PARTS MANUAL. RGV6100/6101 Generators. Models. PUB-GP1201A Rev. 12/99

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1 PARTS MANUAL Models RGV6100/6101 Generators PUB-GP1201A Rev. 12/99

2 RGV6100 & RGV '99-12

3 GROUP INDEX Group Name Page GENERATOR GROUP - RGV GENERATOR GROUP - RGV FRAME for RECOIL STARTER TYPE... 8 FRAME for ELECTRIC STARTER TYPE CONTROL BOX CONTROL PANEL for 60Hz-120V FUEL TANK MUFFLER CRANKCASE CRANKSHAFT and PISTON INTAKE and EXHAUST GOVERNOR OPERATION COOLING and STARTING CARBURETOR MAGNETO for RECOIL STARTER TYPE MAGNETO for ELECTRIC STARTER TYPE STARTING MOTOR SOLENOID OIL SENSOR Lively Blvd. Wood Dale, IL Phone: Fax: Copyright 1999 Robin America, Inc. RGV6100 & RGV '99-12

4 FIG. 1A GENERATOR GROUP - RGV6100 RGV6100 & RGV '99-12

5 FIG. 1A GENERATOR GROUP - RGV6100 REF PART NUMBER DESCRIPTION QTY REMARKS FRONT COVER BOLT and WASHER ASS Y (M8 x 20mm) 4 * ROTOR, compl. 1 Includes item BALL BEARING (6205DDU) THROUGH BOLT (M10 x 260mm) D STATOR, compl. 1 For 60Hz-120V/240V 7 31D REAR COVER D STATOR COVER BUSHING D COVER BOLT (M6 x 160mm) SPRING WASHER FLANGE NUT CAP D CAP 1 RGV6100 & RGV '99-12

6 FIG. 1B GENERATOR GROUP - RGV6101 RGV6100 & RGV '99-12

7 FIG. 1B GENERATOR GROUP - RGV6101 REF PART NUMBER DESCRIPTION QTY REMARKS FRONT COVER BOLT and WASHER ASS Y 4 M8 20mm *3 31D ROTOR, compl BALL BEARING DDU THROUGH BOLT 1 M10 260mm 6 31D STATOR, compl. 1 For 60Hz-120V/240V *7 31D REAR COVER 1 Includes items 16 and D STATOR COVER BUSHING D COVER BOLT 4 M6 160mm SPRING WASHER FLANGE NUT CAP D CAP BRUSH COVER BOLT and WASHER ASS Y 2 M5 12mm RGV6100 & RGV '99-12

8 FIG. 2A FRAME for RECOIL STARTER TYPE - RGV6100/6101 RGV6100 & RGV '99-12

9 FIG. 2A FRAME for RECOIL STARTER TYPE - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS 1 31D PIPE FRAME, compl. 1 RGV D PIPE FRAME, compl. 1 RGV D RUBBER MOUNT UNIT 2 generator side 3 31D RUBBER MOUNT UNIT 2 engine side FLANGE NUT C SPACER A EARTH CORD SCREW and WASHER ASS Y (M5 x 8mm) 1 M5 x 8mm 8 31D STOPPER PLATE D SIDE PLATE LABEL 1 RGV D LABEL, trademark 1 RGV6101 RGV6100 & RGV '99-12

10 FIG. 2B FRAME for ELECTRIC STARTER TYPE - RGV100/6101 RGV6100 & RGV '99-12

11 FIG. 2B FRAME for ELECTRIC STARTER TYPE - RGV100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS 1 31D PIPE FRAME, compl. 1 RGV D PIPE FRAME, compl. 1 RGV D RUBBER MOUNT UNIT 2 generator side 3 31D RUBBER MOUNT UNIT 2 engine side FLANGE NUT C SPACER A GROUND CABLE SCREW and WASHER ASS Y 1 M5 x 8mm 8 31D STOPPER PLATE D SIDE PLATE LABEL 1 RGV D SIDE PLATE LABEL 1 RGV BATTERY RETAINER BATTERY SUPPORT SPRING WASHER C WING NUT BATTERY BOLT D BATTERY CABLE (+) D BATTERY CABLE (-) 1 RGV6100 & RGV '99-12

12 FIG. 3 CONTROL BOX - RGV6100 RGV6100 & RGV '99-12

13 FIG. 3 CONTROL BOX - RGV6100 REF PART NUMBER DESCRIPTION QTY REMARKS 1 31D CONTROL BOX, compl CONDENSER, compl. (28µF x 2) C CONDENSER BRACKET TAPPING SCREW (M4 x 10mm) GROMMET B BOLT and WASHER ASS Y (M5 x 12mm) B BOLT and WASHER ASS Y (M5 x 25mm) DIODE STACK 1 For Recoil starter type DIODE STACK 2 For Electric starter type WASHER 1 For Recoil starter type WASHER 2 For Electric starter type 10 31B TAPPING SCREW (M4 x 25mm) 1 For Recoil starter type 10 31B TAPPING SCREW (M4 x 25mm) 2 For Electric starter type 11 KU IDLE CONTROL UNIT SCREW (M6 x 20mm) NUT (M6) SPRING WASHER (M6) 2 RGV6100 & RGV '99-12

14 FIG. 3 CONTROL BOX - RGV6101 RGV6100 & RGV '99-12

15 FIG. 3 CONTROL BOX - RGV6101 REF PART NUMBER DESCRIPTION QTY REMARKS 1 31D CONTROL BOX, compl CONDENSER, compl. 1 28µF 3 31C CONDENSER BRACKET TAPPING SCREW (M4 x 10mm) GROMMET B BOLT and WASHER ASS Y (M5 x 12mm) B BOLT and WASHER ASS Y (M5 x 25mm) DIODE STACK 1 For Recoil starter type DIODE STACK 2 For Electric starter type WASHER 1 For Recoil starter type WASHER 2 For Electric starter type 10 31B TAPPING SCREW (M4 x 25mm) 1 For Recoil starter type 10 31B TAPPING SCREW (M4 x 25mm) 2 For Electric starter type 11 KU IDLE CONTROL UNIT SCREW (M6 x 20mm) NUT (M6) SPRING WASHER (M6) 2 RGV6100 & RGV '99-12

16 FIG. 4 CONTROL PANEL for 60Hz-120/240V - RGV6100/6101 RGV6100 & RGV '99-12

17 FIG. 4 CONTROL PANEL for 60Hz-120/240V - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS *1 31D CONTROL PANEL ASS Y, recoil starter type 1 Includes items 1 thru 25 *1 31D CONTROL PANEL ASS Y, electric starter type 1 Includes items 1 thru D PANEL A, compl. 1 For Recoil starter type 1 31D PANEL A, compl. 1 For Electric starter type 2 31D NO FUSE BREAKER 1 1P30A 3 31B SCREW and WASHER ASS Y 10 M3 x 5mm AC VOLTMETER 1 RGV AC VOLTMETER 1 RGV NUT (M3) B ENGINE SWITCH 1 For Recoil starter type KEY SWITCH 1 For Electric starter type 6A KEY SET (2) 1 For Electric starter type TOGGLE SWITCH TERMINAL BOLT (COLOR: RED) TERMINAL BOLT (COLOR: BLACK) CIRCUIT PROTECTOR (10A) WING NUT (M5) SPRING WASHER WASHER LOCK WASHER NUT SCREW 1 M5 x 15mm TOGGLE SWITCH B AC RECEPTACLE (GFCI) SCREW & WASHER ASS Y 2 M4 x 10mm WASHER (M4) NUT (M4) RECEPTACLE (125V-30A) 1 125V-30A SCREW RECEPTACLE C NO FUSE BREAKER (2P20A) 1 RGV C NO FUSE BREAKER 1 RGV TAPPING SCREW (M4 x 10mm) 6 RGV SCREW and WASHER AY (M4 x 10mm ) 6 RGV6101 RGV6100 & RGV '99-12

18 FIG. 5 FUEL TANK - RGV6100/6101 RGV6100 & RGV '99-12

19 FIG. 5 FUEL TANK - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS 1 31D FUEL TANK, compl LABEL, starting 1 RGV LABEL, warning 1 RGV LABEL, stopping 1 RGV LABEL, caution 1 RGV LABEL, caution 1 RGV FUEL GAUGE, compl FUEL TANK CAP, compl. 1 RGV FUEL TANK CAP, ASS'Y 1 RGV SCREW (counter head) FUEL FILTER 1 * FUEL STRAINER ASS Y 1 Includes items 10 thru FILTER PACKING CUP RUBBER PIPE 1 ø6 x ø12 x 210mm RUBBER PIPE 1 ø6 x ø12 x 80mm HOSE CLAMP RUBBER (tank) FLANGE BOLT FLANGE BOLT 1 RGV6100 & RGV '99-12

20 FIG. 6 MUFFLER - RGV6100/6101 RGV6100 & RGV '99-12

21 FIG. 6 MUFFLER - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS 1 31D MUFFLER, compl D SPARK ARRESTER, compl D MUFFLER COVER 1, compl D MUFFLER COVER D MUFFLER STAY GASKET, compl. (exhaust) NUT SPRING WASHER BOLT and WASHER ASS Y BOLT and WASHER ASSly TAPPING SCREW 4 RGV6100 & RGV '99-12

22 FIG. 7 CRANKCASE - RGV6100/6101 RGV6100 & RGV '99-12

23 FIG. 7 CRANKCASE - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS * CRANKCASE, compl. 1 Includes items 3 thru OIL SEAL (ø35 x ø48 x 8mm) BALL BEARING (BB6207C3) BALL BEARING (BB6202C3) DOWEL PIN 2 * GOVERNOR GEAR, compl. 1 Includes items 8 and GOVERNOR SLEEVE 1 * MAIN BEARING COVER, compl. 1 Includes items 12 thru OIL SEAL (ø35 x ø48 x 8mm) BALL BEARING (BB6207C3) BALL BEARING (BB620203) OIL GAUGE GASKET 1 * CYLINDER HEAD, compl. 1 Includes items 18 and VALVE GUIDE (over size) STUD GASKET (head) GASKET (bearing cover) PLUG GASKET BLIND COVER 1 For Recoil starter type ROCKER COVER, compl GASKET (rocker cover) RUBBER PIPE (ø11 x ø8) DOWEL PIN BREATHER COVER, compl BREATHER PLATE, compl GASKET (breather cover) GASKET (breather plate) BOLT and WASHER ASS Y FLANGE BOLT FLANGE BOLT FLANGE BOLT BOLT 2 For Recoil starter type FLANGE BOLT FLANGE NUT 2 * GASKET SET (STD.) 1 RGV6100 & RGV '99-12

24 FIG. 8 CRANKSHAFT and PISTON - RGV6100/6101 RGV6100 & RGV '99-12

25 FIG. 8 CRANKSHAFT and PISTON - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS CRANKSHAFT, compl. 1 * CONNECTING ROD ASS Y 1 Includes items 3 and CONNECTING ROD BOLT OIL SCRAPER PISTON PIN PISTON (For STD) PISTON (over size 0.25mm) PISTON (over size 0.50mm) PISTON RING SET (For STD) PISTON RING SET (over size 0.25mm) PISTON RING SET (over size 0.50mm) CLIP SPACER (t=0.6) 1 select one piece only SPACER (t=0.8) 1 select one piece only SPACER (t=1.0) 1 select one piece only BALANCER SHAFT NUT WASHER SPRING WASHER WOODRUFF KEY 1 RGV6100 & RGV '99-12

26 FIG. 9 INTAKE and EXHAUST - RGV6100/6101 RGV6100 & RGV '99-12

27 FIG. 9 INTAKE and EXHAUST - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS * CAMSHAFT, compl. 1 Includes item SPRING PIN RELEASE LEVER, compl spacer (t=0.6) 1 select one piece only spacer (t=0.7) 1 select one piece only spacer (t=0.8) 1 select one piece only RETURN SPRING TAPPET INTAKE VALVE EXHAUST VALVE VALVE SPRING SPRING RETAINER ROCKER SHAFT PUSH ROD, compl. 2 * ROCKER ARM ASS Y 2 Includes items 14 and ADJUSTING SCREW NUT WASHER SPACER (rocker shaft) COLLET-VALVE 4 * INTAKE PIPE, compl. 1 Includes item STUD GASKET (intake pipe) BOLT and WASHER ASS Y 3 * AIR CLEANER ASS Y 1 Includes items 31 and PACKING ELEMENT SET GROMMET FLANGE NUT BOLT and WASHER ASS Y INSULATOR GASKET 2 (insulator) LABEL (cleaner ID) 1 RGV6100 & RGV '99-12

28 FIG. 10 GOVERNOR, OPERATION - RGV6100/6101 RGV6100 & RGV '99-12

29 FIG. 10 GOVERNOR, OPERATION - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS GOVERNOR LEVER, compl GOVERNOR SHAFT GOVERNOR SPRING GOVERNOR ROD ROD SPRING BOLT and WASHER ASS Y NUT CLIP SPEED CONTROL, compl BOLT and WASHER ASS Y SCREW (pan head) NUT KNOB, compl FLANGE BOLT 1 For Electric starter type RGV6100 & RGV '99-12

30 FIG. 11 COOLING and STARTING - RGV6100/6101 RGV6100 & RGV '99-12

31 FIG. 11 COOLING and STARTING - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS BLOWER HOUSING, compl LABEL (TRADE MARK) FLANGE BOLT 4 * RECOIL STARTER ASS Y 1 Includes items 6 thru REEL RATCHET SPIRAL SPRING FRICTION SPRING RETURN SPRING RATCHET GUIDE SET SCREW STARTER ROPE 1 RGV STATER ROPE 1 RGV STARTER KNOB 1 RGV STARTER KNOB 1 RGV STARTER PULLEY FLANGE BOLT BOLT CYLINDER BAFFLE FLANGE BOLT BOLT LABEL (warning) LABEL (emission control) 1 RGV LABEL (emission control) 1 RGV LABEL (OHV MARK) 1 RGV6100 & RGV '99-12

32 FIG. 12 CARBURETOR - RGV6100/6101 RGV6100 & RGV '99-12

33 FIG. 12 CARBURETOR - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS * CARBURETOR ASS Y 1 Inc. items 1 thru 34 RGV6100 * CARBURETOR ASS'Y 1 Inc. items 1 thru 43 RGV SCREW THROTTLE VALVE (#180) SCREW CHOKE VALVE SPRING PILOT SCREW PILOT JET (#42.5) THROTTLE SHAFT ASS Y RING (choke) CHOKE LEVER ASS Y CHAMBER PACKING FLOAT ASS Y MAIN NOZZLE MAIN JET (#95) WASHER JET HOLDER RING 1 RGV RING 1 RGV NEEDLE ASS Y PIN GUIDE HOLDER FLOAT CHAMBER BODY SCREW SEAL CAP BOLT SPRING (adjuster) CLIP 1 RGV CLIP 1 RGV SEAL PACKING CAP O RING SOLENOID ASS Y WASHER 1 RGV6100 & RGV '99-12

34 FIG. 13A MAGNETO for RECOIL STARTER TYPE - RGV6100/6101 RGV6100 & RGV '99-12

35 FIG. 13A MAGNETO for RECOIL STARTER TYPE - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS FLYWHEEL, compl IGNITION COIL, compl CHARGE COIL, compl BOLT and WASHER ASS Y SCREW and WASHER ASS Y CLAMP, compl SCREW (pan head) GROMMET SPARK PLUG (BR-6ES) SPARK PLUG CAP PLUG TERMINAL WIRE 1, compl CLAMP CLAMP FLANGE BOLT 2 RGV6100 & RGV '99-12

36 FIG. 13B MAGNETO for ELECTRIC STARTER TYPE - RGV6100/6101 RGV6100 & RGV '99-12

37 FIG. 13B MAGNETO for ELECTRIC STARTER TYPE - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS FLYWHEEL, compl IGNITION COIL, compl CHARGE COIL, compl BOLT and WASHER ASS Y SCREW and WASHER ASS Y CLAMP, compl SCREW (pan head) GROMMET SPARK PLUG (BR-6ES) SPARK PLUG CAP BRACKET FLANGE BOLT WIRE CASING PLUG TERMINAL WIRE 1, compl CLAMP CLAMP RING GEAR MAGNETIC SWITCH WIRE 13, compl SPRING WASHER NUT BOLT and WASHER ASS Y 2 RGV6100 & RGV '99-12

38 FIG. 14 STARTING MOTOR - RGV6100/6101 RGV6100 & RGV '99-12

39 FIG. 14 STARTING MOTOR - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS * STARTING MOTOR ASS Y 1 Includes items 1 thru YOKE ASS Y BRUSH (+) SPRING (brush) 2 * HOLDER ASS Y (brush) 1 Includes items 3 and ARMATURE ASS Y PINION ASS Y STOPPER SET PINION 1 * FRONT COVER ASS Y 1 Includes item BRUSH (-) 1 * REAR COVER ASS Y 1 Includes item THROUGH BOLT WASHER KIT M BUSH (1) M BUSH (2) REAR METAL FRONT METAL O RING BOLT, compl. (starter) WASHER SPRING WASHER NUT SPRING WASHER BATTERY CORD (+) WIRE CASING 1 RGV6100 & RGV '99-12

40 FIG.15 SOLENOID - RGV6100/6101 RGV6100 & RGV '99-12

41 FIG.15 SOLENOID - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS SOLENOID ASS Y BRACKET (solenoid) 1, compl BRACKET (solenoid) 2, compl SPRING (solenoid) BOLT and WASHER ASS Y BOLT and WASHER ASS Y WIRE BAND WIRE 19, compl CLAMP FLANGE BOLT 1 RGV6100 & RGV '99-12

42 FIG. 16 OIL SENSOR - RGV6100/6101 RGV6100 & RGV '99-12

43 FIG. 16 OIL SENSOR - RGV6100/6101 REF PART NUMBER DESCRIPTION QTY REMARKS 1 KS OIL SENSOR, compl WIRE 3, compl FLANGE BOLT SHELTER PLATE TAPPING BOLT 1 RGV6100 & RGV '99-12

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