Saito FG-61TS User manual

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standbehindtheenginewhenoperatingtheengine.
●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.
Φ37.2mmx2 28mmx2 60.9cc
D21”~23”xP10”xP11
・Filterwithweight[G36-154] ・DurabletubeforGasoline(1m)[G36-155]
・Aluminumspinnernut[57T-30] ・Tappetadjustingkit[120S-161] ・Digitaltachometer[G17-167]
Bore
Mainbody:2,090g/Muffler:100g/Ignition:170g
Stroke Disp.
Weight(Approx.） Practicalspeed Approx.1,500-7,400rpm Maxonground Approx.6,200-7,400rpm
Propeller CM-6Plug
Optionalparts
Gasoline50㏄classApplications
Batteryforignitionsystem
・Limitgauge(0.1t)fortappetadjustment1pc ・Spannerfortappetadjustinglocknut1pc ・Carburetoradjustmentbar1pc
・Sparkplug[CM-6](Attachedtotheengine)2pcs ・Mufflerset  1set・Chokebar  1pc
・Ignitionsystem（w/sensor） 1set ・Mufflerbracket 1set・Plugwrench  1pc
・Standoffmount1set ・Anti-looseningnut 1pc ・Hexagonalwrench 1set
Specifications
FG-61TSInstructionManual
CorrectGap
Mustnotbeinserted
Closeto“0”withnolimit
Limitgauge
(0.1mm)
Slowneedle
CCW
Rich
CW
Lean
Mainneedle
Throttle
lever
1.Fuel
●Thefuelismixtureofcommercialregulargasolineandreliableoilfor2-strokeengines.
●[Exampleofoilrecommendation]
・KlotzKL-200OriginalTechniplate・MorgansCoolPower'Blue'SyntheticLubricant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).
●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.
Standard
accessories
●Starttheengine(usingastarterisrecommendedforsafety).
●Runforabout30secondsatlowspeedtowarmup.
●Openthethrottlegraduallyuptooverhalfopen.InthemeantimeturnthemainneedleCCW.
ContinuetoturnthemainneedleCCWuntiltheRPMdeclines,keepingthethrottleopenedover
half.
●IfopeningmainneedledoesnʼtdropRPM,thenopentheslowneedletoo.
●Runinthisveryrichconditionfor1literoffuel.
ForCCW
Makerich Main
needle
ForCW
Open
Throttle
lever
ver.Dec,2018
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
Setthecenterofthecarb
slightlyabovethefuellevel
Closeaspossible
Firewall
Standoffmount
Hollowout
2.Ignition
●Ignitionarrangement-Placethemainunitasfarfromotherelectricaldevices
aspossible.
(1)Plugcord(meshedhightensioncord)
2cordscompatibleforleft/rightcylinder.Insertthecapdeeplyinto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.(6-8.4V,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
Plugcap
Switch(morethan3A)
Sensor
(2)Sensorcord
(1)Plugcord Mainunit
(3)Battery
cord
(4)Tachometercord
Recommendedbattery
Voltage:6-8.4V
Capacity:1,000mA~
Voltage:6-8.4V,greaterthan1,000mA
3.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adjust-
ment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.
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
4.Break-inMOSTIMPORTANT!!
●Prop-recommendation:Mejzlik-22x10.
●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open(CCW)fromfullyclosed.
5.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.2.5~3turnsCCWfromfullyclosed
●Slowneedle：Approx.4~5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performance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.
●TurntheslowneedleCCWslightlyiftheenginehesitatesforamomentorstallsbeforetheenginereachesmaxRPMbecausethemixture
istoolean.
●TurntheslowneedleCWslightlyiftheengineisslowtoreachpeakRPM(fullthrottleset)becausethemixtureistoorich.
●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.Thendothesame
adjustmentfortheothercylinder.
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losecompression.Then
adjustagain.
1.Removethesparkplugandrocker
armcoversofacylinder.Then
turnthepropCCWbyhandto
placethepistonatTDCof
compressionstroke.

No. Item Qty No. Item Qty
01 Cylinder（Left） 1Rockerarmscrew&Nut
02 Cylinder（Right） 1 42-1,-2
06 Piston 2 43 Rockerarmscrew&Nut 4
07 Pistonpin 2 44 Rockerarmbracket,left 2
08 Pistonpinretainer 4 45 Rockerarmbracket,right 2
09 Pistonring 2 46 Valveset（吸気＆排気） 4
10 Connectingrod(conrod) 2Valvespring&Keeper&Retainer
13 Conrodscrew 4 47-1,-2,48
Cylinderscrewset 48 Cotter(Valvespringretainerrock) 4
14-1,-2,-3,-4 49 Rockerarmcover 4
15 Crankcase 1 69 Intakepipe,left 1
17 Rearcover 1 70 Intakepipe,right 1
19 Breathernipple 1 78 Mufflercomplete 2
20 Frontballbearing 1 80 Mufflernut 4
21 Mainballbearing 1Carburetorcomplete
22 Rearballbearing 1
82-1-1,-1-2,-1-3,-1-6,-1-7,-1-8,
-1-9,-1-10,-1-11,-1-12,88,93
23 Crankshaft 1Carburetorbody,assembly
Tapercollet&Driveflange 82-1-1,-1-2,-1-3,88
27-1,-2 88 Throttlelever 1
Propwasher&Nut Carburetorscrew&springset
28-1,-2,-3 82-1-9,-1-10,-1-11,-1-12
Crankcasescrewset Carburetorgasketset
31-1,-2,-3,-4 82-1-6,-1-7,-1-8
Enginegasketset 93 Intakevelocitystack 1
32-1,-2,-3,-4,-8,-9 Enginemountset
33-1 Camgearhousing 1 95-1,-2,-3,-4,-5
33-2 Camgearhousing(right) 1Mufflerbracket
34 Camgear,left 1 99-1,-2,-3,-4,-5,-6,-7,-8
35 Camgear,right 1 110 Antilooseningnut 1
36 Camgearshaft 1 120 Sparkplug（NGKCM-6）2
Steelwasherset 128 Heatsink 1
37-1,-2 140 Mufflerrightangleadapter 2
38 Tappet（valvelifter） 4 152 Screwpinfordriveflange 1
39 Pushrod 4Electronicignitionsystem 1set
Pushrodcover&Rubberseal 153-1,-2,-3,-4
40-1,-2,-3 Intakemanifoldassembly 1set
41 Rockerarm 4 164-1,-2,-3,-4,-5,-6,-7
164
153
37 1set
40 1set
32 1set
95 1set
99 1set
28 1set 90 1set
31 1set 91
1set
82-1 1set
83-1 1set
27 1set
42 1set
47 1set
14 1set
153
153-1
153-4153-3
153-2
60
53
103
35
134 68.5
32.2 6
49.551
38
M10x1.25
78
66
(97)
(85)
4-Φ5.2
78
140
80
14-3
49
42-2
41
37-2
43
14-2
48
47-2
14-1 02 09 06 0807 10C
01 120
128
31-4
19
3436A
37-1 32-1
33-1
31-2
31-1
38110
28-2A
28-3
28-1
27-2
27-1
20
23
152 40-3
40-1
39
40-2
44
42-1
46
47-1
32-8
15
13
32-2
33-2
35
45
82-1
-1 82-1 -11 82-1 -8 82-1 -9 82-1 -12
93
82-1
-2
82-1
-3
88B
82-1
-6
82-1
-7
164-7
164-5
6932-432-9
70
164-3
164-1
82-1
-9
82-1
-10
164-6164-4
128
164-2
14-4
99-5
99-4
99-8
99-6
99-199-7
99-2
99-7 99-3
99
95-495-231-3
95-195-3
1732-3A2221 95-5
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.