Saito FA-30S (H) User manual

SINGLE-CYLINDER 4-STROKE ENGINES
Version 2000
INSTRUCTION MANUAL
• FA-30S (H)
• FA-30S Golden Knight
• FA-50
• FA-50 Golden Knight
• FA-56
• FA-56 Golden Knight
• FA-65
• FA-65 Golden Knight
• FA-72
• FA-72 Golden Knight
• FA-80
• FA-80 Golden Knight
• FA-91 Special
• FA-91S Golden Knight
• FA-120 Special
• FA-120S Golden Knight
• FA-150
• FA-150 Golden Knight
• FA-180
• FA-180 Golden Knight
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 1

VERY
IMPORTANT
Failure to read
and follow these
instructions before
you proceed to
start your engine
may result in
engine damage
and the voiding of
your warranty.
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 2

Introduction
Congratulations on purchasing a Saito
4-cycle engine. When cared for
properly, these high-quality, finely
crafted engines offer many years of
modeling enjoyment.
This instruction manual has been
developed to ensure optimum
performance from the Saito engine you
have purchased. The instructions must
be read through completely and
understood thoroughly prior to
mounting and running the engine.
Safety Instructions
This model engine will give you
considerable pleasure, satisfaction, and
performance if you strictly follow
these safety instructions and take heed
of the warnings as to its safe and
proper use. Remember at all times
it is not a toy, but a precision-built
machine with more than enough power
to cause harm if misused or if the
safety precautions are not observed.
You should always:
1. Mount the engine securely in a
“bench mount” or high-quality motor
mount. Never clamp the engine in
a vice.
2. When running the engine, be sure
all spectators, especially children, are
at least 20 feet away.
3. Use the correct size and pitch
of propeller for your engine; refer
to the "Propeller Chart" on page 16 of
this manual.
4. It is extremely important to balance
the propeller prior to installation of the
engine. Failure to do so may cause
damage to the Saito engine and/or the
airframe. Install the propeller with the
convex (curved) side facing forward.
Securely tighten the propeller nut
against the washer and propeller. An
anti-loosening nut (or “jam” nut) is
suggested for all 4-cycle engines.
5. Inspect the tightness of the propeller
nut prior to each flight.
6. Keep your face and body away
from the path of the propeller blades
when starting or running your engine.
7. Never allow your hands to come
close to the propeller. Utilize either
a “chicken stick” or electric starter to
start the engine.
8. Discard any propeller that is nicked,
scratched, cracked or damaged in any
way.
9. Make all carburetor adjustments
from behind the propeller.
10. To stop the engine, cut off the fuel
supply (pinch or disconnect the fuel
line to the carburetor) or use the
throttle linkage to shut off the air.
S A F E T Y I N S T R U C T I O N S 1
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 3

Do not use hands, fingers, or any other
part of the body to stop the propeller.
Do not throw any object into a
propeller to stop it.
It is highly recommended that:
• Safety glasses or goggles be
used when starting and running
your engine.
• You do not run the engine in the
vicinity of loose gravel or sand.
The propeller may throw such
materials into your face and eyes.
The engine may also ingest these
harmful materials.
• Loose clothing should be avoided
when operating your model engine.
Loose clothing may become
entangled in the propeller, creating
the possibility of bodily harm.Also,
all loose objects (screwdrivers,
pencils, nickle cadmium starters, etc.)
should be removed from your
pockets so that they do not fall
into the propeller.
• Glow plug clips and cords are kept
away from the propeller.
• Your glow fuel is kept in a safe place
well away from sparks, heat, or
anything that can ignite the fuel.
Beware:
• Model engines get very hot while
running. Do not attempt to handle
them until they have cooled.
• Always run your model engines in a
well-ventilated area. Similar to
automotive engines, model engines
produce possible harmful carbon
monoxide fumes.
• Remember that model engines
produce a substantial amount of
power, more than enough to seriously
injure people and/or do considerable
damage to property. Always use
common sense, skill and constant
observation of safety precautions.
Disassembly
Do not needlessly disassemble your
Saito engine. Only qualified
individuals should perform engine
repairs. Damage due to improper
disassembly will not be covered under
warranty. If it becomes necessary to
repair the engine, such as after a crash,
you can send your engine to the
authorized service center at:
Horizon Hobby, Inc.
Attention: Saito Service
4105 Fieldstone Road
Champaign, IL 61822
Phone: [phone]
2 S A F E T Y I N S T R U C T I O N S
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 4

Engine Parts
Identification
It is important to be able to identify the
parts of your Saito engines. Attached
you will find an exploded view of a
Saito 4-stroke engine, as well as charts
that include part numbers and
descriptions. This will assist you in
easily and rapidly identifying the
respective parts of your Saito engine.
Support Equipment
Thefollowingitems,whicharenotincluded
withyourSaitoengine,arenecessaryin
ordertooperatethemodelengine:
1. Fuel. For maximum protection and
longevity of Saitoengines, Saito
recommends a fuelcontaining 20% oil
and 10-15% nitro methane. If this blend is
not readily available, the next best
selection is a high quality 2-cycle glow
fuel,such as Hangar 9Aero-Blend,
Omega,Cool Power, K&B, Power
Master, etc.Use of fuels composed
entirely of castoroil is not recommended.
Amix of synthetic-castor oilis acceptable
and can be found in the various fuels
described above.
2. Propeller. Refer to the "Propeller
Selection" chart, located on page 16, to
determine the best initial propeller for
your particular application. Propellers
should be balanced prior to use.
3. Glow Plug Battery. Your glow
plug may be properly heated by
several different sources. The Hangar 9
Power Panel (HAN106), when
accompanied by a 12-volt Sealed Lead
Acid Battery (HAN102) and a Glow
Plug Locking Socket (HAN120) is an
ideal source of heat for your glow
plug. A conventional 1.5-volt heavy-
duty dry cell battery with a Glow Plug
Locking Socket (HAN120) or alligator
clips may also be used. Additionally,
there are several very good glow-
starters (nickel cadmium-powered
glow plug igniters) that work well.
4. Glow Plug Wrench. Used to
removeand tightenglow plugs.The
Hangar9 Long Reach PlugWrench
(HAN2510) is an excellent wrench to
utilize, as a longer shaft may be necessary
to access the glowplug.This depends
mostlyupon engineinstallation.
5. Manual or Electric Starter. For
manual starts, a “chicken stick” is
highly recommended. Never use
your fingers to start any model engine.
To do so invites injury. There are a
variety of electric starters on the
market. The Hangar 9 12V heavy-duty
Super Starter (HAN110) will work
perfectly on all Saito engines.
6. Tachometer. The use of a
tachometer for setting the high-speed
needle valve prior to flight is
encouraged. It will also be helpful
when setting the idle adjustment of the
carburetor(s).
S U P P O R T E Q U I P M E N T 3
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 5

Break-In
The first run on any engine, whether
2-cycle or 4-cycle, is critical to the
future of the engine itself. During this
time, metal mating parts (piston and
cylinder, ball bearings, etc.) wear in.
Care must be taken that the engine is
clean and free of any dust or grit that
may have accumulated while building
the model.
There are two accepted methods for
breaking in a new engine: test stand
mounted and run or aircraft mounted
and run. Either method is acceptable;
however, mounting the engine to a test
stand allows the engine to be observed
throughout its operation, as well as
elevating it above the ground and away
from harmful dust and dirt.
Note: Because your engine may have
been siting for an extended period of
time prior to running it, a few drops of
light oil applied through the crankcase
breather nipple (19 on the exploded
view) and down the push-rod tubes
(40) will ensure proper lubrication for
the first run.
Regardless of the mounting method
chosen for break-in, the following
procedures are applicable:
1. Use of a fuel as described in the
“Support Equipment” section on
page 3 of this manual for “break-in”
purposes is perfectly acceptable.
2. Use the proper glow plugs. Your
engine includes the Hangar 9/McCoy
MC-4C (HAN3010) glow plugs,
which are standard replacement glow
plugs for these engines.
3. To select the correct propeller, refer
to the "Propeller Selection" chart on
page 16 of this manual. Remember to
balance the propeller prior to use.
4. Ensure that the high-speed needle
valve (85) is opened (turned
counterclockwise) five full turns. This
guarantees a very rich setting
Do not adjust the low-speed needle
valve (89) at this time. The low-speed
needle valve is preadjusted at the
factory for initial break-in. Specific
instructions for adjusting the idle
of engines (FA-30S(H)) using an
“air-bleed” type carburetor will be
described in the section “Carburetor
Adjustments for Air Bleed
Carburetors” on page 7.
5. The use of a tachometer is highly
recommended since the adjustment of
a 4-cycle engine, while similar to that
of a 2-cycle engine, is more difficult to
“set by ear,” making it much easier to
damage the engine by “over-leaning.”
4 S T A R T I N G T H E E N G I N E
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 6

Starting The Engine
1. Make sure the glow plug(s) is/are
installed and tightened.
2. Be sure the propeller is properly
secured. The use of an anti-loosening
nut, or “jam nut,” is encouraged on
4-cycle engines.
3. Make sure that the fuel tank line(s)
are properly connected. The fuel
pickup line should be connected to the
carburetor spray bar (84), and the vent
line should be connected to the
pressure nipple on the muffler. The
proper “plumbing” of the lines is
extremely important to the
performance of any engine. Saito
recommends the tank be mounted
approximately 5 mm lower than the
carburetor center.
4. Be certain that the muffler is
installed properly by oiling the threads
prior to inserting the muffler into the
cylinder head and that the pressure line
is properly connected.
5. Fill the fuel tank.
6. Prime the engine:
• Check to make sure the glow plug is
not connected to the heat source
(glow plug clip/locking socket)
• Open the throttle fully
• Rotate the propeller in a counter-
clockwise direction 5 to 6 times
while plugging the end of the muffler
with your finger to draw fuel into
the carburetor.
Note: Saito single cylinder engines
are now manufactured without the
choke valve (92). Due to the excellent
fuel draw characteristics of the Saito
engines, the use of the choke was
determined not to be necessary.
7. Start the engine:
• Turn through the prop 2 to 3 times
slowly to ensure that the engine is
not hydro-locked (see note below).
Note: When using an electric starter,
care should be taken to be sure the
engine does not become “hydro-
locked” (flooded with fuel). While the
electric starter will turn the engine
over, it may damage the connecting
rod or other components. If the engine
becomes hydro-locked, simply remove
the glow plug and turn the engine over
a few times with the “chicken stick” or
electric starter. The excess fuel will be
forced to exit the engine via the
cylinder head.
• Close throttle to 1/4– 1/3
open position.
• Rotate propeller clockwise until it is
against the compression stroke.
S T A R T I N G T H E E N G I N E 5
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 7

• Connect the heating source to the
glow plug.
• Using either the “chicken stick” or
electric starter, spin the propeller until
the engine is running.
Note: A very common error is to
remove the glow plug igniter too early.
It is suggested that the igniter be left
attached until after the engine has been
run up and the high-speed needle valve
has been properly adjusted.
8. Initial break-in:
Do not exceed 4,000 rpm for the first
10 minutes of operation. This allows
all parts to mate properly with good
lubrication.
Note: Due to the excessively “rich”
mixture setting, it may be necessary to
leave the heat source attached to the
glow plug.
Subsequent runs may be made while
slightly leaning out the mixture with
each tank full of fuel. Forty minutes is
considered sufficient time for normal
break-in prior to the first flight.
9. After break-in:
If a test stand was used for the break-in
procedure, the engine may now be
mounted in the aircraft using a high-
quality motor mount such as those
available from Saito specifically or for
Saito engines.
The idle needle valve (89) (or air bleed
needle valve) for the Saito .30S(H)/
GK engines) may now be refined.
Please refer to the "Carburetor
Adjustments" section on page 6 for
information on how to do so.
The valves may also be checked at this
time. Refer to the "Engine
Maintenance" section on page 8 for
information on the valve/tappet
adjustments.
The use of a tachometer is encouraged
for setting the high-speed needle valve
(85) prior to flight. The peak rpm
should be obtained and then reduced
by approximately 200 – 300 rpm by
turning the high-speed needle valve
counter-clockwise (richen). Each
engine’s peak rpm can be found on the
"Propeller Chart" on page 16. Over-
revving of a 4-stroke engine can cause
internal damage to the engine.
Carburetor
Adjustments for Two
Needle Carburetors
The low-speed, or idle needle valve
(89), is preadjusted at the factory for
best performance during break-in.
After break-in it may be necessary to
“fine tune” the low speed adjustment
using the following procedure:
1. Start the engine and let it warm up
prior to attempting any adjustments.
6 S T A R T I N G T H E E N G I N E
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 8

2. Close the throttle slowly and adjust
the low speed setting by rotating the
idle needle valve (89) clockwise to
lean the mixture and counterclockwise
to richen the mixture.
Note: The fuel mixture is too rich if
when openning the throttle rapidly the
engine emits white smoke and
“stutters” or “stumbles.” Correct this
by rotating the idle needle valve
clockwise 1/4to 1/2turn at a time
until the engine transitions smoothly
without hesitation upon opening the
throttle rapidly.
The fuel mixture may be too lean if the
engine stops at the lowest idle position,
or when the throttle is rapidly opened
from idle. Attempt to correct this by
rotating the idle needle valve counter-
clockwise 1/4to 1/2turn at a time until
the engine transitions smoothly without
hesitation upon opening the throttle
rapidly. If the situation is not rectified
by counterclockwise rotations of the
idle needle valve, turn the idle
needle valve clockwise in 1/4to 1/2
turn increments.
3. After obtaining the proper idle
setting, the low rpm setting may be
made through the positioning of the
throttle adjustment screw, if applicable.
If not, adjust the idle setting via the
throttle trim of your transmitter.
Carburetor
Adjustments for Air
Bleed Carburetors
Note: The Saito FA-30S(H) and
FA-30SGK use an air bleed carburetor.
1. Start the engine and let it warm up
prior to attempting any adjustments.
2. Close the throttle slowly and adjust
the airscrew setting by rotating the
airscrew (89) counterclockwise to lean
the mixture and clockwise to richen the
mixture.
Note: The fuel mixture is too rich if
when openning the throttle rapidly the
engine emits white smoke and
“stutters” or “stumbles.” Correct this
by rotating the airscrew counter-
clockwise 1/4to 1/2turn at a time until
the engine transitions smoothly without
hesitation upon opening the throttle
rapidly.
The fuel mixture may be too lean if the
engine stops at the lowest idle position
or if the engine stops when the throttle
is rapidly opened from idle. Attempt to
correct this by rotating the airscrew
clockwise 1/4to 1/2turn at a time until
the engine transitions smoothly without
hesitation upon opening the throttle
rapidly. If the situation is not rectified
by clockwise rotations of the airscrew,
turn the airscrew counter-clockwise in
1/4to 1/2turn increments.
C A R B U R E T O R A D J U S T M E N T S 7
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 9

3. After obtaining the proper idle
setting, the low rpm setting may be
made through the positioning of the
throttle adjustment screw, if applicable.
If not, adjust the idle setting via the
throttle trim of your transmitter.
Normal Engine
Operation
If break-in was accomplished on a test
bench your engine may be mounted to
the aircraft and flown. The initial flight
should be performed with the engine
adjusted for a rich fuel mixture.
1. Your Saito engine should be
securely mounted to the aircraft. There
are many motor mounts available;
however, a high-quality metal mount,
such as those manufactured by Saito
exclusively for Saito engines, is
considered to be the best.
2. General operating procedures that
will ensure long engine life are:
• Do not operate the engine with a
“lean” mixture.
• Regularly check all screws and nuts
on both the engine and muffler.
• After 1 to 2 hours of operation, valve
adjustment may be necessary. Adjust
the valves as shown in the "Engine
Maintenance" section.
• The Saito engines are equipped with
a breather nipple (19). It is
recommended that a length of
silicone tubing be attached to this
crankcase breather nipple (19) and
routed away from the engine
compartment so the excess oil can be
expelled outside of the aircraft.
Engine Maintenance
Do not needlessly dismantle your
Saito single cylinder engine.
If you must disassemble your single
cylinder engine, please refer to the
following steps. Remember, a qualified
individual should do disassembly.
1. Cylinder screws should be loosened
in a criss-cross pattern.
2. Assemble the cam gear lining up the
timing mark at the “6 o’clock”
position. The crankshaft must be
positioned at the “12 o’clock” or
“top dead center” (TDC) position
(refer to Figure 1 below).
>insert Figure 1 here
8N O R M A L E N G I N E O P E R A T I O N
Figure 1
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 10