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

3. Reassemble the piston, rod, rocker
arm, pins, pushrod, tappet, etc., in their
original positions. Engine parts are
mated after running the engine and
they must be reassembled as close as
possible to their original position.
4. Assemble the engine, reversing the
criss-cross pattern used in the
disassembly. Prior to tightening each
of the screws, apply a drop of oil to
prevent thread damage.
Normal engine maintenance, such as
adjusting the valves or carburetor
maintenance, is permissible without
voiding the warranty. If you have
any questions concerning
maintenance procedures, please
contact the Saito Service Center at
[phone]. Our technicians will
be happy to advise you on
maintenance issues.
Valve/Tappet Gap
Adjustment
After approximately one hour of
operation, tappet gap adjustment may
be necessary. When you check the
valves, lubricate the moveable parts.
Also make sure the screw is in tight
before making adjustments to valves.
Adjust the valves to a clearance of
.03 mm to .10 mm (.002"– .004")
using the supplied gauge. The valves
must be adjusted with the engine cold
due to thermal expansion.
Note: Valves must be in the
compression stroke or closed position
as shown in Figure 2 below. When
adjustment is completed, make sure
you tighten the lock nut.
>insert Figure 2 of tappet adjust here<
E N G I N E O P E R A T I O N 9
Figure 2
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 11

10 C A R B U R E T O R M A I N T E N A N CE
Carburetor
Maintenance
Should you experience difficulty with
the carburetor of your engine:
1. Check the position of the idle
needle valve (89) by fully opening the
throttle barrel (87). Look down
through the barrel and check the
space between the idle needle and the
spray bar (84). The spacing should be
approximately 1mm. If not, adjust
accordingly. Refer to Figure 3 below.
Note: Step 1 applies to .50 through
.80 engines only.
>insert Figure 3 illus of carb opening here<
2. Remove the high-speed needle
(85) and flush out the spray bar with
clean fuel. Replace the high-speed
needle and follow the instructions in
the Carburetor Adjustment section.
3. Always use a high-
quality 4-cycle glow plug.
The Hangar 9/McCoy MC-4C is
highly recommended.
Tips For Extended
Engine Life
To add longer life to your Saito
engine, the following
recommendations are made:
1. Use a high-quality fuel containing
20% lubricants.
2. Use recommended glow plugs.
3. Use the proper propeller size and
balance the propeller prior to use.
4. Use a tachometer for precise
engine adjustments.
5. Use an “after-run” oil when you’re
finished flying for the day. Hangar 9
After Run fuel is recommended.
6. For long-term storage, make sure
there is no fuel left in the tank and the
engine. Remove the glow plug(s) and
apply several drops of high-quality
light oil (e.g., a good quality light
machine oil or Marvel Air Tool Oil)
to the top of the engine, into the glow
plug hole, down the pushrod tubes,
and through the crankcase pressure
vent (breather nipple). Rotate the
crankshaft several times. Store the
engine in the box or on the airplane
with the nose down in order to keep
oil in the bearings.
Figure 3
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 12

T R O U B L E S H O O T I N G 11
Troubleshooting
Generally speaking, there are very
few things that will keep today’s
modern glow engines from starting.
To that end, make sure you’re using
good quality “fresh” fuel, there are
good glow plugs installed, and the
starting battery is charged and in good
condition. Should the engine fail to
start after these items are verified,
refer to the following troubleshooting
chart on page 12.
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 13

12 T R O U B L E S H O O T I N G
SYMPTOM CAUSE CORRECTIVE ACTION
Engine fails to Low voltage on Replace/recharge the
start starting battery starting battery
Bad glow plug(s) Inspect/replace bad glow plug
Insufficient priming Repeat priming procedure
“Flooded” due to Disconnect battery, remove the
excessive priming glow plugs, and rotate the
propeller several times to
“clear” the cylinder
Engine fires but Over primed Disconnect battery and rotate
does not run propeller several times to
“clear” cylinder
Engine starts but Mixture too rich Close high-speed needle valve
slows down and 1/2turn and start again. Repeat
then stops until engine is running smoothly.
Engine starts, Mixture too lean Open high-speed needle valve
speeds up, and 1/2turn and start again. Repeat
then quits until engine is running smoothly.
Engine quits Mixture too rich Close high-speed needle valve
when starter 1/2turn and restart
battery is
removed Incorrect glow plugs Change glow plugs
Incorrect or bad fuel Change fuel
In the event that none of the above procedures results in the engine running
properly, contact our service department for suggestions:
Horizon Service Center
4105 Fieldstone Road
Champaign, Illinois 61822
217-355-9511 (Mon-Fri 8:00-5:00 CST)
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 14

P A R T S L I S T 13
Small Single-Cylinder Cross-Reference Chart
PART NN MM E F II JJ RR SS
FA-30S-GK FA30-S (H) FA-50 FA-50GK FA-56 FA-56GK FA-72 FA-72GK
01 Cylinder, Left 30S01 30SH01 5001B 50GK01B 5601B 56GK01B 8001C 80GK01C
06 Piston 30S06 30S06 5006 5006 5606 5606 8006A 8006A
07 Piston Pin 30S07 30S07 5007 5007 6507 6507 8007 8007
08 Piston Pin Retainer (6 Pc) 30S08 30S08 5008 5008 6508 6508 8008 8008
09 Piston Ring 60T09 60T09 5009 5009 6509 6509 8009 8009
10 Connecting Rod 30S10A 30S10A 5010A 5010A 5610 5610 7210 7210
14 Cylinder Screw Set 5014 5014 5014 5014 5014 5014 6514 6514
15 Crankcase 30S15 30SH15 5015B 50GK15B 5615A 56GK15A 7215 72GK15
17 Rear Cover (A) 30S17 30SH17 5017B 50GK17B 5017B 50GK17B 7217 7217
19 Breather Nipple 30S19 30S19 5019 5019 5019 5019 6519 6519
20 Front Ball Bearing 30S20A 30S20A 5020A 5020A 5020A 5020A 6520A 6520A
22 Rear Ball Bearing 30S22 30S22 5022A 5022A 5022A 5022A 6522A 6522A
23 Crankshaft 30S23 30S23 5623A 5623A 5623A 5623A 7223 7223
24 Pinion-Crankshaft 30S24 30S24 5024 5024 5024 5024 — —
25 Pinion Gear Pin 5025 5025 5025 5025 5025 5025 — —
26 Collar, Crankshaft — — 5026 5026 5026 5026 — —
27 Tapered Collet & Drive Flange 30S27 30S27 5027 5027 5027 5027 7227 7227
28 Prop Washer & Nut 30S28 30S28 5628 5628 5628 5628 5628 5628
29 Prop Nut, Spinner — — — — — — — —
30 Prop Nut, Electric Starter 30S30 30S30 5030A 5030A 5030A 5030A 5030A 5030A
31 Crankcase Screw Set 30S31 30S31 5031 5031 5031 5031 7231 7231
32 Engine Gasket Set 30S32A 30S32A 5032A 5032A 5632A 5632A 7232 7232
33 Cam Gear Housing 30S33 30SH33 5033A 50GK33A 5033A 50GK33A 7233 7233
35 Cam Gear, Right 30S35 30S35 5035 5035 5035 5035 6535A 6535A
36 Cam Gear Shaft 30S36 30S36 5036 5036 5036 5036 7236 7236
37 Teflon/Steel Washer Set 30S37 30S37 5037 5037 5037 5037 5037 5037
38 Tappet (2 Pc) 30S38 30S38 5038 5038 5038 5038 5038 5038
39 Pushrod (2 Pc) 30S39 30S39 5039 5039 5039 5039 7239 7239
40 Pushrod Cover Rubber Seal (Pr) 30S40 30S40 5040 5040 5040 5040 7240 7240
41 Rocker Arm (Pr) 60T41 60T41 5041 5041 5041 5041 5041 5041
42 Rocker Arm Screw Nut (2 Sets) 5042 5042 5042 5042 5042 5042 5042 5042
43 Rocker Arm Pin (2 Pc) 30S43 30S43 5043 5043 5043 5043 5043 5043
44 Rocker Arm Bracket, Left — — — — — — — —
45 Rocker Arm Bracket, Right — — — — — — — —
46 Valve-In/Out (Pr) 30S46 30S46 5046 5046 5646 5646 6546 6546
47 Valve Spring, Keeper, Retainer (2 Sets) 30S47 30S47 5047 5047 5047 5047 6547 6547
48 Valve Retainer (4 Pc) 5048 5048 5048 5048 5048 5048 5048 5048
49 Rocker Arm Cover (Pr) 30SGK49 30SH49 5049 50GK49 5049 50GK49 5049 50GK49
68 Check Valve-In/Out (Pr) — — — — — — — —
69 Intake Manifold, Left — — 5069 5069 5669A 5669A 7269 7269
74 Muffler, Right 30S74 30S74 5074B 5074B 5074B 5074B 8074A 8074A
75 Muffler Manifold, Standard 30S75 30S75 5075A 5075A 5075A 5075A 8075A 8075A
79 Muffler Gasket (5 Pc) — — — — — — — —
80 Muffler Nut (2 Pc) 30S80 30S80 5080A 5080A 5080A 5080A 8080A 8080A
821 Carburetor-Complete, Left 30S821 30S821 50821B 50821B 50821B 50821B 72821 72821
822 Carburetor-Complete, Right — — — — — — — —
831 Carburetor Body Assembly, Left 30S831 30S831 50831 50831 50831 50831 72831 72831
84 Spray Bar Assembly 30S84 30S84 — — — — — —
85 High Speed Needle Valve 30S85 30S85 5085 5085 5085 5085 5085 5085
86 High Speed Needle Valve Extension — — 5086 5086 5086 5086 5086 5086
87 Throttle Barrel Assembly 30S87 30S87 5087A 5087A 5087A 5087A 7287 7287
88 Throttle Lever 30S88 30S88 5088B 5088B 5088B 5088B 5088B 5088B
89 Idle Needle Valve 30S89 30S89 5089 5089 5089 5089 130T89 130T89
90 Carburetor Screw & Spring Set 30S90 30S90 5090A 5090A 5090A 5090A 7290 7290
91 Carburetor Gasket Set 30S91 30S91 5091 5091 5091 5091 8091A 8091A
92 Choke Valve Assembly — — 5092 5092 5092 5092 5092 5092
93 Intake Velocity Stack — — — 50GK93 — 50GK93 — 50GK93
95 Engine Mount 30S95 30S95 5095 5095 5095 5095 5095 5095
96 Tool Set 30S96 30S96 5096A 5096A 5096A 5096A 5096A 5096A
97 Instruction Manual MAN1 MAN1 MAN1 MAN1 MAN1 MAN1 MAN1 MAN1
102 Fuel Pump System — — — — — — — —
109 F-1 Fuel Filler 50109 50109 50109 50109 50109 50109 50109 50109
110 Anti-Loosening Nut — — 56110 56110 56110 56110 56110 56110
111 Flexible Exhaust Pipe — — — — — — 65111 65111
112 Tuned Silencer — — — — — — 62112 65112
113 Flexible Exhaust Pipe — — — — — — — —
114 Engine Bed — — 50114 50114 50114 50114 50114 50114
115 Engine Bed — — — — — — — —
116 M3 Nut for Spinner — — 50116 50116 50116 50116 — —
117 M4 Nut for Spinner — — — — — — 65117 65117
118 M5 Nut for Spinner — — — — — — 65118 65118
122 Spray Bar/O-Ring — — 65122 65122 65122 65122 72122 72122
135 Prop Washer/Nut/Anti-Loosening Nut — — 56135 56135 56135 56135 56135 56135
136 Intake Manifold — — — — — — — —
137 Prop Washer — — — — — — — —
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 15

14 P A R T S L I S T
Medium Single-Cylinder Cross-Reference Chart
PART G H I J K EE
FA-65 FA-65GK FA-80 FA-80GK FA-91S FA-91SGK
01 Cylinder, Left 6501C 65GK01C 8001C 80GK01C 91S01A 91SGK01A
06 Piston 6506A 6506A 8006A 8006A 91S06 91S06
07 Piston Pin 6507 6507 8007 8007 91S07 91S07
08 Piston Pin Retainer (6 Pc) 6508 6508 8008 8008 6508 6508
09 Piston Ring 6509 6509 8009 8009 91S09 91S09
10 Connecting Rod 6510C 6510C 6510C 6510C 6510C 6510C
14 Cylinder Screw Set 6514 6514 6514 6514 6514 6514
15 Crankcase 6515A 65GK15A 8015A 80GK15A 91S15 91SGK15
17 Rear Cover (A) 6517A 80GK17A 6517A 80GK17A 91S17 91SGK17
19 Breather Nipple 6519 6519 6519 6519 6519 6519
20 Front Ball Bearing 6520A 6520A 91S20A 91S20A 91S20A 91S20A
22 Rear Ball Bearing 6522A 6522A 6522A 6522A 91S22A 91S22A
23 Crankshaft 6523A 6523A 8023 8023 91S23 91S23
24 Pinion-Crankshaft — — — — — —
25 Pinion Gear Pin — — — — — —
26 Collar, Crankshaft — — — — — —
27 Tapered Collet & Drive Flange 6527 6527 6527 6527 6527 6527
28 Prop Washer & Nut 5628 5628 5628 5628 5628 5628
29 Prop Nut, Spinner — — — — — —
30 Prop Nut, Electric Starter 5030A 5030A 5030A 5030A 5030A 5030A
31 Crankcase Screw Set 5031 5031 5031 5031 5031 5031
32 Engine Gasket Set 6532A 6532A 8032A 8032A 91S32 91S32
33 Cam Gear Housing 6533B 65GK33B 6533B 80GK33A 6533B 80GK33A
35 Cam Gear, Right 6535A 6535A 6535A 6535A 6535A 6535A
36 Cam Gear Shaft 5036 65GK36A 5036 5036 5036 5036
37 Teflon/Steel Washer Set 5037 5037 5037 5037 5037 5037
38 Tappet (2 Pc) 5038 5038 5038 5038 5038 5038
39 Pushrod (2 Pc) 6539 6539 6539 6539 91S39 91S39
40 Pushrod Cover Rubber Seal (Pr) 6540 6540 6540 6540 60T40 60T40
41 Rocker Arm (Pr) 5041 5041 5041 5041 5041 5041
42 Rocker Arm Screw Nut (2 Sets) 5042 5042 5042 5042 5042 5042
43 Rocker Arm Pin (2 Pc) 5043 5043 5043 5043 5043 5043
44 Rocker Arm Bracket, Left — — — — — —
45 Rocker Arm Bracket, Right — — — — — —
46 Valve-In/Out (Pr) 6546 6546 6546 6546 91S46 91S46
47 Valve Spring, Keeper, Retainer (2 Sets) 6547 6547 6547 6547 6547 6547
48 Valve Retainer (4 Pc) 5048 5048 5048 5048 5048 5048
49 Rocker Arm Cover (Pr) 5049 50GK49 5049 50GK49 5049 50GK49
68 Check Valve-In/Out (Pr) — — — — — —
69 Intake Manifold, Left 6569 6569 8069A 8069A 91S69 91S69
74 Muffler, Right 6574A 6574A 8074A 8074A 91S74 91S74
75 Muffler Manifold, Standard 8075A 8075A 8075A 8075A 8075A 8075A
79 Muffler Gasket (5 Pc) — — — — — —
80 Muffler Nut (2 Pc) 8080A 8080A 8080A 8080A 8080A 8080A
821 Carburetor-Complete, Left 50821B 50821B 80821B 80821B 91S821A 91S821A
822 Carburetor-Complete, Right — — — — — —
831 Carburetor Body Assembly, Left 50831 50831 80831A 80831A 91S831A 91S831A
84 Spray Bar Assembly — — — — — —
85 High Speed Needle Valve 5085 5085 5085 5085 5085 5085
86 High Speed Needle Valve Extension 5086 5086 5086 5086 5086 5086
87 Throttle Barrel Assembly 5087A 5087A 8087A 8087A 91S87 91S87
88 Throttle Lever 5088B 5088B 5088B 5088B 5088B 5088B
89 Idle Needle Valve 5089 5089 5089 5089 130T89 130T89
90 Carburetor Screw & Spring Set 5090A 5090A 5090A 5090A 91S90 91S90
91 Carburetor Gasket Set 6591A 6591A 8091A 8091A 91S91 91S91
92 Choke Valve Assembly 5092 5092 5092 5092 5092 5092
93 Intake Velocity Stack — 50GK93 — 50GK93 — 50GK93
95 Engine Mount 6595 6595 6595 6595 6595 6595
96 Tool Set 6596A 6596A 6596A 6596A 6596A 6596A
97 Instruction Manual MAN1 MAN1 MAN1 MAN1 MAN1 MAN1
102 Fuel Pump System — — — — — —
109 F-1 Fuel Filler 50109 50109 50109 50109 50109 50109
110 Anti-Loosening Nut 56110 56110 56110 56110 56110 56110
111 Flexible Exhaust Pipe 65111 65111 65111 65111 65111 65111
112 Tuned Silencer 65112 65112 65112 65112 65112 65112
113 Flexible Exhaust Pipe — — — — — —
114 Engine Bed 65114 65114 65114 65114 65114 65114
115 Engine Bed — — — — — —
116 M3 Nut for Spinner 50116 50116 — — — —
117 M4 Nut for Spinner 65117 65117 65117 65117 65117 65117
118 M5 Nut for Spinner 65118 65118 65118 65118 65118 65118
122 Spray Bar/O-Ring 65122 65122 65122 65122 91S122 91S122
135 Prop Washer/Nut/Anti-Loosening Nut 56135 56135 56135 56135 56135 56135
136 Intake Manifold — — — — — —
137 Prop Washer — — — — — —
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 16

Large Single-Cylinder Cross-Reference Chart
P A R T S L I S T 15
PART M FF CC GG OO PP
FA-120SH FA-120SGK FA-150 FA-150GK FA180 FA-180GK
01 Cylinder, Left 120S01A 120SGK01A 15001 150S01 18001 180GK01
06 Piston 120S06 120S06 150S06 150S06 18006 18006
07 Piston Pin 120S07 120S07 120S07 120S07 18007 18007
08 Piston Pin Retainer (6 Pc) 120S08 120S08 300T08 300T08 300T08 300T08
09 Piston Ring 120S09 120S09 300T09A 300T09A 18009 18009
10 Connecting Rod 120S10C 120S10C 120S10C 120S10C 18010A 18010A
14 Cylinder Screw Set 120S14 120S14 120S14 120S14 120S14 120S14
15 Crankcase 120S15B 120SGK15A 15015A 150S15A 18015 18015
17 Rear Cover (A) 120S17A 150S17 120S17A 150S17 18017 18017
19 Breather Nipple 6519 6519 6519 6519 6519 6519
20 Front Ball Bearing 120S20A 120S20A 12020A 12020A 120S20A 120S20A
22 Rear Ball Bearing 120S22 120S22 120S22 120S22 120S22 120S22
23 Crankshaft 120S23A 120S23A 150S23A 150S23A 18023 18023
24 Pinion-Crankshaft — — — — — —
25 Pinion Gear Pin — — — — — —
26 Collar, Crankshaft — — — — — —
27 Tapered Collet & Drive Flange 120S27A 120S27A 120S27A 120S27A 120S27A 120S27A
28 Prop Washer & Nut 170R328 170R328 170R328 170R328 170R328 170R328
29 Prop Nut, Spinner 120S29 120S29 120S29 120S29 120S29 120S29
30 Prop Nut, Electric Starter 120S30 120S30 120S30 120S30 120S30 120S30
31 Crankcase Screw Set 5031 5031 5031 5031 5031 5031
32 Engine Gasket Set 120S32 120S32 150S32 150S32 18032 18032
33 Cam Gear Housing 120S33 150S33 120S33 150S33 120S33 150S33
35 Cam Gear, Right 120S35 120S35 120S35 120S35 120S35 120S35
36 Cam Gear Shaft 5036 5036 5036 5036 5036 5036
37 Teflon/Steel Washer Set 120S37 120S37 120S37 120S37 120S37 120S37
38 Tappet (2 Pc) 120S38 120S38 120S38 120S38 120S38 120S38
39 Pushrod (2 Pc) 120S39 120S39 120S39 120S39 120S39 120S39
40 Pushrod Cover Rubber Seal (Pr) 120S40 120S40 120S40 120S40 120S40 120S40
41 Rocker Arm (Pr) 120S41 120S41 120S41 120S41 120S41 120S41
42 Rocker Arm Screw Nut (2 Sets) 120S42 120S42 120S42 120S42 300T42 300T42
43 Rocker Arm Pin (2 Pc) 120S43 120S43 120S43 120S43 120S43 120S43
44 Rocker Arm Bracket, Left 120S44 150S44 120S44 150S44 120S44 150S44
45 Rocker Arm Bracket, Right 120S45 150S45 120S45 150S45 120S45 150S45
46 Valve-In/Out (Pr) 120S46 120S46 120S46 120S46 18046 18046
47 Valve Spring, Keeper, Retainer (2 Sets) 120S47 120S47 120S47 120S47 120S47 120S47
48 Valve Retainer (4 Pc) 120S48 120S48 120S48 120S48 120S48 120S48
49 Rocker Arm Cover (Pr) 150S49 120S49 150S49 120S49 150S49 120S49
68 Check Valve-In/Out (Pr) — — — — — —
69 Intake Manifold, Left 150S69A 150S69A 150S69A 150S69A 18069 18069
74 Muffler, Right 120S74A 120S74A 120S74A 120S74A 18074 18074
75 Muffler Manifold, Standard 120S75A 120S75A 120S75A 120S75A 120S75A 120S75A
79 Muffler Gasket (5 Pc) — — — — — —
80 Muffler Nut (2 Pc) 120S80 120S80 120S80 120S80 120S80 120S80
821 Carburetor-Complete, Left 120S821C 120S821C 150S821A 150S821A 180821 180821
822 Carburetor-Complete, Right — — — — — —
831 Carburetor Body Assembly, Left 120S831B 120S831B 150S831A 150S831A 180831 180831
84 Spray Bar Assembly 450R3D84A 450R3D84A 450R3D84A 450R3D84A 450R3D84A 450R3D84A
85 High Speed Needle Valve 120S85 120S85 120S85 120S85 120S85 120S85
86 High Speed Needle Valve Extension 5086 5086 5086 5086 5086 5086
87 Throttle Barrel Assembly 120S87A 120S87A 150S87 150S87 18087 18087
88 Throttle Lever 5088B 5088B 5088B 5088B 5088B 5088B
89 Idle Needle Valve 120S89 120S89 120S89 120S89 18089 18089
90 Carburetor Screw & Spring Set 120S90A 120S90A 120S90A 120S90A 120S90A 120S90A
91 Carburetor Gasket Set 120S91 120S91 150S91 150S91 150S91 150S91
92 Choke Valve Assembly 120S92 120S92 120S92 120S92 — —
93 Intake Velocity Stack 120S93 120S93 120S93 120S93 18093 18093
95 Engine Mount 120S95 120S95 120S95 120S95 120S95 120S95
96 Tool Set 120S96 120S96 120S96 120S96 120S96 120S96
97 Instruction Manual MAN1 MAN1 MAN1 MAN1 MAN1 MAN1
102 Fuel Pump System — — — — — —
109 F-1 Fuel Filler 50109 50109 50109 50109 50109 50109
110 Anti-Loosening Nut 170R3110 170R3110 170R3110 170R3110 170R3110 170R3110
111 Flexible Exhaust Pipe 120S111 120S111 120S111 120S111 120S111 120S111
112 Tuned Silencer — — — — — —
113 Flexible Exhaust Pipe — — — — — —
114 Engine Bed — — — — — —
115 Engine Bed — — — — — —
116 M3 Nut for Spinner — — — — — —
117 M4 Nut for Spinner — — — — — —
118 M5 Nut for Spinner — — — — — —
122 Spray Bar/O-Ring 450R3D122A 450R3D122A 450R3D122A 450R3D122A 450R3D122A 450R3D122A
135 Prop Washer/Nut/Anti-Loosening Nut 170R3135 170R3135 170R3135 170R3135 170R3135 170R3135
136 Intake Manifold — — — — — —
137 Prop Washer — — — — — —
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 17

16 P R O P E L L E R S E L E C T I O N
Propeller Selection
In the chart below you will find a
propeller selection list. This chart will
enable you to select the best propeller
for initial setup of your Saito engine.
Remember, it is imperative to balance
each propeller prior to installation
onto your Saito engine. Failure to do
so may cause unwanted vibration in
your aircraft.
Figure 5
Saito Single-Cylinder Propeller Chart
NOTE: All recommendations are based on engines using APC props, Power Master 15%
2-stroke fuel, and McCoy MC-4C glow plugs.
ENGINE SPORT SCALE AEROBATICS
FA-30S (H)/30SGK
2,200 – 12,000 rpm 10 x 5 10 x 5, 10 x 6 9 x 6, 10 x 5
FA-50/50GK
2000 – 12,000 rpm 11 x 7, 11 x 8, 12 x 6 12 x 5, 12 x 6 11 x 7, 11 x 8, 12 x 6
FA-56/56GK
2000 – 12,000 rpm 11 x 8, 12 x 6, 12 x 7 12 x 6, 12 x 7 11 x 8, 12 x 6, 12 x 4
FA-65/65GK
2000 – 11,500 rpm 12 x 6, 12 x 8, 13 x 8 13 x 8, 14 x 5, 14 x 6 11 x 9, 12 x 8, 13 x 6
FA-72/72GK
2000 – 11,500 rpm 12 x 8, 13 x 6, 13 x 8, 13 x 6, 13 x 8, 14 x 6, 11 x 9, 11 x 10,12 x 8,
14 x 6 15 x 4 12 x 9
FA-80/80GK
2000 – 11,500 rpm 12 x 8, 13 x 6, 13 x 8, 13 x 6, 13 x 8, 14 x 6, 11 x 9, 11 x 10,12 x 8,
14 x 6 15 x 4 12 x 9
FA-91S/91SGK
2000 – 11,000 rpm 12 x 8, 13 x 7,13 x 8, 13 x 7, 13 x 8, 14 x 5 11 x 10, 11 x 11, 12 x 9
14 x 6, 14 x 8 14 x 6, 15 x 4 12 x 10N, 13 x 9
FA-120S/120SGK
2000 – 11,000 rpm 14 x 10,15 x 8, 15 x 10 15 x 8, 16 x 6, 16 x 8, 13.5 x 13.5, 14 x 10N
16 x 16, 16 x 8 18 x 6 14 x 12
FA-150/150GK
2000 – 10,500 rpm 15 x 8, 15 x 10, 16 x 8 16 x 8, 18 x 6, 18 x 8, 14 x 10N, 14 x 14,
18 x 6, 18 x 8 15 x 10, 15 x 11
FA-180/180GK
2000 – 11,000 rpm 15 x 8, 15 x 10, 15 x 11 16 x 8, 16 x 10, 14 x 13.5,
16 x 8, 16 x 10 18 x 6 15 x 12
NOTE: Observe operating rpm ranges as excessive rpm can result in damage to the engine.
You will note a letter (A, B,C, etc.) stamped on the top of the motor mount. This letter
identifies the production version of your engine. Should you ever need to order a part or have a
question pertaining to your engine, specify this letter along with the engine type. This will
allow for easier identification of your engine.
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 18

I
Figure 6
Figure 7
Figure 8
OUTSIDE DIMENSIONS (mm)
Items A B B1 B2 C1 C2 D E F G H I
FA-30S (H)/30S GK 36 14 — — 88 110 43 87 47 29 33 72
FA-50/FA-50GK 46 15 — — 103 130 54 102 59 32 52 84
FA-56/FA-56GK 46 15 — — 103 130 54 102 59 32 52 84
FA-65/FA-65GK 50 21 — — 113 144 60 113 66 40 55 93
FA-72/FA-72GK 46 — — — 113 136 54 112 77.5 36 59.5 94
FA-80/FA-80GK 50 21 — — 113 144 60 113 66 40 55 93
FA-91 Special/FA-91SGK 50 21 — — 114 146 60 113 66 40 55 93
FA-120 Special/FA-120SGK 59 24 — — 150 175 69 132 80 45 68 110
FA-150/FA-150GK 59 24 — — 150 175 69 132 80 45 68 110
FA-180/FA-180GK 59 24 — — 150 175 69 132 80 45 68 110
SPECIFICATIONS
Items Disp Bore Stroke Weight K Cylinder HP
(cc) (mm) (mm) (g) (ISO)
FA-30S (H)/30S GK 5.03 20 16 270
1
/4
x28 AAC —
FA-50/FA-50GK 8.2 23.4 19.0 435 M7x1 — ABC 0.85
FA-56/FA-56GK 9.2 24.8 19.0 440 M7x1 — ABC 0.93
FA-65/FA-65GK 10.6 24.8 22.0 550 M7x1 — ABC 0.95
FA-72/FA-72GK 11.8 27.0 20.6 470 M7x1 — AAC 1.2
FA-80/FA-80GK 13.1 27.0 22.8 540 M7x1 — ABC 1.3
FA-91 Special/FA-91SGK 14.9 28.2 24.0 520 M7x1 — AAC 1.7
FA-120 Special/FA-120SGK 20.0 32.0 24.8 820 M8x1.25 — AAC 2.2
FA-150/FA-150GK 25.0 34.0 27.6 850 M8x1.25 — AAC 2.5
FA-180/FA-180GK 29.1 36.0 28.6 880 M8x1.25 — AAC 2.8
E N G I N E S P E C S 17
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 19

No. Description Qty.
01 Cylinder (left) 1
06 Piston 1
07 Piston pin 1
08 Piston pin retainer 2
09 Piston ring 1
10 Connecting rod 1
14 Cylinder screw set 1 set
15 Crankcase 1
17 Rear cover 1
19 Breather nipple 1
20 Front bearing 1
22 Rear bearing 1
23 Crankshaft 1
24 Pinion (crankshaft) 1
25 Pinion gearpin
26 Collar (crankshaft) 1
27 Taper collet & drive flange 1 each
28 Prop washer & nut 1 set
29 Prop nut-spinner
30 Prop nut-electric starter
31 Crankcase screw set 1 set
32 Engine gasket set 1 set
33 Cam gear housing 1
35 Cam gear 1
36 Cam gear shaft 1
37 Steel washer set 1 set
38 Tappet 2
No. Description Qty.
39 Pushrod 2
40 Pushrod cover & rubber seal 2 each
41 Rocker arm 2
42 Rocker arm screw & nut 2 each
43 Rocker arm pin 2
44 Rocker arm bracket (left) 1
45 Rocker arm bracket (right) 1
46 Valve (in & out) 2
47 Valve spring & keeper & retainer 2 each
48 Valve retainer
49 Rocker arm cover 2
68 Checkvalve (in & out) 1 pair
69 Intake manifold 1
74 Muffler 1
75 Muffler manifold 1
77 Muffler gasket 5
80 Muffler nut 2
89 Idle needle valve 1
821 Carburetor complete 1 set
831 Carburetor body assembly 1 set
84 Spray bar assembly
85 High speed needle valve 1
87 Throttle barrel assembly 1 set
91 Carburetor gasket set 1 set
93 Intake velocity stack 1 set
102 Fuel pump system complete 1 set
110 Anti-loosening nut 1
31
33
36
38
37
32
27
06
07
24
09
46
14
32 69 87
93 92
91
44
68
47 74
75
26
28
110
10
15
01
821
102
20
35
40
39
08
22 23
25
32 17 31 19 68
14
45
48
41
84 85
831
80
14
32
49
42 43 Fuel Pump System Complete
(Optional)
choke
89
Figure 9
P A R T S L I S T
Saito Single Cyl Manual 9-00 9/11/00 10:06 AM Page 20