Saito FA-30S, FA-56, FA-50, FA-65, FA-72 Instruction Manual

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Page 1
SINGLE-CYLINDER 4-STROKE ENGINES
INSTRUCTION MANUAL
Version 2000
FA-30S (H)
FA-30S Golden Knight
FA-50
FA-50 Golden Knight
FA-56
FA-56 Golden Knight
FA-65
FA-72
FA-80
FA-80 Golden Knight
FA-91 Special
FA-91S Golden Knight
• FA-120 Special
FA-120S Golden Knight
FA-150
FA-150 Golden Knight
FA-180
FA-180 Golden Knight
Page 2
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.
Page 3
S A F E T Y I N S T R U C T I O N S 1
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 take heed of the warnings as to its safe and
3. Use the correct size and pitch of propeller for your engine; refer to the "Propeller Chart" on page 16 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.
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.
7. Never allow your hands to come close to the propeller. Utilize either a “chicken stick” 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.
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2 S A F E T Y I N S T R U C T I O N S
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.
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
• 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, nickle 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.
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: (217) 355-9511
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S U P P O R T E Q U I P M E N T 3
Engine Parts Identification
It is important to be able to identify the parts of your Saito engines. 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 Saito 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 A e r o - B l e n d , Omega, Cool Power, K&B, Power M a s t e r, etc. Use of fuels composed entirely of castor oil is n o tr e c o m m e n d e d . Amix of synthetic-castor oil is acceptable and can be found in the various fuels described above.
2. Propeller. Refer to the "Propeller Selection" chart, located on page 16, 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 glow­starters (nickel cadmium-powered glow plug igniters) that work well.
4. Glow Plug Wrench. Used to remove and tighten glow plugs. T h e Hangar 9 Long Reach Plug Wr e n c h (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 “chicken stick” 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 12V heavy-duty Super Starter (HAN110) will work perfectly on all Saito engines.
6. Tachometer. The use of a tachometer for setting the high-speed needle valve prior to flight is encouraged. It will also be helpful when setting the idle adjustment of the carburetor(s).
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4 S T A R T I N G T H E E N G I N E
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.
2. Use the proper glow plugs. Your engine includes the Hangar 9/McCoy MC-4C (HAN3010) glow plugs, which are standard replacement glow plugs for these engines.
3. To select the correct propeller, refer to the "Propeller Selection" chart on page 16 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. The low-speed needle valve is preadjusted at the factory for initial break-in. Specific instructions for adjusting the idle of engines (FA-30S(H)) using an
Note: Because your engine may have been siting 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.
“air-bleed” type carburetor will be described in the section “Carburetor Adjustments for Air Bleed Carburetors” on page 7.
5. The use of a tachometer 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.”
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S T A R T I N G T H E E N G I N E 5
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
• 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).
performance of any engine. Saito recommends the tank be mounted approximately 5 mm 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
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 “chicken 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.
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6 S T A R T I N G T H E E N G I N E
• Connect the heating source to the glow plug.
• Using either the “chicken stick” or electric starter, spin the propeller until the engine is running.
Note: A very common error is to remove the glow plug igniter too early. It is suggested that the igniter be left attached until after the engine has been run up and the high-speed needle valve has been properly adjusted.
8. Initial break-in:
Do not exceed 4,000 rpm for the first 10 minutes of operation. This allows all parts to mate properly with good lubrication.
The idle needle valve (89) (or air bleed needle valve) for the Saito .30S(H)/ GK engines) may now be refined. Please refer to the "Carburetor Adjustments" section on page 6 for information on how to do so.
The valves may also be checked at this time. Refer to the "Engine Maintenance" section on page 8 for information on the valve/tappet adjustments.
The use of a tachometer is encouraged for setting the high-speed needle valve (85) prior to flight. The peak rpm should be obtained and then reduced by approximately 200 – 300 rpm by turning the high-speed needle valve
Note: Due to the excessively “rich” mixture setting, it may be necessary to leave the heat source attached to the glow plug.
Subsequent runs may be made while slightly leaning out the mixture with each tank full of fuel. Forty minutes is considered sufficient time for normal break-in prior to the first flight.
9. After break-in:
If a test stand was used for the break-in procedure, the engine may now be mounted in the aircraft using a high­quality motor mount such as those available from Saito specifically or for Saito engines.
counter-clockwise (richen). Each engine’s peak rpm can be found on the "Propeller Chart" on page 16. Over­revving of a 4-stroke engine can cause internal damage to the engine.
Carburetor Adjustments for Two Needle Carburetors
The low-speed, or idle needle valve (89), is preadjusted at the factory for best performance during break-in. After break-in it may be necessary to “fine tune” the low speed adjustment using the following procedure:
1. Start the engine and let it warm up prior to attempting any adjustments.
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C A R B U R E T O R A D J U S T M E N T S 7
2. Close the throttle slowly and adjust the low speed setting by rotating the idle needle valve (89) clockwise to lean the mixture and counterclockwise to richen the mixture.
Note: The fuel mixture is too rich if when openning the throttle rapidly the engine emits white smoke and “stutters” or “stumbles.” Correct this by rotating the idle needle valve clockwise 1/4 to 1/2 turn at a time until the engine transitions smoothly without hesitation upon opening the throttle rapidly.
The fuel mixture may be too lean if the engine stops at the lowest idle position, or when the throttle is rapidly opened from idle. Attempt to correct this by rotating the idle needle valve counter­clockwise 1/4 to 1/2 turn at a time until the engine transitions smoothly without hesitation upon opening the throttle rapidly. If the situation is not rectified
Carburetor Adjustments for Air Bleed Carburetors
Note: The Saito FA-30S(H) and FA-30SGK use an air bleed carburetor.
1. Start the engine and let it warm up prior to attempting any adjustments.
2. Close the throttle slowly and adjust the airscrew setting by rotating the airscrew (89) counterclockwise to lean the mixture and clockwise to richen the mixture.
Note: The fuel mixture is too rich if when openning the throttle rapidly the engine emits white smoke and “stutters” or “stumbles.” Correct this by rotating the airscrew counter­clockwise 1/4 to 1/2 turn at a time until the engine transitions smoothly without hesitation upon opening the throttle rapidly.
by counterclockwise rotations of the idle needle valve, turn the idle needle valve clockwise in 1/4 to 1/2 turn increments.
3. After obtaining the proper idle setting, the low rpm setting may be made through the positioning of the throttle adjustment screw, if applicable. If not, adjust the idle setting via the throttle trim of your transmitter.
The fuel mixture may be too lean if the engine stops at the lowest idle position or if the engine stops when the throttle is rapidly opened from idle. Attempt to correct this by rotating the airscrew clockwise 1/4 to 1/2 turn at a time until the engine transitions smoothly without hesitation upon opening the throttle rapidly. If the situation is not rectified by clockwise rotations of the airscrew, turn the airscrew counter-clockwise in
1
/4 to 1/2 turn increments.
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8 N O R M A L E N G I N E O P E R A T I O N
3. After obtaining the proper idle
setting, the low rpm setting may be made through the positioning of the throttle adjustment screw, if applicable. If not, adjust the idle setting via the throttle trim of your transmitter.
Normal Engine Operation
If break-in was accomplished on a test bench your engine may be mounted to the aircraft and flown. The initial flight should be performed with the engine adjusted for a rich fuel mixture.
1. Your Saito engine should be
securely mounted to the aircraft. There are many motor mounts available; however, a high-quality metal mount, such as those manufactured by Saito exclusively for Saito engines, is considered to be the best.
2. General operating procedures that
will ensure long engine life are:
• Do not operate the engine with a
silicone tubing be attached to this crankcase breather nipple (19) and routed away from the engine compartment so the excess oil can be expelled outside of the aircraft.
Engine Maintenance
Do not needlessly dismantle your Saito single cylinder engine.
If you must disassemble your single cylinder engine, please refer to the following steps. Remember, a qualified individual should do disassembly.
1. Cylinder screws should be loosened in a criss-cross pattern.
2. Assemble the cam gear lining up the timing mark at the “6 o’clock” position. The crankshaft must be positioned at the “12 o’clock” or “top dead center” (TDC) position (refer to Figure 1 below).
>insert Figure 1 here
Figure 1
“lean” mixture.
• Regularly check all screws and nuts on both the engine and muffler.
• After 1 to 2 hours of operation, valve adjustment may be necessary. Adjust the valves as shown in the "Engine Maintenance" section.
• The Saito engines are equipped with a breather nipple (19). It is recommended that a length of
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E N G I N E O P E R A T I O N 9
3. Reassemble the piston, rod, rocker arm, pins, pushrod, tappet, etc., in their original positions. Engine parts are mated after running the engine and they must be reassembled as close as possible to their original position.
4. Assemble the engine, reversing the criss-cross pattern used in the disassembly. Prior to tightening each of the screws, apply a drop of oil to prevent thread damage.
Normal engine maintenance, such as adjusting the valves or carburetor maintenance, is permissible without voiding the warranty. If you have
any questions concerning maintenance procedures, please contact the Saito Service Center at (217) 355-9511. Our technicians will
Valve/Tappet Gap Adjustment
After approximately one hour of
operation, tappet gap adjustment may
be necessary. When you check the valves, lubricate the moveable parts. Also make sure the screw is in tight before making adjustments to valves.
Adjust the valves to a clearance of
.03 mm to .10 mm (.002" – .004") using the supplied gauge. The valves must be adjusted with the engine cold due to thermal expansion.
Note: Valves must be in the compression stroke or closed position as shown in Figure 2 below. When adjustment is completed, make sure you tighten the lock nut.
be happy to advise you on
Figure 2
maintenance issues.
>insert Figure 2 of tappet adjust here<
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10 C A R B U R E T O R M A I N T E N A N CE
Carburetor Maintenance
Should you experience difficulty with the carburetor of your engine:
1. Check the position of the idle needle valve (89) by fully opening the throttle barrel (87). Look down through the barrel and check the space between the idle needle and the spray bar (84). The spacing should be approximately 1mm. If not, adjust accordingly. Refer to Figure 3 below.
Note: Step 1 applies to .50 through .80 engines only.
>insert Figure 3 illus of carb opening here<
Figure 3
Tips For Extended Engine Life
To add longer life to your Saito engine, the following recommendations are made:
1. Use a high-quality fuel containing 20% lubricants.
2. Use recommended glow plugs.
3. Use the proper propeller size and
balance the propeller prior to use.
4. Use a tachometer for precise engine adjustments.
5. Use an “after-run” oil when you’re finished flying for the day. Hangar 9 After Run fuel is recommended.
2. Remove the high-speed needle (85) and flush out the spray bar with clean fuel. Replace the high-speed needle and follow the instructions in the Carburetor Adjustment section.
3. Always use a high­quality 4-cycle glow plug. The Hangar 9/McCoy MC-4C is highly recommended.
6. For long-term storage, make sure there is no fuel left in the tank and the engine. Remove the glow plug(s) and apply several drops of high-quality light oil (e.g., a good quality light machine oil or Marvel Air Tool Oil) to the top of the engine, into the glow plug hole, down the pushrod tubes, and through the crankcase pressure vent (breather nipple). Rotate the crankshaft several times. Store the engine in the box or on the airplane with the nose down in order to keep oil in the bearings.
Page 13
Troubleshooting
Generally speaking, there are very few things that will keep today’s modern glow engines from starting. To that end, make sure you’re using good quality “fresh” fuel, there are good glow plugs installed, and the starting battery is charged and in good condition. Should the engine fail to start after these items are verified, refer to the following troubleshooting chart on page 12.
T R O U B L E S H O O T I N G 1 1
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12 T R O U B L E S H O O T I N G
SYMPTOM CAUSE CORRECTIVE ACTION
Engine fails to Low voltage on Replace/recharge the start starting battery starting battery
Bad glow plug(s) Inspect/replace bad glow plug Insufficient priming Repeat priming procedure “Flooded” due to Disconnect battery, remove the
excessive priming glow plugs, and rotate the
propeller several times to “clear” the cylinder
Engine fires but Over primed Disconnect battery and rotate does not run propeller several times to
“clear” cylinder
Engine starts but Mixture too rich Close high-speed needle valve slows down and then stops
1
/2 turn and start again. Repeat
until engine is running smoothly.
Engine starts, Mixture too lean Open high-speed needle valve speeds up, and then quits
1
/2 turn and start again. Repeat
until engine is running smoothly.
Engine quits Mixture too rich Close high-speed needle valve when starter
1
/2 turn and restart
battery is removed Incorrect glow plugs Change glow plugs
Incorrect or bad fuel Change fuel
In the event that none of the above procedures results in the engine running properly, contact our service department for suggestions:
Horizon Service Center 4105 Fieldstone Road Champaign, Illinois 61822 217-355-9511 (Mon-Fri 8:00-5:00 CST)
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P A R T S L I S T 1 3
Small Single-Cylinder Cross-Reference Chart
PART NN MM E F II JJ RR SS
01 Cylinder, Left 30S01 30SH01 5001B 50GK01B 5601B 56GK01B 8001C 80GK01C 06 Piston 30S06 30S06 5006 5006 5606 5606 8006A 8006A 07 Piston Pin 30S07 30S07 5007 5007 6507 6507 8007 8007 08 Piston Pin Retainer (6 Pc) 30S08 30S08 5008 5008 6508 6508 8008 8008 09 Piston Ring 60T09 60T09 5009 5009 6509 6509 8009 8009 10 Connecting Rod 30S10A 30S10A 5010A 5010A 5610 5610 7210 7210 14 Cylinder Screw Set 5014 5014 5014 5014 5014 5014 6514 6514 15 Crankcase 30S15 30SH15 5015B 50GK15B 5615A 56GK15A 7215 72GK15 17 Rear Cover (A) 30S17 30SH17 5017B 50GK17B 5017B 50GK17B 7217 7217 19 Breather Nipple 30S19 30S19 5019 5019 5019 5019 6519 6519 20 Front Ball Bearing 30S20A 30S20A 5020A 5020A 5020A 5020A 6520A 6520A 22 Rear Ball Bearing 30S22 30S22 5022A 5022A 5022A 5022A 6522A 6522A 23 Crankshaft 30S23 30S23 5623A 5623A 5623A 5623A 7223 7223 24 Pinion-Crankshaft 30S24 30S24 5024 5024 5024 5024 — 25 Pinion Gear Pin 5025 5025 5025 5025 5025 5025 — 26 Collar, Crankshaft 5026 5026 5026 5026 — 27 Tapered Collet & Drive Flange 30S27 30S27 5027 5027 5027 5027 7227 7227 28 Prop Washer & Nut 30S28 30S28 5628 5628 5628 5628 5628 5628 29 Prop Nut, Spinner — 30 Prop Nut, Electric Starter 30S30 30S30 5030A 5030A 5030A 5030A 5030A 5030A 31 Crankcase Screw Set 30S31 30S31 5031 5031 5031 5031 7231 7231 32 Engine Gasket Set 30S32A 30S32A 5032A 5032A 5632A 5632A 7232 7232 33 Cam Gear Housing 30S33 30SH33 5033A 50GK33A 5033A 50GK33A 7233 7233 35 Cam Gear, Right 30S35 30S35 5035 5035 5035 5035 6535A 6535A 36 Cam Gear Shaft 30S36 30S36 5036 5036 5036 5036 7236 7236 37 Teflon/Steel Washer Set 30S37 30S37 5037 5037 5037 5037 5037 5037 38 Tappet (2 Pc) 30S38 30S38 5038 5038 5038 5038 5038 5038 39 Pushrod (2 Pc) 30S39 30S39 5039 5039 5039 5039 7239 7239 40 Pushrod Cover Rubber Seal (Pr) 30S40 30S40 5040 5040 5040 5040 7240 7240 41 Rocker Arm (Pr) 60T41 60T41 5041 5041 5041 5041 5041 5041 42 Rocker Arm Screw Nut (2 Sets) 5042 5042 5042 5042 5042 5042 5042 5042 43 Rocker Arm Pin (2 Pc) 30S43 30S43 5043 5043 5043 5043 5043 5043 44 Rocker Arm Bracket, Left — 45 Rocker Arm Bracket, Right — 46 Valve-In/Out (Pr) 30S46 30S46 5046 5046 5646 5646 6546 6546 47
Valve Spring, Keeper, Retainer (2 Sets) 48 Valve Retainer (4 Pc) 5048 5048 5048 5048 5048 5048 5048 5048 49 Rocker Arm Cover (Pr) 30SGK49 30SH49 5049 50GK49 5049 50GK49 5049 50GK49 68 Check Valve-In/Out (Pr) — 69 Intake Manifold, Left 5069 5069 5669A 5669A 7269 7269 74 Muffler, Right 30S74 30S74 5074B 5074B 5074B 5074B 8074A 8074A 75 Muffler Manifold, Standard 30S75 30S75 5075A 5075A 5075A 5075A 8075A 8075A 79 Muffler Gasket (5 Pc) — 80 Muffler Nut (2 Pc) 30S80 30S80 5080A 5080A 5080A 5080A 8080A 8080A 821 Carburetor-Complete, Left 30S821 30S821 50821B 50821B 50821B 50821B 72821 72821 822 Carburetor-Complete, Right — 831 Carburetor Body Assembly, Left 30S831 30S831 50831 50831 50831 50831 72831 72831 84 Spray Bar Assembly 30S84 30S84 — 85 High Speed Needle Valve 30S85 30S85 5085 5085 5085 5085 5085 5085 86 High Speed Needle Valve Extension — 5086 5086 5086 5086 5086 5086 87 Throttle Barrel Assembly 30S87 30S87 5087A 5087A 5087A 5087A 7287 7287 88 Throttle Lever 30S88 30S88 5088B 5088B 5088B 5088B 5088B 5088B 89 Idle Needle Valve 30S89 30S89 5089 5089 5089 5089 130T89 130T89 90 Carburetor Screw & Spring Set 30S90 30S90 5090A 5090A 5090A 5090A 7290 7290 91 Carburetor Gasket Set 30S91 30S91 5091 5091 5091 5091 8091A 8091A 92 Choke Valve Assembly 5092 5092 5092 5092 5092 5092 93 Intake Velocity Stack 50GK93 50GK93 50GK93 95 Engine Mount 30S95 30S95 5095 5095 5095 5095 5095 5095 96 Tool Set 30S96 30S96 5096A 5096A 5096A 5096A 5096A 5096A 97 Instruction Manual MAN1 MAN1 MAN1 MAN1 MAN1 MAN1 MAN1 MAN1 102 Fuel Pump System — 109 F-1 Fuel Filler 50109 50109 50109 50109 50109 50109 50109 50109 110 Anti-Loosening Nut 56110 56110 56110 56110 56110 56110 111 Flexible Exhaust Pipe 65111 65111 112 Tuned Silencer 62112 65112 113 Flexible Exhaust Pipe — 114 Engine Bed 50114 50114 50114 50114 50114 50114 115 Engine Bed — 116 M3 Nut for Spinner 50116 50116 50116 50116 — 117 M4 Nut for Spinner 65117 65117 118 M5 Nut for Spinner 65118 65118 122 Spray Bar/O-Ring 65122 65122 65122 65122 72122 72122 135
Prop Washer/Nut/Anti-Loosening Nut 136 Intake Manifold — 137 Prop Washer
FA-30S-GK FA30-S (H) FA-50 FA-50GK FA-56 FA-56GK FA-72 FA-72GK
30S47 30S47 5047 5047 5047 5047 6547 6547
56135 56135 56135 56135 56135 56135
Page 16
14 P A R T S L I S T
Medium Single-Cylinder Cross-Reference Chart
PART G H I J K EE
01 Cylinder, Left 6501C 65GK01C 8001C 80GK01C 91S01A 91SGK01A 06 Piston 6506A 6506A 8006A 8006A 91S06 91S06 07 Piston Pin 6507 6507 8007 8007 91S07 91S07 08 Piston Pin Retainer (6 Pc) 6508 6508 8008 8008 6508 6508 09 Piston Ring 6509 6509 8009 8009 91S09 91S09 10 Connecting Rod 6510C 6510C 6510C 6510C 6510C 6510C 14 Cylinder Screw Set 6514 6514 6514 6514 6514 6514 15 Crankcase 6515A 65GK15A 8015A 80GK15A 91S15 91SGK15 17 Rear Cover (A) 6517A 80GK17A 6517A 80GK17A 91S17 91SGK17 19 Breather Nipple 6519 6519 6519 6519 6519 6519 20 Front Ball Bearing 6520A 6520A 91S20A 91S20A 91S20A 91S20A 22 Rear Ball Bearing 6522A 6522A 6522A 6522A 91S22A 91S22A 23 Crankshaft 6523A 6523A 8023 8023 91S23 91S23 24 Pinion-Crankshaft — 25 Pinion Gear Pin — 26 Collar, Crankshaft — 27 Tapered Collet & Drive Flange 6527 6527 6527 6527 6527 6527 28 Prop Washer & Nut 5628 5628 5628 5628 5628 5628 29 Prop Nut, Spinner — 30 Prop Nut, Electric Starter 5030A 5030A 5030A 5030A 5030A 5030A 31 Crankcase Screw Set 5031 5031 5031 5031 5031 5031 32 Engine Gasket Set 6532A 6532A 8032A 8032A 91S32 91S32 33 Cam Gear Housing 6533B 65GK33B 6533B 80GK33A 6533B 80GK33A 35 Cam Gear, Right 6535A 6535A 6535A 6535A 6535A 6535A 36 Cam Gear Shaft 5036 65GK36A 5036 5036 5036 5036 37 Teflon/Steel Washer Set 5037 5037 5037 5037 5037 5037 38 Tappet (2 Pc) 5038 5038 5038 5038 5038 5038 39 Pushrod (2 Pc) 6539 6539 6539 6539 91S39 91S39 40 Pushrod Cover Rubber Seal (Pr) 6540 6540 6540 6540 60T40 60T40 41 Rocker Arm (Pr) 5041 5041 5041 5041 5041 5041 42 Rocker Arm Screw Nut (2 Sets) 5042 5042 5042 5042 5042 5042 43 Rocker Arm Pin (2 Pc) 5043 5043 5043 5043 5043 5043 44 Rocker Arm Bracket, Left — 45 Rocker Arm Bracket, Right — 46 Valve-In/Out (Pr) 6546 6546 6546 6546 91S46 91S46 47 Valve Spring, Keeper, Retainer (2 Sets) 6547 6547 6547 6547 6547 6547 48 Valve Retainer (4 Pc) 5048 5048 5048 5048 5048 5048 49 Rocker Arm Cover (Pr) 5049 50GK49 5049 50GK49 5049 50GK49 68 Check Valve-In/Out (Pr) — 69 Intake Manifold, Left 6569 6569 8069A 8069A 91S69 91S69 74 Muffler, Right 6574A 6574A 8074A 8074A 91S74 91S74 75 Muffler Manifold, Standard 8075A 8075A 8075A 8075A 8075A 8075A 79 Muffler Gasket (5 Pc) — 80 Muffler Nut (2 Pc) 8080A 8080A 8080A 8080A 8080A 8080A 821 Carburetor-Complete, Left 50821B 50821B 80821B 80821B 91S821A 91S821A 822 Carburetor-Complete, Right — 831 Carburetor Body Assembly, Left 50831 50831 80831A 80831A 91S831A 91S831A 84 Spray Bar Assembly — 85 High Speed Needle Valve 5085 5085 5085 5085 5085 5085 86 High Speed Needle Valve Extension 5086 5086 5086 5086 5086 5086 87 Throttle Barrel Assembly 5087A 5087A 8087A 8087A 91S87 91S87 88 Throttle Lever 5088B 5088B 5088B 5088B 5088B 5088B 89 Idle Needle Valve 5089 5089 5089 5089 130T89 130T89 90 Carburetor Screw & Spring Set 5090A 5090A 5090A 5090A 91S90 91S90 91 Carburetor Gasket Set 6591A 6591A 8091A 8091A 91S91 91S91 92 Choke Valve Assembly 5092 5092 5092 5092 5092 5092 93 Intake Velocity Stack 50GK93 50GK93 50GK93 95 Engine Mount 6595 6595 6595 6595 6595 6595 96 Tool Set 6596A 6596A 6596A 6596A 6596A 6596A 97 Instruction Manual MAN1 MAN1 MAN1 MAN1 MAN1 MAN1 102 Fuel Pump System — 109 F-1 Fuel Filler 50109 50109 50109 50109 50109 50109 110 Anti-Loosening Nut 56110 56110 56110 56110 56110 56110 111 Flexible Exhaust Pipe 65111 65111 65111 65111 65111 65111 112 Tuned Silencer 65112 65112 65112 65112 65112 65112 113 Flexible Exhaust Pipe — 114 Engine Bed 65114 65114 65114 65114 65114 65114 115 Engine Bed — 116 M3 Nut for Spinner 50116 50116 — 117 M4 Nut for Spinner 65117 65117 65117 65117 65117 65117 118 M5 Nut for Spinner 65118 65118 65118 65118 65118 65118 122 Spray Bar/O-Ring 65122 65122 65122 65122 91S122 91S122 135 Prop Washer/Nut/Anti-Loosening Nut 56135 56135 56135 56135 56135 56135 136 Intake Manifold — 137 Prop Washer
FA-65 FA-65GK FA-80 FA-80GK FA-91S FA-91SGK
Page 17
P A R T S L I S T 1 5
Large Single-Cylinder Cross-Reference Chart
PART M FF CC GG OO PP
01 Cylinder, Left 120S01A 120SGK01A 15001 150S01 18001 180GK01 06 Piston 120S06 120S06 150S06 150S06 18006 18006 07 Piston Pin 120S07 120S07 120S07 120S07 18007 18007 08 Piston Pin Retainer (6 Pc) 120S08 120S08 300T08 300T08 300T08 300T08 09 Piston Ring 120S09 120S09 300T09A 300T09A 18009 18009 10 Connecting Rod 120S10C 120S10C 120S10C 120S10C 18010A 18010A 14 Cylinder Screw Set 120S14 120S14 120S14 120S14 120S14 120S14 15 Crankcase 120S15B 120SGK15A 15015A 150S15A 18015 18015 17 Rear Cover (A) 120S17A 150S17 120S17A 150S17 18017 18017 19 Breather Nipple 6519 6519 6519 6519 6519 6519 20 Front Ball Bearing 120S20A 120S20A 12020A 12020A 120S20A 120S20A 22 Rear Ball Bearing 120S22 120S22 120S22 120S22 120S22 120S22 23 Crankshaft 120S23A 120S23A 150S23A 150S23A 18023 18023 24 Pinion-Crankshaft — 25 Pinion Gear Pin — 26 Collar, Crankshaft — 27 Tapered Collet & Drive Flange 120S27A 120S27A 120S27A 120S27A 120S27A 120S27A 28 Prop Washer & Nut 170R328 170R328 170R328 170R328 170R328 170R328 29 Prop Nut, Spinner 120S29 120S29 120S29 120S29 120S29 120S29 30 Prop Nut, Electric Starter 120S30 120S30 120S30 120S30 120S30 120S30 31 Crankcase Screw Set 5031 5031 5031 5031 5031 5031 32 Engine Gasket Set 120S32 120S32 150S32 150S32 18032 18032 33 Cam Gear Housing 120S33 150S33 120S33 150S33 120S33 150S33 35 Cam Gear, Right 120S35 120S35 120S35 120S35 120S35 120S35 36 Cam Gear Shaft 5036 5036 5036 5036 5036 5036 37 Teflon/Steel Washer Set 120S37 120S37 120S37 120S37 120S37 120S37 38 Tappet (2 Pc) 120S38 120S38 120S38 120S38 120S38 120S38 39 Pushrod (2 Pc) 120S39 120S39 120S39 120S39 120S39 120S39 40 Pushrod Cover Rubber Seal (Pr) 120S40 120S40 120S40 120S40 120S40 120S40 41 Rocker Arm (Pr) 120S41 120S41 120S41 120S41 120S41 120S41 42 Rocker Arm Screw Nut (2 Sets) 120S42 120S42 120S42 120S42 300T42 300T42 43 Rocker Arm Pin (2 Pc) 120S43 120S43 120S43 120S43 120S43 120S43 44 Rocker Arm Bracket, Left 120S44 150S44 120S44 150S44 120S44 150S44 45 Rocker Arm Bracket, Right 120S45 150S45 120S45 150S45 120S45 150S45 46 Valve-In/Out (Pr) 120S46 120S46 120S46 120S46 18046 18046 47 Valve Spring, Keeper, Retainer (2 Sets) 120S47 120S47 120S47 120S47 120S47 120S47 48 Valve Retainer (4 Pc) 120S48 120S48 120S48 120S48 120S48 120S48 49 Rocker Arm Cover (Pr) 150S49 120S49 150S49 120S49 150S49 120S49 68 Check Valve-In/Out (Pr) — 69 Intake Manifold, Left 150S69A 150S69A 150S69A 150S69A 18069 18069 74 Muffler, Right 120S74A 120S74A 120S74A 120S74A 18074 18074 75 Muffler Manifold, Standard 120S75A 120S75A 120S75A 120S75A 120S75A 120S75A 79 Muffler Gasket (5 Pc) — 80 Muffler Nut (2 Pc) 120S80 120S80 120S80 120S80 120S80 120S80 821 Carburetor-Complete, Left 120S821C 120S821C 150S821A 150S821A 180821 180821 822 Carburetor-Complete, Right — 831 Carburetor Body Assembly, Left 120S831B 120S831B 150S831A 150S831A 180831 180831 84 Spray Bar Assembly 450R3D84A 450R3D84A 450R3D84A 450R3D84A 450R3D84A 450R3D84A 85 High Speed Needle Valve 120S85 120S85 120S85 120S85 120S85 120S85 86 High Speed Needle Valve Extension 5086 5086 5086 5086 5086 5086 87 Throttle Barrel Assembly 120S87A 120S87A 150S87 150S87 18087 18087 88 Throttle Lever 5088B 5088B 5088B 5088B 5088B 5088B 89 Idle Needle Valve 120S89 120S89 120S89 120S89 18089 18089 90 Carburetor Screw & Spring Set 120S90A 120S90A 120S90A 120S90A 120S90A 120S90A 91 Carburetor Gasket Set 120S91 120S91 150S91 150S91 150S91 150S91 92 Choke Valve Assembly 120S92 120S92 120S92 120S92 — 93 Intake Velocity Stack 120S93 120S93 120S93 120S93 18093 18093 95 Engine Mount 120S95 120S95 120S95 120S95 120S95 120S95 96 Tool Set 120S96 120S96 120S96 120S96 120S96 120S96 97 Instruction Manual MAN1 MAN1 MAN1 MAN1 MAN1 MAN1 102 Fuel Pump System — 109 F-1 Fuel Filler 50109 50109 50109 50109 50109 50109 110 Anti-Loosening Nut 170R3110 170R3110 170R3110 170R3110 170R3110 170R3110 111 Flexible Exhaust Pipe 120S111 120S111 120S111 120S111 120S111 120S111 112 Tuned Silencer — 113 Flexible Exhaust Pipe — 114 Engine Bed — 115 Engine Bed — 116 M3 Nut for Spinner — 117 M4 Nut for Spinner — 118 M5 Nut for Spinner — 122 Spray Bar/O-Ring 450R3D122A 450R3D122A 450R3D122A 450R3D122A 450R3D122A 450R3D122A 135 Prop Washer/Nut/Anti-Loosening Nut 170R3135 170R3135 170R3135 170R3135 170R3135 170R3135 136 Intake Manifold — 137 Prop Washer
FA-120SH FA-120SGK FA-150 FA-150GK FA180 FA-180GK
Page 18
16 P R O P E L L E R S E L E C T I O N
Propeller Selection
Remember, it is imperative to balance
In the chart below you will find a propeller selection list. This chart will enable you to select the best propeller for initial setup of your Saito engine.
Figure 5
You will note a letter (A, B,C, etc.) stamped on the top of the motor mount. This letter identifies the production version of your engine. Should you ever need to order a part or have a question pertaining to your engine, specify this letter along with the engine type. This will allow for easier identification of your engine.
Saito Single-Cylinder Propeller Chart
NOTE: All recommendations are based on engines using APC props, Power Master 15% 2-stroke fuel, and McCoy MC-4C glow plugs.
ENGINE SPORT SCALE AEROBATICS
each propeller prior to installation onto your Saito engine. Failure to do so may cause unwanted vibration in your aircraft.
FA-30S (H)/30SGK
2,200– 12,000 rpm 10 x 5 10 x 5, 10 x 6 9 x 6, 10 x 5
FA-50/50GK
2000– 12,000 rpm 11 x 7, 11 x 8, 12 x 6 12 x 5, 12 x 6 11 x 7, 11 x 8, 12 x 6
FA-56/56GK
2000– 12,000 rpm 11 x 8, 12 x 6, 12 x 7 12 x 6, 12 x 7 11 x 8, 12 x 6, 12 x 4
FA-65/65GK
2000– 11,500 rpm 12 x 6, 12 x 8, 13 x 8 13 x 8, 14 x 5, 14 x 6 11 x 9, 12 x 8, 13 x 6
FA-72/72GK
2000– 11,500 rpm 12 x 8, 13 x 6, 13 x 8, 13 x 6, 13 x 8, 14 x 6, 11 x 9, 11 x 10,12 x 8,
14 x 6 15 x 4 12 x 9
FA-80/80GK
2000– 11,500 rpm 12 x 8, 13 x 6, 13 x 8, 13 x 6, 13 x 8, 14 x 6, 11 x 9, 11 x 10,12 x 8,
14 x 6 15 x 4 12 x 9
FA-91S/91SGK
2000– 11,000 rpm 12 x 8, 13 x 7,13 x 8, 13 x 7, 13 x 8, 14 x 5 11 x 10, 11 x 11, 12 x 9
14 x 6, 14 x 8 14 x 6, 15 x 4 12 x 10N, 13 x 9
FA-120S/120SGK
2000– 11,000 rpm 14 x 10,15 x 8, 15 x 10 15 x 8, 16 x 6, 16 x 8, 13.5 x 13.5, 14 x 10N
16 x 16, 16 x 8 18 x 6 14 x 12
FA-150/150GK
2000– 10,500 rpm 15 x 8, 15 x 10, 16 x 8 16 x 8, 18 x 6, 18 x 8, 14 x 10N, 14 x 14,
18 x 6, 18 x 8 15 x 10, 15 x 11
FA-180/180GK
2000– 11,000 rpm 15 x 8, 15 x 10, 15 x 11 16 x 8, 16 x 10, 14 x 13.5,
16 x 8, 16 x 10 18 x 6 15 x 12
NOTE: Observe operating rpm ranges as excessive rpm can result in damage to the engine.
Page 19
E N G I N E S P E C S 1 7
Figure 6
I
Figure 7
OUTSIDE DIMENSIONS (mm)
Items A B B1 B2 C1 C2 D E F G H I
FA-30S (H)/30S GK 36 14 FA-50/FA-50GK FA-56/FA-56GK FA-65/FA-65GK FA-72/FA-72GK FA-80/FA-80GK FA-91 Special/FA-91SGK FA-120 Special/FA-120SGK FA-150/FA-150GK FA-180/FA-180GK
46 15 103 130 54 102 59 32 52 84 46 15 103 130 54 102 59 32 52 84 50 21 113 144 60 113 66 40 55 93 46 113 136 54 112 77.5 36 59.5 94 50 21 113 144 60 113 66 40 55 93 50 21 114 146 60 113 66 40 55 93 59 24 150 175 69 132 80 45 68 110 59 24 150 175 69 132 80 45 68 110 59 24 150 175 69 132 80 45 68 110
88 110 43 87 47 29 33 72
Figure 8
SPECIFICATIONS
Items Disp Bore Stroke Weight K Cylinder HP
(cc) (mm) (mm) (g) (ISO)
FA-30S (H)/30S GK 5.03 20 16 270 FA-50/FA-50GK FA-56/FA-56GK FA-65/FA-65GK FA-72/FA-72GK FA-80/FA-80GK FA-91 Special/FA-91SGK FA-120 Special/FA-120SGK FA-150/FA-150GK FA-180/FA-180GK
8.2 23.4 19.0 435 M7x1 — ABC 0.85
9.2 24.8 19.0 440 M7x1 — ABC 0.93
10.6 24.8 22.0 550 M7x1 — ABC 0.95
11.8 27.0 20.6 470 M7x1 — AAC 1.2
13.1 27.0 22.8 540 M7x1 — ABC 1.3
14.9 28.2 24.0 520 M7x1 — AAC 1.7
20.0 32.0 24.8 820 M8x1.25 — AAC 2.2
25.0 34.0 27.6 850 M8x1.25 — AAC 2.5
29.1 36.0 28.6 880 M8x1.25 — AAC 2.8
1
4
x28 AAC
/
Page 20
P A R T S L I S T
No. Description Qty.
01 Cylinder (left) 1 06 Piston 1 07 Piston pin 1 08 Piston pin retainer 2 09 Piston ring 1 10 Connecting rod 1 14 Cylinder screw set 1 set 15 Crankcase 1 17 Rear cover 1 19 Breather nipple 1 20 Front bearing 1 22 Rear bearing 1 23 Crankshaft 1 24 Pinion (crankshaft) 1 25 Pinion gearpin 26 Collar (crankshaft) 1 27 Taper collet & drive flange 1 each 28 Prop washer & nut 1 set 29 Prop nut-spinner 30 Prop nut-electric starter 31 Crankcase screw set 1 set 32 Engine gasket set 1 set 33 Cam gear housing 1 35 Cam gear 1 36 Cam gear shaft 1 37 Steel washer set 1 set 38 Tappet 2
No. Description Qty.
39 Pushrod 2 40 Pushrod cover & rubber seal 2 each 41 Rocker arm 2 42 Rocker arm screw & nut 2 each 43 Rocker arm pin 2 44 Rocker arm bracket (left) 1 45 Rocker arm bracket (right) 1 46 Valve (in & out) 2 47 Valve spring & keeper & retainer 2 each 48 Valve retainer 49 Rocker arm cover 2 68 Checkvalve (in & out) 1 pair 69 Intake manifold 1 74 Muffler 1 75 Muffler manifold 1 77 Muffler gasket 5 80 Muffler nut 2
89 Idle needle valve 1 821 Carburetor complete 1 set 831 Carburetor body assembly 1 set
84 Spray bar assembly
85 High speed needle valve 1
87 Throttle barrel assembly 1 set
91 Carburetor gasket set 1 set
93 Intake velocity stack 1 set 102 Fuel pump system complete 1 set 110 Anti-loosening nut 1
Figure 9
110
36
28
39
40 31
37 35 32
38
27
42
41
14 49 32
20
33
26
48
14 45
14
46 09 06
10
43
47
44
15
91
01
07
08
24
32
74
80
69
22
25
75
68
102
Fuel Pump System Complete
89
87
32
23
93
17
31
19
821
831
84
92
(Optional) choke
68
85
Page 21
W A R R A N T Y & R E P A I R S 1 9
Consumer Warranty and Repair Policy
Saito engines are guaranteed against workmanship and manufacturing defects for a period of 3 years from the original date of purchase. This warranty is limited to the original purchaser of the engine and is not transferable. Warranty repairs will not cover:
• Normal engine wear
• Damage due to insufficient maintenance
• Damage related to over-revving of engine due to small prop size or unreasonable use
• Rusted bearings
• Crash damage
• Damage due to use of improper fuel and/or glow plug
• Damage due to lean runs, such as rusted bearings, seized connecting rod or piston, etc.
• Damage caused by foreign objects (dirt or broken glow plug filaments)
• Damage caused by unreasonable mounting or running conditions (dust, insufficient cooling, improper mounting, improper propeller size, or lack of balancing, etc.)
• Damage due to improper disassembly
• Modifications of any kind
If your engine needs repair, please do the following:
1. Ship your engine in its original box, freight prepaid to:
2. Include a note containing a brief
summary of the difficulty and include the following information:
Horizon Service Center
Attn: Saito Service
4105 Fieldstone Road Champaign, IL 61822 Phone: (217) 355-9511
• Nitro content and brand of fuel
• Propeller size and brand used
• Type of glow plug used
• Type of engine mount
• Approximately how much running
Include complete name and address
time the engine had before difficulty
information inside the carton, as well as clearly writing it on the outer label/return address area.
Date your correspondence and be sure your name and address appear on this enclosure. Also, include a phone number where you can be reached during the business day.
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20 W A R R A N T Y & R E P A I R S
Warranty Repairs To receive warranty service, you
must include your original dated sales receipt to verify your proof-of­purchase date. Providing that warranty conditions have been met, your engine will be repaired without charge.
Non-Warranty Repairs Should your repair cost exceed 50%
of the retail purchase cost, you will be provided with an estimate advising you of your options. Any return freight for non-warranty repairs will be billed to the consumer.
Please advise us of the payment method you prefer to use. The Horizon Service Center accepts VISA, MasterCard, or money orders. If you prefer to use a credit card, include your card number and expiration date.
The Consumer Warranty Registration in the back of this manual must be completely filled out and mailed to:
Horizon Service Center Attn: Saito Warranty 4105 Fieldstone Road Champaign, IL 61822
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Page 24
© Copyright, 2000 Stock #SAIMAN1 updated 9-7-2000
Exclusively distributed by
Horizon Hobby, Inc., Champaign, IL 61822
www.horizonhobby.com
SAI.99.36
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