Sachs SA 290, SA 340 C User Manual
TAKING DOWN
THE
ENGINE
Remove a
ll
connections fr
om
engi
ne
10 frame
or
unit (cables. electric
connect
ions etc.).
Un
scr
ew
exhaust
muffler,
i.
e.
manifold
and brocket.
Remove t
he engine
and
clean t
horoughly
before
taki
ng
down.
When giving the engine a
general
overhaul, components should be removed
in
the
sequ
ence
indicated.
Fig. 1
Fig. 2
6
Exhoust muffler, corburettor ond
electric s
tart
er
Fi
g. 1
Screw
down engine
on
Ihe as-
sembly
jig with 2 he)(090n
head
bolts M 10
)(
40,
as
shown in Ihe
adjoining
ill
ustration.
Re
move
intake
silencer (I).
Unscr
ew
adapter flange
cnd
la ke
off
cover
plate
(21
or
un-
screw
intake sil
encer
(Fig. 302,
p.
53) with c
over plale.
Pull o
ff
impul
se
pipe (4).
Remove co rbur
ellor
(3).
Rem
ove
insula ting sleeves
and
insula tin g f
lange.
If th
ere
is
on
intake
stack be-
tween
cor
burettor
and
cylinder,
r
emove
it only
if
necessary.
Unscrew electric
starter.
Re
coil s
tarter, star
ter hub
and fan
Fig. 2
Detach recoil sl
arter
.
Unlod;
nut
in
Ihe slorl
er
hub
(1).
Hold
starler
hub with
retaining
l
ever
(2, repair too
l no. 6), un-
screw
the
nut
and remove
sta
rter
h
ub
with spring ring
and
washer.
Nol
e:
In
the
case
of
the
Fairbanks
recoil
starte
r re l
ease nut,
hold
starter hub
with
strap
spanner
and
unscrew nut.
I~
the
case
of the. recoil
starter
with friction iows rele<lse nut, hold sl
orte
r hub with
pin
spanner (repair
tool no.
7)
ond
unscr
ew
il.
T
oke
off
storler hub
with spring ring a nd
washer.
Remove
th~
cylindrical
pin
and
.the
beorin!;! roll
er from
the
magneto
flywheel (Fair-
banks reCOil
starter) resp. 2
bearing
rollers (recoil
starter
with friction jaws).
Toke
off
cove
r disc
(3).
Unsc
rew
fan
and
remove
gasket.
Cover
plate and
fan
hou
ling
Fig. J
Un
screw
fixin~
clip
(3)
for igni-
tion le a d (n
ot
In
the
case
of
75 W
eq
uipment) a nd
cover
(1).
Detach le
ads
at
termina
ls 1, 2
and 3
of
the terminal
box
{5}
and
rem
ove
fan housi ng (4
).
Note
:
Rem
ove
cov
er flanges
on
fan
housing f
or
electric sta rt
er
con-
nectian,
if
fitted.
T
ak
e core
of
dowel tu
bes.
Nole
:
Remove
shor
t-circuiting button
on
ly if necessary.
Remove ru b
ber cop
(2)
and
sho
rt-circuiting builo n.
D
eta
ch short-circuiting
lead from
insulato r.
Remounl parts
in
reverse
orde
r.
Magnelo
flywheel
Fig. 4
Fit pro
tective
cop
(reroir
tool no.
4)
to thr
eaded
end 0 crankshaft.
Fit retaining lever
(1,
repair
tool
no.
6)
10 m
agneto
flywheel
and
pull off the flywhee
l by m
eans
of
the extr
actor (2,
repair too
l no.5).
Fig.
~
7
Fig. 6
8
Labyrinth ring
ond
ormature
bo
se
plote
Fig. 5
Uns!;rew
lab
yrinth ring
(5).
Pull ignition
lead
with spring out
of the
spar
k plug lerminal
{61,
pull
off
rubber sleeve {l}
and
rubber
cap
(2)
and
screw out the
igni
li
on
lead
socket.
Unscrew
armature
bose
plate
(4)
and
remove
it
together with igni-
tion
lead
(not
in
Ihe
case
of
75 W
equi
pmen t)
and
insulaling tub e
(with lead).
Remove
Woodruff
key.
Cylinder
head
, cylinder
and
piston
Fig. 6
Unscrew cylinder
head and
cylinder.
Pull
off cylinder withoul twisting
(danger
of
breaking piston
rings).
Remove cylinder
fl
ange
goskel.
Note:
The
SACHS
SA
280 A
and
SA
280
cylinders can be
rebored
three
limes,
and
those
of
Ihe
SA
290
and
SA
340 C twice. Use
appro-
pria te piston (see
Spore
Ports
lisl
).
When
fitting new
or replacement
cylinders
and
pistons,
care
should be laken to ensure Ihol
Ihe co lored spot
on
Ihe crown
of
the piston
is
Ihe
some
color os
Ihal
in
Ihe induction port
of
Ihe
cylinder (i. e. red
or
white
).
Place cylinder
on
home-mo
de
sloll
ed
wooden
board
(1
).
Cover Ihe
crankcase
, t
oke autlh
o
two wire cirdips. If necessary,
force
oul
gudgeon
ein with gud-
geon
pin e)(traclor
(3,
repair
tool
no.
1)
and
inserl (2, repair tool
no.
2).
When
filting the sleel
bond,
core
should be token
10
ensure
Ihat
the piston rings
are
in
their Woo-
ves
(danger
of breaking piston
rings).
Remove slotted wo
oden board
.
Cronkcose
ond
crank
shaft
Fig
. 7
Unscrew 6 he)(ogon socket
heod
screws fr
om
crankcase.
Note:
When
dismantling Ihe
crankcase
,
have a look
at
the
loble
of
crankshaft
bearings on
poge
10.
Split
crankcase
by topping Ihe
crankcase
half
power
takeoff
side slighlly with a rubb
er
ham-
me
r.
Remove crank!;ose half
power
lakeoff side
and
gasket.
Toke
core
of dowel lubes.
Unscrew screw
ed
nipple
(1)
and
oil
dra
in
cock
{2}.
Unscrew crankcase half
magneto
side from the assembly ii!
aod
hea t ilia 100 ... 1500 C 212 ...
3020 Fl for removing the cra
nk-
shaft
(grooved boll bearing).
Toke oul
crankshaft.
Clean
all parts thoroughly, check
for
wear
and
replace
when ne-
cessary.
Use
only
genuine
SACHS spar
es.
9
10
v
'0
1:;
•
..
£
"
o •
~
.~
• 0
. f
....
'.
0-
~~
• 0
·
~
v
'0
1:;
•
..
';
o
£
"
~
o
'0
o
•
~
o
o
.~
~
x
g>
I
•
"
•
2
•
o
~
o
E
x
~
o
'0
o
1i
x
:&
1
~
x
•
~
o
;;
o
~
o
E
x
x
•
~
••
ci
I
x
~
o
'0
o
1i
-
-
x
~
o
'0
o
1i
..
•
~
••
2
•
o
~
o
E
z
x
x
•
"
.
x
x
-
-
•
"
o
"
o
~
o
E
x
x
~
o
'0
o
1i
..
e
o
v
'0
~
o
>.
v
•
"
•
ci
x
~
o
o
o
1i
-
-
•
"
.
~
o
~
o
E
u
x
•
~
••
ci
WORK ON INDIVIDUAL PARTS
SACHS
special
ext
racting
tool
for
crankshaft oil seals
(without
dismantling
the e
ngin
e)
FICHTEL & SACHS
AG
have developed a special extracting
1001
by
means
of
which
damaged
oil
seals can be
replaced
without a major disassembly
of
Ihe
engine
being
necessary.
Engine troubles
caused
by leaking or
damaged
oil
seo
ls
can
thus
be
remed ied
in
a
relatively short lime.
When replac
ing oil seals, Ihe following poi nls
should
be
borne
in
mind:
Extracting oil seal
s
Fig.8
Before
extracting
oil
sea
l be sure
to establish installation dimen-
sion
x,
a or
y,
in
order that the
new oil seal
can
be fitted 10 the
some dimension
.
Note:
If the
corr
ect
installation
dimen-
sion is not
adhered
to, engine
troubl
es
may
occ
ur by closed o
il
bores
in
the
crankcase
or
by
rotating
par
ts moving
against
other
parts.
F'll. 9
If
Ihe oil
seal
is
laded
towards
outside by means
of
a collar (a)
or
other
locking e lement,
it
can·
not be extracted.
/
fig
. 8
/
11
Fin. 10
f ig .
11
Fitting the oil s
eal
12
Fig.l0
Place the extracting tool
in
posi-
tion
in
such a way that the two
hooks
(4) grip beh ind the
sheet
steel
rim
of
the oil seal. Pre-ten-
sion the two legs
(2)
evenly with
cylinder
head
screws
(1),
taking
core
lhat
shaft
(5)
and thrus t
screw
(3)
are
in
alignment.
Screw
in
thrust screw
and
extrac
t
oil seal.
Fig
.
11
If the
gop
between
shaft
and
sheet
steel
rim
of oil seal
is
too
narrow
and
the extracting tool
cannot
completely be placed
in
position, toke
off
one
leg
of
the
extracting tool
and
insert both
hooks
(1)
in
inclined position.
Remount leg
and
exlract oil
seal
as
described under Fig.
10,
Note
:
tf
the o il seal has
gal stuck
(oxi
-
dation). the sheet steel
rim
may
break, Therefore
it
is
advisable
to knock the oil seal out
of
its
force
fit
by means
of
a tube.
Fig.
12
Before fitting the oil seal,
fill
the
space
around
the tension spring
with a litt
le
heat-resisting
grease
and
lightly
smear
the
seal
ing lip.
Ta
protect the sealing lip
of
the
oil seal from
damage
caused by
sharp
edges
on
the shaft, use
shell sleeve.
If
necessary, put
smooth adhesive t
ape
around
sharp
edges.
Pl
ace
oil seal
in
position
and
press
it
in
by means
of
a suitable
tube, taking
core
of
exact instal-
lation dimension
x, a and
y
(Fig.
8).
The oil seal must not be tilted
when being pressed
in.
Changing cranksha
ft
bearings
Heat
crankcase
halves to
about
100
...
150· C (212
...
302·
Fl.
Remove
outer
race of
bearing
and
crankshaft oils
seals.
Insert new
outer
race
of
roller
bearing
into the warm
crankcase
half until they strike
a stop.
Press
in
oil
sea
l (with
sealing
lip inwards) until they
ore
flush.
Press
in
new
grooved
ball
bearing
into the worm crankcase ha lf
on
the
magneto
side unt
il
it
strikes a stop. Press
in
crankshaft oil
sea
l until flush only
after
the crank-
case
halves have
been
screwed together.
Have a look
at
the
table
of
crankshaft
bearings
on
page
10.
Removal
of
inner race
of
rolle r
bearing
and
grooved
ball
bearing
Fig.
13
Puil
off
inner race
(1)
and
groov-
ed
boll
bearing
(S)
by means
of
the
appropriate
extractor
shells
(10
and
7),
clamping rings
(9
and
8)
and
withdrawal tool (11; re-
pair
tool no.
17
to
23).
Remove compensating washers
(2),
shim
(3),
spacer
(4)
or
spacer
bush.
Fig.
13
13
T
ype
of engine
SACHS
SA
280 A
280
290
SACHS
SA
280
290
SACHS
SA
280
290
340
C
Crankshaft
,',
\
\!
'.
_'
);'
EE-3=
-
=-8-1-
---
r,'-=1
\
\:'--
) )
- - -
~
- -
-jf-
-
r;
'~
\ ' - -V ;'
<E
-
E-
=ffij
- -
'
.........
-
Note:
"
I'i
3
3
Fig.
IS
,
~
00
~
i-.) 0.,
U,
000
33
3
33
3
Ven
ion
S-piece
cran
kshaft (with cove r
plates
)
1
magneto
side cronk pin
2
spacer bush (21.4
mm
long. with electric storter,
23.4
mm
long, without electric slorler)
o
3
3
o
•
9..:
"
a
•
~
o
..
3
washer
(2
mm
thick; only for measuring, then
10
be
removed)
1
power
takeoff
side
cronk
pin
F
ig.
16
3'piece
crankshaft f
or
engine with cylindrical roller
bearing
(NJ
205 Ee3 lS) on m
agneto
side
1
magneto
si
de cra
nk pin
2
washer
(2
mm
thick)
3 spacer
(5
mm
th
ick,
bevel pointing
towards
crankshaft web)
4
washer
(1.5
mm thick,
bevel point ing
towards crankshaft
web
)
5
power
t
akeoff
side cronk pin
fig.
17
3-piece crankshaft for
engine
with
grooved
boll
bearing
(6305
C3)
on
magne
to side
1
magneto side
cronk pin
2
spacer
(5
mm
thick, bevel pointing
towards
cranksha
ft
web)
3 washer
(1.5
mm thick, bevel pointing
towards
crankshaft web)
4 power t
akeo
ff
side cr
ank
pin
For
the
eng
ines SACHS
SA
280,
SA
290
and
SA
340 C on
ly the 3. piece cronkshaft
ond
for SACHS
SA
280
A only the 5-pi
ece
crankshaft will
be
supplied for
replacement
purposes.
Pay attention
to
the
above
table
when
mounting
the
crankshaft.
Removal and
replacement
of
small end
bushing
When ta
rrying
01.11
repairs
to
engines
it
wi
ll
sometimes
be
necessary to repl
ace
the
sm
all end bushing
of
the connecting rod. A special
1001
has been designed for this
purpose (
rep
air tool no. 9).
A special reoming attachment
is
required when reaming out a newly fitted bushing,
cnd
this h
as
been developed
in
collaboration with the Germon firm of Hunger (re-
pair
too
ls
no.
10, 11,
12
and 13).
The
following procedure should be
adopt
ed when replacing a small
end
bushing:
Fig.
18
f ig.
19
16
Removing small
end
bushing
Fig.
18
F
ix
the gui
de
roil
11/,
as illustrat-
ed,
adjust it in fe
olion
10
the
connecting rod,
cnd
light
ly
se-
cure it by meons
of
two washers
(2)
and two nuts (
3),
Press gui
de rail
uniformly
against
the two studs
and
tighten nuts
(3)
.
Clomp the connecting r
od
by
means of eccen tri c pins
(9)
and
press
out
the small e nd bushing
as
follows:
Insert withdrawal boll
(4)
with
guide
bush
(5)
and
pressure bush
(6) into the small
end
bushing.
Fit holding sleeve (7), screw the
nut
(S)
and
press out the small
end
bushing.
Inserting
replacem
ent
bushing
fig
.
19
When inserting the
replacement
bushing
(k),
core
should
be
lake
n
to ensure that both oil holes (in
the bus hing
and
in
the connect ·
ing rod)
are
in
alignment.
Carefully insert withdrawal tool
Ie)
with
,ressure
bush (
g)
into
small
en
bushing
(kj.
Fit guide bush
(f)
and
holding
sleeve (h
),
screw the nut
(i)
and
press
in
the bushing
Ik)
so that
it
projects equally
on
both sides.
Centering the c
onn
ecting rod
Fill.
20
Mount su
ppor
t Ir) with
guide
bush
(g)
on
guide
rail
(0
)
and
screw
it
tigh
t.
Insert
reamer
(t),
shonk foremost,
in
to the
guide
bush
(g)
and
accu'
rately
center
the connec ting r
od
(v)
with the
aid
of
the
toper
.
Care should
be
token not to dis·
place
the connecting r
od
axially
or
radia
lly.
Then bring eccentric pin
(w)
lightly into
contact
with the
can·
necting rod a nd secure
it
with
nut
(x).
Press eccentric pin
(y)
firmly
against
connecting rod
and tig
h-
ten nut (z).
Reaming the
sma
ll
end
bushing
Fig. 21
(ove
r the crankcase.
The front adjusting nut
(q)
of
the
reamer
is
provided with mark·
ings:
each
division
corresponds
to 0.02 mm (0.00079 in
.).
Insert
reamer
and,
with the
aid
C?f
adjusting nu
ts
(q
and
pI,
ad·
tust
it
to the
diameter
of
the
bore
of
the small
end
bushing.
~'S40$4."
Fill.
20
-
fig.
21
Rem
ove
rea'!l~r.
from the bushing,
slacken lock nut (p),
alter
position
of
adjusting n
ut
(q) by o ne
diVIS
ion,
and
secure the blodes with lock nut (
p).
The s.mall
end
bushing
can
now be r
eamed
car
efully with the
aid
of
the adjustabl e
reaming tool
(I)
and
the
addi
tion
of
oil or paraffin.
Check the fit with the
aid
of the
gudgeon
pin.
~eaming
should
be
continu
ed until
the oil
ed
gudgeon
pin slides with a d
ose Msucking
M
fit
thr
ough
the r
eamed
small
end
bushing.
Bore tolerance for the bushing
=
(/J
18 t
g:g~
mm
0708
+0
.000
78.
.
66
+ 0.00118
In.
dia.
FICHTEL & SACHS AG,
8720
SCHWEINFURT, GERMANY
supply this special reaming tool
in
two
venions
or
individual c
ompon
ents
if
required.
Relevant prospectuses
are
available
from
us
on reques
t.
17
Fairbanks recoil starter
The recoil
starter
is
available
for clockwise
or
anti-clockwise starting direction.
II
can
also
be
subsequently
con
verted for the
other
storting direction.
The
illu
strat ion below shows the two
starting directions.
Fig.
22
Recoil
starter
for engine running Recoil
starter
for engine runnin g
in
clockwise direction in anti-clockwise direction
Fig.
23
18
(as
seen
on
the
power
take-off side
of
the crankshaft)
Dismantling
Fig.
23
Unscrew the housing.
Pullout
the cord
as
shown
in
the
illustrotion.
Withdraw
knot from
sl
orter
han
dle
and
undo il.
Remove
tubular riyet
(01.
beering
pl
ate
(b)
and
starter
hand
le
(c),
and
let cord run bock comp letely.
Remove retainer
(d)
and
cover
plate
(e).
Fig .
24
Remoye compression spring
(f),
friction disc (gl, drive assembly
(h
),
ond
second
friction disc.
Carefully toke out pulley (i).
Toke
core
not to let the co
il
spring
under
it
jump out.
Detad!
starter
cord
from pulley.
Take
oul
coil spring by
han
d.
Ass
embly
Fig.
25
Lubric
ate
the coil sprinlil
and
the
piyot pin
(k) lig
htly wi
th
Moly-
c
ote
before
assembling.
Note:
For clockwise starting direction,
insert
coil spring
as
shown
in
il-
lustration. For anti-clockwise
sta rling direction insert
coil
spr
ing the
other
way round.
Check
if
coil spring lies flat
and
even.
Bend the
end
of
the spring up-
wards
a little.
Fig.
26
Fit the
cord
into the pulley,
as
shown
tn
the tllus trattOn,
and
wind it on,
according
to the start-
ing direction.
Fit
pulley on to pivot pin
and
engage
the
end
of
the spring
in
the pulley
according
to the start-
ing direction.
Replace st
arter
handle,
bearing
plate
and
tubulor riyet (see Fig.
23)
in
position
on
the
starte
r
cord, knot the
end
of
the
cord
and
pull
it
into the handle.
Fig.
2~
rlS4Q!.4
,.
Fig.
2S
Fig. 26
•
19
rl
s
'O~4':O
Fig.
27
Recoil
starter
with
friction
jaws
Fig.
27
Fit
friction d isc, drive assembly
(with proiections
in
starting
dIrection for clockwise starting direction, see
arrow
in
illustration;
for
anti-clockwise
starti
ng direction fit drive assembly counterwise), second friction disc
and
compression spring on to pivot
pin.
Pl
ace
cov
er
plate
in
position
and
insert retainer.
With the
aid
of
the cord, tension
the pulley 1 ... 2 turns so that the
starter grip
is
pulled bock unt
il
it encounters the stop.
Let
cord run back.
Fit
the housing
in
position
and
screw tight.
The recoil
starter
is
available
for clockwise
or
anti-clockwise starting direction.
It
can be subsequently converted for the other starting direction,
if
the driving levers
are
exchanged for the required direction
of
rotation.
The illustration below shows both start
ing
directions.
F&54l0,121
Fip.28
Recoil starter for engine running
in
clockwise direction
, ,
-
•
Recoil
starter fer
engine run ning
in
enli-clockwise direction
(as see n on
the
power
lake-off side
of
the crankshaft)
20
Dismontling
Fig.
29
Screw off cover
plete
(b).
Remove retaining ring (g),
paeking discs, spring disc, friction
disc,
bearer
(xl with drive levers
and
pocking discs.
Fig.
30
Pu
ll
out
cord
opprOK. 50
em
(19.7
in
.)
and
hold the pulley with a
hom
e-mode
retaining clip (see
ad
ioining illustration).
Fi
g.
31
Remove reta ining bolt from starter
handle
and
open clam
ping
sleeve
(m)
br
tappi
ng with ham-
mer.
Pull
of
retaining bolt
and
starter handle from slarter co rd.
Remove reta ining
clip
again
and
lei cord run bock completely.
Fig.
2'1
\
Fig.
30
21
nsu,.,u
Fig.
32
FtS
' )(1"15
fig. 33
22
Fig.
32
Carefully
take
aut
the.
pull.ey,
taking tare that the cod spring
u
nder
it does nat jump aut.
Detach starter
tord
from pulley.
Take out
spacer
ring (n)
ond
ring (g
).
f ig.
33
The best way
10
take aut the cod
spring
is
to strike the storter
housing with the
open
side
downwards on
th
e work bench.
Broke the ejecting coi l spr
in
g
with the start
er
housing.
Nole:
If
the slorling disc must be re·
placed
or inserted for the oth
er
starting direclion
heat
the bush
well, lei
ilcooland
then remove it.
Assembly
Fig.
3-1
F
it
the slarling disc
50
that the
bent.up clip
(h)
lies in
Ihe.slarl.
ing direction shortly
afler Insert·
ing the spring, a nd the recesses
(x) clip into
place
in
Ihe corres·
ponding rib.on the bollom
of
Ihe
starter
hOUSing.
Press bush up
againsl
slop (use
only new bushes).
Fig.
35
lubricate
the coil spr ing with
Molycole b
efore
assembling.
Note
:
For clockw
is
e starting direction
(
B)
insert co
il
spring
as
shown
in
(b),
and
for anli·clockwise slort·
ing direction (A)
as
in
(a) wilh the
tubul
ar
rivet (collar facing
dow
n·
wards).
The first coil
of
the coil spring
must lie
oulside the
plate (h,
Fig.
34),
whereas
all oth
er
coils must
f
it
inside.
Ensure
tha
t coi l spring lies per·
fectly even.
Insert
spacer
ring
(n,
Fig.
32
).
Insert
contact
ring (g, Fig.
32
)
so
Ihot the riveting
of
the spring
lies snugly
in the gr
oaye
of the
contact ring.
Fig.
36
When
filling the pulley, attach
Ihe end
of
Ihe spring to the driv.
ing pin
of
the pulley.
Tension pulley/coil spring
in
di·
rection o f cord exil unlil stop
is
encountered. Release coil spring
1 ... 2 turns until the recess for the
soldering nipple
in
the pulley
rests n
ear
the cord duct
of
the
housing.
lubricate
the cord lightly with
Molycote
before
assemb
ling.
F
it
rubber
grip on
10 clamping
sleeve, loy
double
loop
of
cord
around
retain
er
boll (see F
ig
31)
and
secure wilh clamping sleeve.
Pull
retainer bolt into rubber grip
and
lei starter cord run bode.
__ " __
o.!
f&S
....
."u
Fill. 36
Fit
on padeing rings,
beore
r with drivin
g lever, and inserl Ihe
angled
ends
of
the
driving leve
rs
inio the recesses
of
the pull ey.
Fit
friction disc, spring disc, podeing rings
and rela
iner ring.
Remove packing rings from u
nder the
bearer,
should the driving levers not move out-
wards when slarling.
The
bearer
shou ld
have
a tolerance of
0.1
.. . 0.2
mm
(0.0039
... 0.0079 in.).
Screw on cover plate
(b, Fig.
29)
with 4 cyl indrical screws M 5 x
12
and
was
her
s.
23
Loading...