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PARTS
MANUAL
DY23-2 / DY27-2
Models
ENGINE
PUB-EP5754A
Rev. 07/00
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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.
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 2 3 2
X X X X
SPEC NO. (11 digits)
CODE NO. (4 digits)
PRODUCT NO. (15 digits)
- 3 -
'00-07
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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
6. DESCRIPTION
7. QTY.
It is the number assigned for sales unit. Use the PART No. when making an order.
It is designation of the part.
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-
- 2100
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.
- 4 -
'00-07
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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
INDEX OF DESCRIPTION SYMBOLS
SYMBOL
DESCRIPTION
SYMBOL
DESCRIPTION
AY .......................... ASSEMBLY
CP .......................... COMPLETE
EX .......................... EXPORT (from Japan)
FIG. ........................ FIGURE
P= .......................... PITCH (in mm)
P.T.O. (PTO) .......... POWER TAKE OFF
REF. ....................... REFERENCE
R.H. (RH) ............... RIGHT HAND SIDE
RR. ......................... REAR
FR. ......................... FRONT
" .............................. INCH
INCL. ...................... INCLUDE
~L ........................... LITER
L= ........................... LENGTH (in. mm)
L.H. (LH) ................ LEFT-HAND SIDE
MECH .................... MECHANICAL
NO (NON) .............. NONE
STD. ....................... STANDARD
SW ......................... SWITCH
T= ........................... THICKNESS (in mm)
UN .......................... UNIT
U.S. ........................ UNDER SIZE
~V .......................... VOLTAGE
~W ......................... WATT
OPT. ....................... OPTIONAL
O.S......................... OVER SIZE
W/ .......................... WITH
W/O........................ WITHOUT
- 5 -
'00-07
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SECTION 1
CRANKCASE GROUP
FIG. 100
DY23-2 / DY27-2
- 6 -
'00-07
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SECTION 1
CRANKCASE GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
100
10 243-10101-61 CRANKCASE CP
243-10105-61 CRANKCASE CP
10 244-10101-61 CRANKCASE CP
244-10105-61 CRANKCASE CP
30 044-03000-60 OIL SEAL
1
1
1
1
1
1
1
2
3
1
2
2
2
3
1
1
1
1
1
2
2
1
2
2
1
12
1
1
1
1
1
DY23-2
DY23-2, Electric Start
DY27-2
100
100
DY27-2, Electric Start
100
100
100
100
36 044-00800-30 OIL SEAL
45 060-01700-40 BALL BEARING
50 005-26081-80 DOWEL PIN
65 001-37062-21 STUD
66 031-00500-10 DOWEL PIN
80 040-11400-30 PLUG
100
100
100
100
90 021-11400-20 GASKET
100
100
100
100
105 031-00600-10 DOWEL PIN
135 244-16002-11 TENSION BOLT CP
155 244-16002-11 TENSION BOLT CP
205 243-75001-03 GROMMET
210 244-11009-21 MAIN BEARING COVER CP
220 044-03000-30 OIL SEAL
250 243-45011-07 GOVERNOR GEAR SET
251 220-41601-03 FLYWEIGHT
252 030-73000-70 PIN
260 205-41901-03 GOVERNOR SLEEVE
270 214-63601-13 OIL GAUGE
280 021-32000-10 GASKET
290 243-15026-03 GASKET, main bearing cover
300 001-13083-50 BOLT and WASHER AY
310 001-13084-00 BOLT and WASHER AY
320 243-15801-03 MAIN BEARING
243-15802-03 MAIN BEARING
Electric Start
100
100
100
100
100
100
100
100
100
100
100
100
STD.
0.25mm undersize
0.50mm undersize
100
100
100
100
243-15803-03 MAIN BEARING
361 212-15008-13 BLIND PLUG
DY23-2 / DY27-2
- 7 -
'00-07
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SECTION 1
CRANKCASE GROUP
FIG. 110
DY23-2 / DY27-2
- 8 -
'00-07
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SECTION 1
CRANKCASE GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
20 243-14204-13 VALVE GUIDE
60 001-37082-01 STUD
610 243-13001-71 CYLINDER HEAD CP
620 243-15027-13 GASKET, T= 0.2
243-15028-13 GASKET, T= 0.3
2
2
1
1
1
1
1
4
1
1
1
1
4
1
1
1
110
110
110
110
110
110
110
110
110
110
110
110
110
110
Select one piece only, DY23-2
Select one piece only, DY23-2
Select one piece only, DY27-2
Select one piece only, DY27-2
620 244-15027-13 GASKET, T= 0.2
244-15028-13 GASKET, T= 0.3
635 018-00900-10 FLANGE NUT
650 001-39066-00 STUD
660 010-50601-50 STUD
680 243-17101-01 ROCKER COVER CP
690 243-1 5032-13 GASKET, rocker cover
710 011-00601-70 FLANGE BOLT
730 243-15030-03 PLUG
*960 255-99001-07 GASKET SET
*960 256-99001-07 GASKET SET
DY23-2
DY27-2
* 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
DY23-2 / DY27-2
- 9 -
'00-07
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SECTION 2
CRANKSHAFT GROUP
FIG. 200
430
440
DY23-2 / DY27-2
- 10 -
'00-07
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SECTION 2
CRANKSHAFT GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
200
10 244-20401-11 CRANKSHAFT CP
25 060-03500-20 BALL BEARING
50 002-18180-00 NUT
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
4
1
200
200
60 003-20180-00 SPRING WASHER
70 032-30300-10 WOODRUFF KEY
85 243-25001-03 THRUST WASHER, T=0.8
243-25002-03 THRUST WASHER, T=1.0
243-25003-03 THRUST WASHER, T=1.2
86 011-00600-10 FLANGE BOLT
210 243-24301-01 BALANCER CP
215 023-01700-20 SPACER, T= 0.8
023-01700-30 SPACER, T= 1.0
023-01700-40 SPACER, T= 1.2
310 243-22510-00 CONNECTING ROD AY
320 243-23002-03 CONNECTING ROD BOLT
350 243-23301-03 PISTON PIN
360 243-23401-13 PISTON
200
200
200
200
Select one piece only
Select one piece only
Select one piece only
200
200
200
200
Select one piece only
Select one piece only
Select one piece only
200
200
200
200
200
200
200
200
STD., DY23-2
243-23402-13 PISTON
243-23403-13 PISTON
0.25mm oversize, DY23-2
0.50mm oversize, DY23-2
STD., DY27-2
0.25mm oversize, DY27-2
0.50mm oversize, DY27-2
STD., DY23-2
360 244-23401-13 PISTON
200
200
200
200
244-23402-13 PISTON
244-23403-13 PISTON
370 243-23501-27 PISTON RING SET
243-23502-27 PISTON RING SET
243-23503-27 PISTON RING SET
370 244-23501-27 PISTON RING SET
244-23502-27 PISTON RING SET
244-23503-27 PISTON RING SET
380 056-52000-30 CLIP
395 243-22801-03 LARGE END BEARING
243-22802-03 LARGE END BEARING
243-22803-03 LARGE END BEARING
430 244-17501-13 ADAPTER
0.25mm oversize, DY23-2
0.50mm oversize, DY23-2
STD., DY27-2
0.25mm oversize, DY27-2
0.50mm oversize, DY27-2
200
200
200
200
200
200
200
200
(1/2)
STD.
0.25mm undersize
0.50mm undersize
(1/2)
(1/2)
200
200
200
200
440 001-13082-50 BOLT and WASHER AY
500 243-22410-13 FLYWHEEL
DY23-2 / DY27-2
- 11 -
'00-07
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SECTION 3
INTAKE and EXHAUST GROUP
FIG. 300
DY23-2 / DY27-2
- 12 -
'00-07
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SECTION 3
INTAKE and EXHAUST GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
10 255-31703-01 CAMSHAFT CP
35 243-35503-23 RELEASE LEVER
36 005-19031-00 SPRING PIN
38 243-35505-03 RELEASE LEVER
39 243-35022-03 SHAFT, release
41 005-26081-80 DOWEL PIN
45 243-35021-03 SPRING, release
50 243-33301-03 TAPPET
60 243-33601-03 VALVE SPRING
70 243-33701-13 SPRING RETAINER
75 243-33801-13 RETAINER LOCK
80 243-33401-23 INTAKE VALVE
85 237-16008-01 STEM SEAL
90 243-33501-23 EXHAUST VALVE
100 023-01900-20 SPACER, T= 0.8
023-01900-30 SPACER, T= 1.0
1
1
1
1
1
1
1
2
2
2
4
1
1
1
1
1
1
2
2
2
2
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
Select one piece only
Select one piece only
200 243-35034-03 ROCKER SHAFT
210 243-35032-01 PUSH ROD CP
220 243-36002-01 ROCKER ARM CP
230 014-90800-21 ADJUSTING SCREW
240 017-00800-90 NUT
DY23-2 / DY27-2
- 13 -
'00-07
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SECTION 3
INTAKE and EXHAUST GROUP
FIG. 310
DY23-2 / DY27-2
- 14 -
'00-07
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SECTION 3
INTAKE and EXHAUST GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
300 255-30103-00 MUFFLER AY
310 243-30101-51 MUFFLER CP
320 243-34201-01 MUFFLER COVER CP
340 243-35002-03 GASKET, exhaust
350 002-19080-00 NUT
360 001-10061-00 BOLT and WASHER AY
380 243-37002-11 TAIL PIPE CP
395 015-00400-60 TAPPING SCREW
500 243-33101-13 INTAKE MANIFOLD
510 243-32601-00 AIR CLEANER AY
-2 243-32651-08 PACKING
1
1
1
1
2
4
1
3
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
310
-7 243-32650-08 PACKING
-110 243-32640-08 COVER CP
-120 243-32620-08 BACK PLATE CP
-160 243-32660-08 WASHER
-170 243-32670-08 WING BOLT
520 243-32600-08 ELEMENT CP
525 243-32611-08 ELEMENT
555 243-35503-13 GASKET, intake manifold
556 001-13083-50 BOLT and WASHER AY
580 001-13061-20 BOLT and WASHER AY
584 001-13081-60 BOLT and WASHER AY
900 243-92302-03 LABEL, air cleaner
DY23-2 / DY27-2
- 15 -
'00-07
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SECTION 4
GOVERNOR GROUP
FIG. 400
DY23-2 / DY27-2
- 16 -
'00-07
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SECTION 4
GOVERNOR GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
10 243-42902-21 CONTROL LINK CP
20 243-42301-12 GOVERNOR LEVER
21 002-18080-00 NUT
22 003-20080-00 SPRING WASHER
80 243-42503-01 GOVERNOR SPRING CP
310 243-43301-30 SPEED CONTROL AY
340 227-43501-13 STOP PLATE
350 227-45002-03 SPRING WASHER
360 004-31041-00 SCREW
380 017-60600-30 SELF LOCK NUT
390 243-44202-01 WIRE BRACKET 1 CP
410 243-44210-01 WIRE BRACKET 2 CP
415 243-46001-03 RETURN SPRING
490 002-18060-00 NUT
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
2
3
1
1
1
1
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
491 001-66063-00 BOLT
495 243-45002-03 BOLT
496 003-10060-00 WASHER
497 010-00603-70 BOLT
500 255-40166-01 CONTROL PANEL CP
501 001-14061-20 BOLT and WASHER AY
502 001-13081-60 BOLT and WASHER AY
510 243-92101-03 LABEL, operation
520 243-92102-03 LABEL, operation
650 243-45502-00 SMOKE SET AY
660 002-27100-00 NUT
DY23-2 / DY27-2
- 17 -
'00-07
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SECTION 5
COOLING and STARTING GROUP
FI
DY23-2 / DY27-2
- 18 -
'00-07
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SECTION 5
COOLING and STARTING GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
10 243-51201-21 BLOWER HOUSING CP
40 001-13082-00 BOLT and WASHER AY
60 243-52601-33 CYLINDER BAFFLE
80 011-00600-10 FLANGE BOLT
150 001-13083-00 BOLT and WASHER AY
210 243-50201-20 RECOIL STARTER AY
-1 106-50116-08 SPIRAL SPRING
-2 239-50220-08 REEL CP
1
2
1
5
2
1
1
1
1
1
2
1
1
1
1
1
1
1
3
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
-3 243-50110-08 STARTER ROPE
-4 236-50101-08 STARTER KNOB
-5 106-50128-18 RATCHET
-6 106-50132-08 FRICTION SPRING
-7 106-50136-18 RETURN SPRING
-8 106-50144-08 FRICTION PLATE
-9 106-50185-08 THRUST WASHER
-10 106-50186-08 CLIP
-11 243-50145-08 STARTING PULLEY
215 243-95004-13 LABEL, diesel mark
230 001-14061-20 BOLT and WASHER AY
DY23-2 / DY27-2
- 19 -
'00-07
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SECTION 6
FUEL, LUBRICANT GROUP
FIG. 600
DY23-2 / DY27-2
- 20 -
'00-07
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SECTION 6
FUEL, LUBRICANT GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
10 243-60102-41 FUEL TANK CP
16 255-91701-03 LABEL, trademark
256-91701-03 LABEL, trademark
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
2
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
DY23-2
DY27-2
20 243-91907-13 LABEL, instruction
27 073-20039-00 LABEL, warning
30 043-04300-15 FUEL TANK CAP CP
40 064-13600-10 FUEL FILTER
80 085-14500-00 RUBBER PIPE
81 085-14500-00 RUBBER PIPE
86 228-65032-13 CHECK VALVE
88 150-75201-03 CLAMP
89 001-10061-00 BOLT and WASHER AY
90 056-10800-10 HOSE CLAMP
95 056-10800-20 HOSE CLAMP
100 085-00500-40 VINYL PIPE
105 001-13082-00 BOLT and WASHER AY
4.5 X 9 X 45
4.5 X 9 X 95
5 X 8 X 120
DY23-2 / DY27-2
- 21 -
'00-07
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SECTION 6
FUEL, LUBRICANT GROUP
FIG. 610
DY23-2 / DY27-2
- 22 -
'00-07
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SECTION 6
FUEL, LUBRICANT GROUP
REF. PART NO.
250 243-63201-00 NOZZLE AY
-1 243-63204-08 NOZZLE
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
610
1
1
1
4
1
1
1
1
1
1
1
2
2
610
260 228-65004-03 GASKET, nozzle
265 002-38060-00 FLANGE NUT
270 243-66001-01 BRACKET CP, nozzle 1
300 255-63103-00 INJECTION PUMP AY
-1 243-63131-08 PLUNGER AY
-2 243-63103-08 DELIVERY VALVE
-3 243-63104-08 DELIVERY SPRING
-4 243-63105-08 GASKET
610
610
610
610
610
610
610
610
-5 243-63107-08 O RING
-6 243-63129-08 O RING
-21 243-63130-08 SCREW
610
610
610
305 243-65001-03 GASKET, T= 0.1
243-65002-03 GASKET, T= 0.2
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
2
1
1
1
1
3
Select one piece only
610
Select one piece only
Select one piece only
6 X 12 X 120
610
610
610
610
243-65003-03 GASKET, T= 0.3
310 085-10600-00 RUBBER PIPE
330 085-10600-00 RUBBER PIPE
340 085-14500-00 RUBBER PIPE
350 085-14500-00 RUBBER PIPE
355 056-11100-20 HOSE CLAMP
356 056-10800-10 HOSE CLAMP
400 243-62101-20 FUEL FILTER AY
-7 228-62112-08 PACKING
6 X 12 X 180
4.5 X 9 X 90
4.5 X 9 X 315
610
610
610
610
610
610
610
610
-8 228-62111-08 PLUG
420 243-66520-10 T-CONNECTOR AY
-1 243-66521-08 NUT
610
610
610
610
-2 243-66506-08 PACKING
430 243-63301-21 INJECTION PIPE CP
600 243-64301-00 OIL FILTER AY
610 001-14061-60 BOLT and WASHER AY
620 006-26202-00 O RING
700 228-63902-03 OIL PUMP, outer
710 006-26103-30 O RING
610
610
610
610
720 243-66020-01 COVER CP, oil pump
730 004-11061-60 SCREW, countersink
610
610
DY23-2 / DY27-2
- 23 -
'00-07
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SECTION 7
ELECTRIC DEVICE GROUP
FIG. 700
DY23-2 / DY27-2
- 24 -
'00-07
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SECTION 7
ELECTRIC DEVICE GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
10 243-70110-41 FLYWHEEL CP
11 243-70102-21 CHARGE COIL CP
20 243-71002-13 RING GEAR
35 004-35062-50 SCREW and WASHER AY
90 226-75101-03 CLAMP
92 004-35061-00 SCREW and WASHER AY
130 001-14083-00 BOLT and WASHER AY
170 001-13081-60 BOLT and WASHER AY
200 243-40601-11 CONTROL BOX CP
210 073-20010-90 LABEL, starter switch
220 066-00003-30 SWITCH
1
1
1
2
1
1
2
1
1
1
1
2
1
1
2
1
1
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
-1 066-00099-80 KEY
230 243-71401-01 DIODE RECTIFER CP
240 001-10061-00 BOLT and WASHER AY
261 056-60001-70 CLAMP
262 001-13081-20 BOLT and WASHER AY
340 243-73104-11 WIRE 2 CP
DY23-2 / DY27-2
- 25 -
'00-07
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SECTION 7
ELECTRIC DEVICE GROUP - STARTER MOTOR
FIG. 710
DY23-2 / DY27-2
- 26 -
'00-07
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SECTION 7
ELECTRIC DEVICE GROUP - STARTER MOTOR
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
120 255-70502-00 STARTING MOTOR AY
-1 255-70580-08 YOKE AY
-2 255-70551-08 BRUSH SET
1
1
1
4
1
1
1
1
1
2
1
1
1
1
2
1
1
1
2
1
1
710
710
710
710
710
710
710
710
710
710
710
710
710
710
710
710
710
710
710
710
710
-3 228-70516-08 BRUSH SPRING
-4 255-70531-08 BRUSH HOLDER AY
-6 255-70561-08 AMATEUR AY
-7 255-70521-08 PINION AY
-8 210-70534-08 PINION STOPPER SET
-9 255-70501-08 GEAR CASE AY
-10 228-70514-08 BRUSH (-)
-11 255-70505-08 REAR COVER AY
-12 210-70542-08 REAR COVER METAL
-14 243-70525-08 SHIFT LEVER KIT
-15 255-70515-08 MAGNETIC SWITCH AY
-17 207-70524-08 THROUGHBOLT
-25 210-70533-08 THRUST WASHER KIT
-29 210-70542-08 REAR COVER METAL
-30 255-70570-08 DUST COVER KIT
-32 228-70522-08 BOLT
140 002-28080-00 NUT
160 003-20080-00 SPRING WASHER
DY23-2 / DY27-2
- 27 -
'00-07
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SECTION 8
ACCESSORIES GROUP
FIG. 800
40
DY23-2 / DY27-2
- 28 -
'00-07
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SECTION 8
ACCESSORIES GROUP
REF. PART NO.
DESCRIPTION
QTY. REMARKS
FROM-TO FIG.
10 243-90301-00 TOOL KIT
30 243-65006-00 OIL FEEDER AY
40 207-26001-03 KEY
1
1
1
800
800
800
DY23-2 / DY27-2
- 29 -
'00-07
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PRINTED IN THE USA
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