Saito | FA-100 | Instruction manual | Saito FA-100 Instruction manual

TWIN-CYLINDER FOUR-STROKE ENGINES
INSTRUCTION MANUAL
・FA-60T
・FA-182TD
・FA-90TS
・FA-300TL
・FA-100T
・FA-300TTDP
VERY
IMPORTANT
Failure to read
and follow these
instructions before
you proceed may
result in engine
damage and the
voiding of your
warranty.
SAFETY INSTRUCTIONS
Introduction
Congratulations on purchasing a Saito
4-cycle engine. 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
proper use. Remember at all times,
IT IS NOT A TOY, but a precisionbuilt machine with more than enough
power to cause harm if misused, or
if the safety precautions are not
observed.
2. When running the engine, be sure
that 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 18 of this manual.
4. It is extremely important to
balance the propeller prior to
installation. 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. A“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. Use either a
“Start stick”or electric starter to
start the engine.
You should always:
1. Mount the engine securely on the
test bench using the high-quality Saito
motor mount supplied. Never clamp
the engine in a vice.
1
8. Make all carburetor adjustmets
from behind the propeller.
9. 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.
2
SAFETY INSTRUCTIONS
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.
10. Discard any propeller that is
nicked, scratched, cracked or
damaged in any way.
It is highly recommended
that:
1. Safety glasses or goggles be worn
when starting and running your
engine.
2. 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.
3. 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 they do not fall into the propeller.
4. Glow plug clips and cords are
kept well away from the propeller.
5. Your glow fuel is kept in a safe
place well away from sparks, heat or
anything which can ignite the fuel.
Beware:
1. Model engines get very hot while
running. Do not attempt ot handle
them until they have cooled.
2. Always run your model engines
in a well-ventilated area. Similar to
automotive engines, model engines
produce possibly barmful carbon
monoxide fumes.
3. 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. Engine repairs should
be performed only by qualified
individuals. Damage due to improper
disassembly will not be covered under
the warranty.
SUPPORT
Engine Parts
Identification
It is important to be able to identify
the parts of your Saito engines. In the
back of this manual you will find an
exploded view of Saito twin-cylinder
engines, as well as a chart which
includes 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 Cool Power, K&B, Power
Master, etc. Fuels composed entirely of
castor oil are not recommended. Use of
such fuels will void the warranty.
2. Propeller. Refer to the Propeller
Selection Chart, located on page 18,
to determine the best initial propeller
for your particular application.
EQUIPMENT
3
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 12V sealed lead acid battery
(HAN102) and a glow plug locking
socket (HAN120), is an ideal source of
heat for your glow plug.A
conventional 1.5V heavy-duty dry cell
battery with a glow plug locking
socket (HAN120) or alligator clips can
also be used. Additionally, there are
several very good glow-starters (nickel
cadmium powered glow plug ignitors)
which work well. (HAN7101).
4. Glow Plug Wrench. A glow plug
wrench is 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, as
doing so invites injury. There are a
variety of electric starters on the
market. The Hangar 9 PowerPro-HD
12V Starter (HAN102) will work
perfectly on all of the twin-cylinder
Saito engines.
4
S TA R T I N G T H E E N G I N E
Break-In
The first run on any engine, wheter
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 bo 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), if applicable, and down
the pushrod 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 a break-in fuel as described in
the“Support Equipment”Section on
page 3 of this manual.
2. Use the proper glow plugs. Your
engine includes the Saito 400P
(SAIP400S glow plug(s), which are
also the standard replacement glow
plugs for these engines You can also use
Hanger 9’s Four Cycle Super Plug
(HAN3011).
3. Select the correct propeller. To do
so, refer to the Propeller Selection
Chart on page 18 of this manual.
4. Make sure that the high speed needle
valve(s)(85) are opened (turned
counterclockwise) five full turns. This
guarantees a very rich setting.
Do not adjust the low-speed needle
valve(s) or airbleed screws (89) at this
time. The low speed needle valve(s), or
airbleed screws, are pre-adjusted at the
factory for initial break-in.
5. The use of tachometer (HAN111) is
highly recommended since the
adjustment of a four-cycle engine:
while similar to that of a 2-cycle
engine, is more difficult to“set by ear,”
therefore making it easier to damage
the engine by“over leaning.”
S TA R T I N G T H E E N G I N E
Starting The Engine
1. Make sure the glow plugs are
installed and tightened.
2. Be sure the propeller is properly
secured. The use of a“jam nut”is
encouraged on 4-cycle engines.
3. Make sure the fuel tank
line(s) are properly connected, The
main line should be connected to the
carburetor nipple on the carburetor
spray bar
NOTE: If your Saito engine is
equipped with dual carburetors it’s
imperative that the fuel lines are
identical in length from the Y-fitting
to the fuel inlets.
Air out nipple
Vent line
Air intake nipple
Pressure adjusting valve
Excess pressure outlet
Figure 2 FA-300TTDP
Tank vent line
Connect the fuel tank lines as shown in
Figures 1,2 and 3.
Vent line
Breather
nipple
Figure 3 FA-100T
Connect this end of fuel tubing to the
nipple on the muffler conncected to the
rignt cylinder. This connection will carry
the fuel residue away from your aircraft.
Figure 1 FA-300TL
The proper“plumbing”of the lines
is extremely important to the
performance of any engine.
5
6
S TA R T I N G T H E E N G I N E
4. Be certain the mufflers are
installed properly by oiling the
threads and inserting the muffler
gasket(79) if applicable, and that the
lines are properly connected.
5. Fill the fuel tank.
6. Prime the engine:
• check to make sure the glow
plugs are not connected to the
heat source (glow plug
clip/locking socket)
• open throttle fully
• close choke valve(92), if
applicable
• rotate propeller in a counterclockwise direction 2-3 times
or until fuel begins to drain
from the carburetor
• open choke valve(92), if
applecable
NOTE: Instructions for the FA-90Ts
Flat Twin AAC 4 Stroke Engines. For
priming, inject approximate quantity of
fuel (about 1-2 cc) into the carburetor
with a syringe etc., as illustrated.
NOTE: This process is not
applicable for owners of the Saito
FA-182TD. Ibstead, remove the
aluminum stopper from the silicone
tubing leading to the right
cylinder/carburetor spray bar. Inject
approximately 5cc of fuel into the
silicone tubing. Replace the
aluminum stopper. Please refer to
Figure 4.
7. Start the engine:
• close the throttle to 1/4-1/3 open
position
• rotate propeller clockwise until it’s
against the compression stroke
• connect the heating source to the
glow plugs
Aluminum stopper
Right card spray bar
Figure4
FA-182TD
NOTE: It is not necessary to ignite
all four glow plugs in the dual
plugged versions (two glow plugs per
cylinder) of the Saito engines. It’s
only necessary to apply heat to the
two rear plugs. The front glow plugs
will ignite once the engine reaches
operating temperature.
NOTE: A very common error is to
remove the glow plug ignitor too
early. It is suggested that the ignitor is
left attached until after the engine has
been run up and the high speed needle
valve(s) has been properly adjusted.
S TA R T I N G T H E E N G I N E
• Using either the“Start stick”or
electric starter, spin the propeller
until the engine is running.
NOTE: When using an electric
starter, care should be taken to be sure
that the engine does not become
“hybro-locked.”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 plugs 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 heads.
8. Initial break-in:
Do not exceed 4,000 rpm for the first
ten(10) minutes of operation. This
allows all parts to mate properly with
good lubrication.
NOTE: Due to the excessively“rich”
mixture setting, it may be necessary
to leave the heat source attached to
the glow plugs.
Subsequent runs may be made while
slightly leaning out the mixture with
each tank full of fuel. Generally, 40
minutes is considered sufficient for
normal break-in prior to the first
flight.
9. After break-in:
7
If a test stand was used for the break-in
procedure, the engine may now be
mounted in the aircraft using the integral
motor mount and mounting hardware
supplied with the Saito engine.
NOTE: Always use the engine’s
mounting spacers. Place the mounting
spacer between the integral motor
mount and the firewall of the aircraft.
Engine mounting
spacer (washer)
Engine
Firewall
When tightening bolts, put washers between the engine mount and
firewall to minimize depression on the firewall and for reinforcement.
Figure 5
The spacers will minimize firewall
depression and serve to reinforce.
Soft mounting of Saito engines is not
required due to low vibration levels
found in the Saito twins. The idle
needle valve(s)(89) may now be
refined. Please refer to the Carburetor
Adjustments Section on pages 8 & 9
for infrmation on bow to do so.
The valves may be checked at this
time. Refer to the Engine
Maintenance Section on page 13 for
information on the valve adjustment.
8
E N G I N E
O P E R AT I O N
The use of a tachometer is encouraged
for setting the high-speed needle
valve(s)(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(s) counterclockwise.
Low Speed
Carburetor
Adjustments
The low speed, or idle needle
valve(s), or airbleed screws(s)(89),
is/are pre-adjusted 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.
2. Close the throttle slowly and adjust
the low speed setting by rotating the
needle valve(s)(89) clockwise to lean te
mixture and counterclockwise to richen
the mixture. The direction of rotation is
reversed for the Saito FA-100T and
FA-182TD. These engines are equipped
with airbleed style carburetors, rotating
the airbleed screw clockwise will richen
the mixture. If the airbleed screw is
rotated counterclockwise the mixture
will become lean.
NOTE: The fuel mixture is too rich if
when you open the throttle rapidly the
engine emits white smoke and“stutters”
or“stumbles.”Correct this by rotating
the idle needle valve(s) clockwise (or
airbleed screws counterclockwise) 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 when 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 idle needle
valve(s) counterclockwise (or airbleed
screws 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
counterclockwise rotations of the idle
needle valve(s) (or airbleed screws
clockwise), try turning the idle needle
valve clockwise (re airbleed screws
counterclockwise) in 1/4 to 1/2 turn
increments.
3. After obtaining the proper idle
setting, the low rpm setting can 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.
E N G I N E
FA-100T
FA-182TD
Dual Carburetor
Adjustment
Upon completing the break-in and
carburetor adjustment procedures
mentioned previously, the following
method should be utilized to balance
the dual carburetor Saito engines:
1. Start the engine and allow it to
warm up prior to attempting any
adjustments.
2. Rotate both high speed needle
valves clockwise an equal amount
until the engine reaches the peak rpm.
3. Back off both high speed needles
(rotate counterclockwise) equally until
the rpm drops by 300.
4. Rotate the high speed needle valve
clockwise on the right cylinder to peak
the engine. Next, rotate the needle
valve counterclockwise until an rpm
drop of 300 is noticed.
5. Repeat Step 4 for the left cylinder.
The cylinders of your Saito twin are
now correctly balanced.
O P E R AT I O N
9
FA-300TTDP Dual
Carburetor/Fuel
Pump Adjustment
Prior to starting the FA-300TTDP it’s
imperative that the fuel pump
connections are properly installed.
Please refer to Figure 2 on page 5.
High Speed Needle Valve
Adjustments
1. Start tne engine and allow it to
warm up prior to attempting any
adjustment.
2. Advance the engine to full throttle.
3. Rotate the high speed needle valve
of the right cylinder clockwise
(leaning the mixture) until the rpms
begin to sag or drop slightly. Then
richen the mixture for the right
cylinder by 4 or 5 clicks, not turns, of
the high speed needle valve. Rotate
the high speed needle valve of the left
cylinder clockwise (leaning the
mixture) until the rpms begin to sag or
drop slightly. Then richen the mixture
for the left cylinder by 4 or 5 clicks,
not turns, of the high speed needle
valve.
Again, lean the right cylinder by
turning the high speed needle valve
clockwise until the rpms begin to
drop. This time, however, richen the
10
E N G I N E
O P E R AT I O N
fuel mixture by rotating the high
speed needle valve counterclockwise
3 clicks. Lean the left cylinder by
turning the high speed needle valve
clockwise until the rpms begin to
drop. This time, however, richen the
fuel mixture by rotating the high
speed needle valve counterclockwise
3 clicks. The high speed needle
valve adjustments are now
completed.
Idle Needle Valve
Adjustment
1. Lower the throttle of the Saito FA300TTDP to the lowest possible idle
while retaining its reliability. Make sure
the carburetor linkage assembly is
secured to prevent movement of the
throttle levers.
2. Lean the right cylinder low speed
mixture screw (turning the screw
clockwise) until the rpms dorp off
slightly. Richen the low speed
mixture by turning the idle screw 1/8
to 1/4 turn counterclockwise. Lean the
left cylinder low speed mixture screw
(turning the screw clockwise) until
the rpms drop off slightly. Richen the
low speed mixture by turning the idle
screw 1/8 to 1/4 turn counterclockwise.
Fuel Pump Adjustment
See Figure 6.
Air out nipple
Vent line
Air intake nipple
Pressure adjusting valve
Excess pressure outlet
Figure 6 FA-300TTDP
1. Begin with the pressure adjusting
valve open 2 3/4 turns.
2. start the engine and allow it to
warm up prior to attempting any
adjustments.
3. Advance the engine to full
throttle.
4. Rotate the pressure adjusting valve
in 1/4 turn increments--first clockwise
1/ turn (rich) then rotate
4
counterclockwise 1/4 turn (lean) until
the best rpm is achieved. It’s
important to note that the pump
system has a definite response lag.
This lag is approximately 2-5
seconds. With each 1/4 turn change of
the pressure adjusting valve, allow
the engine rpm enough time to
stabilize. This will prevent“chasing”
of the correct setting.
E N G I N E
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 using
the motor mount and hardware kit
provided. Soft mounting of the Saito
twins is not necessary due to the
extremely low vibration level of these
engines. Please refer to Step 9 in the
Starting The Engine section for the
proper mounting procedure.
2. General operating procedures
which ensure long engine life are:
Do not operate the engine with a
“lean”mixture setting.
When installing the mufflers, oil both
the manifold threads and the engine
cylinder threads. Secure the mufflers
to the airframe using the muffler
brackets supplied.
NOTE: The muffler brackets are
not supplied with the FA-182TD.
Regularly check all screws and nuts
on both the engine and muffler.
O P E R AT I O N
11
After 1-2 hours of operation, valve
adjustment may be necessary. Adjust
the valves as shown in the Engine
Maintenance Section following.
For engines equipped with a breather
nipple, it’s recommended that a
length of silicone fuel tubing be
attached to this crankcase breather
nipple(19). This is used to route
away expelled oil from the engine
compartment.
Engine Maintenance
DO NOT DISMANTLE THE
ENGINE UNLESS ABSOLUTELY
NECESSARY.
If it becomes necessary to dismantle
your Saito engine, the following
procedure should be followed:
It’s important to maintain identification
of the“left”and“right”cylinder parts
when dismantling and reassembling the
engine. Looking forward from the rear
of the engine with the engine upright, the
cylinder on the right side is indeed the
right cylinder. Therefore, the cylinder to
the left is, of course, the left cylinder.
1. Cylinder and cam housing screws
should be loosened in a criss-cross
pattern.
12
ENGINE
MAINTENANCE
2. Cam Gear Alignment-Refer to the
specific section below pertaining to
your Saito engine.
it’s important that neither the
crankshaft nor the cam gear are
moved from their alignment marks.
Refer to Figure 9.
FA-60T/90TS
a. The crankshaft alignment mark
should line up with the crankcase
mark when the crankshaft is at the top
dead center. Refer to Figure 7.
NOTE: Crankshaft
alignment mark and
cam gear reference
mark are aligned with
their respective
crankcase marks.
This is extremely
important.
Crankshaft
alignment
mark
Crankcase
mark
Figure 9 Finished assembly
FA-100T/FA-182TD
Figure 7
b. Locate the cam gear reference
mark and align it with the crankcase
mark. See Figure 8.
Crankcase
alignment
mark
Camgear
reference
mark
Figure 8
c. Be sure there is a spacer on the
counter gear shaft. Next, insert the
counter gear onto the shaft, followed
by another spacer. During this step
a. Viewing the engine from the rear
and looking forward, adjust the cam
timing beginning with the right
cylinder.
b. Position the cam gear timing mark
(dot) at the 9 o’clock position
(directly into the crankcase) with the
right piston at top dead center. Secure
the right cam gear housing in place.
c. Rotate the crankshaft counterclockwise 180 degrees, placing the
left piston at top dead center. Refer to
Figure 10.
ENGINE
MAINTENANCE
13
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.
Figure 10
d. Position the left cam gear timing
mark (etched line) at the 3 o’clock
position (directly into the crankcase)
and secure the left cam gear housing.
See Figure 11.
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.
5. Adjust the valves to a clearance of
.03mm-.10mm (.002''-.004'') using
the supplied gauge. The valves must
be adjusted with the engine cold due
to thermal expansion.
Figure 11
NOTE: Valves must be in the closed
position.
NOTE: When tightening the cam
gear housing bolts, apply a drop of oil
to each bolt to prevent thread
damage. Also, tighten the bolts in a
criss-cross pattern to avoid warping.
FA-300TL/FA-300TTDP
e. Follow the same procedure as
described for the FA-100T/FA130TD/FA
-182TD. However, instead of rotating the
crankshaft 180 degrees, rotate the
crankshaft 360 degrees to place the left
piston at the top dead center.
Figure 12 Tappet adjustment
Carburetor
Maintenance
Should you experience difficulty with
the carburetor of your engine:
14
CARBURETOR MAINTENANCE
1. Remove the high speed needle(s)
(85) and flush out the spray bar with
clean fuel. Replace the high speed
needle(s) and follow the instructions
in the carburetor adjustment section.
2. Always use a high-quality 4-cycle
glow plug. The Hangar 9/McCoy
MC-4C is highly recommended.
Tips For Extended
Engine Life
To add longer life to your Saito engine,
we recommend the following:
1. Use a fuel containing 20%
lubricants.
2. Use the 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.
6. For long-term storage, make sure
there is no fuel left in the tank and the
engine. Remove the glow plug and
apply several drops of high-quality
oil (i.e., Marvel Air Tool Oil) to the
top of the engine, down the pushrod
tubes, and through the crankcase
pressure vent if applicable. 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.
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 chart on the
following page.
T R O U B L E S H O O T I N G
15
SYMPTOM
CAUSE
CORRECTIVE ACTION
Engine fails to
fire
Low voltage on starting
battery
Replace/recharge the starting
battery
Bad glow plug(s)
Inspect/replace bad glow plug(s)
Insufficient priming
Repeat priming procedure
“Flooded”due to
excessive priming
Disconnect battery, remove glow
plugs, and rotate propeller several
times to“clear”cylinder
Over primed
Disconnect battery and rotate
propeller several times to
“clear”cylinder
Incorrect glow
plugs
Remove plugs and verify
proper heat range
Engine starts but
slows down and
then stops
Mixture too rich
Close high speed needle valve(s)
1/2 turn and start again. Repeat
until engine is running smoothly.
Engine starts,
speeds up, and
then quits
Mixture too lean
Open high speed needle valve(s)
1/2 turn and start again. Repeat
until engine is running smoothly.
Engine quits
when starter
battery is
removed
Mixture too rich
Close high speed needle valve(s)
1/2 turn and restart
Incorrect glow plugs
Change glow plugs
Incorrect or bad fuel
Change fuel
Plug
Change plug type
Engine fires but
does not run
Rough idle
In the event that none of the above procedures results in the engine running
properly, contact our service department for suggestions at:
Horizon Service Center
4105 Fieldstone Road
Champaign, Illinois 61822
217-355-9511 (Mon-Fri 8:00-5:00 CST)
16
T R O U B L E S H O O T I N G
TWIN CYLINDER CROSS REFERENCE CHART (2006)
ITEM
01 Cylinder, Left
02 Cylinder, Right
06 Piston
07 Piston Pin
08 Piston Pin Ret
09 Piston Ring
10 Con Rod
11 Linked Con Rod
12 Conrod Linkpin/Scr
13 Con Rod Screw
14 Cyl Screw Set
15 Crankcase
17 Rear Cover(A)
18 Rear Cover(B)
19 Breather Nipple
20 Frt Ball Bearing
21 Main Ball Bearing
22 Rear Ball Bearing
23 Crankshaft
24 Pinion-crankshaft
25 Pinion gear pin
26 Collar, Crankshaft
27 Tapered Collet & Drv
28 Prop Wash/Nut
29 Prop Nut Spinner
30 Prop Nut Elect
31 Crankcase Screw S
32 Eng Gasket Set
33 Cam Gear Housing
34 Cam Gear Left
35 Cam Gear Right
36 Cam Gear Shaft
37 Tef/Steel Wash Set
38 Tappet
39 Pushrod
40 Push Rd Cvr Rb sea
41 Rocker Arm
42 Rckr arm scrw nut
43 Rckr arm pin
44 Rckr arm brak left
45 Rckr arm brak right
46 Valve in/out
47 Vlv spg/kpr/rtr
48 Vlv Retainer
49 Rocker Arm Cover
52 Counter Gear
53 Counter Gear Shft
64 Air pump Assy
65 Air pump housing
66 Dlap/chk vlv rbr set
67 Dlap/push rd/retn sp
68 Check valve in/out
69 Intake manifold, rt
70 Intake manifold, lft
71 Intake manifold nut
P
FA-60T
60T01A
60T02A
60T06A
60T07
5008
60T09
60T10
*
*
60T13
60T14
60T15
60T17
60T18
6519
5020A
60T21
60T22
60T23A
*
*
*
60T27
5628
*
5030A
60T31
60T32
*
*
60T35
*
60T37
5038
60T39
60T40
60T41
60T42
60T43
*
*
60T48
5047
5048
60T49
325R552
60T53
*
*
*
*
*
60T69
60T70
60T71
LL
FA-90TS
90TS01
90TS02
90TS06
4507A
5008
45S09
90TS10
*
*
90TS13
60T14
90TS15
90TS17
90TS18
6519
5020A
60T21
60T22
90TS23A
*
*
*
60T27
5628
*
5030A
60T31
60T32
*
*
60T35
*
60T37
5038
90TS39
90TS40
60T41
60T42
60T43
*
*
90TS46
5047
5048
60T49
325R552
60T53
*
*
*
*
*
90TS69
90TS70
100T71
AA
FA-100T
100T01
100T02
5006
5007
5008
5009
100T10
100T11
*
*
5014
100T15
*
*
5019
100T20A
*
100T22A
100T23A
100T24
5025
100T26
6527
5628
*
5030A
100T31
100T32A
5033A
130T34
5035
5036A
5037
5038
5039
5040
5041
5042
5043
*
*
5046
5047
5048
5049A
*
*
*
*
*
*
*
100T69
100T70
100T71
DD
FA-182TD
182TD01
182TD02
91S06
91S07
6508
91S09
182TD10
182TD11
*
*
6514
182TD15
*
*
6519
182TD20
*
182TD22
182TD23A
*
*
*
120S27A
170R328
120S29
120S30
182TD31
182TD32A
182TD33A
182TD34
6535A
182TD36A
5037
5038
91S39
60T40
5041
60T42
5043
*
*
91S46
6547
5048
5049A
*
*
*
*
*
*
*
182TD69
182TD70
182TD71
Z
FA-300TL
300T01A
300T02A
300T06A
120S07
300T08
300T09A
300T10C
*
*
300T13
120S14A
300T15B
300T17
*
6619
300T20A
300T21
300T22
300T23D
*
*
*
300T27B
300T28B
*
*
300T31
300TL32A
300T33
300T34
120S35
5036A
120S37
120S38
300T39
300T40A
120S41
300T42
120S43
120S44
120S45
120S46
300T47
120S48
120S49
*
*
*
*
*
*
*
300TL69A
300TL70B
300TL71
W
FA-300TTDP
300TTDP01A
300TTDP02A
300T06A
120S07
300T08
300T09A
300T10C
*
*
300T13
120S14A
300T15B
300T17
*
*
300T20A
300T21
300T22
300T23D
*
*
*
300T27B
300T28B
*
*
300TTDP31
300TTDP32A
300T33
300T34
120S35
5036A
120S37
120S38
300T39
300T40A
120S41
300T42
120S43
120S44
120S45
120S46
300T47
120S48
120S49
*
*
*
*
*
*
130T68A
*
*
*
P
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17
TWIN CYLINDER CROSS REFERENCE CHART (2006)
ITEM
72 Intake manif w/prim
73 Muffler, Left
74 Muffler, Right
79 Muffler gasket
80 Muffler nut
81 Priming hamess
821 Carb comp left
822 Carb comp Right
831 Carb body assy lft
832 Carb body assy rt
84 Spray bar assy
85 High spd need vlv
86 High spd nd vlv ext
87 Throttle barr assy
88 Throttle lever
89 ldle needle valve
90 Carb scr/spring set
91 Carb gasket set
92 Choke Valve assy
93 Intake velocity stk
94 Glow plug harness
95 Engine mount
96 Tool set
97 Instruction Manual
99 Muffler bracket
101 Twin carb cont asy
102 Fuel pump system
103 Carb fitt flange/scr
104 Cam gear ber, rear
105 Cam gear ber, Frt
106 Cam gear ber shiel
107 Carb bracket
109 Fuel Fillter
110 Anti-loos Prop nut
111 Flex Exh Pipe
116 M3 Nut for spinner
117 M4 Nut
118 M5 Nut
119 Rear Cvr/w int mm
120 SAIP400S Glow pl
121 Crank pin spacer
122 Spr bar w/p2/p5
123 Rub bush PRC U
124 Rub bush PRC L
125 Muffler (right) Opt
126 Needle stopper/nut
131 Thro Vlv Ext Adpt
135 Prop w/nut/entl nu
139 Valve Guide
140 Muff Rt Angle Adp
143 Flex exh pipe w/2n
145 Spbr w/int P2“O”
147 Carburelor nipple
P
FA-60T
*
60T73B
60T74B
60T79
60T80
*
60T821C
*
60T831A
*
60T84
60T85
5086
60T87A
60T88B
60T89
60T90A
60T91
60T92
*
60T94
60T95A
60T96
saiman2
60T99
*
*
*
60T104
60T105
60T106
*
50109
56110
*
50116
65117
65118
*
50120B
*
60T122
50123
50124
*
50126
*
56135
50139
100Ti140
50143
*
30S147
LL
FA-90TS
*
90TS73
90TS74
60T79
60T80
*
90TS821C
*
90TS831
*
60T84
90TS85
5086
90TS87A
60T88B
60T89
90TS90A
90TS91
*
*
60T94
60T95A
60T96
saiman2
60T99
*
*
*
60T104
60T105
60T106
*
50109
56110
*
*
65117
65118
50120B
*
60T122
50123
50124
*
50126
90TS131
56135
50139
100Ti140
50143
*
30S147
AA
FA-100T
*
100T73
100T74
60T79
60T80
*
100T821
*
100T831
*
*
100T85
100T86
100T87
100T88
100T89
100T90
100T91
100T92
*
60T94
*
100T96
saiman2
60T99
*
*
*
*
*
*
*
50109
56110
*
*
65117
65118
100T119B
50120B
100T121
100T122
50123
50124
*
56135
50139
100Ti140
50143
*
100T147
DD
FA-182TD
*
182TD73
182TD74A
325R579
325R580
182TD81
182TD821
*
182TD831
*
*
182TD85
100T88
182TD87
182TD88
182TD89
182TD90
182TD91
*
182TD93
300T94
*
182TD96
saiman2
300T99A
*
*
*
*
*
*
*
50109
170R3110
182TD111
*
120S117
120S118
182TD119
50120B
*
*
50123
50124
*
50126
*
170R3135
65139
65140
65143
*
30S147
Z
FA-300TL
*
300T73B
300T74B
300T79
300T80
*
300T821C
*
300T831B
*
450R3D84A
120S85A
5086
300T87A
300T88A
120S89
120S90A
300T91A
120S92
120S93
300T94
325R595A
300T96
saiman2
300T99A
*
*
*
*
*
*
300TL107
50109
300T110
*
*
*
*
*
50120B
*
*
300T123
120S124
*
120S126
*
300T135
120S139
120S140
120S143
120S145
30S147
W
FA-300TTDP
*
300T73B
300TTDP74B
300T79
300T80
*
300TTDP821B
300TTDP822B
300TTDP831A
300TTDP832A
450R3D84A
120S85A
100T86
300TTDP87A
300TTDP88A
120S89
120S90A
300TTDP91
120S92
120S93
300T94
325R595A
300TTDP96
saiman2
300T99A
300TTDP101
300TTDP102
300TTDP103
*
*
*
*
50109
300T110
*
*
*
*
*
50120B
*
*
300T123
120S124
*
120S126
*
300T135
120S139
120S140
120S143
120S145
30S147
18
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Remember, it is imperative to balance
each propeller prior to installation onto
your Saito engine.
Failure to do so may cause unwanted
vibration in your aircraft.
Propeller Selection
Below you will find a propeller
selection chart. This chart will enable
you to select the best propeller for
initial set-up of your Saito engine.
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 ease in identifying your engine.
Saito Twin Cylinder Prop Chart
NOTE: All recommendations are based on engines using APC props, Power Master 15%
2-stroke fuel, and Saito SAIP 400S glow plugs.
ENGINE
SPORT
SCALE
FA-60T
10×6, 10×7
11×5, 11×6, 12×4
2,000-10,500 rpm
11×5, 11×6, 12×5
12×5
12×8, 13×6, 13×8
13×8, 14×6
12×8, 13×6, 14×6
14×6
FA-182TD
14×12, 14×10,15×10
16×6, 16×8, 16×10
2,000-10,500 rmp
15×8, 16×6, 16×8
18×6
FA-300TL/300TTDP
18×10, 20×8, 20×10
20×8, 20×10, 22×8
2,000-5,000 rpm
20×12, 22×8, 22×10
22×10, 24×8
FA-90TS
2,000-10,000 rpm
FA-100T
2,000-10,500 rpm
NOTE: Observe operating rpm ranges as excessive rpm can result in damage to the engine.
PROPELLER SELECTION
19
OUTSIDE DIMENSIONS (mm)
Items
A
B1
B2
C
D
E
F
FA-60 Twin Cylinder
61
10
43
125
160
64
50
FA-90TS Twin Cylinder
61
10
42
121
170
64
52
FA-100 Twin Cylinder
50
35
35
100
169
80
63
FA-182 Twin Cylinder/Dual Plugs/Dual Carb
70
28
28
133
195
81
73
FA-300 Twin Cylinder
112
30
49
175
233
92
83
FA-300 Twin Cylinder/Dual Plugs/Fuel Pump/Dual Carb 112
30
49
175
233
102
83
K
(ISO)
Cylinder
HP
0.9
SPECIFICATIONS
Items
Disp Bore Stroke Weight
(cc) (mm) (mm)
(g)
FA-60 Twin Cylinder
10.0
20.0
16.0
750
M7x1
5ccx2 ABC
FA-90TS Twin Cylinder
14-98
22.4
19.0
723
M7x1
7.4x2AAC
1.4
FA-100 Twin Cylinder
16.4
23.4
19.0
820
M7x1
8.2ccx2 ABC
1.6
2.8
FA-182 Twin Cylinder/Dual Plugs/Dual Carb 29.98
28.2
24.0
1,040
M8x1.25
14.99ccx2 AAC
FA-300 Twin Cylinder
50.0
34.0
28.0
1,750
M10x1.25
25ccx2 AAC
4.7
FA-300 Twin Cylinder/Dual Plugs/Fuel Pump/Dual Carb
50.0
34.0
28.0
1,800
M10x1.25
25ccx2 AAC
4.8
20
E N G I N E
FA-60T
S P E C S
P
FA-90TS
A
R
T
S
L
I
S
T
21
22
P
A
FA-100T
R
T
S
L
I
S
T
P
FA-182TD
A
R
T
S
L
I
S
T
23
24
P
A
R
T
FA-300TL
FA-300TTDP
S
L
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25
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 overrevving 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:
• Nitro content and brand of fuel
1. Ship your engine, freight prepaid,
• Propeller size and brand used
in its original box packed inside a
• Type of glow plug used
sturdy shipping container, to:
• Type of engine mount
• Approximately how much running
Horizon Service Center
time the engine had before
Attn: Saito Service
experiencing the difficulty
4105 Fieldstone Road
Champaign, IL 61822
Date your correspondence and be
Phone:(217)355-9511
sure your name and address appear
on this enclosure. Also, include a
Include complete name and address
phone number where you can be
information inside the carton, as well
reached during the business day.
as clearly writing it on the outer
label/return address area.
2. Include a note containing a brief
summary of the difficulty
experienced and include the
following information:
26
W A R R A N T Y & R E P A I R
3. Warranty Repairs
To receive warranty service you
must include your original dated
sales receipt to verify your proofof-purchase date. Providing that
warranty conditions have been
met, your engine will be repaired
without charge.
4. 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.
5. Please advise us of the payment
method you prefer to use. Please
specify VISA or MasterCard, or
we can return C.O.D. cash only. If
you prefer to use a credit card,
include your card number and
expiration date.
The consumer warranty
registration card in this manual
must be completely filled out and
mailed to:
Horizon Service Center
Attn: Saito Warranty
4105 Fieldstone Road
Champaign, IL 61822
Please cut on dotted line.
City/State/Zip
Street Address
Dealer'S Name
Purchased From:
Daytime Phone Number
City/State/Zip
Street Address
Owner's Name
Date of Purchase
Engine Type
Complete this form and mail along with your dated sales receipt (send copy, keep original for your files) within 10
days of purchase to: Horizon Service Center
Attn: Saito Warranty Dept.
4105 Fieldstone Road
Champaign, IL61822
Consumer Warranty Registration
Exclusively Distributed by Horizon Hobby, Inc.
Champaign, IL61822
© Copyright 2006
Stock#SAIMAN2
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