SIMPLIFIED MAINTENANCE MANUAL

All information in this publication is based on latest specification’s product available at the time of approval for printing.

CISCOMOTORS reserves the right to make changes at any time without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.

CISCOMOTORS 2008 .

INDEX Page 2

1. OPERATING INSTRUCTIONS Page 3

• 1.1 Basic operation

• 1.2 Start engine

• 1.3 Running in procedure

Page 3

Page 4

Page 6

2. SPECIFICATIONS Page 7

• 2.1 Engine installation on chassis

• 2.2 Technical characteristics

Page 7

Page 8

3. MAINTENANCE Page 9

Page 9

Page 9

Page 10

• 3.1 General service information

• 3.2 Routine cleaning

• 3.3 Maintenance schedule

4. STORAGE

5.

6. ASSEMBLY/DISASSEMBLY STARTER

7. REGULATION BELT TRANSMISSION

8. REGULATION CARBURATION

9. ELECTRICAL SCHEDULE C-MAX ELECTRIC

10. TROUBLESHOOTING

• 10.1 The engine don’t start

• 10.2 Engine laks power

• 10.3 Exessive vibrations of the engine

11. TORQUE VALUES ENGINE

Page 11

Page 12

Page 13

Page 14

Page 15

Page 16

Page 16

Page 16

Page 17

Page 18

Page 3

1. OPERATING INSTRUCTIONS

1.1 BASIC OPERATION

FUEL

C----Max has a two-stroke engine that requires a gasoline-oil mixture.

• Use gasoline with a pump octane number of 92 or higher .If “knocking” or

“pinging” occurs, try a different brand of gasoline or a higher octane grade.

• Vegetable oils separate from gasoline more easily than mineral oils, especially in cold weather. It is advisable to use synthetic oil.

CAUTION:

• To mix gasoline and oil in a ratio of

33:1. Prepare the fuel mixture in a clean container fig. 1 , and shake until thoroughly mixed before filling the fuel tank.

• Do not mix vegetable and mineral based oils.

WARNING

• USE A GOOD QUALITY OF

SYNTHETIC 2-STROKE OIL

CAUTION:

To much oil will cause excessive smoking and spark plug fouling. Too little oil will cause engine damage or premature wear. Mix fuel in a ratio of 40 parts gasoline to 1 part oil

(33:1)

• Gasoline is extremely flammable and is explosive under certain conditions.

Perform this operation in a wellventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stores and where the fuel tank is refuelled.

Synthetic oil cl

FUEL 92/98 octane litres

1

2

3

4

5

10

0,3

0,6

0.9

12

15

30

Figure 1

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1.2 START ENGINE

WARNING

• Never run the engine in an closed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death.

• Attention to start the engine without the reducer provokes the outbreak of the clutch and can cause injury or damages.

• Never run the engine without propeller.

• The starter attempt can carry to the spin of the propeller and therefore to possible lesions.

• The motor running emits disturbs electromagnetic

Version manual starter with clutch:

1. Starter engine to warm:

1. To carry in a pressure (by manual pump) circuit of the gasoline, if necessary help by press the diagram.

Fig. 2

Figure 1

2. Don’t engulf the engine but make sure the gasoline goes in intake pipe.

3. Insert the Block Clutch System (Fig.1)

4. Grasp the start and pull gently just after point more hard (try repeatedly to be sure)

5. Pull whit energy the handgrip without speed for 3 o 4 and without groped to start.

6. Pull with energy the handgrip and speed slightly after first turn of engine.

7. In case of start failed to repeat again the operation.

8. After starter engine heat it 2/3 minutes speeding from 3000 to 4000 turns max.

Starter the engine to warm:

1 Insert the Block Clutch System (Fig.1)

2 Pull with energy the handgrip and speeding slightly.

Stopping The Engine

• Press the stop button of the engine until the engine stop completely.

.

Figure 2

Version manual starter without clutch: Version electric starter:

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1. To carry in a pressure the circuit of the gasoline, to help itself pressing the diagramm (Fig.2)

2. Don’t engulf the engine but make sure the gasoline goes in intake pipe.

3. To pull the starter and delicately pull just after the hard point (try repeatedly for be sure).

4. Pull with energy the handgrip and speed slightly.

5. In case of start failed to repeat again the operation .

6. After starter engine heat it 2/3 minutes speeding from 3000 to 4000 turns max.

Start the engine to warm:

1. Pull the handgrip with energy without speed.

Stop the engine

• To press the stop button of engine until the engine stop completely .

1. To carry in pressure the circuit of the gasoline, to help itself pressing the pushbutton (Fig.2)

2. Don’t engulf the engine but make sure the gasoline goes in intake pipe.

3. Act on the start button without speed for

5 or 6 turns engine.

4. In case of start failed to repeat again the operation.

Start the engine to warm :

1. Pull the handgrip with energy without

speed.

Stop the engine

• To press the stop button of engine until the engine stop completely .

1.3 RUNNING-IN PROCEDURE

Following proper break-in procedure helps censure that some of the most important and expensive components on your new C-Max will provide maximum performance and service life. (Also follow proper run-in procedure for a newly rebuilt engine)

1. Do not hold the throttle in one position for more than a few seconds. It’s better to roll the throttle on and off, without getting too high altitudes and forcing the engine.

2. Use the motor for features of 10 minutes at a time and to leave to cool it.

3. After 5 hours of use or approximately 20 litres of gasoline the motor should be broken in.

4. This same procedure should be followed each time

• Piston is replaced

• Cylinder is replaced

• Crankshaft or crank bearings are replaced

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2. SPECIFICATIONS

2.1 ENGINE INSTALLATION ON CHASSIS

Page 7

1. Support engine

Picture 3

2. Manual starter 3. Electric starter

Page 8

2.2 TECNICALS CHARACTERISTICS

Motor C-MAX

Type

Disposition cylinder

Bore max

Stroke max

Displacement

Compression ratio

Maxim Power

Max Torque

Max turn of engine

Electrical system

Ignition

Rotor

Spark plug standard

Spark plug summer +30° c

Starter

Carburettor

Type

Transmission

Clutch Type

Reduction

Reduction ratio

Exhaust

Type

Silencer

Support engine

Type

The standard carburation

Temperature 10°c

P 1024 Mb

UR 50%

Altitude (S.L.M.) 50 m

\

2 strokes cooled to air

Mono cylinder

65mm

53mm

175cc

11 : 1

20 kw (27cv) 7800 turns

25 Nm 7400 turns

8100 turns

Inductive coil

Neodynium Magnet

Ngk B8BS

Ngk B9BS

Manual / Electric

Walbro

Centrifugal 3 shoe

Pulley/Pinion

1/2,6 – 1/2,8 – 1/3

Expansion chamber

Glass wool

N.4 Silent-block

3. MAINTENANCE

3.1 GENERAL SERVICE INFORMATION:

• Wear gloves and glances when you make the maintenance;

• Do not perform maintenance while engine is running. Injury to your fingers, hands or head may result ;

• Perform maintenance on firm, level ground, using hard work plain , and not directly on chassis;

• Always install new gaskets, o-rings, piston pin clips, rings etc .when reassemble some parts.

• When tightening bolts, nuts or screw, start with the larger diameter or inner fasteners, and tighten them to the specified torque using a criss-cross pattern;

Page 9

• Clean parts in not-flammable cleaning solvent when disassembling. Lubricate any sliding surface, o-rings and seals before reassembling.

W A R N I I N G

Gasoline or low flash point solvents are highly flammable or explosive and must never be used for cleaning parts . Fire or explosion could result.

• After reassembling, check all parts for proper installation and operation

NOTE:

• Specification are listed chapter 2.

3.2 ROUTINE CLEANING

C----Max is only little dirty to clean up it with clean dusts cloth without solvents solvents, lubricate where is necessary.

Engine Number

Figure B

Page 10

3.3 MAINTENANCE SCHEDULE

FREQUENCY

Before and after each use

Every 50 hours

Every 100 hours

INSPECT

All screw nuts, bolts correctly tighten, silent-block in, and check carburation.

Belt transmission

Clean air filter

Cylinder head decarbonizing

Diameter of clutch and clutch bell

Every 200 hours

Every 500 hours

REPLACE

Transmission belt

Bearing crankshaft

Glass wool

Silencer

Spark plug

Oil seal crankshaft

Piston complete

Cooling belt

Crankshaft bearing

Each year

Thermical group .

Connecting rod

All rubber and plastic components.

Fuel diaphragm carburettor , spark plug.

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4. STORAGE

Extended storage such as for winter, requires that you take certain steps to reduce the effects of

C----Max . In addition necessary repairs should be made before removed from storage.

6. ASSEMBLY/DISASSEMBLY STARTER

1. Remove 4 screws (Fig.18)

2. Remove the screw (Fig.20) for to arrive to the pulley

3. Remove the pulley (Fig.21)

4. Control the screws (Fig.19) are in a good conditions and locked.

1. Install the pulley and tighten the screw

(pict. 20) to the specified torque

TORQUE : 15Nm( 1,5 kgf/m)

2. Insert the starter in 4 screws (Fig.19)

TORQUE: 12Nm (1.2 kgf/m)

3. Tighten the screws (Fig.18) to the specific torque using light locking agent

Figure 18

Figure 19

Page 12

Figure 20 Figure 21

Page 13

7. REGULATION BELT TRANSMISSION

The tension of belt must be done very carefully

1. Slightly little the 4 fix screws of bracelet (Fig.32)

3. Tighten the 4 Allen using the cross method the specified torque

2. Insert an Allen key 8 m / m in the seat

(Fig32-1 point 2) and rotate counterclockwise torque of 400 Nm (40kgf / m)

• TORQUE: 12Nm (1,2 kgf/m)

Figure.32

Figure 32-1

CAUTION:

Control the tension as Fig.32-2

1. Tension too taut it’s cause of early usury of bearing

2. Tension too loose it’s cause of exessive consumpion of belt.

Figure.32-2

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8. CARBURATION REGULATION

1. Regulation min.throttle engine

2. Regulation gasoline/air min. (L)

3. Regulation gasoline/air max (/H)

Standard regulation

Figure 35

In case problems of wrong carburation , replace the originals levels.

Screw regulation of min. 1 turn from all closing. . (Fig.35 point 2)

Attention: regulation of carburation must be made at warm motor.

1. Start the engine.

2. To warm the motor for 4 or 5 minute to the regimen of spin of 3500/4000rpm;

3. Regulate the screw of max jet H, ((Fig.35 point 3) from 1 turn to 1-1/4 from all closing.

4. Regulate the screw of the minimal jet L, (Fig. 35 point 2)from 3/4 to 1 turn, to put the motor to 5000 rpm, to screw or to unscrew the screw until when the motor turns cleaned up and does not mutter;

5. To leave the motor for some second ones at minimum, to accelerating normally , now the motor must quickly accelerate without mumbling or to come less.

6. To regulate the lessened motor spin of the 2000/2200 rpm. (Fig. 35 point 1) C-Max clutch

7. To regulate the lessened motor spin of the 2500/2600 rpm. (Fig. 35 point 1) C-Max electric or manual starter.

8. ELECTRICAL SCHEDULE

Electric starter with recharge battery

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Page 16

10. TROUBLESHOOTING

10.1 THE ENGINE DON’T START

CHECK POSSIBLE CAUSES

Check if fuel is jetting to the carburettor

Check electric

No fuel in tank

Clogged fuel line or fuel filter

Diaphragm fuel pump broken

The engine stop switch is to ON

Faulty spark plug

Broken or shorted ignition coil

Replace

Replace

SOLUTION

Fill tank for fueling

Replace and clean

Replace the diaphragm

(Fig. 5)

Move it on OFF

10.2 ENGINE LAKS POWER

CHECK

Check the carburation

POSSIBLE CAUSES

Fuel air mixture to lean

Fuel air mixture to reach

SOLUTION

Unscrew the min screw

(Fig. 35- 2)

To screw the max screw

(Fig. 35- 2)

Replace or clean Clogged fuel line or fuel filter

Diaphragm fuel pump broken Replace the diaphragm

(Fig. 27)

10.3 EXESSIVE VIBRATIONS OF THE ENGINE

CHECK

Silent-block engine

POSSIBLE CAUSES

Excessive wear, holder rubber

Prop out of balance

SOLUTION

Replace (Max 70 Sh)

Balance or replace

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11. TORQUE VALUES ENGINE

ITEM

Cap screw propeller hub M6

Cap screw propeller hub M8

Spark plug

Cap screw cooling air duct

Cap screw crankcase starter

Bolt cylinder head

Screw transmission eccentric

Bolt silent-block exhaust

*Bolt clutch

All bolts

*Bolts starter

Bolts pinion transmission

* Apply locking agent

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Thread diam. x pitch

M 6 x 1,0

M 8 x 1,25

M14 x 1,25

M 5 x 0.8

M 6 x 1

M 8 x 1,25

M 6 x 1,0

M 8 x 1,25

M 18 x 1.25

M 6 x 1

M 10 x 1,25

M 12 x 1.25

Torque

Kgf-m

1.2

1.5

1,8

0,6

1.2

1,5

1,2

1.5

4.0

1

3,0

4,0