Saito FG-90R3 User manual

5.Break-inMOSTIMPORTANT!!
●Prop-recommendation:Mejzlik-24”x12”.
●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theslowneedle
Approx.5turnsCCWeachfromfullyclosed.
●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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.
●ThenturntheslowneedleCCWtomakemixturemuchricher.
●Runinthisveryrichconditionfor1literoffuel..
●Now“initial”break-inisdone.
●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.
Φ37.2mm 27.6mm 89.99cc
D24”~25”xP10”xP12”
Bore
Mainbody:3,161g/Muffler:157g/Ignition:250g
Stroke Disp.
Weight(Approx.) RPMRange Approx.1,300-7,000rpm Maxonground Approx.6,000-6,500rpm
Propeller CM-6Plug
Optionalparts
Gasoline60-70㏄classApplications
Batteryforignitionsystem Voltage:6-8.4V,greaterthan1,000mA
・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) 3pcs ・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-90R3InstructionManual
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(1)Plugcorddeeplyintotheplugof#1cylinder
tomakesureitwillnotcomeoff.Theothercapsandplugsshouldbe
installedbythesameway.(Refertocylinder#onthereverseside)
(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normallyvacant.
ForCCW
Makerich Main
needle
ForCW
Open
Throttle
lever
Standard
accessories
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
Standoffasrequired
Hollowoutreferringto
thecuttingsheet
PlugCap
SwitchCapacity:3A〜
Sensor
(2)Sensorcord
Battery
Voltage:6-8.4V
Capacity:1,000mA〜:
( 1)PlugCord MainUnit
(3)BatteryCord
(4)TachometerCord
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thescrewsaroundcylindersetc.
1.Removethesparkplugand
rockerarmcoversof#1
cylinder.Thenturntheprop
CCWbyhandtoplacethe
pistonatTDCofcompres-
sion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.Dothesame
adjustmentforthe#3-#2
cylindersinorder.
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)
Loosenthelocknut
Adjustthegapturning
thesetscrew
TopDeadCenter
(Thestatebothvalvesareclosed) Tightenthelocknut
tofixthesetscrew
Slowneedle
CCW
Rich
CW
Lean
Mainneedle
Throttle
lever
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willnotbecoveredbywarranty.
●Donotusegasolinecontainingethanol.Itmaycausenotonlypowerlossbutalsocorrosioninsidetheengine.
ver.Aug,2018
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.2.5~3turnsCCWfromfullyclosed
●Slowneedle：Approx.4+1/2~5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.
・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]
3.Propeller
●RecommendedpropellerisMejzlik24x12.
●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6boltseveryhourofoperation.
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.
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

No. Item Qty No. Item Qty
01 Cylinder 3 Pushrodcover&Rubberseal
06 Piston 3 40-1,-2,-3
07 Pistonpin 3 41 Rockerarm 6
08 Pistonpinretainer 6 Rockerarmscrew&Nut
09 Pistonring 3 42-1,-2
10 Masterrod 1 43 Rockerarmpin 6
11 Linkedconrod 2 44 RockerarmbracketL 3
Conrodlinkpin&E-ring 45 RockerarmbracketR 3
12-1L,-2,-3 Valve(In&Ex)
Cylinderscrewset 46-1,-2
14-1,-2,-3,-4 Valvespring&Keeper&Retainer
15 Crankcase 1 47-1,-2,48
17 RearcoverA(Intakemanifold) 1 48 Valveretainer(Cotter) 6
19 Breathernipple 1 49 Rockerarmcover 6
20 Frontballbearing 1 69 Intakepipe 3
22 Rearballbearing 1 Flexibleexhaustpipe
23 Crankshaft 1 78-1,-2,-3
Tapercollet&Driveflange Carburetorcomplete
27-1,-2 82-1-1,-1-2,-1-3,-1-4,-1-5,-1-6
Propwasher&Nut -1-7,-1-8,-1-9
28-1,-2,-3 88 Throttlelever 1
Crankcasescrewset 93 Airfunnel 1
31-1,-2,-3,-5,-6,-7 Enginemountset
Enginegasketset 95-1,-2,-3,-4
32-1,-2,-3,-4,-5,-8,-9 Mufflerbracketset
33 Camgearhousing 3 99-1,-5,-7
35 Camgear 3 110 Antilooseningnut 1
36 Camgearshaft 3 120 Sparkplug(NGKCM-6) 3
Steelwasherset 128 Heatsink 3
37-1,-2 129 Lubricationadopter 1
38 Tappet 6 152 Screw-pin 1
39 Pushrod 6 Electronicignitionsystem
153-1,-2,-3,-4
37 1set
153 1set
31 1set
95 1set
32 1set
99 2set
78 3
27 1set 82-1 1set
28 1set
42 1set
12 2ea.
46 3ea.
14 1set
47 1set
40 1set
250
100 70 52
222
86
16 36
70
80
M10x1.25
Rotationdirection
回転方向
#1
#3
#2
CylinderIDNumber(Viewfromfront)
シリンダ番号(前方向より見て)
Dimensions
外形寸法図
38
39
14-4
31-5
32-8
48
152
44
40-2
36
78-1 78-3
07
40-1
06
09
08
32-2
14-3
42-1
43
47-1
14-2
47-2
45
14-1
37-2 32-9
41
42-2
32-5
110
23
31-6
22
32-4
69
120
01
40-3
19
31-7
129
15
27-2 20
33
28-2 28-3 28-1 27-1
49
99-1
99-5
99-7
35
37-1 128
32-1
31-3
78-2
46-2
46-1
153
-2
153
-4
153
-3
153
-1
1011 12-3 12-2 32-3
17 31-1
12-1L
82-1
-6
82-1
-4
82-1
-5
82-1
-1
82-1
-2
82-1
-3
88
93
82-1
-8
82-1
-7
82-1
-9
95-3 95-1 31-2 95-2 95-4
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.
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.
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.