Saito FA-120 Special, FA-120S Golden Knight, FA-150 Golden Knight, FA-180 Golden Knight, FA-220a Golden Knight Instruction Manual

INSTRUCTION MANUAL

Large Single Cylinder 4-Stroke Engines

Version 2005

• FA-120 Special

•

FA-120S Golden Knight

• FA-150

• FA-150 Golden Knight

• FA-180

• FA-180 Golden Knight

• FA-220a

• FA-220a Gold

en Knight

Introduction

Congratulations on purchasing a
Saito™ 4-cycle engine. When cared
for properly, these high-quality, finely
crafted engines offer many years of
modeling enjoyment.

This instruction manual has been
developed to ensure optimum
performance from the Saito engine you
have purchased. The instructions must
be read through completely and
understood thoroughly prior to
mounting and running the engine.

Safety Instructions

This model engine will give you
considerable pleasure, satisfaction,
and performance if you strictly follow
these safety instructions and heed the
warnings for its safe and proper use.
Remember at all times it is not a toy,
but a precision-built machine with
more than enough power to cause harm
if misused or if the safety precautions
are not observed.

You should always:

1. Mount the engine securely in a
“bench mount” or high-quality motor
mount. Never clamp the engine in
a vice.

2. When running the engine, be sure
all spectators, especially children, are
at least 20 feet away.

3. Use the correct size and pitch
of propeller for your engine; refer
to the "Propeller Chart" on page 14
of this manual.

4. It is extremely important to balance
the propeller prior to installation of
the engine. Failure to do so may cause
damage to the Saito engine and/or the
airframe. Install the propeller with the
convex (curved) side facing forward.
Securely tighten the propeller nut
against the washer and propeller. An
anti-loosening nut (or “jam” nut) is
suggested for all 4-cycle engines.

5. Inspect the tightness of the propeller
nut prior to each flight.

6. Keep your face and body away from
the path of the propeller blades when
starting or running your engine.

7. Never allow your hands to come
close to the propeller. Utilize either
a “start stick (HAN113)” or electric
starter to start the engine.

8. Discard any propeller that is nicked,
scratched, cracked or damaged in any
way.

9. Make all carburetor adjustments
from behind the propeller.

10. To stop the engine, cut off the
fuel supply (pinch or disconnect the
fuel line to the carburetor) or use the
throttle linkage to shut off the air.

S A F E T Y I N S T R U C T I O N S 1

VERY
IMPORTANT

Failure to read
and follow these
instructions before
you proceed to
start your engine
may result in
engine damage
and the voiding of
your warranty.

Engine Parts
Identification

It is important to be able to identify the
parts of your Saito™ engine. Attached
you will find an exploded view of
a Saito 4-stroke engine, as well as
charts that include part numbers and
descriptions. This will assist you in
easily and rapidly identifying the
respective parts of your Saito engine.

Support Equipment

The following items, which are not
included with your Saito engine, are
necessary in order to operate the
model engine:

1. Fuel. For maximum protection
and longevity of their engines, Saito
recommends a fuel containing 20%
oil and 10–15% nitro methane. If this
blend is not readily available, the
next best selection is a high quality
2-cycle glow fuel, such as Hangar 9

®

Aero-Blend, Omega, Cool Power,
K&B, Power Master, etc. Use of fuels
composed entirely of castor oil is not
recommended. A mix of synthetic­castor oil is acceptable and can be
found in the various fuels described
above.

2. Propeller.

Refer to the “Propeller
Selection” chart, located on page 14, to
determine the best initial propeller for
your particular application. Propellers
should be balanced prior to use.

3. Glow Plug Battery.

Your glow plug
may be properly heated by several
different sources. The Hangar

9 Power

Panel (HAN106), when accompanied
by a 12-volt Sealed Lead Acid
Battery (HAN102) and a Glow Plug
Locking Socket (HAN120) is an ideal
source of heat for your glow plug. A
conventional 1.5-volt heavy-duty dry
cell battery with a Glow Plug Locking
Socket (HAN120) or alligator clips
may also be used. Additionally, there
are several very good glow-starters
(nickel cadmium-powered glow plug
igniters)(HAN7101) that work well.

4. Glow Plug Wrench.

Used to
remove and tighten glow plugs. The
Hangar 9 Long Reach Plug Wrench
(HAN2510) is an excellent wrench
to utilize, as a longer shaft may be
necessary to access the glow plug.
This depends mostly upon engine
installation.

5. Manual or Electric Starter.

For manual starts, a “Start Stick
(HAN113)” is highly recommended.
Never use your fingers to start any
model engine. To do so invites
injury. There are a variety of electric
starters on the market. The Hangar
9® PowerPro Heavy-Duty 12V starter
(HAN162) will work perfectly on all
Saito engines.

6. Tachometer.

The use of a
tachometer for setting the high­speed needle valve prior to flight is
encouraged. It will also be helpful
when setting the idle adjustment of
the carburetor(s). The Hangar 9 Micro
Digital Tachometer (HAN156) is a
good choice.

S U P P O R T E Q U I P M E N T 3

Do not use hands, fingers, or any other
part of the body to stop the propeller.

Do not throw any object into a
propeller to stop it.

It is highly recommended that:

• Safety glasses or goggles be
used when starting and running
your engine.

• You do not run the engine in the

vicinity of loose gravel or sand.
The propeller may throw such
materials into your face and eyes.
The engine may also ingest these
harmful materials.

• Loose clothing should be avoided
when operating your model engine.
Loose clothing may become
entangled in the propeller, creating
the possibility of bodily harm. Also,
all loose objects (screwdrivers,
pencils, nickel cadmium starters, etc.)
should be removed from your
pockets so that they do not fall
into the propeller.

• Glow plug clips and cords are kept
away from the propeller.

• Your glow fuel is kept in a safe place

well away from sparks, heat, or
anything that can ignite the fuel.

Beware:

• Model engines get very hot while
running. Do not attempt to handle
them until they have cooled.

• Always run your model engines in
a well-ventilated area. Similar to
automotive engines, model engines
produce possible harmful carbon
monoxide fumes.

• Remember that model engines
produce a substantial amount of
power, more than enough to seriously
injure people and/or do considerable
damage to property. Always use
common sense, skill and constant
observation of safety precautions.

Disassembly

Do not needlessly disassemble
your Saito™ engine. Only qualified
individuals should perform engine
repairs. Damage due to improper
disassembly will not be covered under
warranty. If it becomes necessary
to repair the engine, such as after a
crash, you can send your engine to the
authorized service center at:

Horizon Hobby, Inc.
Attention: Saito Service
4105 Fieldstone Road
Champaign, IL 61822
Phone: [phone]

2 S A F E T Y I N S T R U C T I O N S

Starting The Engine

1. Make sure the glow plug(s) is/are
installed and tightened.

2. Be sure the propeller is properly
secured. The use of an anti-loosening
nut, or “jam nut,” is encouraged on
4-cycle engines.

3. Make sure that the fuel tank line(s)
are properly connected. The fuel
pickup line should be connected to
the carburetor spray bar (84), and
the vent line should be connected to
the pressure nipple on the muffler.
The proper “plumbing” of the
lines is extremely important to the
performance of any engine. Saito

™

recommends the tank be mounted
approximately 5mm lower than the
carburetor center.

4. Be certain that the muffler is
installed properly by oiling the threads
prior to inserting the muffler into the
cylinder head and that the pressure line
is properly connected.

5. Fill the fuel tank.

6. Prime the engine:

• Check to make sure the glow plug
is not connected to the heat source
(glow plug clip/locking socket)

• Open the throttle fully

• Rotate the propeller in a counter­clockwise direction 5 to 6 times while
plugging the end of the muffler with
your finger to draw fuel into
the carburetor.

Note: Saito single cylinder engines
are now manufactured without the
choke valve (92). Due to the excellent
fuel draw characteristics of the Saito
engines, the use of the choke was
determined not to be necessary.

7. Start the engine:

• Turn through the prop 2 to 3 times

slowly to ensure that the engine is not
hydro-locked (see note below).

Note: When using an electric starter,
care should be taken to be sure the
engine does not become “hydro­locked” (flooded with fuel). While
the electric starter will turn the engine
over, it may damage the connecting
rod or other components. If the engine
becomes hydro-locked, simply remove
the glow plug and turn the engine over
a few times with the “start stick” or
electric starter. The excess fuel will
be forced to exit the engine via the
cylinder head.

• Close throttle to 1/4 – 1/3
open position.

• Rotate propeller clockwise until it is
against the compression stroke.

S T A R T I N G T H E E N G I N E 5

Break-In

The first run on any engine, whether
2-cycle or 4-cycle, is critical to the
future of the engine itself. During this
time, metal mating parts (piston and
cylinder, ball bearings, etc.) wear in.
Care must be taken that the engine is
clean and free of any dust or grit that
may have accumulated while building
the model.

There are two accepted methods for
breaking in a new engine: test stand
mounted and run or aircraft mounted
and run. Either method is acceptable;
however, mounting the engine to a test
stand allows the engine to be observed
throughout its operation, as well as
elevating it above the ground and away
from harmful dust and dirt.

Note: Because your engine may have
been sitting for an extended period of
time prior to running it, a few drops of
light oil applied through the crankcase
breather nipple (19 on the exploded
view) and down the push-rod tubes
(40) will ensure proper lubrication for
the first run.

Regardless of the mounting method
chosen for break-in, the following
procedures are applicable:

1. Use of a fuel as described in the
“Support Equipment” section on
page 3 of this manual for “break-in”
purposes is perfectly acceptable.

2. Your engine includes the Saito™
SAIP400S glow plug. Use the
proper glow plugs. The Hangar 9

®

Four Cycle Super Plug (HAN3011)
is a standard replacement to use in
these engines.

3. To select the correct propeller, refer
to the “Propeller Selection” chart on
page 14 of this manual. Remember to
balance the propeller prior to use.

4. Ensure that the high-speed
needle valve (85) is opened (turned
counterclockwise) five full turns. This
guarantees a very rich setting

Do not adjust the low-speed needle
valve (89) at this time.

5. The use of a tachometer (HAN156)
is highly recommended since the
adjustment of a 4-cycle engine, while
similar to that of a 2-cycle engine, is
more difficult to “set by ear,” making
it much easier to damage the engine by
“over-leaning.”

4 S T A R T I N G T H E E N G I N E