CONTENTS - RCJapan
It is of vital importance, before attempting to operate your
engine, to read the general 'SAFETY INSTRUCTIONS
AND WARNINGS' section on pages 2-5 of this booklet
and to strictly adhere to the advice contained therein.
Also, please study the entire contents of this instruction
manual, so as to familiarize yourself with the controls
and other features of the engine.
Keep these instructions in a safe place so that you may
readily refer to them whenever necessary.
It is suggested that any instructions supplied with the
vehicle, radio control equipment, etc., are accessible for
checking at the same time.
CONTENTS
SAFETY INSTRUCTIONS AND
WARNINGS ABOUT YOUR O.S. ENGINE
2-5
ENGINE CONSTRUCTION, NOTES WHEN
APPLYING AN ELECTRIC STARTER
6-7
NOTES ON OPERATION,
ABOUT THE ENGINE
TOOLS, ACCESSORIES, etc.
BASIC ENGINE PARTS
INSTALLATION OF THE STANDARD
ACCESSORIES, GLOWPLUG
INSTALLATION,
CARBURETOR CONTROLS,
8-9
10-12
13-14
STARTING THE ENGINE & RUNNING-IN
('Breaking-in)
18-22
FINAL ADJUSTMENT
23-25
CARE AND MAINTENANCE
26-27
TROUBLE SHOOTING
28-31
ENGINE EXPLODED VIEW & PARTS LIST
32-33
CARBURETOR EXPLODED VIEW & PARTS LIST
34-35
O.S. GENUINE PARTS & ACCESSORIES
36-37
THREE VIEW DRAWING
15-17
1
38
SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE
Remember that your engine is not a "toy", but a highly efficient internalcombustion machine whose power is capable of harming you, or others, if it is
misused.
As owner, you, alone, are responsible for the safe operation of your engine, so act
with discretion and care at all times.
If at some future date, your O.S. engine is acquired by another person, we would
respectfully request that these instructions are also passed on to its new owner.
The advice which follows applies basically to ALL MODEL ENGINES and is
grouped under two headings according to the degree of damage or danger
which might arise through misuse or neglect.
!
!
WARNINGS
NOTES
These cover the many other
possibilities, generally less obvious
sources of danger, but which, under
certain circumstances, may also
cause damage or injury.
These cover events which
might involve serious (in
extreme circumstances, even
fatal) injury.
2
!
WARNINGS
• Never operate your engine in an enclosed space. Model engines, like
automobile engines, exhaust deadly
carbon-monoxide. Run your engine
only in an open area.
• Model engine fuel is poisonous. Do not allow it to
come into contact with the
eyes or mouth. Always store
it in a clearly marked container and out of the reach
of children.
• Model engines generate
considerable heat. Do not
touch any part of your
engine until it has cooled.
Contact with the muffler
(silencer), cylinder head
or exhaust header pipe, in
particular, may result in a
serious burn.
• Model engine fuel is also
highly flammable. Keep it
away from an open flame,
excessive heat, sources of
sparks, or anything else
which might ignite it. Do not
smoke or allow anyone else
to smoke, near to it.
3
!
NOTES
• This engine is intended for model cars.
Do not attempt to use it for any other
purpose.
• The wearing of safety glasses is also
strongly recommended.
• Mount the engine in your model
securely, following the manufacturers'
recommendations, using appropriate
screws and locknuts.
• Take care that the glowplug clip or
battery leads do not come into contact
with rotating parts. Also check that the
linkage to the throttle arm is secure.
• Install an effective silencer (muffler).
Frequent close exposure to a noisy
exhaust (especially in the case of the
more powerful highspeed engines)
may eventually impair your hearing
and such noise is also likely to cause
annoyance to others over a wide area.
• For their safety, keep all onlookers
(especially small children) well back
(at least 20 feet or 6 meters) when
preparing your model for running.
4
!
NOTES
Before starting the engine, always check
the tightness of all the screws and nuts
especially those of joint and movable
parts such as throttle arm. Missing
retightening the loose screws and nuts
often causes the parts breakage that is
capable of harming you.
• Warning! Immediately after a glowplugignition engine has been run and is still
warm, conditions sometimes exist
whereby it is just possible for the engine
to abruptly restart if it is rotated over
compression WITHOUT the glowplug
battery being reconnected.
• To stop the engine, fully retard the
throttle stick and trim lever on the
trans-mitter, or, in an emergency, cut
off the fuel supply by pinching the fuel
delivery line from the tank.
5
Near TDC
ENGINE CONSTRUCTION
With this engine, the piston will
feel tight at the top of its stroke
Piston
(TDC) when the engine is cold.
Cylinder Liner
This is normal. The cylinder bore
has a slight taper. The piston
and cylinder are designed to
achieve
clearance
a
perfect
when
Crankshaft
running
they
Slight taper
reach
operating temperature.
When the engine is cold.
6
NOTES WHEN APPLYING
AN ELECTRIC STARTER
Do not over-prime. This could
cause a hydraulic lock and damage
the engine on application of the
electric starter.
If over-primed, remove glowplug,
close needle-valve and apply
starter to pump out surplus fuel.
Cover the head with a rag to
prevent any pumped out fuel from
getting into your eyes.
7
When the engine is hot.
NOTES ON OPERATION
While Operating
ABOUT THE WARRANTY
Please do not run on a public street, this
could cause serious accidents, personal
injuries and/or propetry damage.
Since this is a special SPEED
version, individual special
parts are available only for
limited period (one year after
finishing the production).
Also, the engine is free of
warranty due to damage
and/or wear occurred during
running.
Please do not run near pedestrians or
small children.
Please do not run in small or confined
areas.
Please do not run where loud noises can
disturb others, such as hospitals and
residential areas.
NOTE
As delivered, the engine has the
carburetor lightly fit into its intake.
Secure it changing its angle
according to the car chassis.
8
ABOUT THE ENGINE
The O.S. SPEED 21XZ-R is a high
Standard accessories
performance engine designed expressly
Glow Plug RP7
T-type head (Turbo head) 1piece
for 1/8 On-Road Racing.
Based on the MAX-21XZ-R, major parts
Exhaust Seal Ring 1piece
have been refined to have a powerful
potential
equal
to
more
expensive
Cylinder-head gasket
(0.2mm) 1 piece
specially tuned or modified engines.
Carburetor Reducer 9mm
(Red) 1piece
Flywheel No.1E Collet 1piece
Dust Cap 3, 16, 18 1piece each
9
TOOLS, ACCESSORIES, etc.
Tools, accessories, etc.The following items are
necessary for operating the engine.
TOOLS
O.S. SPEED DRIVER TOOLS
Optional Extras
SUPER AIR CLEANER 202 ASSEMBLY
INDUCTION SILENCER
ON-ROAD FILTER OIL (20ml)
T-2080SC TUNED SILENCER COMPLETE SET
This is a set of T-2080SC Tuned Silencer and
M2001SC Exhaust Header Pipe Assembly.
O.S. SPEED FLYWHEEL KEY
T-2080 TUNED SILENCER COMPLETE SET
This is a set of T-2080 Tuned Silencer and
M2001 Exhaust Header Pipe Assembly.
O.S. SPEED
CLUTCH WRENCH & ADJUSTER
O.S. SPEED
FLYWHEEL PULLER
PRESSURE CHAMBAR
This is connected between the fuel tank and
the silencer to maintain exhaust pressure.
O.S. SPEED PLUG WRENCH
10
Items necessary for starting
FUEL
Generally, it is suggested that the user selects a fuel
that is commercially available for model two-stroke
engines. When the brand of fuel is changed, or the
nitro content increased, it is advisable to reset the
carburetor settings. Please note that with high-nitro
fuels, although power may be
increased for competition purposes,
glowplug elements do not last as long
and engine life will be shortened.
FUEL FILTER
To be installed in the fuel line between
fuel tank and carburetor to prevent
dust from entering the carburetor.
GLOWPLUG IGNITER
Commercialy available handy
glowplug heater in which the
glowplug battery and battery
leads are integrated.
STARTER BOX
For starting the engine.
REMINDER!
Model engine fuel is poisonous. Do not
allow it to come into contact with the eyes or
! mouth. Always store it in a clearly marked
container and out of the reach of children.
!
FUEL PUMP
For filling the fuel tank, a simple,
polyethylene "squeeze" bottle,
with a suitable spout, is required.
SILICONE FUEL LINE
Heatproof silicone tubing of
approx. 5mm o.d. and 2mm i.d. is
required for the connection
between the fuel tank and engine.
Model engine fuel is also highly flammable.
Keep it away from open flame, excessive
heat, sources of sparks, or anything else
which might ignite it. Do not smoke or
allow anyone else to smoke, near to it.
11
BASIC ENGINE PARTS
Outer Head
Exhaust
Cover Plate
Carburetor
Type 21M(B)
Crankshaft
Mounting Lugs
Crankcase
Crankshaft Ball Bearing (Front)
12
INSTALLATION OF THE STANDARD ACCESSORIES
About the Head Gasket
The engine is installed with a 0.1mm thick and
a 0.2mm thick gasket for 25% nitro fuel when it
leaves the factory. Also, a 0.2mm thick gasket
is supplied with the engine as standard. Adjust
the total thickness according to atmospheric
temperature, humidity and glowplug used.
Installing the glow plug.
Insert RP7 plug supplied
into heat-sinkhead carefully, making sure that it is
not cross-threaded before
Glowplug
tightening firmly.
(All the O.S. T-Type plugs
including the RP7 are not
supplied with a washer.)
INSTALLATION OF THE TAPER COLLET
Insert the taper collet on the crankshaft, taking
care not to push the crankshaft back so that it
contacts the coverplate face.
Install the exhaust seal
ring supplied.
Installing the
Exhaust
carburetor reducer
Seal Ring
Replace the reducer according to the courseconditions.
8.5mm
Standard with the carburetor when it leaves the
factory.
Cover Plate
Taper Collet
9mm Supplied with the engine.
13
GLOWPLUG
Glowplug life
Since the compatibility of the glowplug
and fuel may have a marked effect on
performance and reliability, it is suggested
to use the O.S. RP7 plug when it is
necessary to replace. Carefully install plug
finger-tight, before final tightening with the
correct size plug wrench.
Particularly in the case of very high performance
engines, glowplugs must be regarded as expendable
items. However, plug life can be extended and engine
performance maintained by careful use, i.e.:
Install a plug suitable for the engine.
Use fuel containing a moderate percentage of
nitromethane unless more is essential for racing events.
Do not run the engine too lean and do not leave the
battery connected while adjusting the needle.
The role of the glowplug
With a glowplug engine, ignition is initiated by the
application of a 1.5-volt power source. When the
battery is disconnected, the heat retained within the
combustion chamber remains sufficient to keep the
plug filament glowing, thereby continuing to keep the
engine running. Ignition timing is 'automatic' : under
reduced load, allowing higher rpm, the plug becomes
hotter and, appropriately, fires the fuel/air charge
earlier; conversely, at reduced rpm, the plug become
cooler and ignition is retarded.
When to replace the glowplug
Apart from when actually burned out, a plug may
need to be replaced because it no longer delivers its
best performance, such as when:
Filament surface has roughened and turned white.
Filament coil has become distorted.
Foreign matter has adhered to filament or plug
body has corroded.
Engine tends to cut out when idling.
Starting qualities deteriorate.
14
INSTALLATION OF THE CARBURETOR
As delivered, the engine has its carburetor lightly
installed in the intake boss. Secure it as follows.
1. Loosen the retainer screw, rotate the
carburetor to its correct position and make
sure that it is pressed well down into the
intake boss, compressing the rubber gasket,
before retightening screw.
Note
Be careful not to damage the O rings when
removing the carburetor retainer from the
engine.
First, remove the retainer Retaining screw,
then pull out each part. Do not push the
part in or damage the O rings.
2. Rotate the retainer screw gently until it
stops, then tighten a further 120-180 .
Do not overtighten the screw as this will
damage the carburetor body.
Retaining Screw
Rotate the retainer nut
gently until it stops.
"O" Ring
"O" Ring
Tighten a further
120-180
15
ENGINE INSTALLATION
Make sure that the vehicle's engine mounting
surfaces are level and in the same plane. Poor
installation may cause distortion of the
crankcase, bearings, etc., resulting in erratic
running and loss of performance.
The recommended screws for securing the
engine are 3mm or 4-40 steel Allen hexagon
socket type.
If existing holes in the engine mount do not align
perfectly with engine mounting lugs, enlarge
them slightly with a needle-file so that screws are
in alignment with the mounting holes.
Also, make sure the engine does not interfere
with chassis, etc.
Do not allow bottom
of crankcase to
touch chassis.
Chamfer inside edges of bearers.
16
CARBURETOR CONTROLS
Four adjustable controls are provided on
this carburetor.
The Needle-Valve(Adjusted at the factory):
For adjusting the mixture strength when the
throttle is fully open.
Carburetor Reducer
The Mixture Control Valve:
For changing the mixture strength at mid
speed and acceleration. (Do not rotate the
screw more chan one turn.)
The Metering Needle:
For adjusting the mixture strength at partthrottle and idle speed, to obtain steady
idling and smooth acceleration to mid speed.
Ball Link
Metering Needle
Mixture Control Valve
Dust Cover
Throttle Stop
Screw
The Throttle Stop Screw
(Adjusted at the factory):
For setting the minimum idle speed:
NOTE: Readjustment may be necessary,
occasionally to allow for changes in fuel
formula, gear ratio or clutch engagement point.
Needle Valve
17
STARTING THE ENGINE & RUNNING-IN ('Breaking-in)
!
PRESSURIZED FUEL SYSTEM
Before starting the engine, always
check the tightness of all the screws
and nuts especially those of joint and
movable parts such as throttle arm.
Missing retightening the loose screws
and nuts often causes the parts breakage that is capable of harming you.
The somewhat violent changes of the fuel
level in the tank may occur during running
due to road surface condition.
In addition, the fuel tank is often located
some distance from the carburetor.
These mean that the fuel ‘head’ at the
carburetor can vary and upset running.
Therefore, it is recommended that a muffler
pressurized fuel feed system be used.
RUNNING-IN ('Breaking-in)
Running- in is a procedure for an engine to
come close to actual running conditions
(fuel, r.p.m., engine temperature, etc.).
Excessively rich running and prolonged
low speed running should be avoided.
Prolonged low speed running and low
temperature running may result in the oil in
the fuel becoming gelled and the
piston/liner becoming stuck together.
Never run your vehicle without installing the
air cleaner. Dust and dirt that may otherwise
be drawn into the engine will rapidly shorten
its life.
18
The following procedure is suitable when a
fuel containing 25% nitro-methane is used.
The needle-valve is set approx. 3 turns
opened from the fully closed position.
Fill the tank completely with fuel.
Close (clockwise)
Temporarily remove the glowplug to check
that it glows bright red when energized.
Element glows when energized.
Open
Pliers
Needle Valve
Turn the needle-valve clockwise until it stops. This is the
fully closed position.
Do not force it to turn further.
Throttle is set approx. 0.5mm open.
approx 0.5mm
Replace the plug when the
element does not glow or is
burnt out.
Approx. 0.5mm open
factory setting with the
reducer removed
Glow Plug Igniter
The carburetor is set at the factory as shown
at the right. Start the engine as it is.
Metering needle and mixture control valve
are set at basic position. (Refer to P25.)
19
Switch on the transmitter and make sure that
each linkage moves correctly.
Do not force the needlevalve to turn beyond
a lightly closed position.
Set the throttle opening a little wider that the
factory setting by adjusting the Throttle Stop
Screw.
Turn the engine with starter box to draw fuel
into the engine.
approx 1mm
Deliver fuel into the carburetor.
Fuel
Fuel tank side
When the engine starts, warm it up by
repeatedly increasing the rpm to medium
speed and back again to a fast idle with the
mixture set very rich, the glowplug
connected, and the driving wheels clear of
the ground. The rich mixture will provide
adequate lubrrication and cooling indicated
by profuse exhaust smoke.
Now connect glowplug battery lead to heat
the plug filament and start the engine.
When the engines does not start or stops
right after started, try the followings.
Set the needle-valve approx. 2.5 turns open
from the fully closed position.
20
Next, disconnect the glowplug battery and try
running the car on the track.
If the engine stalls, open the throttle
fractionally, but try to keep the engine running
as rich as possible: if it stops because of
being excessively over-rich, close the NeedleValve 30˚ and try again.
throttle trigger
Attention:
It is vitally important to set
the throttle at the correct
position before starting the
engine. If the engine is
allowed to run with the throttle
too far open under ''no load'' conditions (i.e.
with the driving wheels not in contact with the
ground) it will rapidly over-heat and may be
seriously damaged.
Run the car on the track until one tank of fuel
has been consumed, then close the NeedleValve 10-15˚ and run the car for 1 to 2 full tanks
of fuel.
Repeat this procedure until approx. 2 liters of
fuel have been consumed, during which time
the throttle may be opened for brief bursts of
increased power.
If the engine stops at medium speeds, close
the Mixture Screw 45˚.
21
How to stop the engine
The position of the needle-valve
when starting the engine.
Needle
To stop the engine, close the throttle to idle
speed and shut it off completely with the trim
lever on the transmitter then cut off the fuel
supply by pinching the fuel delivery tube to
the carburetor.
Close the needle-valve approx.
15˚ after running the vehicle for
1 to 2 full tanks of fuel.
Repeat this procedure until
approx. 2 liters of fuel have
been consumed.
Note:
In the event of any major working parts
(e.g. piston/cylinder liner assembly) being
replaced or the fuel being changed,
especially to high nitro fuel, the complete
running-in should be repeated.
Fuel
Warning!
Do not touch rotating parts, engine and silencer when stopping the engine as they
become very hot, and contact with them
may result in a serious burn.
22
FINAL ADJUSTMENT
Final adjustment should be carried out only after
the running-in has been completed.
Throttle
Stop Screw
Run the vehicle (with throttle fully open) over
the longest available straight course, in order
to observe the model's speed. Next return
the car to the starting point, close the NeedleValve 10-15˚ and repeat the run, taking note
of the improvement in performance.
Continue with further runs, gradually
reducing the Needle-Valve setting and
aiming to achieve the highest straight-line
speed. Remember, however, that, if the
Needle-Valve is shut down too far, the
engine will overheat and, accompanied by
visibly diminished exhaust smoke, the model
will lose speed. At this point, throttle down
immediately, stop the vehicle and reopen the
Needle-Valve 30˚.
Needle Valve
Metering
Needle
Needle Valve
Metering Needle
Open
Close
Open
More fuel
Less fuel
More fuel
Close
Less fuel
23
Warning!
With the engine running, close the throttle
and allow it to idle for about five seconds,
then reopen the throttle fully. If, at this point,
the engine puffs out an excessive amount of
smoke and the vehicle does not accelerate
smoothly and rapidly, it is probable that the
idle mixture is too rich.
Mixture adjustments (whether via the
Metering Needle, or the Needle-Valve)
cannot be made accurately under 'no-load'
conditions, which, in any case, are not
advised, since such operation carries the
risk of seriously damaging the engine
through over-revving and overheating.
In this case, turn the Metering Needle
clockwise 30-45˚. If, on the other hand, the
engine tends to speed up momentarily and
then cut out abruptly when the throttle is
opened, the idle mixture is too lean. Correct
this by turning the Metering Needle
counter-clockwise 30-45˚.
With the optimum mixture control position,
light smoke is visible during high speed
running,and the engine rpm increases
smoothly during acceleration. Remember
that, if the engine is operated with the fuel/air
mixture slightly too lean, it will overheat and
run unevenly. As with all engines, it is
advisable to set both the needle-valve and
metering needle slightly on the rich side of
the best rpm setting, as a safety measure.
Carry out adjustments patiently, under actual
running conditions, until the engine responds
quickly and positively to the throttle control.
24
If the engine runs too fast with the throttle
closed, the throttle stop screw should be
turned counter-clockwise to allow the throttle
opening to be reduced.
Ball Link
Finally, beyond the nominal break-in period,
a slight readjustment toward a leaner needle
setting may be required to maintain
maximum performance.
Rotate the Metering
Needle until its slotted
head is extruded by the
ball link body, then
screw it out approx. 1.2
turns (approx. 0.6mm)
This is the standard
position.
Slide Valve
Metering Needle
Carburetor Body
REALIGNMENT OF METERING NEEDLE AND
MIXTURE CONTROL VALVE
In the course of making carburetor
adjustments, it is just possible that the
Metering Needle and the Mixture Control
Valve may be inadvertently screwed in or out
too far and thereby moved beyond its
effective adjustment range. The basic
positions can be found by rotating the
Metering Needle until its slotted head is flush
with the ball link body.
First rotate the Mixture
Control Valve until its
slotted head is flush with
the carburetor body.
This is the standard
position.
Mixture Control Valve
Carburetor Body
25
CARE AND MAINTENANCE
1. The minute particles of foreign matter, that
are present in any fuel may, by accumulating
and partially obstructing fuel flow, cause
engine performance to become erratic and
unreliable. O.S. 'Super-Filters' (large and
small) are available, as optional extras, to
deal with this problem. One of these filters
installed to the pickup tube inside your
refueling container, will prevent the entry of
foreign material into the fuel tank. It is also
recommended that a good in-line filter be
installed between the tank and carburetor.
3. At the end of each operating session, drain out
any fuel that may remain in the fuel tank.
Afterwards,energize the glow-plug and try to
restart the engine, to burn off any fuel that may
remain inside the engine. Repeat this
procedure until the engine fails to fire. Do this
while the engine is still warm.
2. Do not forget to clean the filters regularly to
remove dirt and lint that accumulate on the
filter screens. Also, clean the carburetor itself
occasionally.
Note:
Do not inject after-run oil into the
carburetor as this may cause the O-rings
inside the carburetor to deteriorate. These
procedures will reduce the risks of starting
difficulties or corrosion after a period of
storage.
4. Then, inject some after-run oil into the
engine, and rotate the engine with an
electric starter for 4 to 5 seconds to
distribute the oil to all the working parts.
26
Note:
Crankshaft of this engine is filled with
silicone. Do not use light oil nor
kerosene, etc. for washing, or the
silicone will swell. Use alcohol or fuel for
washing.
Installing Dust Caps
When storing the engine, install the cap on
the exhaust port, carburetor, etc. to prevent
dust from entering the engine.
CHECKING THE ENGINE
Engine will not develop normal performance
after long time running due to wearing of parts.
It is suggested to replace necessary parts when
the following symptoms are detected.
5. Finally, when cleaning the exterior of the
engine, use methanol or a household
cleaning agent. Do not use gasoline,
kerosene, or any petroleum based chemical
which can damage silicone fuel tubing.
Engine sound changes and easily overheats.
Dirt and dust may lodge in
marked places.
Power has dropped extremely.
Idling is unstable and/or engine tends to stop
at idling.
In most cases, ball bearings, cylinder & piston
assembly, connecting rod and/or crankcase have
become worn out or abnormal. Check the
parts carefully and replace them if necessary.
27
TROUBLE SHOOTING
Symptom
Engine fails to fire.
Corrective action
Cause
Fuel tank is empty.
Fuel not reaching the engine.
Fill the tank with fuel and repeat
Priming procedure.
Glowplug element is burnt out.
Glowplug battery discharged
Replace glowplug.
Recharge or replace the battery.
Clogged fuel filter
Air cleaner and silencer inside is dirty.
Clean or replace fuel filter.
Replace cleaner element and clean inside silencer.
Over priming
Remove glowplug and pump out excess fuel.
Fuel tubing is disconnected.
Fuel tubing is kinked, split or has a hole.
Connect fuel tubing securely.
Check the tubing carefully and replace if necessary.
Incorrect servo linkage
Connect correctly after setting servo at neutral.
Reverse rotating direction of starter box.
Mare sure it rotates counter clockwise seen
from crankshaft side.
28
Symptom
Engine fires intermittently but does not run.
Corrective action
Cause
Insufficient fuel in the tank.
Fill the tank with fuel.
Deteriorated glowplug
Replace glowplug.
Clogged fuel filter
Air cleaner and silencer inside is dirty.
Clean or replace fuel filter.
Replace cleaner element and clean inside silencer.
Engine overheated
Wait until engine is cool.
Incorrect clutch release
Adjust the tension of clutch spring.
Starting battery disconnected too soon.
Do not disconnect plug battery and wait until
r.p.m. becomes stable.
Vibration causing air bubbles in fuel.
Install "O" rings to the tank screws to
prevent bubbles.
29
Symptom
Unstable idle
Corrective action
Cause
Unsuitable glowplug
Use suggested glowplug in the instructions.
Unsuitable fuel
Do not use extremely high nitro or low oil content fuel.
Extremely light flywheel
Add heavier flywheel.
Silencer is disconnected or has play
Install silencer securely.
Symptom
Not reaching expected peak r.p.m.
Corrective action
Cause
Insufficient warming up or running-in.
Set the needle only after warming up.
Complete running-in.
Silencer or manifold is not securely connected
or disconnected.
Replace seal ring.
Check the connections and secure them.
Fuel tubing from tank is split or broken.
Replace the tubing.
30
Symptom
Poor response
Corrective action
Cause
Deteriorated glowplug
Replace glowplug.
Incorrect carburetor settings
Readjust low r.p.m. range with metering
needle and mixture control valve.
Incorrect setting of transmitter Exponential function.
Check the transmitter setting.
Incorrect linkage
Make sure the throttle servo linkage does not
bind and is connected correctly.
Symptom
Poor r.p.m. drop
Corrective action
Cause
Close metering needle to adequate position
to lower idle r.p.m.
Throttle position open too far.
Carburetor not fully seated
Install carburetor securely.
Metering needle closed too far.
Open the metering meedle a little.
31
33
22014050
22014110
22014160
22014170
22013020
22013010
22016010
21817000
23755020
22082020
23981740
24881824
23731000
22011020
23730020
22012040
23764020
22427000
71642070
22014160
22826140
71533290
22615000
71801100
22884250
Outer Head
Inner Head
Head Gasket Set (0.2mm)
Head Gasket Set (0.1mm)
Built-Up Parts Set
Cylinder & Piston Assembly
Piston Pin
Piston Pin Retainer (2pcs.)
Connecting Rod
Carburetor Complete (Type 21M(B))
Carburetor Retainer Assembly
"O" Ring (2pcs.)
Crankshaft Ball Bearing (Front)
Crankcase
Crankshaft Ball Bearing (Rear)
Crankshaft
Cover Gasket
Cover Plate
Glow Plug RP7
Head Gasket Set (0.2mm)
Exhaust Seal Ring (2pcs.)
Carburetor Reducer 9mm (Red) W/"O"Ring
"O" Ring
Flywheel No.1E Collet
Dust Cap Set ( 3mm,16mm, 18mm)
Description
The specifications are subject to alteration for improvement without notice.
* marked parts are available only for limited period
(one year after finishing the production).
1
2
3
4
5
5-1
5-2
5-3
5-4
6
7
7-1
8
9
10
11
12
13
No. Code No.
ENGINE PARTS LIST
32
8
*Type of screw
C…Cap Screw
7
C.M2.6x18
5-3
6
C.M3x18
5-2
9
7-1
10
5-1
11
5
12
Size
Pcs. used in an engine
13
C.M2.6x7
79871020 M2.6x7 Cover Plate Retaining Screw (4pcs.)
79871055 M2.6x18 Carburetor Retainer Retaining Screw (1pc.)
79871180 M3x18 Cylinder Head Retaining Screw (4pcs.)
Code No.
CAP SCREW SETS (10pcs./sets)
5-4
4
3
2
1
ENGINE EXPLODED VIEW
CARBURETOR EXPLODED VIEW
2
5
2-1
5-1
5-1
3
3-1
4
4-1
1-1
1-2
1
8
7
8-1
6
9
11
10
10-1
Type of screw
S.M3x3
S...Set Screw
34
CARBURETOR PARTS LIST
No. Code No.
1
1-1
1-2
2
2-1
3
3-1
4
4-1
5
5-1
6
7
8
8-1
9
10
10-1
11
22082600
46066319
22781800
22082970
46066319
22082940
22082950
22848160
27881820
71533085
22615000
22082110
22082200
22082350
27881820
23981520
23781400
26381501
29015019
Description
Mixture Control Valve Assembly
"O" Ring (L) (2pcs.)
"O" Ring (S) (2pcs.)
Needle Assembly
"O" Ring (2pcs.)
Needle Holder Assembly
No.15 Universal Nipple Assembly
Throttle Stop Screw
"O" Ring (S) (2pcs.)
Carburetor Reducer (8.5mm Red)
"O" Ring (1pc.)
Carburetor Body
Slide Valve
Metering Needle Assembly
"O" Ring (S) (2pcs.)
Dust Cover
Ball Link No.3
Set Screw
Carburetor Rubber Gasket
* marked parts are available only for limited period
(one year after finishing the production).
The specifications are subject to alteration for improvement without notice.
35
O.S. GENUINE PARTS & ACCESSORIES
GLOWPLUG
RP6
T-2080 TUNED SILENCER COMPLETE SET
(72106800)
(71642060)
M2001
Exhaust Header Pipe Assembly
T-2080 Tuned Silencer Assembly
(72106810)
(72106860)
(71642070)
Silencer Ring (21) Set
(W/Ring 2pcs./Silencer C Spring 1pc.)
(72106820)
(72101272)
RP8
Silencer C Spring (21) (3pcs.)
Exhaust Seal Ring (2pcs.)
RP7
(71642080)
Header Pipe Spring (2pcs.)
(72106830)
(22826140)
Adapter Seal Ring (2pcs.)
(22826140)
T-2080SC TUNED SILENCER COMPLETE SET
PRESSURE CHAMBER SET
(71550000)
(72106850)
T-2080SC Tuned Silencer Assembly
(72106851)
Joint Spring (3pcs.)
M2001SC
Exhaust Header Pipe Assembly
(72106870)
(72106042)
Header Pipe Spring (2pcs.)
Exhaust Seal Ring (2pcs.)
(72101272)
(22826140)
Exhaust Seal Ring (2pcs.)
(22826140)
INDUCTION SILENCER
(72414000)
Induction Silencer Filter
(3pcs.) (72414100)
ON-ROAD FILTER OIL
(20ml)
(72414200)
36
SUPER AIR CLEANER 202 ASSEMBLY
On-road Type (72412000)
202 Cleaner Body
(72412100)
202 Filter Element (4pcs.)
(72412200)
DUST CAP SET
3mm (5pcs.) (73300305)
16mm (3pcs.) (73301612)
18mm (3pcs.) (73301812)
O.S. SPEED
CLUTCH WRENCH & ADJUSTER
(71415300)
O.S. SPEED FLYWHEEL KEY
(71415200)
O.S. SPEED FLYWHEEL PULLER
(71415100)
O.S. SPEED PLUG WRENCH
(71520100)
O.S. SPEED DRIVER TOOLS
Code No.
71410150
71410200
71410250
71410300
71411200
71411250
71412300
71413550
71413600
71413700
Code No.
71414015
71414020
71414025
71414030
71414120
71414125
71414230
71414355
71414360
71414370
The specifications are subject to alteration for improvement without notice.
37
Description
O.S. SPEED HEX WRENCH DRIVER 1.5
O.S. SPEED HEX WRENCH DRIVER 2.0
O.S. SPEED HEX WRENCH DRIVER 2.5
O.S. SPEED HEX WRENCH DRIVER 3.0
O.S. SPEED HEX BALL WRENCH DRIVER 2.0
O.S. SPEED HEX BALL WRENCH DRIVER 2.5
O.S. SPEED FLAT HEAD SCREWDRIVER 3.0
O.S. SPEED NUT DRIVER 5.5
O.S. SPEED NUT DRIVER 6.0
O.S. SPEED NUT DRIVER 7.0
Description
O.S. SPEED HEX WRENCH TIP ONLY 1.5
O.S. SPEED HEX WRENCH TIP ONLY 2.0
O.S. SPEED HEX WRENCH TIP ONLY 2.5
O.S. SPEED HEX WRENCH TIP ONLY 3.0
O.S. SPEED HEX BALL WRENCH TIP ONLY 2.0
O.S. SPEED HEX BALL WRENCH TIP ONLY 2.5
O.S. SPEED FLAT HEAD SCREWDRIVER TIP 3.0
O.S. SPEED NUT DRIVER TIP ONLY 5.5
O.S. SPEED NUT DRIVER TIP ONLY 6.0
O.S. SPEED NUT DRIVER TIP ONLY 7.0
THREE VIEW DRAWING
SPECIFICATIONS
37
■ Displacement
3.49 cc (0.213 cu.in.)
■ Bore 16.27 mm (0.640 in.)
Stroke ■
16.8 mm (0.661 in.)
Practical
R.P.M. ■
4,000-45,000 r.p.m.
Power
output ■
2.8 ps / 2.84 hp / 33,000 r.p.m.
Weight
■
338 g (11.92 oz.)
4- 3.3
78.8
21
15.6
28.5
UNF1/4-28
31.6
45
29.5
44
21.6
Dimensions (mm)
38
6-15 3-Chome Imagawa Higashisumiyoshi-ku
Osaka 546-0003, Japan TEL. (06) 6702-0225
FAX. (06) 6704-2722
C Copyright 2011 by O.S.Engines Mfg. Co., Ltd. All rights reserved. Printed in Japan.
60092550
071101
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