Rato R80 User manual

GASOLINE ENGINE
R80-R440 HORIZONTAL SHAFT
SERVICE MANUAL
CHONGQING RATO POWER
MANUFACTURING CORPORATION

This manual contains information about how to perform routine maintenance and how to do
troubleshooting.
Keep this manual handy, so you can refer to it at any time.
This service manual describes correct methods for maintaining this equipment. If any
personal casualty or equipment damage is caused due to disregard of our rules, our company
does not assume any responsibility.
NOTICE:
Copyright is reserved, and no part of this publication may be reproduced without RATO
Company’s written permission.

SAFETY MESSAGES
Your safety and the safety of others are very important. We have provided important safety
messages in this manual and on the generator. Please read these messages carefully.
A safety message alerts you to potential hazards that could injure you or others. Each safety
message is preceded by a safety alert symbol and one of three words: DANGER,
WARNING, or CAUTION. These messages mean:
You WILL be KILLED or SERIOUSLY INJURED if you don’t follow
instructions.
You CAN be KILLED or SERIOUSLY INJURED if you don’t follow
instructions.
You CAN be INJURED if you don’t follow instructions.
Your generator or other property could be damaged if you don’t
follow instructions.

CONTENTS
1. INTRODUCTION ·············································································································· 1
1-1 PARTS DESCRIPTION····························································································· 1
1-2 SPECIFICATION ······································································································ 2
1-3 SERVICE LIMIT······································································································· 3
2. DIMENSIONS AND TORQUE·························································································· 6
2-1 ENGINE DIMENSIONS··························································································· 6
2-1-1 R100······················································································································· 6
2-1-2 R80/R160/R180/R200/R210/R225 ·································································· 7
2-1-3 R270/R280/R300····························································································· 8
2-1-4 R390/R420/R440····························································································· 9
2-2 TORQUE VALUES ································································································· 10
2-3 STANDARD Torque valueS ···················································································· 12
3. MAINTENANCE ············································································································· 13
3-1. Maintenance schedule····························································································· 13
3-2 engine oil ················································································································· 14
3-3 Air cleaner ··············································································································· 15
3-4 Cleaning of the fuel filter························································································· 15
3-5 spark plug cleaning and adjusting ············································································ 16
3-6 valve clearance adjustment ······················································································ 16
3-7 governor··················································································································· 17
4. DISASSEMBLING AND SERVICING ··········································································· 18
4-1 Troubleshooting······································································································· 18
4-1-1 Hard starting·································································································· 18
4-1-2 Engine lacks power························································································ 20
4-1-3 Speed is unstable ··························································································· 21
4-1-4 Motor is unable to start·················································································· 21
4-1-5 Exhaust gas color is abnormal ······································································· 22
4-1-6 Unable to ignite ····························································································· 22
4-1-7 Oil alert system malfunction·········································································· 23

4-1-8 GASOLINE ENGINE IS OVERERHEATED ··············································· 23
4-2 Preparation of servicing ··························································································· 24
4-2-1 Safety precautions ························································································· 24
4-2-2 Special tools ·································································································· 28
4-3 DISASSEMBLING chart ························································································ 29
4-4 Engine······················································································································ 30
4-4-1 Recoil starter·································································································· 31
4-4-2 Flywheel········································································································ 33
4-4-3 Air cleaner ····································································································· 35
4-4-4 Carburetor······································································································ 37
4-4-5 Cylinder head /valve······················································································ 40
4-4-6 Crankshaft/piston··························································································· 46
4-4-7 Starting control box ······················································································· 55

1
1. INTRODUCTION
1-1 PARTS DESCRIPTION
Throttle grip
Fuel tank
Recoil starter
Muffler
S
p
ark
p
lu
g
Choke lever
Air cleaner
Fuel tank cove
r
Start handle
Drain plug
Oil dipstick

2
1-2 SPECIFICATION
Model
items R210 R225
L×W×H 390×320×345mm 390×320×345mm
Dry Weight 16.5 kg 16.5kg
Engine Type 4-stroke, OHV, single cylinder
Displacement 212 cm3 223cm3
Compression Ratio 8.5±0.3
Bore×Stroke 70×55 mm 70×58mm
Maximum Output Power 4.2／3600 rpm 4.4kW/3,600rpm
Maximum Torque 12N·m/2500rpm 13N·m/2,500rpm
Cooling System Forced Air-cooled
Ignition System Transistorized Magneto Ignition(TCI)
Spark Plug BPR6ES(NGK)，NHSP LD F7RTC，F7TC
Lubrication System Forced Splash
PTO Shaft Rotation Counterclockwise
Model
items R420
L×W×H 465×415×440mm
Dry Weight 28kg
Engine Type 4-stroke, OHV, single cylinder
Displacement 420cm3
Compression Ratio 8.5：1
Bore×Stroke 90×66mm
Maximum Output Power 8.5kW/3,600rpm
Maximum Torque 25N·m /2,500rpm
Cooling System Forced Air-cooled
Ignition System Transistorized Magneto Ignition(TCI)
Spark Plug BPR6ES(NGK)，NHSP LD F7RTC，F7TC
Lubrication System Forced Splash
PTO Shaft Rotation Counterclockwise

3
1-3 SERVICE LIMIT
1-3-1 R210
Parts Item Standard Value Service Limit
Gasoline
Engine
Maximum Speed (No Load)
Cylinder Compression
3750-3810rpm
1.17Mpa≧（1400rpm）--
Cylinder Cylinder Bore I.D. 70.0-70.015 mm 70.165mm
Cylinder
Head Warpage -- 0.10mm
Piston
Skirt O.D.
Piston-to-Cylinder Clearance
Piston Pin Bore I.D.
Piston Pin O.D.
Piston Pin-to-Piston Pin Bore Clearance
69.965-69.985 mm
0.015-0.050mm
18 .002-18.008 mm
18.0-17.994 mm
0.002-0.014mm
69.845mm
0.12mm
18.048mm
17.954mm
0.06mm
Piston Rings
Ring Side Clearance：Top /Second Ring
OilRing
Ring End Gap: Top /Second Ring
OilRing
Ring Width：Top /Second/Oil Ring
0.035-0.070mm
--
0.2-0.35mm
0.2-0.7mm
1.5-1.450 mm
2.5-2.450 mm
0.15mm
--
1.0mm
1.0mm
1.37mm
2.37mm
Connecting
Rod
Small End I.D.
Big End I.D.
Big End Oil Clearance
Big End Side Clearance
18.005-18.020mm
30.020-30.033mm
0.040-0.063mm
0.1-0.7mm
18.07mm
30.066mm
0.12mm
1.1mm
Crankshaft Crankshaft pin O.D 29.970-29.980mm 29.920mm
Valve
Valve Clearance
Stem O.D
Guide I.D
Stem-to-Guide Clearance
Seat Width
Spring Free Length
IN
EX
IN
EX
IN／EX
IN
EX
0.15±0.02mm
0.20±0.02mm
5.468 -5.48mm
5.425 -5.44mm
5.50-5.512 mm
0.02-0.044mm
0.06-0.087mm
0.7-0.9 mm
30.0 mm
--
--
5.318mm
5.275mm
5.572mm
0.1mm
0.12mm
2.0mm
28.5mm
Camshaft CamHeight IN 27.500-27.900mm 27.450mm

4
EX
Journal O.D
27.547-7.947mm
13.966 -13.984mm
27.500mm
13.916mm
Crankcase
Cover Camshaft Holder I.D. 14-14.018mm 14.048mm
Carburetor
Main Jet
Float Height
Pilot Screw Opening
0.85
13.7±1.5mm
2-1/8 circle
--
--
--
Spark Plug Gap 0.7-0.8mm --
Spark Plug
Cap Resistance 7.5-12.5kΩ--
Ignition Coil
Resistance
Air gap
Primary Coil
Secondary Coil
0.8-1.0Ω
5.9-7.1kΩ
0.4-0.6mm
--
--
--
1-3-2 R420
Parts Item Standard Service limit
Engine
Maximum speed (No load)
Cylinder compression
3750-3850rpm
1.2Mpa≧（1400rpm）--
Cylinder
head Sleeve I.D 90-90.015mm 90.17mm
Cylinder
head Warpage -- 0.10mm
Piston
Skirt O.D.
Piston-to-cylinder clearance
Piston pin bore I.D.
Piston pin O.D
Piston pin-to-piston pin bore clearance
89.96-89.97 mm
0.03-0.055 mm
20.002-20.008 mm
19.992-19.998 mm
0.004-0.016 mm
89.85mm
0.27mm
20.042mm
19.950mm
0.08mm
Piston rings
Ring side clearance: first/ second
Oil
Ring end gap: first/second
Oil
Ring width：first/second
Oil
0.02-0.06mm
--
0.2-0.4 mm
0.2-0.7 mm
1.960-1.990mm
1.960-1.975 mm
0.15mm
--
1.0mm
1.0mm
1.940mm
1.940mm
Connecting
rod
Small end I.D
Big end I.D
20.011-20.022 mm
36.025-30.039 mm
20.07mm
36.07mm

5
Big end oil clearance
Big end side clearance
0.25-0.65 mm
0.1-0.4 mm
0.12mm
1.0mm
Crankshaft Crankshaft pin O.D 35.975-35.985 mm 35.92mm
Valve s
Valve clearance
Stem O.D
Guide I.D
Stem clearance
Seat width
Spring free length
IN
EX
IN
EX
IN/EX
IN
EX
0.15±0.02-
0.20±0.02mm
6.565-6.590 mm
6.535-6.550 mm
6.6-6.615 mm
0010-0.040mm
0.050-0.080mm
0.65-0.95
38.5-39.5mm
--
--
6.44mm
6.4mm
6.66mm
0.11mm
0.13mm
2.0mm
37.5mm
camshaft
Cam height
Journal O.D
IN
EX
32.59mm
32.07
15.966-15.984 mm
32.54mm
32.02mm
15.92mm
Crankcase
cover Camshaft holder I.D 16.000-16.018 16.050mm
Carburetor
Main jet
Float height
Pilot screw opening
Φ1.1
13.2±1.5 mm
2-1/4
--
--
--
Spark plug Gap 0.7-0.8mm --
Spark plug
cap Resistance 7.5-12.5kΩ--
Ignition coil
Resistance
Air gap
Primary coil
Secondary coil
0.6-0.9Ω
5.6-6.9kΩ
0.3-0.5mm
--
--
--

6
2. DIMENSIONS AND TORQUE
2-1 ENGINE DIMENSIONS
2-1-1 R100/R80

7
2-1-2 R160/R180/R200/R210/R225

8
2-1-3 R270/ R280/R300

9
2-1-4 R390/R420/R440

10
2-2 TORQUE VALUES
Ser.
no. Part MODEL Part description and specifications
Torque
value Connecting components
1 Oil drain plug
R100
R160-R225
R270-R440
M10×1.5×15 8.8-A
M10×1.5×15 8.8-A
M12×1.5×18 8.8-A
22±2 Oil drain plug-flat
washer-crankcase
2 Oil sensor
R100
R160-R225
R270-R440
M6×14 8.8-A
M6×14 8.8-A
M6×16 8.8-A
8±2
Oil sensor-crankcase
R100
R160-R225
R270-R440
M10×1.5 8-A 7±1
3 Connecting rod
R100
R160-R210
R225
R270-R420
R440
M6×25 10.9-A
M7×32 10.9-A
M5×32 10.9-A
M8×35 10.9-A
M8×35 10.9-A
12±1
13±1
8±1
15±1
18±1
Connecting rod
cover-crankcase-connecting
rod
4 Crankcase
cover
R100
R160-R420
M6×25 8.8-A
M8×32 8.8-A
11±2
28±2
Crankcase cover-crankcase
gasket-crankcase
5 Flywheel
subassembly
R100
R160-R225
R270-R300
R390-R440
M12×1.25 8-A
M14×1.5 8-A
M16×1.5 8-A
M16×1.5 8-A
55±4
75±4
95±4
133±4
Starter
pulley-impeller-flywheel
subassembly-crankcase
assy.
6 Ignition coil
R100
R160-R225
R270-R440
M6×20 8.8-A
M6×25 8.8-A
M6×28 8.8-A
11±1 Ignition coil-crankcase
7 Cylinder head
subassembly
R100
R160-R225
R270-R440
M6×20 10.9-A
M8×32 10.9-A
M8×35 10.9-A
32±2
30±2
40±3
Cylinder head
subassembly- gasket-
crankcase
8 Rocker shaft
bolt
R100
R160-R225
R270-R440
M8×1.25 8.8-A
M8×1.25 8.8-A
M8×1.25 8.8-A
24±2 Rocker shaft bolt- cylinder
head subassembly
9 Cylinder head
cover
R100 M6×12 8.8-A 10±1 Cylinder head cover
subassembly - cylinder

11
subassembly R160-R225
R270-R440
M6×12 8.8-A
--
head subassembly
10 Spark plug R100-R440 M14×1.25 30±4 Spark plug-cylinder head
subassembly
11 Cylinder
shroud
R100
R160-R210
R270-R4440
M6×10 8.8-A
M6×8 8.8-A
M6×12 8.8-A
10±2 Cylinder shroud-cylinder
head subassembly
12 Lower shield
R100
R160-R225
R270-R440
--
M6×16 8.8-A
--
10±2 Lower shield- crankcase
13 Oil protector
R100
R160-R225
R270-R440
--
M6×12 8.8-A
M6×12 8.8-A
8±2 Oil protector - crankcase
14 Shroud
R100
R160-R225
R270-R440
M6×12 8.8-A
M6×12 8.8-A
M6×12 8.8-A
10±2 Shroud- crankcase
15 Recoil starter
R100
R160-R225
R270-R440
M6×8 8.8-A
M6×8 8.8-A
M6×8 8.8-A
10±2 Recoil starter- shroud
16 Air cleaner R100-R440 M6 8-A 10±2 Air cleaner- gasket-
carburetor
17 Throttle control
subassembly
R100
R160-R225
R270-R440
M6×8 8.8-A
M6×12 8.8-A
M6×12 8.8-A
10±2
Throttle control
subassembly- crankcase -
cylinder head subassembly
18
Governor
support
subassembly
R100-R400 M6 8-A 8±1
Governor support
subassembly - Governor
arm- governor support
subassembly
19 Charging coil
subassembly
R100
R160-R225
R270-R440
--
M6×28 8.8-A
M6×32 8.8-A
10±2 Charging coil subassembly
- crankcase
20 Charging coil
clamp
R100
R160-R225
R270-R440
--
M6×10 8.8-A
M6×10 8.8-A
10±2 Charging coil clamp -
crankcase
21 Starter motor R100 -- 11±1 Starter motor subassembly -

12
subassembly R160-R225
R270-R440
M6×35 8.8-A
M6×30 8.8-A
crankcase
2-3 STANDARD TORQUE VALUES
Item Specifications Torque valve
N·m Kg·m
Standard
torque
5mm bolt, nut 5.5 0.55
6mm bolt, nut 10 1.0
8mm bolt, nut 21 2.4
10mm bolt, nut 37.5 3.75
12mm bolt, nut 55 5.5

13
3. MAINTENANCE
3-1. MAINTENANCE SCHEDULE
Good maintenance is essential for safe, economical, and trouble-free operation. It will also
help reduce air pollution.
Exhaust gas contains poisonous carbon monoxide. Shut off the
engine before performing any maintenance. If the engine must be
running during maintenance, make sure the area is well ventilated.
Periodic maintenance and adjustment are necessary for keeping the generator in a good
operating condition. Perform the service and inspection at the intervals shown in the
Maintenance Schedule below:
Time option Eachuse
First month
or 20 Hrs.
(3)
Every 3
months or 50
Hrs. (3)
Every 6
months or 100
Hrs. (3)
Every year or
300 Hrs.
(3)
Oil Check ○
Oil Replace ○○
Air cleaner element
Check ○
Air cleaner element
Clean ○※
Fuel strainer Clean ○
Spark plug Clean
Adjust ○
Valve gap Check
Adjust ○
Fuel tank, fuel element
Clean ○
Fuel tube Check
Replace
Every 2 years (2
Every 4 years (4)
Clean the air cleaner o※nce every 10 hours or once every day when engine is used in dusty
areas.

14
3-2 ENGINE OIL
●Oil change
1）Dismount the oil filler cap and oil
drain bolt to drain dirty oil.
2）Tighten the oil drain plug
See 2-2-1Maintenance Standard
3）Add the clean oil from the filler neck.
R100 Oil capacity 0.35L
R160/R180/R200/R210/R225 Oil capacity 0.6L
R270/R300/R390/R420 Oil capacity 1.1L
Recommended oil
General oil: SAE15W-40 SJ class or equivalent API classifie
d
SJ class SAE10W-30 oil.
In※a low temperature range （below 10℃）,use oil with the
grade higher than SAE10W-30。
In※a cold environment（temperature is below -15℃）, use
SAE5W-30，or equivalent API classified SJ class SAE5W-30
oil.
4）After filling, check oil level. If the oil is insufficient, add the oil to the upper limit.
CAUTION: Run with insufficient engine oil may damage the engine severely.
Oil di
p
stic
k
Oil drain plug Oil drain hole
Lowe
r
limit
Uppe
r
limit