It is of vital importance, before attempting to operate your engine, to read the general
'SAFETY INSTRUCTIONS AND WARNINGS' section on pages 2-5 of this booklet and to strictly adhere to the advice contained therein.
●Also, please study the entire contents of this instruction manual, so as to familiarize yourself with the controls and other features of the engine.
●Keep these instructions in a safe place so that you may readily refer to them whenever necessary.
●It is suggested that any instructions supplied with the vehicle, radio control equipment, etc., are accessible for checking at the same time.
CONTENTS
SAFETY INSTRUCTIONS AND |
2-5 |
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WARNINGS ABOUT YOUR O.S. ENGINE |
CARBURETOR CLEANLINESS |
17 |
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INTRODUCTION, BASIC ENGINE PARTS |
6 |
BEFORE STARTING THE ENGINE |
18-19 |
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CARE AND MAINTENANCE |
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INSTALLATION |
7 |
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19 |
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8-9 |
GUARANTEE |
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SUPER AIR CLEANER 203 |
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ENGINE EXPLODED VIEW & |
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GLOWPLUG |
10 |
PARTS LIST |
20-21 |
TOOLS, ACCESSORIES, etc. |
11-12 |
CARBURETOR EXPLODED VIEW & |
22 |
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PARTS LIST |
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CARBURETOR CONTROLS |
12 |
O.S. GENUINE PARTS & |
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STARTING THE ENGINE & |
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13-14 |
ACCESSORIES |
23-24 |
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RUNNING-IN ('Breaking-in) |
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IF THE ENGINE FAILS TO START |
15 |
THREE VIEW DRAWING |
25 |
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FINAL ADJUSTMENT |
15-16 |
MEMO |
26 |
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1
SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE
Remember that your engine is not a "toy", but a highly efficient internalcombustion machine whose power is capable of harming you, or others, if it is misused.
As owner, you, alone, are responsible for the safe operation of your engine, so act with discretion and care at all times.
If at some future date, your O.S. engine is acquired by another person, we would respectfully request that these instructions are also passed on to its new owner.
The advice which follows applies basically to ALL MODEL ENGINES and is grouped under two headings according to the degree of damage or danger which might arise through misuse or neglect.
!WARNINGS
These cover events which might involve serious (in extreme circumstances, even fatal) injury.
!NOTES
These cover the many other possibilities, generally less obvious sources of danger, but which, under certain circumstances, may also cause damage or injury.
2
!WARNINGS
•Model engine fuel is poisonous. Do not allow it to come into contact with the eyes or mouth.Always store it in a clearly marked container and out of the reach of children.
•Model engine fuel is also highly flammable. Keep it away from an open flame, excessive heat, sources of sparks, or anything else which might ignite it. Do not smoke or allow anyone else to smoke, near to it.
•Never operate your engine in an enclosed space. Model engines, like automobile engines, exhaust deadly carbon-monoxide. Run your engine only in an open area.
•Model engines generate
considerable heat. Do not touch any part of your engine until it has cooled. Contact with the muffler (silencer), cylinder head or exhaust header pipe, in particular, may result in a serious burn.
3
!NOTES
•This engine is intended for model cars. Do not attempt to use it for any other purpose.
•Mount the engine in your model securely, following the manufacturers' recommendations, using appropriate screws and locknuts.
•Install an effective silencer (muffler). Frequent close exposure to a noisy exhaust (especially in the case of the more powerful highspeed engines) may eventually impair your hearing and such noise is also likely to cause annoyance to others over a wide area.
•The wearing of safety glasses is also strongly recommended.
•Take care that the glowplug clip or battery leads do not come into contact with rotating parts. Also check that the linkage to the throttle arm is secure.
•For their safety, keep all onlookers (especially small children) well back (at least 20 feet or 6 meters) when preparing your model for running.
4
!NOTES
•To stop the engine, fully retard the throttle stick and trim lever on the trans-mitter, or, in an emergency, cut off the fuel supply by pinching the fuel delivery line from the tank.
•Warning! Immediately after a glowplugignition engine has been run and is still warm, conditions sometimes exist whereby it is just possible for the engine to abruptly restart if it is rotated over compression WITHOUT the glowplug battery being reconnected.
5
The MAX-21VZ-B(P) is a high performance 3.5cc class power unit for one-eighth-scale ra- dio-controlled 'off-road' or 'buggy' car. It has been designed to meet the exacting requirements of the world's most expert drivers.
Standard accessories
Glow Plug A5 
Cylinder-head gasket (0.1mm) 
Exhaust Seal Ring 
Dust Cap 3, 16, 18 Super Air Cleaner 203 Assembly
The engine is fit with one each of 0.1mm and 0.2mm cylinder-head gasket when it leaves the factory. Another 0.1mm head gasket is supplied with the engine. You may add it at initial running-in, when a glow plug tends to burn out due to high temperature and / or high humidity or when you prefer fuel economy to power.
NOTE
With this engine, the piston will feel tight at the top of its stroke when the engine is cold. This is normal. The piston and cylinder are designed to achieve a perfect running clearance when they reach their normal running temperatures.
6
BASIC ENGINE PARTS
Heatsink Head
Exhaust
Carburetor
Type 20L
Crankshaft |
Cover Plate |
Mounting Lugs
Crankcase
NOTE
As delivered, the engine has its carburetor lightly fit into its intake. Secure it changing its angle according to the car chassis.
INSTALLING THE GLOW PLUG AND EXHAUST SEAL RING
Fit washer to glowplug and insert carefully into heatsink head, making sure that it is not cross-threaded before tightening firmly.
Install the exhaust seal ring supplied.
INSTALLATION OF THE CARBURETOR
As delivered, the engine has its carburetor lightly install into its intake boss. Secure it as follows.
1.Loosen the retainer screw, rotate the carburetor to its correct position and make sure that it is pressed well down into the intake boss, compressing the rubber gasket, before retightening screw.
2.Rotate the retainer screw gently until it stops, then tighten a further 120-180˚.
Do not overtighten the screw as this will damage the carburetor body.
Rotate the |
Tighten a |
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retainer nut |
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further |
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gently until |
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120-180˚ |
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it stops. |
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ENGINE INSTALLATION
Make sure that the vehicle's engine mounting surfaces are level and in the same plane. Poor installation may cause distortion of the crankcase, bearings, etc., resulting in erratic running and loss of performance.
The recommended screws for securing the engine are 3mm or 4-40 steel Allen hexagon socket type.
If existing holes in the engine mount do not align perfectly with engine mounting lugs, enlarge them slightly with a needle-file so that screws are in alignment with the mounting holes.
Do not allow bottom of crankcase to touch chassis.
Chassis
Chamfer inside edges of bearers.
7
AIR CLEANER TYPE 203
This is a heavy-duty wet type air cleaner that has been developed specifically for 3.5cc 'off-road' model car engines. It is more compact than the former O.S. SUPER AIR CLEANER 202 and this makes it easier to install within a car body.
203 Intake Elbow |
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Element Base |
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Filter Element |
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End Plate |
"O" Ring |
Retaining Screw |
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NOTE:
The element is already impregnated with a special filter oil. As this oil is very sticky, take care, when handling it, to prevent dust or dirt from adhering to the element. If your fingers become contaminated, wash them with soap and water.
8
ASSEMBLY
Insert the filter element on the element base.
Fit the end plate with retaining screw, making sure that the element fits correctly between the end plate and base.
Insert the joint pipe on the element base and secure it with "O" ring.
Fit the end plate, retaining screw, making sure that the element fits correctly between the end plate and base.
Element misaligned
REPLACMENT OF ELEMENT
NOTE:
During storage, the oil may have become unevenly dispersed through the element. This will be indicated if the blue colour of the element material appears patchy. In this case, place the element in a small plastic bag and gently rub the element between finger and thumb to redistribute oil.
It is advisable to replace the filter element after each hour of running time. Be careful not to enter the dirt and dust into the carburetor.
INSTALLATION
Carefully clean the carburettor, removing any old adhesive or sealant that may have been previously used on the outside of the air intake.
"O" Ring
FURTHER PRECAUTIONS
When removing the air cleaner, check the inside of the element base and carburetor venturi. If any dirt is detected, this indicates that the filter element was incorrectly fitted or should have been replaced earlier. In this event, it is vitally important to wash out the inside of the engine thoroughly, with alcohol or fuel, before it is used again, otherwise rapid wear of the piston/cylinder assenbly, bearings, connecting-rod, etc., will occur. Obviously, it will be necessary to carry out the same procedure with the air cleaner and to replace the filter element.
NOTE:
Be careful not to splash alcohol or fuel over the filter element, or the filter oil will be washed away, and the filter capacity will be lowered.
9
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