© Copyright 2003 HCAZ3085

MAX FXi 46

OWNER’S INSTRUCTION MANUAL

It is of vital importance, before attempting tooperate your engine, to read the general“SAFETY INSTRUCTIONS AND WARNINGS”section on pages 2-6 of this booklet and tostrictly adhere to the advice contained therein.

• Also, please study the entire contents of thisinstruction manual, so as to familiarizeyourself with the controls and other featuresof the engine.

• Keep these instructions in a safe place sothat you may readily refer to them whenevernecessary.

• It is suggested that any instructionssupplied with the aircraft, radio controlequipment, etc., are accessible for checkingat the same time.

SAFETY INSTRUCTIONS AND WARNINGSABOUT YOUR O.S. ENGINE ................................3

FEATURES OF FXi SERIES ENGINE ..................7

BEFORE INSTALLING THE ENGINE....................7

BASIC ENGINE PARTS ........................................8

INSTALLATION OF THE ENGINE ........................8

THROTTLE LINKAGE............................................8

MUFFLER ..............................................................9

FUEL TANK LOCATION ........................................9

GLOW PLUG ......................................................10

FUEL....................................................................11

PROPELLERS ....................................................12

MIXTURE CONTROLS........................................12

BEFORE STARTING............................................13

STARTING ..........................................................14

RUNNING-IN (Breaking-in) ..................................15

NEEDLE VALVE ADJUSTMENT DIAGRAM........17

MIXTURE CONTROL VALVE ADJUSTMENT ....19

REALIGNMENT OF MIXTURE CONTROL VALVE ..19

SUBSEQUENT STARTING PROCEDURE..........20

SUBSEQUENT READJUSTMENT ......................20

CARBURETOR CLEANLINESS ..........................21

ENGINE CARE & MAINTENANCE ....................22

O. S. ENGINES LIMITED WARRANTY ..............22

ENGINE EXPLODED VIEW ................................24

ENGINE PARTS LIST ..........................................25

CARBURETOR EXPLODED VIEW ....................26

CARBURETOR PARTS LIST ..............................26

CONTENTS

2

Remember that your engine is not a "toy,"but a highly efficient internal combustionmachine whose power is capable ofharming you, or others, if it is misused.

As owner, you, alone, are responsible forthe safe operation of your engine, so actwith discretion and care at all times.

If at some future date, your O.S. engine isacquired by another person, we wouldrespectfully request that these instructionsare also passed on to its new owner.

The advice which follows is grouped undertwo headings according to the degree ofdamage or danger which might arisethrough misuse or neglect.

NOTES!These cover the many other possibilities,generally less obvious sources of danger,but which, under certain circumstances,may also cause damage or injury.

WARNINGS!These cover events which might involveserious (in extreme circumstances, evenfatal) injury.

SAFETY INSTRUCTIONS ANDWARNINGS ABOUT YOUR O.S. ENGINE

3

NOTES!• This engine was designed for model

aircraft. Do not attempt to use it for anyother purpose.

• Mount the engine in your modelsecurely, following the manufacturers’recommendations, using appropriatescrews and locknuts.

• Be sure to use the muffler supplied withthe engine. Frequent exposure to anopen exhaust may eventually impair

• Never operate your engine in anenclosed space. Model engines, likeautomobile engines, exhaust deadlycarbon monoxide. Run your engine onlyin an open area.

• Model engines generate considerableheat. Do not touch any part of yourengine until it has cooled.Contact with themuffler (silencer), cylinder head orexhaust header pipe, in particular, mayresult in a serious burn.

WARNINGS!• Never touch, or allow any object to

come into contact with, the rotatingpropeller and do not crouch over theengine when it is running.

• A weakened or loose propeller maydisintegrate or be thrown off and, sincepropeller tip speeds with powerfulengines may exceed 600 feet (180 meters)per second, it will be understood thatsuch a failure could result in seriousinjury, (see “NOTES!” section relating topropeller safety).

• Model engine fuel is poisonous. Do notallow it to come into contact with theeyes or mouth. Always store it in aclearly marked container and out of thereach of children.

• Model engine fuel is also highlyflammable. Keep it away from openflame, excessive heat, sources ofsparks, or anything else which mightignite it. Do not smoke or allow anyoneelse to smoke, near fuel.

4

• If you fit a spinner, make sure that it is aprecision made product and that theslots for the propeller blades do not cutinto the blade roots and weaken them.

• Preferably, use an electric starter. Thewearing of safety glasses is alsostrongly recommended.

• Discard any propeller which hasbecome split, cracked, nicked orotherwise rendered unsafe. Neverattempt to repair such a propeller,destroy it. Do not modify a propeller inany way, unless you are highlyexperienced in tuning propellers forspecialized competition work such aspylon racing.

• Take care that the glow plug clip or batteryleads do not come into contact with thepropeller. Also check the linkage to thethrottle arm. A disconnected linkage couldalso foul the propeller.

your hearing. Such noise is also likely tocause annoyance to others over awide area.

• If you remove the glow plug from theengine and check its condition byconnecting the battery leads to it, do nothold the plug with bare fingers. Use anappropriate tool or a folded piece of cloth.

• Install a top-quality propeller of thediameter and pitch specified for theengine and aircraft. Locate the propelleron the shaft so that the curved face of theblades face forward–i.e. in the direction offlight. Firmly tighten the propeller nut,using the correct size wrench.

• Always check the tightness of thepropeller nut and retighten it, ifnecessary, before restarting the engine,particularly in the case of four-strokeengines. If a safety locknut assembly isprovided with your engine, always useit. This will prevent the propeller fromflying off in the event of a "backfire",even if it loosens.

5

Do not start your engine in an areacontaining loose gravel or sand. Thepropeller may throw such material inyour face and eyes and cause injury.

For their safety, keep all onlookers(especially small children) well back (atleast 20 feet or 6 meters) whenpreparing your model for flight. If youhave to carry the model to the take-offpoint with the engine running, beespecially cautious. Keep the propellerpointed away from you and walk wellclear of spectators.

• Warning! Immediately after a glow plugignition engine has been run and is stillwarm, conditions sometimes existwhereby it is just possible for the engineto abruptly restart if the propeller iscasually flipped over compressionWITHOUT the glow plug battery beingreconnected. Remember this if youwish to avoid the risk of a painfullyrapped knuckle!

NOTES!• Adjust the throttle linkage so that the

engine stops when the throttle stick andtrim lever on the transmitter are fullyretarded. Alternatively, the engine may bestopped by cutting off the fuel supply.Never try to stop the engine physically.

• Take care that loose clothing (ties, shirtsleeves, scarves, etc.) do not come intocontact with the propeller. Do not carryloose objects (such as pencils,screwdrivers, etc.) in a shirt pocket fromwhere they could fall through thepropeller arc.

• After starting the engine, carry out anyneedle-valve readjustments from a safeposition behind the rotating propeller.Stop the engine before attempting tomake other adjustments to thecarburetor.

6

This range of engines is ideally suited to avariety of R/C aircraft, including trainer,sports, acrobatic and scale types.

A separate precision-made needle-valveunit is installed at the rear, where manualadjustment is safely remote from therotating propeller.

Common AccessoriesNo. 8 Glow Plug, Silicone Tube, InstructionManual.

Note: With these engines, the piston willfeel tight at the top of its stroke when theengine is cold. This is normal. The pistonand cylinder are designed to achieve aperfect running clearance when theyreach their intended running temperature.

Installing the Glow PlugCarefully insert plug, with washer, fingertight only, before final tightening with thecorrect size plug wrench.

Connecting the Fuel TubingConnect the short length of fuel tubing(supplied) securely between the needle-valve outlet and carburetor inlet as shown inthe illustration on the next page.

In the event of the tubing becomingdamaged, it should be replaced with asuitable length (as indicated below) of bestquality 5mm OD x 2mm ID silicone tubing.Use similar material to connect the fuel inletnipple to the fuel tank.

BEFORE INSTALLING THE ENGINEFEATURES OF FXi SERIES ENGINE

7

Installation in the Model

Make sure that the mounting beams areparallel and that their top surfaces are in thesame plane.

• Before connecting the throttle-lever/servo linkage, make sure that nopart of the linkage interferes with theinternal structure of the aircraft orwiring, etc., when the throttle is fullyopen or fully closed.

• Set the throttle lever linkage so that thethrottle rotor is (a) fully open when thetransmitter throttle stick is fullyadvanced and (b) fully closed when the

THROTTLE LINKAGE

INSTALLATION OF THE ENGINEBASIC ENGINE PARTS

8

throttle stick is fully retarded.Adjustment of the throttle rotor openingat the idling position can then be madewith the throttle trim lever on thetransmitter. (Select throttle-lever andservo-horn hole positions that willavoid excessive pushrod travel causingthe throttle to bind at either end.)

Note: When adjusting the throttle leverangle, relative to the rotor, hold the rotorat about half-way between the open andclosed positions while loosening andtightening the fixing screw, otherwisethe rotor, rotor guide screw, throttle stopscrew or carburetor body may becomeburred and damaged.

The exhaust outlet of the silencer can berotated to any desired position in thefollowing manner:1) Loosen the locknut and assembly screw.

2) Set the exhaust outlet at the requiredposition by rotating the rear part ofthe silencer.

3) Re-tighten the assembly screw,followed by the locknut.

Note: The standard expansion-chambertype silencer is quite effective, butreduces power to some degree.

Reminder: Model engines generateconsiderable heat. Do not touch any part ofyour engine until it has cooled. Contact withthe muffler (silencer), cylinder head orexhaust header pipe, in particular, mayresult in a serious burn.

Keep your hands and face away fromexhaust gas or you will suffer a burn.

Suggested fuel tank capacities are listedopposite.These will allow 12-13 minute flights.Locate the fuel tank so that the top of the

FUEL TANK LOCATIONMUFFLER

9

tank is 5-10mm (1/4-3/8") above the level ofthe needle valve.

Be sure to use a pressurized fuel system byconnecting the muffler pressure nipple tothe vent pipe of the fuel tank.

Since the glow plug and fuel combination usedmay have a marked effect on performance andreliability, it would be worthwhile to experimentwith different plug types.

Recommended O.S. plugs are Nos. 8, A5and A3. Carefully install plug finger-tight,before final tightening with the correct sizeplug wrench.

The Role of the Glow PlugWith a glow plug engine, ignition is initiatedby the application of a 1.5-volt power source.When the battery is disconnected, the heat

retained within the combustion chamberremains sufficient to keep the plug filamentglowing, thereby continuing to keep theengine running. Ignition timing is "automatic,"under reduced load, allowing higher RPM,the plug becomes hotter and, appropriately,fires the fuel/air charge earlier; conversely, atreduced RPM, the plug becomes cooler andignition is retarded.

Glow Plug LifeParticularly in the case of very highperformance engines, glow plugs must beregarded as expendable. However, plug lifecan be extended and engine performancemaintained by careful use, i.e.:

• Install a plug suitable for the engine.• Use fuel containing a moderate

percentage of nitro methane unlessmore is essential for racing events.

• Do not run the engine too lean and donot leave the battery connected whileadjusting the needle.

GLOW PLUG

10

When to Replace the Glow PlugApart from when actually burned out, a plugmay need to be replaced because it nolonger delivers its best performance, suchas when:

• Filament surface has roughened andturned white.

• Filament coil has become distorted.• Foreign matter has adhered to filament

or plug body has corroded.• Engine tends to cut out when idling.• Starting qualities deteriorate.

Select, by practical tests, the most suitablefuel from among the best quality fuelsavailable in your country for model use. Forthe best performance, a fuel containing 5%to 20% nitro methane is preferable.Lubricants may be either castor oil or asuitable synthetic oil (or a blend of both)provided that they are always of top quality.

For consistent performance and longengine life, it is essential to use fuelcontaining AT LEAST 18% lubricant byvolume. Some fuels containing coloringadditives tend to deteriorate and mayadversely affect running qualities.

Once a satisfactory fuel has been selectedand used for a while, it may be unwise toneedlessly change the brand or type. In anyengine, a change of fuel may cause carbondeposits in the combustion chamber or onthe piston head to become detached andlodged elsewhere, with the risk of thiscausing unreliable operation for a while. If,however, the adoption of a different fuel isunavoidable, check the engine for the firstfew flights on the new fuel, by temporarilyreverting to the running-in procedure.

Reminder! Model engine fuel ispoisonous. Do not allow it to come intocontact with the eyes or mouth. Alwaysstore it in a clearly marked container andout of the reach of children.

FUEL

11

Reminder! Model engine fuel is alsohighly flammable. Keep it away fromopen flame, excessive heat, sources ofsparks, or anything else, which mightignite it. Do not smoke, or allow anyoneelse to smoke, near to it.

The suggested propeller size is listed onpage 13. The suitability of the prop dependson the size and weight of the model andtype of flying. Determine the best size andtype after the engine has been run in.Check the balance of the propeller beforefitting it to the engine. Unbalancedpropellers cause vibration and loss ofpower. Wooden propellers are to bepreferred. Some nylon propellers are notstrong enough to withstand the high poweroutput of these engines and a thrown bladecan be very dangerous.

Reminder! Never touch, or allow anyobject to come into contact with, therotating propeller and do not crouchover the engine when it is running.

Two mixture controls are provided onthese engines.

• The Needle Valve (at rear of engine)When set to produce maximum power at fullthrottle, this establishes the basic fuel/airmixture strength.The correct mixture is thenmaintained by the carburetor's built-inautomatic mixture control system to coverthe engine's requirements at reducedthrottle settings.

• The Mixture Control Valve (carburetor)This meters fuel flow at part-throttle andidling speeds to ensure reliable operationas the throttle is opened and closed. TheMixture Control Valve is factory set for the

MIXTURE CONTROLS

PROPELLERS

12

approximate best result. First run theengine as received and readjust the MixtureControl Screw only if necessary.

Tools, Accessories, etc.The following items are necessary foroperating the engine.

1–FuelModel glow plug engine fuel of good quality,preferably containing a small percentage ofnitro methane.

2–Glow PlugO.S. No. 8 glow plug is fitted to the engine.

3–PropellerSuggested sizes are 9x7, 9x8, 10x5, 10x6,10x7, 11x5, 11x6.

4–Glow Plug BatteryThe power source for heating the glow plugmay be either a large heavy-duty 1.5-volt

dry cell, or preferably, a 2-volt rechargeablelead-acid cell.

Warning (Very hot): Never touch thenichrome wire while the battery isconnected.

5–Battery LeadsThese are used to conduct current from thebattery to the glow plug. Basically, twoleads, with clips, are required, but, forgreater convenience, twin leads withspecial glow plug connectors arecommercially available.

6–Fuel TankFor installation in the model, a 300cc(10.6oz.) for 46 FXi is suggested.

7–Fuel Bottle or PumpFor filling the fuel tank, a simple,polyethylene "squeeze" bottle, with asuitable spout is all that is required.Alternatively, one of the purpose-mademanual or electric fuel pumps may be used

BEFORE STARTING

13

to transfer fuel directly from your fuelcontainer to the fuel tank.

8–Electric Starter and Starter Battery An electric starter is recommended forstarting.

9–Fuel Can FilterFit a filter to the outlet tube of your refuelingcontainer to prevent entry of foreign matterinto the fuel tank.

10–Silicone TubingThis is required for the connection betweenthe fuel tank and engine.

11–Plug WrenchUsed for tightening glow plugs. The O.S.long plug wrench is available as an optionalaccessory.

1. Install appropriate propeller and tightensecurely.

2. To facilitate electric starting, install anO.S. solid aluminum alloy spinner-nut forcentering the rubber drive insert of thestarter. Alternatively, a good qualityspinner, enclosing the propeller boss,may be used, but make sure that it is ofprecision-made and sturdy constructionso that the spinner shell cannot loosenwhen the starter is used. Close thethrottle.

3. Fill the fuel tank. Do not allow fuel tooverflow into the silencer, otherwise theengine may become flooded anddifficult to start.

4. Check that the needle valve is closed.(Do not overtighten) Now open theneedle valve counterclockwise to thestarting setting:• 1-1/2 turns open

STARTING

14

5. Open the throttle approx. one-quarter.6. Connect battery leads to glow plug.7. Bring electric starter into contact with

spinner-nut or spinner and depressstarter switch for one or two seconds.Repeat if necessary. When the enginestarts, withdraw the starter immediately.

Attention: Do not choke the carburetor airintake when applying the starter. This couldcause an excessive amount of fuel to bedrawn into the cylinder which may initiate anhydraulic lock and damage the engine.

If the engine does not start within 10 repeatapplications of the starter, remove the glowplug, check that it glows brightly and that thecylinder is not flooded with fuel. (To ejectexcess fuel, close needle valve and applystarter with glow plug removed.) Then try again.

VERY IMPORTANT! Before being operatedat full power (i.e. at full throttle and with theneedle-valve closed to its optimum setting)the engine must be adequately run-in,

otherwise there is a danger of it becomingoverheated and damaged.

All internal-combustion engines benefitfrom extra care when they are run for thefirst few times known as running-in orbreaking-in.

This allows the working parts to mate togetherunder load at operating temperature.Therefore, it is vitally important to complete thebreak-in before allowing the engine to runcontinuously at high speed and beforefinalizing carburetor adjustments.

However, because O.S. engines areproduced with the aid of the finest modernprecision machinery and from the best andmost suitable materials, only a short andsimple running-in procedure is called forand can be carried out with the engine

RUNNING-IN (“Breaking-In”)

15

installed in the model. The process isas follows:

1. Install the engine with the propellerintended for your model. Open theneedle valve to the advised starlingsetting and start the engine. If theengine stops when the glow plugbattery disconnected, open the needlevalve to the point where the enginedoes not stop. Run the engine for oneminute with the throttle fully open, butwith the needle valve adjusted for rich,slow "four-cycle" operation.

2. Now close the needle valve until theengine speeds up to "two-cycle"operation and allow it to run for about10 seconds, then reopen the needle-valve to bring the engine back to "fourcycle" operation and run it for another10 seconds. Repeat this procedureuntil the fuel tank is empty.

3. Re-start and adjust the needle-valve sothat the engine just breaks into "two-

cycle" from "four-cycle" operation, thenmake three or four flights, avoidingsuccessive "nose-up" flights.

4. During subsequent flights, the needlevalve can be gradually closed to givemore power. However, if the engineshows signs of running too lean, thenext flight should be set rich. After atotal of ten to fifteen flights, the engineshould run continuously, on itsoptimum needle-valve setting, withoutloss of power as it warms up.

5. After the completion of the running-inadjust the carburetor at optimum settingreferring to “MIXTURE CONTROLVALVE ADJUSTMENT” section and“SUBSEQUENT READJUSTMENT”section.

Optimum Needle Setting (1)Slowly advance the throttle to its fully openposition, then gradually close the needle-valve until the exhaust note begins tochange 4-cycle to 2-cycle). At this point,

16

disconnect the battery from the glow plug,taking care that the battery leads or glowplug clip do not come into contact with therotating propeller. If the engine stops whenthe battery is disconnected, close theneedle valve about 30° and restart.

Optimum Needle Setting (2)As the needle valve is closed slowly andgradually, the engine RPM. Will increaseand a continuous high-pitched exhaustnote, only will be heard. Close the needlevalve 10-15° and wait for the change ofRPM. After the engine RPM increases turnthe needle valve another 10-15° and waitfor the next change of RPM. As the speed ofthe engine does not instantly change withneedle-valve readjustment, smallmovements, with pauses between, arenecessary to arrive at the optimum setting.

Note: This diagram is for referencepurposes only. Actual needle positionsmay differ from those shown.

• To stop the engine, close the throttlecompletely to cut off fuel/air supply.

NEEDLE-VALVE ADJUSTMENT DIAGRAM

17

18

IDL

ING

AD

JUS

TM

EN

T C

HA

RT

With the engine running, close the throttleand allow it to idle for about five seconds,and then open the throttle fully. If, at thispoint, the engine is slow to pick up andproduces an excess of exhaust smoke, themixture is too rich. Correct this condition byturning the Mixture Control Screw clockwise15-30°. If the mixture is excessively rich,engine RPM will become unstable: openingthe throttle will produce a great deal ofsmoke and RPM may drop suddenly or theengine may stop. This condition may alsobe initiated by excessively prolonged idling.

If, on the other hand, the mixture is too lean,this will be indicated by a marked lack ofexhaust smoke and a tendency for theengine to cut out when the throttle isopened. In this case, turn the MixtureControl Screw counterclockwise 90° to

positively enrich the idle mixture, then turnthe screw clockwise gradually until theengine regains full power cleanly when thethrottle is reopened.

Carry out adjustments patiently until theengine responds quickly and positively tothe throttle control.

Note: Mixture Control Valve adjustmentsshould be made in steps of 15-30° initially,carefully checking the effect, on throttleresponse, of each small adjustment.

In the course of making carburetoradjustments, it is just possible that theMixture Control Valve may be inadvertentlyscrewed in or out too far and thereby movedbeyond its effective adjustment range. Its

REALIGNMENT OF MIXTURECONTROL VALVE

MIXTURE CONTROL VALVEADJUSTMENT

19

basic setting can be re-established asfollows: Close the throttle rotor graduallyfrom the fully opened position until it is justfully closed. (Do not turn further.) Then,screw in the Mixture Control Screw until itstops. Now unscrew the Mixture ControlScrew as indicated below.

Once the optimum needle-valve setting hasbeen established (see page 17, “NEEDLE-VALVE ADJUSTMENT DIAGRAM”) theprocedure for starting may be simplifiedas follows:

1. Open the needle valve one half-turn(180°) from the optimum setting.

2. Set the throttle one-quarter open from thefully closed position, energize the glow plugand apply the electric starter.When the engine

starts, reopen the throttle and re-adjust theneedle valve to the optimum setting.

Note: When re-starting the engine on thesame day, provided that atmosphericconditions have not changedsignificantly, it may be practicable to re-start the engine on its optimum(running) setting.

Once the engine has been run-in and thecontrols properly set up, it should beunnecessary to alter the mixture settings;except to make minor adjustments to theNeedle Valve occasionally, to take accountof variations in climactic conditions.

The use of a different fuel, however,particularly one containing more, or less,nitro methane and/or a different type orproportion of lubricating oil, is likely to call

SUBSEQUENT READJUSTMENTSUBSEQUENT STARTING PROCEDURE

20

for some readjustment of the Needle-Valve.Remember that, as a safety measure, it isadvisable to increase the Needle-Valveopening by an extra half-turncounterclockwise, prior to establishing anew setting. The same applies if thesilencer type is changed.

A different silencer may alter the exhaustpressure applied to the fuel feed and call fora revised Needle-Valve setting.The use of adifferent glow plug may also requirecompensating carburetor readjustments.

The correct functioning of the carburetordepends on its small fuel orifices remainingclear. The minute particles of foreign matterthat are present in any fuel can easily partiallyobstruct these orifices and upset mixturestrength so that engine performancebecomes erratic and unreliable.

O.S. Super-Filters (large and small) areavailable, as optional extras, to deal withthis problem.

One of these filters, fitted to the outlet tubeinside your refueling container, will prevent theentry of foreign material into the fuel tank.

It is also recommended that a good in-linefilter be installed between the tank andneedle valve.

Do not forget to clean the filters regularly toremove dirt and lint that accumulate on thefilter screen. Also, clean the carburetor itselfoccasionally.CARBURETOR CLEANLINESS

21

1. At the end of each operating session,drain out any fuel that may remain inthe fuel tank.

2. Next, energize the glow plug and try torestart the engine to burn off any fuelthat may remain inside the engine.Repeat this procedure until the enginefails to fire. Remove the glow plug andeject any residue by rotating the enginewith an electric starter for 4 to 5seconds while the engine is still warm.

3. Finally, inject some after-run oil into theengine. Rotate the engine a few timesby hand, to make sure that it is free,and then with an electric starter for 4 to5 seconds to distribute the oil to all theworking parts.

Note: Do not inject after-run oil into thecarburetor as this may cause the 0-ringinside the carburetor to deteriorate.

These procedures will reduce the risk ofstarting difficulties and of internal corrosionafter a period of storage.

Your engine is guaranteed to be free ofdefects in parts and workmanship for aperiod of two (2) years from the date ofpurchase when returned for serviceaccompanied by your proof of purchase.Crash damage and problems caused byneglect or abuse will not be covered underwarranty. Damage caused by customerdisassembly, tampering, use ofsubstandard fuel, use of incorrectaccessories (glow plug, prop, etc.), or anyuse of the engine for which it is notspecifically intended will automatically voidthe warranty of the engine.

Should your engine require warranty ornon-warranty service please return it via

O.S. ENGINES LIMITED WARRANTY

ENGINE CARE & MAINTENANCE

22

UPS or insured Parcel Post to our nationalservicing facility:

Hobby Services3002 N. Apollo Dr., Suite 1

Champaign, IL 61821(217) 398-0007

Along with Your engine and proof ofpurchase date please enclose a completewritten explanation detailing the problems.State your name and address clearly.

For repairs not covered under warranty, youmust specify whether you wish the chargesto be billed C.O.D. or if you wish to be notifiedof the charges so you can send a check.

23

24

EX

PL

OD

ED

VIE

W

EN

GIN

E P

AR

TS

LIS

T

No

.C

od

e N

o.

Des

crip

tio

n1

2560

4100

Cyl

inde

r H

ead

225

6030

10C

ylin

der

Pis

ton

Ass

embl

y3

2480

6301

Pis

ton

Pin

424

8171

00P

isto

n P

in R

etai

ner

525

3050

02C

onne

ctin

g R

od6

2568

1010

Car

bure

tor

(Typ

e 40

B)

723

2100

07P

rope

ller

Nut

824

0090

00P

rope

ller

Was

her

925

6080

00D

rive

Was

her

1046

1200

00T

hrus

t Was

her

1126

7310

40C

rank

shaf

t B

all B

earin

g (f

ront

)12

2560

1200

Cra

nkca

se13

2673

0040

Cra

nksh

aft

Bal

l Bea

ring

(rea

r)14

2560

2021

Cra

nksh

aft

1525

6140

10G

aske

t S

et16

2560

7010

Cov

er P

late

1724

0071

20N

eedl

e S

tay

1825

6819

00N

eedl

e V

alve

Bod

y A

ssem

bly

18-1

2268

1980

Nee

dle

Ass

embl

y18

-224

9818

37O

-rin

g18

-326

3815

01S

et S

crew

18-4

2671

1305

Rat

chet

Spr

ing

18-5

2658

2910

Nee

dle

Val

ve H

olde

r18

-626

5829

20N

eedl

e V

alve

Hol

der

Ret

aini

ng S

crew

1925

6130

00S

crew

Set

7160

5300

A3

Glo

w P

lug

2542

5000

873

Muf

fler

Ass

embl

y22

6819

57P

ress

ure

Fitt

ing

2542

5310

Ass

embl

y S

crew

2542

5400

Ret

aini

ng S

crew

(3x

35m

m 2

pcs

.)

26

CARBURETOR PARTS LISTCARBURETOR EXPLODED VIEW

No. Code No. Description1 22781401 Throttle Lever Assembly

1-1 22781411 Throttle Lever1-2 22781420 Throttle Lever Screw2 27783600 Mixture Control Valve

2-1 22781800 O-ring3 25681200 Carburetor Rotor4 26781506 Rotor Spring5 25681100 Carburetor Body6 25681620 Throttle Stop Screw7 22681953 Fuel Inlet (No. 1)8 46215000 Carburetor Gasket9 25081700 Carburetor Retaining Screw

27