SAITO FA 60T, FA 90TS, FA 100T, FA 130TD, FA 182TD, FA 300TL, FA 300TTDP Engine Instruction manual

T

WIN

-C

YLINDER

F

OUR

-S

TROKE

E

NGINES

INSTRUCTION MANUAL

• FA-60T

• FA-90TS

• FA-100T

• FA-130TD

• FA-182TD

• FA-300TL

• 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.

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. 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.

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.

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

“chicken stick” or electric starter to start the engine.

8. Make all carburetor adjustments 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

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.

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 to 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 harmful 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.

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. 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 2cycle 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.

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.

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 “chicken stick” 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 12V Heavy-

Duty Super Starter (HAN110) will work perfectly on all of the twincylinder Saito engines.

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.

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 Hangar 9/McCoy

MC-4C (HAN3010) glow plugs, which are also the standard replacement glow plugs for these engines.

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 preadjusted at the factory for initial break-in.

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,” therefore making it easier to damage the engine by “over leaning.”

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 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 spray bar (84).

Air out nipple

Air intake nipple

Pressure adjusting valve

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.

Connect the fuel tank lines as shown in

Figures 1, 2 and 3.

Tank vent line

Excess pressure outlet

Figure 2

FA-300TTDP

Vent line

Vent line

Breather nipple

Figure 3

FA-100T

Connect this end of fuel tubing to the nipple on the muffler conncected to the right 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.

6

S T A 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 applicable

NOTE: The 90-TS is primed by inserting approximately 1–2cc of fuel into the priming nipple on the carburetor with a syringe.

NOTE: This process is not applicable for owners of the Saito

FA-130 and FA-182TD. Instead, 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 carb spray bar

Figure 4

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

7

• Using either the “chicken 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

“hydro-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

“chicken 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:

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

Engine mounting spacer (washer)

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 information on how 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 A T 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 the 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 (or 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 O P E R A T I O N

9

FA-100T/

FA-130TD/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.

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 the 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 A T 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 FA-

300TTDP 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 drop off slightly. Richen the low speed mixture by turning the idle screw

1 to

1

/

8

/

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

Air intake nipple

Pressure adjusting valve

Vent line

Figure 6

Excess pressure outlet

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

1

/

4 turn increments—first clockwise

/

4 turn (rich) then rotate 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 O P E R A T I O N

11

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-130TD or FA-182TD.

Regularly check all screws and nuts on both the engine and muffler.

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

E N G I N E M A I N T E N A N C E

2. Cam Gear Alignment–Refer to the specific section below pertaining to your Saito engine.

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.

Crankshaft alignment mark

Crankcase mark

it’s important that neither the crankshaft nor the cam gear are moved from their alignment marks.

Refer to Figure 9.

NOTE: Crankshaft alignment mark and cam gear reference mark are aligned with their respective crankcase marks.

This is extremely important.

Figure 9

Finished assembly

Figure 7

b. Locate the cam gear reference mark and align it with the crankcase mark. See Figure 8.

Figure 8

Crankcase alignment mark

Camgear reference mark

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

FA-100T/FA-130/FA-182TD

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.

E N G I N E M A I N T E N A N C E

13

1st (Right cylinder)

Proper crankshaft position

Pinion gear

Bench mark

Cam gear

Figure 10

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.

2nd (Left cylinder)

Revolution

Cam gear Bench mark Pinion gear

Figure 11

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/FA130 TD/ 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.

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.

5. Adjust the valves to a clearance of

.03mm–.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 closed position.

Tappet Adjustment

Adjust between

0.03 - 0.10 mm (.002" - .004")

Gauge

(0.1 mm Max.)

Figure 12

Tappet adjustment

Carburetor

Maintenance

Should you experience difficulty with the carburetor of your engine:

14

C A R B U R E T O R M A I N T E N A N C E

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

Engine fails to fire

Engine fires but does not run

Low voltage on starting battery

Bad glow plug(s)

Insufficient priming

“Flooded” due to excessive priming

Over primed

Engine starts, speeds up, and then quits

Incorrect glow plugs

Engine starts but

Mixture too rich

slows down and then stops

Mixture too lean

Engine quits when starter battery is removed

Mixture too rich

Incorrect glow plugs

Incorrect or bad fuel

Replace/recharge the starting battery

Inspect/replace bad glow plug(s)

Repeat priming procedure

Disconnect battery, remove glow plugs, and rotate propeller several times to“clear” cylinder

Disconnect battery and rotate propeller several times to

“clear” cylinder

Remove plugs and verify proper heat range

Close high speed needle valve(s)

1/2 turn and start again. Repeat until engine is running smoothly.

Open high speed needle valve(s)

1/2 turn and start again. Repeat until engine is running smoothly.

Close high speed needle valve(s)

1/2 turn and restart

Change glow plugs

Change fuel

Rough idle

Plug Change plug type

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)

PART

01 Cylinder, Left

02 Cylinder, Right

06 Piston

07 Piston Pin

08 Piston Pin Retainer (6 Pc)

09 Piston Ring

10 Connecting Rod

11 Linked Connecting Rod

13 Connecting Rod Screw

14 Cylinder Screw Set

15 Crankcase

17 Rear Cover (A)

18 Rear Cover (B)

19 Breather Nipple

20 Front 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 & Drive Flange

28 Prop Washer & Nut

29 Prop Nut, Spinner

30 Prop Nut, Electric Starter

31 Crankcase Screw Set

32 Engine Gasket Set

33 Cam Gear Housing

34 Cam Gear, Left

35 Cam Gear, Right

36 Cam Gear Shaft

37 Teflon/Steel Washer Set

38 Tappet (2 Pc)

39 Pushrod (2 Pc)

40 Pushrod Cover Rubber Seal (Pr)

41 Rocker Arm (Pr)

42 Rocker Arm Screw Nut (2 Sets)

43 Rocker Arm Pin (2 Pc)

44 Rocker Arm Bracket, Left

45 Rocker Arm Bracket, Right

46 Valve-In/Out (Pr)

47 Valve Spring, Keeper, Retainer (2 Sets)

48 Valve Retainer (4 Pc)

49 Rocker Arm Cover (Pr)

52 Counter Gear

53 Counter Gear Shaft

16

T R O U B L E S H O O T I N G

Twin Cylinder Cross Reference Chart

LL

FA-90TS

60T31

60T32

—

—

60T35

—

60T37

5038

90TS39

60T22

90TS23

—

—

—

60T27

5628

—

5030A

90TS40

60T41

5042

60T43

—

—

90TS46

5047

5048

60T49

325R552

60T53

—

90TS13

60T14

90TS15

90TS17

60T18

6519

5020A

60T21

90TS01

90TS02

90TS06

4507A

5008

45S09

90TS10

P

FA-60T

60T31

60T32

—

—

60T35

—

60T37

5038

60T39

60T22

60T23

—

—

—

60T27

5028

—

—

60T40

60T41

4042

60T43

—

—

60T46

5047

5048

60T49

325R552

60T53

—

60T13

60T14

60T15

60T17

60T18

60T19

60T20

60T21

60T01

60T02

60T06

60T07

4008

60T09

60T10

AA

FA-100T

90T31

90T32

5033A

130T34

5035

4036

90T37A

5038

5039

4022

100T23

4024

4025

90T26

6527

5028

—

5030

5040

4041

4042

4043

—

—

5046

5047

5048

40S49

—

—

100T01

100T02

5006

5007

4008

5009

90T10

90T11

—

4014

100T15

—

—

4019

65GK20

—

—

91546

6547

5048

40S49

—

—

—

182TD31

182TD32

182TD33

182TD34

6535A

182TD36

182TD37

5038

91539

60T40

4041

4042

4043

—

130T31

130T32

130T33A

130T34

5035

4036

90T37A

5038

6539

6522A

130T23

—

—

—

130T27A

12028A

12029

—

—

6546

6547

5048

4049

—

—

6540

4041

4042

4043

—

130T11

—

6514

130T15

130T17

—

4019

8020

—

130TD01A

130TD02A

6506

6507

6508

6509

130T10

S DD Z

FA-130TD FA-182TD FA-300TL

182TD01

182TD02

91506

91507

6508

91509

182TD10

182TD11

—

6514

182TD15

—

—

6519

1827D20

—

182TD22

182TD23

—

—

—

12507

12028A

270T22

270T23B

—

—

—

270T27B

270T28A

—

—

300T31

300TL32A

300T33

300T34

120S35

4036

120S37

120S38

300T39

300T40

12041

300T42

12043

12044

12045

120S46

300T47

120S48

120S49

—

—

300T01

300T02

300T06A

12007

300T08

300T09A

270T10C

—

270T13

12014

270T15A

270T17A

—

4019

270T20

270T21

W

FA-300TTDP

270T22

270T23B

—

—

—

270T27B

270T28A

—

—

270TTDP31

300TTDP32

300T33

300T34

120S35

4036

120S37

120S38

300T39

300T40

12041

300T42

12043

12044

12045

120S46

300T47

120S48

120S49

—

—

300TTDP01A

300TTDP02A

300T06A

12007

300T08

300T09A

270T10C

—

270T13

12014

270T15A

270T17A

—

—

270T20

270T21

Twin Cylinder Cross Reference Chart

P A R T S L I S T

17

PART P

FA-60T

LL

FA-90TS

64 Air Pump Assembly

65 Air Pump Housing

66 Diaphragm & Check Valve Rubber Set

67 Diaphragm, Pushrod, Return Spring

68 Check Valve-In/Out (Pr)

69 Intake Manifold, Left

70 Intake Manifold, Right

71 Intake Manifold Nut

72 Intake Manifold w/Primer

73 Muffler, Left

74 Muffler, Right

79 Muffler Gasket (5 Pc)

80 Muffler Nut (2 Pc)

81 Priming Harness

821 Carburetor-Complete, Left

822 Carburetor-Complete, Right

831 Carburetor Body Assembly, Left

832 Carburetor Body Assembly, Right

84 Spray Bar Assembly

85 High Speed Needle Valve

60T831

—

130T84

130T85

86 High Speed Needle Valve Extension 4086

87 Throttle Barrel Assembly 60T87

88 Throttle Lever

89 Idle Needle Valve

60T88

130T89

90 Carburetor Screw & Spring Set

91 Carburetor Gasket Set

92 Choke Valve Assembly

93 Intake Velocity Stack

94 Glow Plug Harness

95 Engine Mount

96 Tool Set

99 Muffler Bracket

60T90

60T91

60T92

—

90T94

60T95

60T96

60T99

—

60T73B

60T74B

4079

4080

—

60T821

—

—

—

—

—

—

60T69

60T70

60T71

101 Twin Carburetor Control Assembly

102 Fuel Pump System

—

—

103 Carburetor Fitting Flange w/Screw —

104 Cam Gear Bearing, Rear 60T104

105 Cam Gear Bearing, Front

106 Cam Gear Bearing Shield

107 Carburetor Bracket

109 F-1 Fuel Filler

60T105

60T106

—

40109

—

—

—

60T104

60T105

60T106

—

—

110 Anti-Loosening Prop Nut

116 M3 Nut for Spinner

117 M4 Nut for Spinner

118 M5 Nut for Spinner

—

—

65117

65118

56-110

—

—

—

119 Rear Cover w/Integrated Motor Mount —

121 Crank Pin Spacer, Teflon —

MAN Saito Twin Cylinder Manual

—

—

SAIMAN2 SAIMAN2

60T90

90TS91

—

—

—

60T95

60T96

60T99

90TS831

—

60T84

90TS85

5086

90TS87

325R588

60T89

—

—

—

—

—

90TS69

90TS70

100T71

—

90TS73

90TS74

—

60T80

—

90TS821

—

S

FA-130TD

130T831A

—

130T84

130T85

90T86

130T87A

130T88

130T89

130T90

130T91

—

—

90T94

130T95A

130T96A

—

130T64C

130T65B

130T66B

130T67A

130T68A

130T69

—

—

130T72A

130T73

130T74

130T79

325R580

130T81A

130T821

—

—

—

—

—

—

—

—

40109

—

—

65117

65118

—

—

SAIMAN2

AA

FA-100T

90T90

90T91

90T92

—

90T94

—

90T96A

60T99

90T831

—

90T84

90T85

90T86

100T87

90T88

90T89

130T64C

100T65B

130T66B

130T67A

130T68A

90T69

90T70

90T71

—

100T73

100T74

4079

4080

—

100T821

—

—

—

—

—

—

—

—

40109

—

—

65117

65118

100T119

100T121

SAIMAN2

DD Z

FA-182TD FA-300TL

300TL831B

—

120S84

12085

4086

300TL87

300TL88A

120S89

300TL90A

300TL91

120S92

12093

270T94

325R595A

270T96AB

270T99A

—

—

—

—

—

300TL69A

300TL70B

300T71

—

270T73B

270T74B

12079

12080

—

300TL821B

—

—

—

—

—

—

—

300TL107

40109

270T110

—

—

—

—

—

SAIMAN2

—

—

12085

90T86

182TD87

182TD88

182TD88

182TD90

182TD91

—

182TD93

90T94

—

182TD96

270799A

—

—

—

—

—

182TD69

182TD70

182TD71

—

182TD73

182TD74

6579

6580

182TD81

182TD821

—

182TD831

—

—

—

—

—

—

—

—

—

—

—

—

182TD119

—

SAIMAN2

W

FA-300TTDP

270TDP831A

270TDP832A

120S84

12085

90T86

270TTDP87

270TTDP88

120S89

270TDP90A

270TTDP91

270TTDP92

12093

270T94

325R595A

270TTDP96

270T99A

—

—

—

—

130T68A

—

—

—

—

270TTDP73B

270TTDP74B

12079

12080

—

270TDP821A

270TDP822A

270TTDP101

120SDP102

270TTDP103

—

—

—

—

40109

270T110

—

—

—

—

—

SAIMAN2

18

P A R T S L I S T

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.

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.

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 McCoy MC-4C glow plugs.

ENGINE SPORT SCALE

FA-60T

2000–10,500 rpm

FA-90TS

2,000–10,000 rpm

FA-100T/130TD

2000–10,500 rpm

FA-182TD

2000–10,500 rpm

FA-300TL/300TTDP

2000–6000 rpm

10x6, 10x7

11x5, 11x6, 12x5

12x8, 13x6, 13x8

12x8, 13x6, 13x8

14x6

14x12, 14x10, 15x10

15x8, 16x6, 16x8

18x10, 20x8, 20x10,

20x12, 22x8, 22x10

11x5, 11x6, 12x4

12x5

13x8, 14x6

13x8, 14x6, 14x8

15x4, 15x5

16x6, 16x8, 16x10

18x6

20x8, 20x10, 22x8

22x10, 24x8

NOTE: Observe operating rpm ranges as excessive rpm can result in damage to the engine.

P R O P E L L E R S E L E C T I O N

19

F

D

K

E

A

B1

B2

C

OUTSIDE DIMENSIONS (mm)

Items A B1

FA-60 Twin Cylinder

FA-90TS Twin Cylinder

FA-100 Twin Cylinder

FA-130 Twin Cylinder/Dual Plugs

FA-182 Twin Cylinder/Dual Plugs/Dual Carb

FA-300 Twin Cylinder

70

112

FA-300 Twin Cylinder/Dual Plugs/Fuel Pump/Dual Carb 112

61

61

50

78

28

30

30

10

10

35

30

B2

28

49

49

43

42

35

43

C

125

121

100

131

133

175

175

D

160

170

169

188

195

233

233

E

81

92

102

64

64

80

82

F

73

83

83

50

52

63

68

SPECIFICATIONS

Items Disp Bore Stroke Weight

(cc) (mm) (mm) (g)

FA-60 Twin Cylinder

FA-90TS Twin Cylinder

FA-100 Twin Cylinder

FA-130 Twin Cylinder/Dual Plugs

10.0

14-98

16.4

21.2

FA-182 Twin Cylinder/Dual Plugs/Dual Carb

FA-300 Twin Cylinder

29.98

50.0

FA-300 Twin Cylinder/Dual Plugs/Fuel Pump/Dual Carb 50.0

20.0

22.4

23.4

24.8

28.2

34.0

34.0

16.0

19.0

19.0

22.0

24.0

28.0

28.0

750

723

820

1,300

1,040

1,750

1,800

K

(ISO)

Cylinder HP

M7x1

M7x1

M7x1

M8x1.25

5ccx2 ABC 0.9

7.4x2AAC

1.4

8.2ccx2 ABC 1.6

10.6ccx2 ABC 1.9

M8x1.25

14.99ccx2 AAC 2.8

M10x1.25

25ccx2 AAC 4.7

M10x1.25

25ccx2 AAC 4.8

20

E N G I N E

FA-60T

S P E C S

52

37

53

32

17

31

92

85

35

104

90

31

79

90A

70

19

83

91

69

32

71

02

28

27

20

87

89

21

13

23

74

106

105

38

15

80

40

10

08

07

06

09

46

39

79

73

47

41

42

22

95

31

14

18

32

14

01

32

43

49

37

FA-90TS

P A R T S L I S T

21

22

P A R T S

FA-100T

L I S T

FA-182TD

P A R T S L I S T

23

24

P A R T S

FA-300TL

L I S T

FA-300TTDP

P A R T S L I S T

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:

1. Ship your engine, freight prepaid, in its original box packed inside a sturdy shipping container, to:

• Nitro content and brand of fuel

• Propeller size and brand used

Horizon Service Center

Attn: Saito Service

4105 Fieldstone Road

Champaign, IL 61822

Phone: (217) 355-9511

• Type of glow plug used

• Type of engine mount

• Approximately how much running time the engine had before experiencing the difficulty

Include complete name and address 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.

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

Exclusively Distributed by Horizon Hobby Distributors, Inc.

Champaign, IL 61822

© Copyright 1999 Stock #SAIMAN2