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
(Brown/Red/Orange)
4.Break-inMOSTIMPORTANT!!
●Prop-recommendation:awellbalancedMejzlik20”x8”carbon-made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run-
ningatlow-speed.
●Beforestartingtheengine,openthemainneedleApprox.3turnsandtheslowneedleApprox.5turns
CCWeachfromfullclose.
●Starttheengine(usingastarterisrecommendedforsafety).
●Runforabout5secondsatlowspeedtowarmup.
●Open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throt-
tlefullyopened.
●IfRPMdoesnʼtdrop,turntheslowneedleCCWtomakemixture
muchricher.
●Runinthisveryrichconditionfor2tanks.
Note:
●Asthefuelcontainsoil,theexhaustwillproducesomeresidueontheairplane.
●Usereliableandwellbalancedprop,otherwiseitcancauseabnormalvibrationandmayresultinseriousaccident.
●Duringoperation,thescrewsallovertheenginecanbeloosenbyheatexpansionofmetal.Tightenthemup
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.
●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theshopordistributoryou
purchasedfrom,sothatourcompanywillrepairthemwithresponsibility.Anyfailureortroublecausedbyunnec-
essarydisassembly,modification,orotherusesthanthoseprovidedintheinstructionmanualisnotsubjecttothe
warranty.
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.） RPMRange 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 Voltage:6-12V,greaterthan1,000mA(2-3SLi-Poor5SNiMH)
Specifications
FG-40InstructionManual
5.Needlereferenceposition(SetAfterBreak-in)
●Mainneedle：Approx.2~2.5turnsfromfullyclose
●Slowneedle：Approx.4.5~5turnsfromfullyclose（Thenthrottleshouldbefullyclosed）
●Actuallythebestconditionoftheneedlevariesdependingontheprop,temperature,humidityandso
on.Pleaseadjustbasedontheengineperformanceduringflight.
6.Tappetadjustment
ThevalveclearanceshouldbecheckedandadjustedafterBreak-inandeveryafter2hourswhilethe
engineiscold.Beforeadjustingtappetgaps,tightenthescrewsaroundcylindersetc.
1.Removethesparkplug
androckerarmcoversfrom
thecylinder.Thenturnthe
propCCWbyhandtoplace
thepistonatTDCof
compressionstroke.
2.Loosenthelocknutand
adjustthegapbyhexago-
nalwrenchuntilyouget
thecorrectgap(below
pic)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sightlyandlose
compression.Thenadjust
again.
CorrectGap
Mustnotbeinserted
Closeto“0”withnolimit
Limitgauge
(0.1mm)
2.Ignition
●Ignitionarrangement-Placethemainunitasfarfromotherelectricaldevicesaspossible.
(1)Plugcord（meshedhightensioncord)
Inserttheplugcapoftheplugcorddeeplyintotheplug
attachedtothecylinder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setaheavydutyswitch
whosecapacityishigherthan3A.
(4)Tachometercord
Connectthedigitaltachometer(Option).Otherwisethe
connectorisnormallyvacant.
3.Methodofchoke（Noneedwhenyouusestarter）
●Inadvance,makeathinholeonthecowlingtoinsertthechokebar/
slowneedleadjustmentbar.
●Duringchoking,besuretoturnofftheswitchoftheignitionsystem.
●Asshowninthefig,passthechokebar(withM3.5threadonitstip)
throughtheholeon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inthedirectionofnormaloperation
(CCW)forseveraltimes,untilthecarburetorgenerateshissing-like
sound.Afterhearingthissoundforabout5times,quicklyflicktheprop
approximately10times.
●Afterthat,removethechokebar.Afterthat,powerontheignitionsystemandflickthepropquicklytostarttheengine.
Iftheenginedoesnʼtstart,repeatthechokingprocedure.
1.Fuel
●Thefuelismixtureofregulargasolineandhigh-quality2-strokeengineoil.
●[Exampleofoilrecommendation]
・KlotzKL-200OriginalTechniplate
・DeluxeMaterialsPowerModel2T-Setc.
●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).
●Duringthebreakinprocess,use15:1mixedfueltoensurethebestlubricationforinitialrunning.
●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containingethanol.Itmaycausenotonlypowerlossbutalsocorrosioninsidetheengine.
Standard
accessories
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
FG-19R3InstructionManual
Allspecificationsandmodelsaresubjecttochangewithoutnotice.
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withthe
mountspacers(option)
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
・Enginemountset 1set ・Limitgauge(0.1t)fortappetadjustment 1pc ・Plugwrench 1pc
・Hexagonalwrench 1set ・Spannerfortappetadjustinglocknut 1pc ・Mufflerset 1set
・Anti-looseningnut 1pc ・Carburetoradjustmentbar   1pc ・Chokebar 1pc
・Ignitionsystem(w/sensor) 1set ・Sparkplug[CM-6](Attachedtotheengine) 1pc
Firewall
Enginecenter
Chokebar
Temporary
fixedbyclip
Throttlelever
M3.5threadfor
Chokebar
Slowneedle
Throttlevalve
(Movetotheleft)
Cowling
Throttlelever
Slowneedle
CCW
torichCW tolean
Mainneedle
CCW
torichCW tolean

153
153-1
153-3
153-4
153-2
No. Item Qty No. Item Qty
01 Cylinder 1
06 Piston 1
07 Pistonpin 1
Valvespring&Keeper&Retainer
08 Pistonpinretainer 2
47-1,-2,48
09 Pistonring 1
48 Valveretainer 2
10 Connectingrod 1
49 Rockerarmcover 2
Cylinderscrewset
69 Intakemanifold(Intakepipe) 1
14-1,-2,-3,-4
74 Muffler 1
15 Crankcase 1
Mufflermanifoldset
17 Rearcover(Backplate) 1
75-1,80
19 Breathernipple 1
80 Mufflernut 2
93 Intakevelocitystack(airfunnel) 1
20 Frontballbearing 1
82-1 Carburetorcomplete 1set
22 Rearballbearing 1
Carburetorbodyassembly
23 Crankshaft 1
82-1-1,-1-2,-1-3,-1-4,-1-5,-1-13
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
Carburetorscrew&springset
33 Camgearhousing 1
82-1-9,-1-10,-1-11,-1-12
35 Camgear 1
Carburetorgasketset
36 Camgearshaft 1
82-1-6,-1-7,-1-8,
37 Steelwasherset 1set
Enginemountset
38 Tappet 1
95-1,-2,-3,-4,-5
39 Pushrod 1
110 Antilooseningnut 1
149 Oilslinger 1
Pushrodcover&Rubberseal 152 Screw-pin(Fordriveflangesetting) 1
40-1,-2,-3 Electronicignitionsystem
41 Rockerarm 1 153-1,-2,-3,-4,-5
1set
1set
1set
1set
1set
1set
Valveset(In&Ex)
46-1,-2
46 1set
Rockerarmbracket(left）44 1
Rockerarmbracket(right)45 1
47 2ea.
75
83-1
90
91
95
153
32
40
1set
1ea.
1ea.
1set
1set
2ea.
14
27
28
31
Rockerarmscrew&Nut
42-1,42-2
43 Rockerarmpin 2
42 2ea.
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
FG-40PartsList