP, nozzle RUBBER PIPE 1 6 X 12 X RUBBER PIPE 1 6 X 12 X 140, Electric Start RUBBER PIPE X 9 X RUBBER PIPE X 9 X RUBBER PIPE X 9 X 220, Electric Start HOSE CLAMP HOSE CLAMP FUEL PIPE 10 CP FUEL PIPE 11 CP 1 Electric Start RUBBER PIPE 1 6 X 12 X RUBBER PIPE 1 6 X 12 X 250, Electric Start HOSE CLAMP BANJO DY30/DY35 & DY41/DY '00-07

28 SECTION 6 FUEL, LUBRICANT GROUP FIG. 600 DY30/DY35 & DY41/DY '00-07

29 SECTION 6 FUEL, LUBRICANT GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG FUEL FILTER AY CUP RING NUT O RING ELEMENT FUEL FILTER BRACKET FUEL FILTER BRACKET 1 Electric Start, DY30/DY FUEL FILTER BRACKET 1 Electric Start, DY41/DY BOLT and WASHER AY WASHER 1 Electric Start CLAMP 1 Electric Start INJECTION PIPE CP 1 DY30 / DY INJECTION PIPE CP 1 DY41/ DY RUBBER PIPE 1 Electric Start GROMMET OIL FILTER AY BOLT and WASHER AY O RING PLUG GASKET DY30/DY35 & DY41/DY '00-07

30 SECTION 6 FUEL, LUBRICANT GROUP - INJECTION PUMP FIG. 610 DY30/DY35 & DY41/DY '00-07

31 SECTION 6 FUEL, LUBRICANT GROUP - INJECTION PUMP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG NUT SPRING WASHER INJECTION PUMP AY 1 DY30 / DY35 / DY PLUNGER AY 1 DY30 / DY35 /DY DELIVERY VALVE 1 DY30 / DY35 /DY SPRING VALVE 1 DY30 / DY35 /DY GASKET 1 DY30 / DY35 /DY O RING 1 DY30 / DY35 /DY INJECTION PUMP AY 1 DY PLUNGER AY 1 DY DELIVERY VALVE 1 DY SPRING VALVE 1 DY GASKET 1 DY O RING 1 DY BOLT 1 DY GASKET 2 DY BOLT 1 DY GASKET 1 DY GASKET, T= Select one piece only GASKET, T= Select one piece only GASKET, T= Select one piece only 610 DY30/DY35 & DY41/DY '00-07

32 SECTION 6 FUEL, LUBRICANT GROUP FIG. 620 Without Starting Motor DY30/DY35 & DY41/DY '00-07

33 SECTION 6 FUEL, LUBRICANT GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG BOLT and WASHER AY INJECTION PIPE 1 DY30 / DY INJECTION PIPE, compl. 1 DY41 / DY FUEL FILTER AY CUP RING NUT O RING ELEMENT FUEL FILTER BRACKET BOLT and WASHER AY BOLT and WASHER AY BOLT and WASHER AY CLAMP DY30/DY35 & DY41/DY '00-07

34 SECTION 7 ELECTRIC DEVICE GROUP FIG DY30/DY35 & DY41/DY '00-07

35 SECTION 7 ELECTRIC DEVICE GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG GENERATOR CP 1 STD. 30 watt GENERATOR CP 1 45 watt GENERATOR CP 1 65 watt GENERATOR CP watt FLYWHEEL 1 STD. 30 watt FLYWHEEL 1 45 watt FLYWHEEL 1 65 watt FLYWHEEL watt STATOR CP 1 STD. 30 watt STATOR CP 1 45 watt STATOR CP 1 65 watt STATOR CP watt SCREW and WASHER AY SCREW CLAMP CP NUT SPRING WASHER CONTROL BOX BOLT and WASHER AY BOLT and WASHER AY BOLT and WASHER AY LABEL, starter switch SWITCH KEY REGULATOR CP 1 30 & 45 & 65 watt REGULATOR CP watt BOLT CLAMP BOLT SPRING WASHER WASHER NUT WIRE 1 CP WIRE 2 CP WIRE BAND * WIRE 5 CP watt only, Not Shown DY30/DY35 & DY41/DY '00-07

36 SECTION 7 ELECTRIC DEVICE GROUP - STARTER MOTOR FIG. 710 DY30/DY35 & DY41/DY '00-07

37 SECTION 7 ELECTRIC DEVICE GROUP - STARTER MOTOR REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TOFIG STARTING MOTOR AY BRUSH (+) BRUSH SPRING BRUSH HOLDER ARMATURE PINION AY PINION STOPPER SET GEAR CASE AY BRUSH (-) REAR COVER AY REAR COVER METAL BLIND COVER SHIFT LEVER KIT MAGNETIC SWITCH AY BOLT THRUST WASHER KIT FIELD COIL SCREW CENTER PLATE GEAR CASE METAL DUST COVER KIT DY30/DY35 & DY41/DY '00-07

38 SECTION 8 ACCESSORIES GROUP FIG. 800 LOOSE SHIP PARTS DY30/DY35 & DY41/DY '00-07

39 SECTION 8 ACCESSORIES GROUP REF. PART NO. DESCRIPTION QTY. REMARKS FROM-TO FIG ACESSORY TOOL KIT RETURN SPRING KEY DY30/DY35 & DY41/DY '00-07

40 PRINTED IN THE USA

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