HKS 700E User manual

HKS 700E
Service Manual
2006 June
Ver. 2.02
HKS CO.,LTD
7181 KITAYAMAFUJINOMIYA
SHIZUOKA
JAPAN 418-0192
TEL [phone]
FAX [phone]
[e-mail]
http://www.hks-power.co.jp/hks_aviation/

Service Manual
Effectivity: HKS700E after S/N 100600 - 1 -
CONTENTS PG1-3
1 Introduction
2 General information
2.1 Special tools
3 Disassembly
3.1 Carburetor disassembly
3.1.1 Upper type
3.1.2 Horizon type
3.2 Intake manifolds removal
3.3 Electric starter removal
3.4 Spark plug removal
3.5 Gearbox removal and disassembly
3.5.1 Atype (ratio 2.58)
3.5.2 B type (ratio 3.47)
3.6 Front cover removal
3.6.1 Drive gear removal
3.7 Rear cover removal and disassembly
3.7.1 Oil pump disassembly
3.8 Stator removal
3.9 Starter idler gear and Driven gear removal
3.10 Flywheel removal
3.11 Cylinder head removal
3.11.1 Cylinder head disassembly
3.12 Cylinder and Piston disassembly
3.13 Crankcase disassembly
3.14 Crankshaft disassembly

Service Manual
Effectivity: HKS700E after S/N 100600 - 2 -
4 Assembly
4.1 Connecting rod reassembly
4.2 Crankcase reassembly
4.2.1 Crankshaft Bearing and Thrust bearing
4.2.2 Crankshaft
4.2.3 Camshaft
4.2.4 Oil strainer
4.2.5 LH crankcase
4.3 Piston reassembly
4.3.1 Piston ring
4.4 Cylinder reassembly
4.4.1 Hydraulic lifter
4.5 Cylinder heads reassembly
4.5.1 Push rod
4.5.2 Rocker arm compartment
4.6 Cylinder head cover reassembly
4.7 Flywheel reassembly
4.8 Driven gear and Starter idler gear reassembly
4.9 Rear cover reassembly
4.9.1 Stator
4.9.2 Oil pump
4.9.3 Pressure regulator
4.9.4 Oil filter
4.10 Front cover reassembly
4.10.1 Atype (ratio2.58)
4.10.2 B type (ratio3.47)
4.11 Gearbox reassembly
4.11.1 Atype (ratio2.58)
4.11.2 B type (ratio3.47)

Service Manual
Effectivity: HKS700E after S/N 100600 - 3 -
4.12 Electric starter reassembly
4.13 Spark plug reassembly
4.14 Intake manifolds reassembly
4.15 Carburetors reassembly
4.15.1 Upper type
4.15.2 Horizon type
5 Table for torque values
6 Selection of metal bearing
6.1 Connecting rod bearing
6.2 Crankshaft bearing
7 Grading of cylinder and piston
8 Wear limits

Service Manual
Effectivity: HKS700E after S/N 100600 - 4 -
WARNING!
This is a non-certified aircraft engine; the possibility of engine failure exists at all times.
Do not operate this engine over densely populated areas. Do not operate this engine
over terrain where a safe, power off landing cannot be performed.
The operating and maintenance instructions supplied with this engine must be followed
at all times. Flying any aircraft involves the risk of injury or death, building and
maintaining your own aircraft requires great personal responsibility.

Service Manual
Effectivity: HKS700E after S/N 100600 - 5 -
1 Introduction

Service Manual
Effectivity: HKS700E after S/N 100600 - 6 -
2 General information
2.1 Special tools
In addition to this service manual, please refer to the following.
(1) HKS 700E Installation instruction Manual
(2) HKS 700E Operations Manual
(3) HKS 700E Parts List
ST-01 ST-02 ST-03 ST-05 ST-06
ST-04
ST-07 ST-08
ST-09

Service Manual
Effectivity: HKS700E after S/N 100600 - 7 -
3 Disassembly
3.1 Carburetors removal
NOTE: Identify both carburetors to RH/LH cylinders.
3.1.1 Upper type
• Remove 2 nuts ①M6.
3.1.2 Horizon type
• Remove tension spring.
• Loosen clamp screw ①and remove carburetor
by turning action.
3.2 Intake manifolds removal
• Remove 2 bolts ①M8 and intake manifold.
• Remove intake gasket ②.
②
①
①
①

Service Manual
Effectivity: HKS700E after S/N 100600 - 8 -
3.3 Electric starter removal
• Remove 2 bolts ①M6.
• Shift to remove electric
starter.
3.4 Spark plug removal
• Remove 4 spark plugs.
①

Service Manual
Effectivity: HKS700E after S/N 100600 - 9 -
3.5 Gearbox removal and disassembly
3.5.1 Atype (ratio2.58)
• Remove 8 bolts ①M6.
3.5.2 B type (ratio3.47)
• Remove 10 bolts ①M6.
• Shift to remove gearbox.
• Remove circlip ①.
• Set ST-07 as shown.
• Compress gear and
remove half rings ①.
S
T
-07
①
①
①

Service Manual
Effectivity: HKS700E after S/N 100600 - 10 -
• Remove Inner race following below instruction..
STEP 1: Compress ST-07 to make clearance between Inner race and Retainer.
STEP 2: Insert one ST-08.
STEP 3: Decompress ST-07. Inner race will move to upward by springwashers.
If three ST-08s are inserted, go to STEP 4 else go to STEP 1.
STEP 4: Remove ST-08s and ST-07. Remove Inner race.
• Remove retainer.
• Remove gear ①, hub dog ②and spring washer ③.
• Remove spacer ①.
• Press PTO shaft to remove from gearbox.
②
①
③
①
STEP 4
STEP 1
STEP 2
STEP 3
3 ST-08s?
Y
es
No
Press Release
S
T
-08

Service Manual
Effectivity: HKS700E after S/N 100600 - 11 -
3.6 Front cover removal
3.6.1 Drive gear removal
• Block crankshaft with ST-02.
• Remove nut ①M25 and washer ②.
• Shift to remove drive gear ③.
• Remove 12 bolts ①M6.
• Shift to remove front cover.
ST-02
①
②③
①

Service Manual
Effectivity: HKS700E after S/N 100600 - 12 -
3.7 Rear cover removal and disassembly
• Remove oil filter with oil filter wrench.
• Remove 10 bolts ①M6.
• Shift to remove rear cover.
NOTE: Do not lose the thrust washer ②.
3.7.1 Oil pump disassembly
• Remove bolt ①.
• Remove spring and valve.
• Remove 5 bolts ①M6.
• Remove oil pump cover. ②
• Remove inner rotor ①(25mm).
• Remove woodruff key ②.
• Shift to remove pump body ③(25mm).
②③
①
①
①
②
②
①

Service Manual
Effectivity: HKS700E after S/N 100600 - 13 -
• Remove inner rotor ①(15mm).
• Remove woodruff key ②.
• Shift to remove pump body ③(15mm).
• Shift to remove inner feed rotorAssy ①.
①
②
③
①

Service Manual
Effectivity: HKS700E after S/N 100600 - 14 -
3.8 Stator removal
• Block crankshaft with ST-02.
• Remove bolts ①M10.
• Remove stator with tightening ST-03 (M16 x P1.5).
• Remove woodruff key ①.
ST-02
①
①
S
T
-0
3

Service Manual
Effectivity: HKS700E after S/N 100600 - 15 -
3.9 Starter idler gear and Driven gear removal
• Remove idler gear ①, idler shaft ②and 2 thrust
washers ③.
• Remove driven gear ①by turning clockwise (left).
3.10 Flywheel removal
• Block crankshaft same as 1.8
• Remove 6 bolts ①M8.
• Shift to remove flywheel ②.
③
①
②
①
①
②

Service Manual
Effectivity: HKS700E after S/N 100600 - 16 -
3.11 Cylinder head removal
• Remove 5 bolts ①M5 and cylinder head cover.
• Remove head cover gasket.
CAUTION: Do not damage contact surface!
• Rotate crankshaft to set piston to bottom dead center position.
• Remove bolt ①M5.
• Remove bolt ②M6.
CAUTION: Do not remove ②M6 first!
• Remove 4 nuts ①M8.
• Shift to remove rocker arm compartment.
• Lift out push rods; stop oil dripping by sealing with finger.
NOTE: Identify both push rods to IN / EX.
• Shift to remove cylinder head.
• Remove gasket ①.
①
EX IN
①
①
②

Service Manual
Effectivity: HKS700E after S/N 100600 - 17 -
3.11.1 Cylinder head disassembly
• Remove bolt ①M5 and banjo bolt ②M10.
• Remove oil jet pipe ③.
• Compress valve spring with valve spring mounting device and
clamp or similar tool.
• Remove valve cotters and release valve spring.
• Remove valve spring retainer, valve springs and valve.
NOTE: To prevent damage to valve guide, trim out burrs which may be present on valve
stems prior to the removal of valves.
• Remove valve spring seat.
①
②
③

Service Manual
Effectivity: HKS700E after S/N 100600 - 18 -
①
3.12 Cylinder and Piston disassembly
NOTE: Identify both cylinders and pistons to RH/LH.
• Rotate crankshaft to set piston to top dead center position.
• Shift to remove cylinder. Support piston by hand to avoid
damaging piston and piston rings.
• Remove gasket ①.
• Remove piston pin circlip ①using the specially shaped
screwdriver.
• Pull out to remove piston pin.
• Remove piston.
CAUTION: Make sure to install rings in initial position.
• Remove piston rings usingthe piston ring pliers.
• Pull to remove hydraulic lifters ①from crankcase.
• Soak the hydraulic lifters in cup of oil.
①
①

Service Manual
Effectivity: HKS700E after S/N 100600 - 19 -
3.13 Crankcase disassembly
• Remove 2 bolt ①M6.
• Remove 8 bolts ①M6.
• Remove 2 bolts ②M8.
• Remove 4 bolts ③M10.
• Set crankcase on ST-01.
• Attach ST-04 at mounting
boss.
• Split crankcase with tightening ①bolt.
①
①
③
②
S
T
-01
S
T
-04
①