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Subaru EX35 User Manual

Subaru EX35
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Subaru EX35 Specifications

General IconGeneral
BrandSubaru
ModelEX35
CategoryEngine
LanguageEnglish

Summary

1. SPECIFICATIONS

2. PERFORMANCE

2-1 MAXIMUM OUTPUT

Definition of maximum engine output.

2-2 CONTINUOUS RATED OUTPUT

Definition of continuous engine output.

2-3 MAXIMUM TORQUE

Definition of maximum engine torque.

2-4 PERFORMANCE CURVES

Graphical representation of engine performance characteristics.

3. FEATURES (EX35, 40 series)

3-1 HIGH OUTPUT

Explanation of high output capability.

3-2 EXTREMELY SILENT - SOFT TONE QUALITY

Description of quiet and soft tone quality.

3-3 EXTREMELY EASY START

Explanation of easy starting system.

3-4 EXTREMELY EASY MAINTENANCE

Description of easy maintenance aspects.

3-5 EXTREMELY ADVANCED TECHNOLOGY

Details on advanced technology used.

3-6 EXTREME POWER AND PERFORMANCE

Explanation of extreme power and performance.

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS

4-1 CYLINDER AND CRANKCASE

Description of cylinder and crankcase.

4-2 MAIN BEARING COVER

Description of the main bearing cover.

4-3 CRANKSHAFT

Description of the crankshaft.

4-4 CONNECTING ROD AND PISTON

Description of connecting rod and piston.

4-5 PISTON RINGS

Description of piston rings.

4-6 CAMSHAFT

Description of the camshaft.

4-7 VALVE ARRANGEMENT

Description of valve arrangement.

4-8 CYLINDER HEAD

Description of the cylinder head.

4-9 GOVERNOR SYSTEM

Description of the governor system.

4-10 COOLING SYSTEM

Description of the cooling system.

4-11 LUBRICATION SYSTEM

Description of the lubrication system.

4-12 TIMING CHAIN

Description of the timing chain.

4-13 IGNITION SYSTEM

Description of the ignition system.

4-14 CARBURETOR

Description of the carburetor.

4-15 AIR CLEANER

Description of the air cleaner.

4-16 BALANCER

Description of the balancer.

4-17 DECOMPRESSION SYSTEM

Description of the decompression system.

4-18 SECTIONAL VIEW OF THE ENGINE

Sectional view of the engine with labels.

5. DISASSEMBLY AND REASSEMBLY

5-1 PREPARATIONS AND PRECAUTIONS

Preparations and precautions for disassembly.

5-2 SPECIAL TOOLS

List of special tools required for disassembly.

5-3 DISASSEMBLY PROCEDURE

Step-by-step procedure for engine disassembly.

5-4 REASSEMBLY PROCEDURE

Step-by-step procedure for engine reassembly.

5-4-1 NOTES ON REASSEMBLY

Important notes and guidelines for reassembly.

5-4-2 ASSEMBLY STEPS AND PRECAUTIONS

Specific steps and precautions for assembly.

33. BREAK-IN OPERATION

Procedure for running in a new or overhauled engine.

6. ENGINE OIL

6-1 CLASSIFICATION BY OIL GRADE

Classification of engine oil by grade.

6-2 CLASSIFICATION BY OIL VISCOSITY

Classification of engine oil by viscosity.

6-3 ADDING AND CHANGING ENGINE OIL

Procedures for adding and changing engine oil.

7. MAGNETO

7-1 MAGNETO

Description of the magneto system.

7-2 INSPECTING THE MAGNETO

Procedure for inspecting the magneto.

8. IGNITION SYSTEM

8-1 IGNITION COIL INTERNAL CIRCUIT

Internal circuit diagram of the ignition coil.

8-2 BASIC THEORY

Basic theory of the ignition system.

9. WIRING DIAGRAM

9-1 MODEL WITHOUT ELECTRIC STARTER

Wiring diagram for models without an electric starter.

9-2 MODEL WITH ELECTRIC STARTER

Wiring diagram for models with an electric starter.

9-3 MODEL WITH OIL SENSOR

Wiring diagram for models with an oil sensor.

10. ELECTRIC STARTER

10-3 COMPONENT PARTS - Magnetic and shift type –

Component parts of the magnetic and shift type starter.

10-1 SPECIFICATIONS

Specifications for the electric starter.

10-2 OPERATING PRINCIPLES

Operating principles of the electric starter.

11. OIL SENSOR

11-1 SPECIFICATIONS

Specifications for the oil sensor.

11-2 CONSTRUCTION AND OPERATION

Construction and operation of the oil sensor.

12. AUTOMATIC DECOMPRESSION SYSTEM

12-1 FUNCTIONS AND CONSTRUCTION

Functions and construction of the auto decompression system.

12-2 INSPECTION

Inspection of the automatic decompression system.

13. CARBURETOR

13-1 SPECIFICATIONS

Specifications for the carburetor.

13-2 FUNCTIONS AND CONSTRUCTION

Functions and construction of the carburetor.

13-2-1 FLOAT SYSTEM

Explanation of the float system.

13-2-2 SLOW SYSTEM

Explanation of the slow system.

13-2-3 MAIN SYSTEM

Explanation of the main system.

13-2-4 CHOKE SYSTEM

Explanation of the choke system.

13-3 DISASSEMBLY AND REASSEMBLY

Disassembly and reassembly of the carburetor.

13-3-1 THROTTLE SYSTEM

Procedure for the throttle system.

13-3-2 CHOKE SYSTEM

Procedure for the choke system.

13-3-3 SLOW SYSTEM

Procedure for the slow system.

13-3-4 MAIN SYSTEM

Procedure for the main system.

13-3-5 FLOAT SYSTEM

Procedure for the float system.

14. RECOIL STARTER

14-1 RECOIL STARTER

Information about the recoil starter.

14-1-1 DISASSEMBLY PROCEDURE

Step-by-step procedure for recoil starter disassembly.

14-1-2 REASSEMBLY PROCEDURE

Step-by-step procedure for recoil starter reassembly.

14-1-3 CHECKING THE RECOIL STARTER AFTER REASSEMBLY

Checking the recoil starter after reassembly.

14-1-4 OTHER GUIDES

Other guides related to recoil starter.

15. INSTALLATION

15-1 INSTALLING

General instructions for installing the engine.

15-2 VENTILATION

Ventilation requirements for engine operation.

15-3 EXHAUST EQUIPMENT

Requirements for exhaust equipment.

15-4 FUEL SYSTEM

Requirements for the fuel system installation.

15-5 POWER TRANSMISSION TO DRIVE MACHINES

Power transmission methods to drive machines.

15-5-1 BELT DRIVE

Guidelines for belt drive installation.

15-5-2 FLEXIBLE COUPLING

Guidelines for flexible coupling.

15-5-3 BELT PULLEY INSTALLATION ONTO KEYWAY-TYPE CRANKSHAFT

Belt pulley installation onto crankshaft.

16.TROUBLESHOOTING

16-1 ENGINE

Troubleshooting for engine starting problems.

Insufficient compression

Problems related to insufficient compression.

Ignition system problems

Problems related to the ignition system.

Fuel system malfunction

Malfunctions in the fuel system.

Low air intake volume

Issues with low air intake volume.

Overheat

Causes and remedies for engine overheating.

Rough Idling

Causes and remedies for rough idling.

Oil leakage

Causes and remedies for oil leakage.

Oil up

Causes and remedies for excessive oil consumption.

High fuel consumption

Causes and remedies for high fuel consumption.

Abnormal engine noise

Causes and remedies for abnormal engine noise.

16-2 ELECTRIC STARTER

Troubleshooting for the electric starter system.

1. Checking of continuity of wiring

Checking continuity of starter wiring.

2. Battery checking

Checking the battery status.

3. Checking of pinion operation

Checking the pinion operation.

4. Checking of magnetic switch

Checking the magnetic switch.

5. Motor checking

Checking the starter motor.

16-3 IGNITION COIL

Troubleshooting ignition coil resistance.

16-4 CHARGE COIL

Troubleshooting charge coil resistance.

17. STANDARD REPAIR TABLES

17-1 STANDARD DIMENSIONS AND LIMITS OF USE

Standard dimensions and limits for engine parts.

17-2 SERVICE DATA

Service data for reference.

17-3 TIGHTENING TORQUE

Specifications for tightening torque of various parts.

17-4 AIR GAP AND CLEARANCE

Specifications for air gap and clearance.

18. MAINTENANCE AND STORAGE

18-1 DAILY MAINTENANCE (EVERY 8 HOURS OF USE)

Daily maintenance tasks and reasons.

18-2 INSPECTION AND MAINTENANCE AFTER THE FIRST 20 HOURS

Maintenance after the first 20 hours of use.

18-7 MAINTENANCE EVERY 1,000 HOURS (ANNUAL MAINTENANCE)

Annual maintenance every 1,000 hours.

18-8 SPARK ARRESTER AND TAIL SCREEN (OPTION)

Maintenance for spark arrester and tail screen.

18-9 ENGINE STORAGE

Procedure for engine storage.

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