TILLOTSON T225RS User manual

T225RS User Manual
Engine Safety Precautions
IMPORTANT SAFETY INFORMATION
Most accidents with engines can be prevented if you follow all instructions in this manual. Some of the most common
hazards are discussed below, along with the best way to protect yourself and others.
OWNER RESPONSIBILITIES
• The engines are designed to give safe and dependable service if operated according to instructions. Read and understand
this owner’s manual before operating the engine. Failure to do so could result in personal injury or equipment damage.
• Know how to stop the engine and understand the operation of all controls.
• Never permit anyone to operate the engine without proper instructions.
• Keep children and pets far away from the area of operation.
• Never modify or change the engine in any way.
Table of Contents
Engine Safety Precautions 1
Product Specification 2
Recommended Torque Values 2
Recommended Maintenance and Tips 2
Assembly Guidelines 3
Starting the Engine 3
Engine Break-in Procedure 3
Safety References 4
For Warranty Matters, contact your local dealer
or [email protected]
READ AND FOLLOW ALL SAFETY
RULES AND INSTRUCTIONS IN THIS
MANUAL BEFORE ATTEMPTING TO
OPERATE THIS MACHINE.
FAILURE TO COMPLY WITH THESE
INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
RE-FUEL WITH CARE
Petrol is extremely flammable, and gasoline vapor can explode.
Refuel outdoors in a well-ventilated area with the engine
stopped. Never smoke near fuel and keep other flames and
sparks away. Always store petrol in an approved container. If
any fuel is spilled, make sure the area is dry before starting the
engine.
HOT EXHAUST
• The muffler becomes very hot during operation and
remains hot for a while after stopping the engine.
Be careful not to touch the exhaust at this time.
It is highly recommended to fit the heat shield
wrap to as protection from the hot exhaust manifold.
• To prevent fire hazards and to provide adequate
ventilation for stationary equipment applications, keep the
engine at least 1metre away from building walls and other
equipment during operation. Do not place flammable
objects close to the engine.
CARBON MONOXIDE HAZARD
Exhaust gas contains poisonous carbon monoxide.
Avoid inhalation of exhaust gas. Never run the engine
in a closed garage or confined area.
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WARNING

T225RS User Manual
Feature Specification
Engine Tillotson 225RS, 2 Valve, 4 Stroke, Single Cylinder
Fuel Type Unleaded Petrol
Bore x Stroke (mm) 72 x 55mm
Displacement (cc) 225cc
Required Oil Capacity Min 500mL
Recommended Oil Type Tillotson T4 Racing Oil
Cooling System Air
Carburettor Tillotson FM22-1A
Compression Ratio 9:1
Ignition System PVL Digital Ignition limited to 6,500rpm
Flywheel Billet flywheel digital ignition type 31° Advance
Camshaft Max Lift Race Cam with built in Compression Release
Cylinder Head 2 Valve OHV
Horsepower 15HP Peak
Description Socket Size Torque (Nm)
Cylinder Head 12mm 37Nm
Flywheel 21mm 70Nm
Rocker Arm Support 12mm 24Nm
Valve Locking Nut 10mm 10Nm
Spark Plug 21mm 24Nm
Crankcase Side Cover 10mm 33Nm
Blower Housing 8mm 10Nm
Carburettor to Manifold 10mm 10Nm
Connecting Rod 10mm 19Nm
Exhaust to Engine 13mm 28Nm
Intake Manifold to Engine 10mm 10Nm
Oil Drain Plug 10mm 22Nm
Valve Cover 8mm 7Nm
Recommended Torque Values
Product Recommendations Product Specification
Description Recommendation
Replace Engine Oil Every 3hours of operation
Ignition Coil – Flywheel Gap 0.75-0.9mm (Every 10hours)
Valve Clearance Gap 0.15mm (After first hour of running new engine / Every 5hours following this)
Clutch Wear Monitor Clutch Plate nuts coming loose / keep clutch clean from oil and
chain grease / monitor tension of clutch springs to maintain optimum performance
Crankcase Side Cover Torque Re-Torque the side cover bolts between events to 33Nm
Cylinder Head Torque Re-Torque the cylinder head bolts between events to 37Nm
Maintain Valve Clearance Required to monitor after 8hrs of running / or every 6 days.
Clean Air Filter with
Compressed Air Required to clean after every 4 days of use or after every day used in rain. Replace annually.
Clean Spark Plug / Replace Every 10hours of operation / or replace annually
Fuel Pump Revision Every 12months
Fuel Pipe Every 6months
Preferred Fuel Type Regular Pump Fuel
Note: Check the Tillotson Racing Youtube Page for Video Link to ‘T225RS Engine Maintenance’:
https://youtu.be/Fc36XblpR4k
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T225RS User Manual
Assembly Guidelines
• Assemble the auxiliary engine components – Intake Manifold,
FM22-1A Carburettor, Air Filter, Exhaust, Clutch, Clutch guard
• It is recommended that the exhaust heat wrap is mounted to
the exhaust manifold to protect from heat build-up
• Ensure the Fuel Pump connections are correct as per photo:
• Mount the 45cm Fuel Pipe supplied from the fuel pump outlet to
the carburettor inlet connector
• Fill the engine with
T4 Engine Oil 500ml (17oz)*
Note: Black Fuel Line represents the Pulse Connection
from the fuel pump to the intake manifold connector.
Note: For a Video Link showing all of the above steps mentioned please visit the Tillotson Racing Youtube Page:
https://youtube.com/channel/UCZgldHZl8EBj93WnvcKFRHA
Installation to Chassis
When mounting to a Tillotson T4 chassis, using the supplied engine mount and no chassis modifications are needed.
However, with other chassis brands there may be a need for an alternative sliding engine mount, which will allow for the
engine to be offset giving more space for the chain & chain guard.
Starting the Engine
When starting the engine from new or when empty of fuel
1. It is necessary to blow the fuel to fill the carb bowl from the overflow pipe on the tank. Make sure to blow for
no less than 15seconds as the bowl requires a large volume of fuel before the engine will start.
2. Lift the Choke to the raised position which means the choke is now ‘ON’ and ensure the engine ignition
switch is in the ‘ON’ position also.
3. Using some small throttle opening (10-30%) pull the starter chord until the engine fires and reset the Choke
so it is in the ‘Off’ position.
4. Once the engine is running it may be necessary to adjust the idle speed screw on the side of the carburetor.
Recommended engine idle is 1,800 - 2,000rpm.
Engine Break-in Procedure
Note: DO NOT REV THE ENGINE HARD WITH NO LOAD FROM NEW.
1. Insert 500ml of T4 Oil (17oz).
2. For the first 10 minutes, drive moderately at varying speeds up to 5,000rpm (half throttle). It is important to
vary the RPM for proper camshaft, piston rings and moving component bed in.
3. Stop and allow the engine to cool, check that there are no fuel or oil leaks.
4. For the second 10 minutes, build up to max 6,500rpm by the end of the session.
5. Once you have completed the running-in procedure it is recommended to change the oil. This is to remove any
metal particles which could arrive from the new components in the engine. Drain the oil when hot so it can
easily transport any particles.
6. After the engine is empty, replace the drain plug (make sure the aluminium washer is still there)
and re-fill the engine with 500ml of fresh oil. The engine is now ready for competition.
*VERY IMPORTANT: If the engine is run on less oil than recommended it will overheat the engine components
and performance / reliability will be reduced for the remainder of the engine life.
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T225RS User Manual
SAFETY REFERENCES
The safety alert symbol is used to identify safety information about hazards that can result in personal injury.
A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential
severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.
DANGER indicates a hazard which, if not avoided, will result in death or serious injury.
WARNING indicates a hazard which, if not avoided, could result in death or serious injury.
CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury.
CAUTION, when used without the alert symbol, indicates a situation that could result in
damage to the engine
This manual contains safety information to make you aware of the hazards and risks associated
with engines, and how to avoid them. Because we do not necessarily know what equipment
this engine will power, it is important that you read and understand these instructions and the
instructions for the equipment this engine powers.
SYMBOLS ASSOCIATED WITH THIS ENGINE
Fire
Read Manual
Kickback
Fuel
Toxic Fumes
Hazardous
Chemicals
Shock
Stop
Explosion
Oil
Hot Surface
Fuel Shutoff
Moving Parts
Choke
Slow
Fast
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
This engine is shipped from us without oil. If you start
the engine without oil, the engine will be damaged
beyond repair and will not be covered under warranty.
WARNING CAUTION
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