Saito FG-40 User manual

SwitchCapacity:3A~
Sensor Battery
Voltage:6-12V
Capacity:1,000mA〜
Plugcap
(2)Sensorcord
(Black)
(1)Plugcord
Mainunit
(3)BatteryCord
(Red/Black)
(4)Tachometercord
FG-40InstructionManual
Fueltank FuelLevel
ToOutsideoftheplane
Ventline
fuelsupplytocarburetor
Fuelfillerline
Ventline
Gasoline-compatible
tankstopper
Gasoline-compatibletubing
Filterwithweight
Closeaspossible(within200mm)
Hollowout
oradjustusingthe
mountspacers(option)
Firewall
Enginecenter
Throttlelever
Slowneedle
CCW
torich
CW
tolean
CCW
torich
CW
tolean
Mainneedle
1.Fuel
●Thefuelisamixtureofcommercialregulargasolineandreliableoilfor2-strokeengines.
●[Exampleofoilrecommendation]
・KlotzKL-200OriginalTechniplate・DeluxeMaterialsPowerModel2T-S・ENEOSRACINGSPECPRO-2T(SAITOSTANDARD)etc.
Ifsuchoilsarenotavailableinyourcountry,thenpleaseasktheofficialSAITOdistributorinyourcountryforanalternative.
●Besuretousethemixture“gasoline:oil=15~20:1”byvolumeratio.(Ex.1000mlofgasolineshouldbemixedwithmorethan50mlofoil).
●InBreak-inprocess,use15:1mixedfueltoensurethebestlubricationforinitialrun.
●Anydamagecausedbythefuelused,inwhichtheoilratioislowerthan20:1ratio,isnotwarranted.
●Donotusegasolineethanolmixed.Itmaycausenotonlypowerlossbutalsocorrosioninsidetheengine.
Φ40.0mm 32.0mm 40.2cc
19”x10”~21”x8”
・Filterwithweight[G36-154] ・DurabletubeforGasoline(1m)[G36-155] ・Mountspacer[G40-169]
・Aluminumspinnernut[120S-30] ・Tappetadjustingkit[120S-161]  ・Digitaltachometer[G17-167]
Bore
Mainbody:1,260g/Muffler:90g/Ignition:100g
Stroke Disp.
Weight(Approx.） Practicalspeed Approx.1,800-8,000rpm Maxonground Approx.6,500-7,500rpm
Propeller CM-6Plug
Optionalparts
4-strokeglow200classApplications
Batteryforignitionsystem
・Limitgauge(0.1t)fortappetadjustment1pc ・Wrenchfortappetadjustinglocknut1pc ・Carburetoradjustmentbar 1pc
・Sparkplug[CM-6](Attachedtotheengine)1pc ・Mufflerset  1set ・Chokebar  1pc
・Ignitionsystem（w/sensor） 1set ・Plugwrench   1pc ・Enginemountset 1set
・Anti-looseningnut 1pc ・Hexagonalwrench  1set
Specifications
Standard
accessories
Voltage:6-12V,greaterthan1,000mA ※
※IfyouuseaLi-Po,werecommendthespeclessthan2,500mAcapacityand
lessthan30Cdischargerate
2.Ignition
●Placethemainunitasfarfromotherelectricaldevicesaspossible.
●PlacethetwoswitchesoftheignitionandtheRCreceiverasfar
fromeachotheraspossible.
(1)Plugcord(meshedhightensioncord)
Insertthecapdeeplyontotheplugtomakesureitwillnotcomeoff.
(2)Sensorcord
Connectwiththecordfromthesensorattachedtotheengine.
(3)Batterycord(black/redcord)
Useafullychargedbatterythathasadequatespec.(6-12V,more
than1000mAisrecommended.).Betweenthebatteryandmainunit,
makesuretoinstallaheavydutyswitchwhosecapacityishigher
than3A.
(4)Tachometercord(optional)
Connectthedigitaltachometer(Option).Otherwisetheconnectorisnormallyvacant.
4.Methodofchoke(Noneedwhenyouusestarter)
※Chokingisthemeansbywhichfuelisfedtotheenginewhenyoustartitbyhandflipping.Thusitisunnecessarywhenusingstarter.
Startingwithaelectricstarterisrecommendedforsafety.
●Inadvance,makeathinholeinthecowlingtoinsertthechokebar/slowneedleadjustmentbar.
●Duringchoking,besuretoturnofftheignitionswitch.
●Asshowninthefig,passthechokebar(withM3.5threadonitstip)throughtheholein
thecowling.ThenturnthebartoinsertintotheM3.5internalthreadatthecenterofthe
throttlelever.
●Fullyclosethethrottleandpullthechokebarandfixitwithacliporclampasshownin
thefigsothatitmaynotgobacktothepreviousposition.
●Graspthepropbyhandandturnitseveraltimesinthedirectionofnormaloperation
(CCW)untilthecarburetorgenerateshissing-likesound.Afterhearingthissoundfor
about5times,quicklyflipthepropapproximately10times.
●Removethechokebar.Thenpowerontheignitionsystemandflipthepropquicklyto
starttheengine.Iftheenginedoesnʼtstart,repeatthechokingprocedure.
3.Propeller
●TheStandardpropisMejzlikD20”xP8”whichbringsapprox.6,900rpm(orFalconD20”xP8”bringsapprox.6,400rpm).
Largersizeorgreaterpitchcancauseenginebrokenduetooverload.
●Useawell-balancedone.Neverusethepropellerthathasbeenscratchedordamagedevenifslightly.
●Asthepropelleriscompressedslightly,tightenthepropellernuteveryhourofoperation.
Cowling
Chokebarforinsert
M3.5screw
Throttlelever
Throttlevalve
(Movetotheleft)
Slowneedle
Chokebar
Temporaryfixed
byaclip
ver.Feb,2021
5.Break-inMOSTIMPORTANT!!
●Prop-recommendation:20”x8”carbonpropforbreak-in.
●Use15:1fuel:oilratioforbreak-in.
●NevermakethefuelmixtureleanduringBreak-in.Itcouldcauseseizureevenduringidlingorlowspeedrunning.
●Beforestartingtheengine,openthemainneedleApprox.3turnsandslowneedleApprox.5turnsopen(CCW)fromfullyclosed.
●Starttheengine(usingastarterisrecommendedforsafety).
●Soonafterstarting,Openthethrottlegraduallyuptofullopen.InthemeantimeturnthemainneedleCCW.Continuetoturnthemain
needleCCWuntiltheRPMdeclines(toapprox.4,000rpm),keepingthethrottlefullyopened.
●IfopeningmainneedledoesnʼtdropRPM,thenopentheslowneedletoo.
●Runinthisveryrichconditionfor1literoffuel.
●Now“initial”break-inisdone.
6.Adjustmentofcarburetorafterinitialbreak-in.
◇Needlereferenceposition(Setafterinitialbreak-in)
●Starttheengineafteradjustingtheneedletothefollowingreferencevalue.
●Mainneedle：Approx.2~2.5turnsCCWfromfullyclosed
●Slowneedle：Approx.4.5~5turnsCCWfromfullyclosed(Thenthrottleshouldbefully
closed)
●Actually,thebestpositionoftheneedlesvarydependingontheprop,temperature,
humidityandsoon.Pleaseadjustasnecessaryafterobservingtheengineperfor-
manceduringflight.
◇Peakadjustment
●Afterstartingtheengine,warmupforapprox.30secondsatlowspeed.
●Achievethepeakatfullthrottle.
→TurnthemainneedleCWgraduallytothepositionwheretheRPMisgreatest(thepeak).ContinuingtoturntheneedleCWpastthe
peakcouldleadtoseizuresoturnitslowlyandcarefully.IftheRPMsuddenlydecreasesafterpassingthepeak,instantlyturnthemain
needleCCWtoagainincreasetheRPM.Otherwiseitcoulddamagetheengineseriously.
●OnceachievingpeakRPM,returnthethrottletolowspeed.Makeanoteofthepositionofmainneedleatthepeakatthattime.
(HowmanyturnsyoudidCWbasedonthereferencevalue.)
◇SlowneedleAdjustment
●AfterachievingpeakRPM,nextisslowneedleadjustment.OpenthethrottlefromlowRPMtofullthrottlequickly.
●IftheenginehesitatesforamomentorstallsbeforetheenginereachesmaxRPM,Itʼsbecausethemixtureistoolean.Thenturntheslow
needleCCWslightly.
●IftheengineisslowtoreachpeakRPM(fullthrottleset),itʼsbecausethemixtureistoorich.ThenturntheslowneedleCWslightly.
●AdjusttheslowneedleasaboveuntiltheRPMfollowsthethrottlemovementsmoothly.Theimportantpointistoadjusttheslowneedle
AFTERthemainneedlehasbeenadjustedtoitspeak.
●Nowbreak-inatgroundlevelisdone.Adjusttappetsbythemethoddescribedlater.
◇Pre-flight/Flightadjustment
●Whentheslowneedleadjustmentisdone,checktheresponsebyrevvingupfromlowspeedtofullthrottlequicklyseveraltimes.
●OpenthethrottlefullyandturnthemainneedleCCWapprox.60〜90degreesfromthepeakposition.Thisistomakethefuelmixture
richerintheairwheretheRPMgethigherthanontheground.
●Afteralladjustmentsaremade,flyyouraircraftandfinetunetheengineaccordingtothesituation.Basicallytuningshouldbedonewith
themainneedle.Readjustmentoftheslowneedleisrarelyneededifthefirstadjustmentoftheslowneedlehasbeendonesuccessfully.
7.Tappetadjustment
Thevalveclearanceshouldbecheckedandadjustedafterbreak-inandeverytimeaftertwohourswhiletheengineiscold.Beforeadjusting
tappetgaps,tightenupthescrewsaroundcylindersetc.
2.Loosenthelocknutandadjust
thegapbyhexagonalwrench
untilyougetthecorrectgapfor
bothofintake&exhaust.
3.Oncethegapisset,tightenthe
locknutandattachtheplugand
covers.
4.Turnthepropbyhandtocheckifthe
compressionisenough.Ifthegapisless
than0,thevalveisalwaysopened
slightlyandwilllosecompression.Then
adjustagain.
1.Removethesparkplugandrocker
armcoversofthecylinder.Then
turnthepropCCWbyhandto
placethepistonatTDCof
compressionstroke.
CorrectGap
Mustnotbeinserted
Closeto“0”withnolimit
Limitgauge
(0.1mm)
Loosenthelocknut
Adjustthegapturning
thesetscrew
TopDeadCenter
（bothvalvesareclosed) Tightenthelocknut
tofixthesetscrew
Note:
●Asitusesoil-mixedfuel,theplanemaysometimesgetdirtyfromtheexhaust.
●Useareliableandwell-balancedprop.Otherwiseitmaycauseanabnormalvibrationandcouldresultinaseriousaccident.
●Duringoperation,allenginescrewscanloosenduetometalheatexpansion.Checkandtightenoccasionally.
●Whentheexhaustvalvegetsdullbycarbonorsludgeespeciallyincoldatmosphere,removetherockercoverandapplysomeanti-rust
spraytotheexhaustvalvetohelpthevalvetomovesmoothly.
●Payattentiontothesurroundingssoasnottodisturbothersbynoiseandexhaust.
●Alwayskeepspectatorsbehindtheenginewhenoperatingtheengine.

64
129
28
M8x1.25
69
86
70
54
27
4-Ø4.3
35
35
71
155.5
84.5
44 16
30
Outsidedimensions
●Asexhaustsmokeisharmful,becarefulnottobreatheinorotherwiseexposeyourselftoitsharmfuleffects.
●Payattentionnottotouchtherotatingpropellerwhenstartingengine,andmovetorearsideoftheaircraftoncetheengineisstarted.
●Allresponsibilitiesfortheuseoftheengine,andotherobligationsandresponsibilitiesbasedonlaws,regulations,etc.arebornebythe
purchaserandtheuser,andSAITOSEISAKUSHOCO.,LTD.isexemptfromanyresponsibilities.
Warranty:
●Ifthereisanydeficiencyfromthefactoryconcerningmanufacture,pleaseconsultwiththeshopordistributoryouboughtfrom.Our
companywillberesponsibleforrepair.However,anyfailureortroublecausedbyunnecessarydisassembly,modification,orotherusesthan
thoseprovidedintheinstructionmanualisnotsubjecttowarranty.
●Ignitionsystemissubjecttothewarrantyonlyforinitialfailure.Oncethesystemhasbeenactivatedsuccessfully,itwillnolongerbesubject
towarranty.
SAITOSEISAKUSHO,CO.,LTD.www.saito-mfg.com
22-7,3-chome,Tokagi,Ichikawa-shi,Chibaprefecture272-0024,JapanPhone:047-378-4156FAX:047-378-4155
Allspecificationsandmodelsaresubjecttochangewithoutnotice.
FG-40PartsList
No.
01
06
07
08
09
10
14
15
17
19
20
22
23
27
28
31
32
33
35
36
37
38
39
40
41
42
Qty
1
1
1
2
1
1
1set
1
1
1
1
1
1
1ea.
1ea.
1set
1set
1
1
1
1set
2
2
2ea.
2
2ea.
Item
Cylinder
Piston
Pistonpin
Pistonpinretainer
Pistonring
Connectingrod
Cylinderscrewset
14-1,-2,-3,-4
Crankcase
Rearcover
Breathernipple
Frontballbearing
Rearballbearing
Crankshaft
Tapercollet&driveflange
27-1,-2
Propwasher&Nut
28-1,-2
Crankcasescrewset
31-1,-2,-3
Enginegasketset
32-1,-2,-3,-4.-5.-6.-8
Camgearhousing
Camgear
Camgearshaft
Steelwasherset
Tappet
Pushrod
Pushrodcover&Rubberseal
40-1,-2,-3
Rockerarm
Rockerarmscrew&nut
41-1,-2
No.
43
44
45
46
47
48
49
69
74
75
80
82-1
83-1
90
91
93
95
110
120
149
152
153
Qty
2
1
1
1set
2ea.
2
2
1
1
1set
2
1set
1set
1set
1set
1
1set
1
1
1
1
1set
Item
Rockerarmpin
Rockerarmbracket(left)
Rockerarmbracket(right)
Valveset(In&Ex)
46-1,-2
Valvespring&Keeper&Retainer
47-1,-2,48
Valveretainer
Rockerarmcover
Intakemanifold(Intakepipe)
Muffler
Mufflermanifoldset
75-1,80
Mufflernut
Carburetorcomplete
Carburetorbodyassembly
82-1-1,-1-2,-1-3,-1-4,-1-5,-1-13
Carburetorscrew&springset
82-1-9,-1-10,-1-11,-1-12
Carburetorgasketset
82-1-6,-1-7,-1-8
Intakevelocitystack(airfunnel)
Enginemountset
95-1,-2,-3,-4,-5
Antilooseningnut
Sparkplug(CM-6)
Oilslinger
Screwpin(Fordriveflangesetting)
Electronicignitionsystem
153-1,-2,-3,-4,-5
153
153ｰ1
153ｰ4
153ｰ3
153ｰ2