Rato RV170 User manual

RV160 RV170
SERVICE MANUAL
Chongqing Rato Power Co., Ltd

CONTENT
CONTENT
1. INTRODUCTION ................................................................................................................ 1
1-1 Parts Description......................................................................................................... 1
1-2 Specifications.............................................................................................................. 2
1-3 Service Limit RV160............................................................................................... 2
2. DIMENSION AND TORQUE .............................................................................................6
2-1 Dimension................................................................................................................... 6
2-2 The Position Of Installing Hole..................................................................................7
2-3 PTO Installing Drawing.............................................................................................. 7
2-4 Torque Value............................................................................................................ 10
2-5 Standard Torque Value.............................................................................................11
3. MAINTENANCE...............................................................................................................12
3-1 Maintenance Schedule.............................................................................................. 12
3-2 Engine Oil................................................................................................................. 12
3-3 Air Cleaner ...............................................................................................................14
3-4 Wash The Strainer....................................................................................................15
3-5 Spark Plug................................................................................................................. 15
3-6 Valve Clearance Adjustment.................................................................................... 16
3-7 Governor...................................................................................................................18
4. DISASSEMBLING AND SERVICING.............................................................................19
4-1 Troubleshooting........................................................................................................19
4-1-1 Starting Difficult ........................................................................................... 19
4-1-2 Power Lack.................................................................................................... 21
4-1-3 Speed Unstable..............................................................................................22
4-1-4 Unable Igniting.............................................................................................. 22
4-1-5 Gasoline Engine Is Overheat......................................................................... 23
4-1-6 Abnormal Sound ........................................................................................... 23
4-2 Preparation Of Servicing.......................................................................................... 24
4-2-1 Safety Precautions......................................................................................... 24
4-2-2 Special Tools................................................................................................. 25

CONTENT
4-3 Dismounting Chart ................................................................................................... 26
4-4 Gasoline Engine........................................................................................................ 27
4-4-1Recoil starter / fan cover ................................................................................ 27
4-4-2 Muffler .......................................................................................................... 30
4-4-3 Fuel Tank....................................................................................................... 31
4-4-4 Air Cleaner.................................................................................................... 32
4-4-5 Governor........................................................................................................ 34
4-4-6 Carburetor...................................................................................................... 36
4-4-7 Flywheel........................................................................................................ 41
4-4-8 Cylinder Head / Valve...................................................................................45
4-4-9 Crankshaft / Piston........................................................................................ 53
4-5 Electric Diagrams..................................................................................................... 62

1. INTRODUCTION
1
1. INTRODUCTION
1-1 Parts Description
SPARK PLUG
START HANDLE
OIL DIPSTICK
MUFFLE
R
AIR CLEANER
FUELTANK COVER

1. INTRODUCTION
2
1-2 Specifications
MODEL
ITEM
RV160
RV170
L×W×H(not including
crankshaft output terminal)
395×348×282(mm)
395×348×282(mm)
Dry Weight
12.1Kg or 13.7kg
12.5Kg or 13.7Kg
Engine Type
Single Cylinder Horizontal,4-Stroke, OHV
Displacement
163cc
173.2cc
Bore ×Stroke
68mm×45mm
70mm×45mm
Theoretical Maximum Power
3.0kW/3,600r/min
3.2kW/3,600r/min
Recommended Using Power
2.3Kw /3600r/min
2.4 kW/3,400r/min
Maximum Torque
8.8N·m/2,500r/min
9.0N·m /2,500r/min
Fuel Consumption
395g/ kw·h
395g/kw·h
Cooling System
Forced Air
Ignition System
Capacitance Discharge Type or Inductance Discharge Type
PTO Shaft Rotation
Vertical Shaft Output
1-3 Service Limit RV160
PARTS
ITEM
STANDARD
SERVICE
LIMIT
Engine
Maximum Speed (No Load)
Idle Speed
Cylinder Compression
3400±100rpm
1900±100rpm
1.38Mpa/1200rpm
--
--
--
Cylinder Head
Sleeve I.D
68
68.165
Cylinder Head
Warpage
--
0.10
Piston
Skirt O.D.
Piston–to-Cylinder Clearance
Piston Pin Bore I.D.
Piston Pin O.D
Piston Pin-to-Piston Pin Bore Clearance
67.985
0.015-0.050
18.002-18.008
17.994-18.00
0.002-0.014
67.845
0.12
18.048
17.954
0.08
Piston Rings
Ring Side Clearance：second
Ring Enc Gap: second
Ring Width：second
0.030-0.065
0.2-0.4
1.5
0.15
1.0
1.37
UNIT：mm

1. INTRODUCTION
3
Connecting Rod
Small End I.D
Big End I.D
Big Oil Clearance
Small End Side Clearance
18.005-18.020
30.020-30.033
0.040-0.063
0.1-0.7
18.052
30.066
0.12
1.1
Crankshaft
Crankshaft Pin O.D
29.970-29.980
29.92
Valve
Valve Clearance
Stem O.D
Guide I.D
Stem Clearance
Seat Width
Spring Free Length
IN
EX
IN
EX
IN/EX
IN
EX
0.10±0.02
0.15±0.02
5.468-5.480
5.435-5.450
5.500-5.512
0.020-0.044
0.050-0.077
0.8
34.0
--
--
5.318
5.275
5.562
0.10
0.12
2.0
32.5
Camshaft
Cam Height
Journal O.D
IN
EX
27.70
27.75
13.966-13.984
27.45
27.50
13.916
Crankcase Cover
Camshaft Bracket I.D
14.0
14.048
Carburetor
Main Jet
Float Height
Pilot Screw Opening
#65
13.7
2-5/8turns
--
--
--
Spark Plug
Gap
0.7-0.8
--
Spark Plug Cap
Resistance
3.75-6.25kΩ
--
Ignition Coil
Resistance
Air Gap
Primary coil
Secondary coil
（at flywheel）
0.8-1.0Ω
5.9-7.2kΩ
0.4±0.2
--
--
--
RV170
PARTS
ITEM
STANDARD
SERVICE
LIMIT
Engine
Maximum Speed (No Load)
Idle Speed
Cylinder Compression
3400±100rpm
1900±100rpm
1.38Mpa at 1200rpm
--
--
--

1. INTRODUCTION
4
Cylinder Head
Sleeve I.D
72
71.165
Cylinder Head
Warpage
-
0.10
Piston
Skirt O.D.
Piston–to-Cylinder Clearance
Piston Pin Bore I.D.
Piston Pin O.D
Piston Pin-to-Piston Pin Bore Clearance
69.985
0.015-0.050
18.002-18.008
17.994-18.00
0.002-0.014
69.845
0.12
18.048
17.954
0.08
Piston Rings
Ring Side Clearance：second
Ring Enc Gap: second
Ring Width：second
0.030-0.065
0.2-0.4
1.5
0.15
1.0
1.37
Connecting Rod
Small End I.D
Big End I.D
Big Oil Clearance
Small End Side Clearance
18.005-18.020
30.020-30.033
0.040-0.063
0.1-0.7
18.052
30.066
0.12
1.1
Crankshaft
Crankshaft Pin O.D
29.970-29.980
29.92
Valve
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±0.02
5.468-5.480
5.435-5.450
5.500-5.512
0.020-0.044
0.050-0.077
0.8
34.0
5.318
5.275
5.562
0.10
0.12
2.0
32.5
Camshaft
Cam Height
Journal O.D
IN
EX
27.70
27.75
13.966-13.984
27.45
27.50
13.916
Crankcase Cover
Camshaft Bracket I.D
14.0
14.048

1. INTRODUCTION
5
Carburetor
Main Jet
Float Height
Pilot Screw Opening
#65
13.7
2-5/8turns
--
--
--
Spark Plug
Gap
0.7-0.8
--
Spark Plug Cap
Resistance
3.75-6.25kΩ
--
Ignition Coil
Resistance
Air Gap
Primary coil
Secondary coil
（at flywheel）
0.8-1.0 Ω
5.9-7.2 kΩ
0.35~0.45mm
--
--
--

2. DIMENSION AND TORQUE
6
2. DIMENSION AND TORQUE
2-1 Dimension

2. DIMENSION AND TORQUE
7
2-2 The Position Of Installing Hole
2-3 PTO Installing Drawing
P1 Shaft P2 Shaft
P1 Shaft P2轴
SEAT FACE
SEAT FACE

2. DIMENSION AND TORQUE
8
P3 Shaft P26 Shaft
P27 Schaft P28 Schaft
SEAT FACE
SEAT FACE
SEAT FACE
SEAT FACE

2. DIMENSION AND TORQUE
9
P29 Shaft
SEAT FACE

2. DIMENSION AND TORQUE
10
2-4 Torque Value
ITEMS
FASTENERS
TORQUE VALUE (N·m )
Connection-Rod Bolt
M7×1.0
12±1
Governor Gear Bolt
M6×12
10±2
Crankcase Cover Bolt
M8×50
26±1
Spark Plug
M14-1.25
18±2
Cylinder Head Bolt
M8×50
26±1
Rotation Shaft Bolt
M8 ×1.25
24±2
Rotation Shaft Locked Nut
M6 ×0.5
10±1
Cylinder Head Cover Bolt
M6×12
6±1
Ventilation Chamber Cover Bolt
M6×12
10±1
Side Shield Bolt
M6×12
10±2
End Shield Bolt
M6×16
10±2
Brake Bolt
M6×12
10±2
M6×20
10±2
Flywheel Nut(Aluminum)
M14×1.5
52±4
Flywheel Nut(Cast Iron)
M14×1.5
78±4
Ignition Wire Bolt
M6×25×1.0
10±2
Stud
M6×86
12±2
M6×88
12±2
Fuel Tank Support Bolt
M6×12
10±2
Fuel Tank Bolt
M6×14
6±2
Recoil Starter Reel Nut
M6
10±2
Throttle Control SubAssemble Bolt
M6×28
10±2
Air Cleaner Nut
M6×1.0
10±2
Governor Support Nut
M6×1.0
6±1
Muffler Support Bolt
M6×12
10±2
Muffler Bolt
M6×80
10±2
Muffler Cover Bolt
M6×12
10±2
Engine Cover Bolt
M5×16
6±1
Drain Plug
M10 ×1.25
15-20(18)
For unspecified bolt, screw and nut, refer to the standard torque value.

2. DIMENSION AND TORQUE
11
2-5 Standard Torque Value
FASTENERS
SPECIFICATION
TORQUE VALUE(N·m )
Bolt, Nut
5mm Bolt, Nut
4.5-6
6mm Bolt, Nut
8-12
8mm Bolt, Nut
18-25
10mm Bolt, Nut
29-34
12mm Bolt, Nut
49-59
4mm Screw
1.5-2.6
5mm Screw
3.5-5
6mm Screw
7-11
5mm Flange Bolt
3.6-6.9
6mm Screw
7-11
5mm Flange Bolt
3.6-6.9
6mm Flange Bolt
10-14
8mm Flange Bolt
20-26
10mm Flange Bolt
35-45

3. MAINTENANCE
12
3. MAINTENANCE
3-1 Maintenance Schedule
FREQUENCY
ITEM
EACH
TIME
FIRST MONTH
OR 20 HRS
EACH SEASON
OR 50 HRS
EVERY 6
MONTH OR 100
HRS
EACH YEAR
OR 300 HRS
Engine Oil
Oil Level
Check
√
Replace
√
√
Air Cleaner
Check
√
Clean Replace
√
Oil Alert
System
Check
√
Spark Plug
Clean,Adjust
√
Replace
√
Oil Strainer
Clean
√
Valve
Clearance
Check-Adjust
√*
Cylinder
Head
Clean
√*
Fuel Tank
Replace
Every three years
*These items should be serviced by company authorized dealer, unless you have the
proper tools and mechanically proficient.
3-2 Engine Oil
● Engine oil is a key factor in deciding the engine’s
performance. Do not apply engine oil with additives or
2-stroke gasoline engine oil, because they haven’t enough
lubrication, and may shorten the engines service life.
●Check the engine with it stopped on a level ground.
● Engine oil capacity: RV160 & RV170 0.6L
Engine oil recommended: SAE 10W-30

3. MAINTENANCE
13
When the temperature in your area is in the frame of the above chart, you can use other
viscosity of engine oil.
CHECK METHOD
1. Remove the dipstick and clean it.
2. Reinsert the dipstick into the oil filling hole without screwing it, and check oil level.
3. If the oil level is too low, add the recommended engine oil up to the oil upper limit.
4. Reinstall the dipstick.
OIL CHANGE
Used engine oil contains substances that have been identified as carcinogenic. If
repeatedly left in contact with the skin for prolonged periods, it may cause skin cancer.
Wash your hands thoroughly with soap and water as soon as possible after contact with
used engine oil.
Please dispose of used oil in manner that will pollute the environment. We suggest you
take it in a sealed container to your local service station or recycling center for
reclamation. Do not throw it in the trash or pour it on the ground.
a) Screw the oil dipstick off.
b) Tilt the engine to drain the oil from the hole.
SEALING RING
(Don’t Refuse)
OIL UPPER LIMIT
OIL LOWER LIMIT
OIL HOLE
OIL DIPSTICK

3. MAINTENANCE
14
3-3 Air Cleaner
Wash the engine each 50 hrs (or 3 months). (Wash more frequently in dust area)
Remove the air cleaner cover and take the element out.
Change the damaged element.
Clean the element before reusing.
Clean the element：
Foam Element
Wash the element with detergent and dry it.
Immerse the element into the oil and squeeze the excessive oil. The element should
be wet, but not drop the oil.
Paper Element
Blow the compressed air from the inner side or lightly tap to move the dust. If dirty
badly, replace in time.
Be careful to prevent dirt from entering the air duct that leads to the carburetor.
Place the foam element over the paper element, and cover the case cover on.
BREATHE TUBE
GASKET
CASE
AIR CLEANER ELEMENT
COVER
NUT M6

3. MAINTENANCE
15
SPARK PLUG CAP
SPARK PLUG SOCKET WRENCH
0.70~0.80mm
SIDE ELECTRODE
3-4 Wash The Strainer
Don’t smoke or use fire near the flammable solvent.
a) Fill the fuel into the container
b) Remove the fuel tube, screw the
strainer bolt off.
c) Check the strainer for damage and
clean the strainer.
d) After Cleaning, install the strainer on
the fuel tank and connect the fuel tube.
e) Check for leaking.
3-5 Spark Plug
a) Remove the spark plug cap. Clear away dirt around
the spark plug base
b) Dismantle the spark plug with a spark plug wrench.
c) Visually check the spark plug. Clean with a Steel brush.
If the insulator is damaged, replace the spark plug
instead.
d) Measure the spark plug clearance with a
feeler. The clearance should be 0.7~0.8mm.
If adjustment is necessary, bend the side
electrode carefully.
CLIP
OILTUBE
STRAINER
FUELTANK

3. MAINTENANCE
16
e) To avoid cross-threading, first, screw in spark plug by hand,
then tighten with a spark plug wrench to compress the gasket.
f) If a new spark plug is used, more twist 1/2 turns after
compressing the gasket.
g) If reinstalling the used spark plug, just more twist 1/8-1/4 turns.
Spark plug torque value：18±2N·m
Spark Plug Type：F7TC
The spark plug must be tightened securely, or it may become very hot to damage the
engine. Only use recommended spark plug or the equivalent. Incorrect heat range of
the spark plug may damage the engine.
3-6 Valve Clearance Adjustment
Measure the valve clearance in the cold of the engine state.
a) Remove the bolt（M6×12）, cylinder head cover, gasket, spark plug cap and spark plug.
SPARK PLUG
SPARK PLUG CAP
BOLT M6×12
CYLINDER HEAD COVER
GASKET