RV160 RV170 SERVICE MANUAL
Contents
1. 68 1 56 7 28 23 VILL mes mg eme di 29 Shaft 925 400 77 2 7 Ka SE LT gem me W Z LIF Su Lond 4 10 9 em 0 007 nm 60 2285 N N 681 Sy Nd ll e gt c 26 M10X125 2 DIMENSION AND TORQUE SEAT FACE 2 DIMENSION AND TORQUE N e o lt 2 e ITEMS Connection Rod Bolt Governor Gear Bolt Crankcase Cover Bolt Spark Plug Cylinder Head Bolt Rotation Shaft Bolt Rotation Shaft Locked Nut Cylinder Head Cover Bolt Ventilation Chamber Cover Bolt Side Shield Bolt End Shield Bolt Brake Bolt Flywheel Nut Aluminum Flywheel Nut Cast Iron Ignition Wire Bolt Stud Fuel Tank Support Bolt Fuel Tank Bolt Recoil Starter Reel Nut Throttle Control Sub Assemble Bolt Air Cleaner Nut Governor Support Nut Muffler Support Bolt Muffler Bolt Muffler Cover Bolt Engine Cover Bolt Drain Plug TORQUE VALUE N m 12 1022 18 2 24 2 10 1 6 10 1 1022 1022 1022 1022 32 4 78 4 1022 1242 1242 1022 6 2 1022 1022 1022 6 10 2 10 2 10 2 6 15 20 18 EN QN EN NOTICE For unspecified bolt screw and nut refer to the standard torque value 2 DIMENSION AND TORQUE 2 5 Standard Torque Value Bolt Nut 3 MAINTENANCE 32. 4 5 Electric Diagrams ENG SWITCH Bl ENG SWITCH SPARK PLUG IGNITION COIL 62
3. in the lifters Be careful not to damage the PUSH ROD GUIDE ROCKER ARM Reassembly Before installing check for wear on the surfaces which contact the EXHAUST VALVE pivot bolt the push rod and Reassembly the rocker arm pivot Before installation ADJUSTING NUT remove carbon deposits and inspect the valve INTAKE VALVE GUIDE LOCKING NUT EXHAUST SPRING RETAINER VALVE GUIDE GUIDE SEAL 47 5 Install the head cover gasket aligning the projection of the head cover gasket with the projection of the cylinder head Valve spring retainer Push down on the valve spring and move the retainer to the side so that valve stem slips through the side hole Do not remove the valve spring retainers while the cylinder head 15 attached to the cylinder or the valves will drop into the cylinder 2 Inspect service repair 1 Valve stem outside diameter Inspect the valve stem outside diameter with the micrometer if finding out of the standard or service limit or if visually inspecting the burn and damaged on the valve face please replace with new one IN 5 468 5 480mm EX 5 435 5 450mm IN 5 318mm EX 5 275mm 48 3 MAINTENANCE 2 Valve spring free length Measure the free length of the valve Springs If out of the p standard or service limit Please replace the spring MU lt S 3 Valve guide Inspect a Inspect the valve guide for smooth scr
4. AI 3 Set the recoil starter spring outside hook into the groove JS of the recoil starter pulley NC p m 4 Set the starter drive cam the recoil starter pulley and GROOVE f install the return spring on the recoil starter pulley while hooking it on the side of the driving cam 5 Install the spring drive guide and fixing screw in order and 9 tighten to the specified torque ED Screw torque value 10 2 N M _ 28 3 MAINTENANCE 6 Pass the recoil starter rope through the recoil starter case and recoil starter grip and make a figure eight knot at the rope end 7 Pull the recoil starter rope lightly to check the drive cam for function 29 4 4 2 Muffler Removal Installation 5S 5MUFFLER GASKET Don t Reuse 3 Bolt M6x80 Bolt M6x12 4 MUFFLER ASSY MUFFLER COVER Disassemble the muffler as shown on the figure The muffler can produce carbon deposits in the long time operation and seriously trouble the exhaust system To get the best performance the muffler must be periodically removed the carbon deposits Lightly tap the muffler and blow it with compressed air in cleaning carbon deposits Replace it if the muffler exist in water and 15 seriously rusted to make noise increasing NOTICE Don t clean with iron wire or the muffler material out to lower the muffler performance Don t reuse the muffler gasket The muffler can glow heat Plea
5. MAINTENANCE 3 1 Maintenance Schedule EVERY 6 EACH FIRST MONTH EACH SEASON EACH YEAR MONTH OR 100 TIME OR20HRS OR 50 HRS OR 300 5 BRE ii Oil Level Engine Oil Check Replace Check Clean Replace Oil Alert Check System gt CH c 5 p e gt Clean Adjust Spark Plug Replace Valv Check Adjust Clearance Cylinder Head Fuel Tank Replace Every three years These items should be serviced by company authorized dealer unless you have proper tools and mechanically proficient 3 2 Engine Oil A CAUTION e Engine oil is a key factor in deciding the engine s SAE VISCOSITY GRADES performance Do not apply engine oil with additives or 2 stroke gasoline engine oil because they haven t enough lubrication and may shorten the engines service life e Check the engine with it stopped on a level ground 20 0 20 40 60 80 100 20 10 0 10 20 30 40 e Engine oil capacity RVI60 amp RVI70 0 6L ENVIRONMENT TEMPERATURE Engine oil recommended SAE 10W 30 12 3 MAINTENANCE When the temperature in your area is in the frame of the above chart you can use other viscosity of engine oil mu 3 OIL DIPSTICK EN SEALING RING A 2 Don t Refuse OIL UPPER LIMIT M LEE OIL HOLE 4 OIL LOWER LIMIT CHECK METHOD 1 Remove the dipstick and clean it
6. 2 Reinsert the dipstick into the oil filling hole without screwing it and check oil level 3 If the oil level is too low add the recommended engine oil up to the oil upper limit 4 Reinstall the dipstick OIL CHANGE A CAUTION e Used engine oil contains substances that have been identified as carcinogenic If repeatedly left in contact with the skin for prolonged periods it may cause skin cancer Wash your hands thoroughly with soap and water as soon as possible after contact with used engine oil e Please dispose of used oil in manner that will pollute the environment We suggest you take it in a sealed container to your local service station or recycling center for reclamation Do not throw it in the trash or pour it on the ground a Screw the oil dipstick off b Tilt the engine to drain the oil from the hole 13 3 MAINTENANCE 3 3 Air Cleaner BREATHE TUBE AIR CLEANER ELEMENT COVER GASKET P NUT M6 Wash the engine each 50 hrs or 3 months Wash more frequently in dust area e Remove the air cleaner cover and take the element out e Change the damaged element e Clean the element before reusing Clean the element Wash the element with detergent and dry it Foam Element Immerse the element into the oil and squeeze the excessive oil The element should be wet but not drop the oil Blow the compressed air from the inner side or lightly tap to move the dust If dirty Paper El
7. amp RATO RV160 RV170 SERVICE MANUAL Chongqing Rato Power Co Ltd CONTENT CONTENT L INSEROIDUC dy ead eee 1 Isl te Eesen ee 1 152 DECIICS DDN 2 Rubbia 2 2 DIMBINSION ANID alal 6 BIN UNTEN D Em 6 2 2 Lhe Positron Of Installing a labii 7 E Installing Draw 10g 7 Lorque Value pese e deut ada c do ot 10 E 11 12 Se 12 FET Pm 12 i oA Lips C Te anie Eo einer TA 14 DS Wash The eds d Uu dee pee 15 SPARI 15 3 6 Valve Clearance Adjustment EE 16 18 4 DISASSEMBLING AND 19 4 1 edle er EE 19 19 der E oeste utente re E A aaa 21 Unsa Diosa 22 ase NE TE E a 22 4 1 5 Gasoline Ensine 16 A E E PA ee totes Rea ve E ae 23 4 1 6 Abnormal SOUNG 23 4 2 Preparation OP Set VICHIe ood nont e o altes rud da fal o Dant ua mut I 24 Ere LONG sca
8. and carburetor body when the float just contacts the seat without compressing the valve spring FLOAT LEVEL GAUGE If the height is out of specification replace the float valve and recheck the float height Tool Float level gauge d Carburetor idle speed adjusting e Start the engine to preheat it to normal running temperatu e Adjust the pilot screw to specified idle speed Specified idle speed 1900 100rpm 40 3 MAINTENANCE 4 4 7 Flywheel Removal a Holding the flywheel with commercially WHEEL PULLER Commercial available strap wrench remove the nut Available MIA aa FLYWHEEL b Disassemble the starter cut and impeller SI eS c Remove with a commercially available flywheel puller e Do not hit the flywheel with a hammer vae e Avoid the magnet section when attaching the puller DEIR Installation A d P a Clean the tapered part of dirt oil grease and other foreign material before installation Be sure that there 15 no washer and other foreign material FLYWHEEL on the magnetic part BRAKE b Setthe key in the key groove c Install the flywheel over the crankshaft NOTICE The flywheel may push the Key out of its slot check after installation Flywheel cast iron e Attach by aligning the four small holes in the flywheel e Attach by aligning the lug on the rear side of the starter cup with the small hole at the center of the flywhe
9. cati usd EUR ien tabu oua denen 24 42 2 SPEC TOOLS agili 25 CONTENT 4 9 Dismountmnb C 26 d Gost DA EN cirie 27 2 4 OVER 27 cca 30 Lez Foel iic 3l FAA x Ie C Ie ale 32 JAS 34 2 440 C ar OUTE Ol 36 EN E LR 4 4 4 S Cylinder Head Nasi 45 C Tan kS hat EL 53 AS BIectric Dido raS EE 62 1 INTRODUCTION 1 INTRODUCTION 1 1 Parts Description START HANDLE OIL DIPSTICK SPARK PLUG MUFFLE FUEL TANK COVER AIR CLEANER I INTRODUCTION 1 2 Specifications LxWxH not including 305x348x282 mm 395x348x282 mm crankshaft output terminal Dry Weight 12 1Kg or 13 7kg 12 5Kg or 13 7Kg Engine Type Single Cylinder Horizontal 4 Stroke OHV 173 2cc 70mm X 45mm 3 2kW 3 600r min 2 4 kW 3 400r min 9 0N m 2 500r min Recommended Using Power 2 3Kw 3600r min Capacitance Discharge Type or Inductance Discharge Type Vertical Shaft Output 1 3 Service Limit RV160 UNIT mm SERVICE PARTS ITEM STANDARD LIMIT Maximum Speed No Load 3400 100rpm Engine Idle Speed 1900 100rpm Cylinder Compression 1 38Mpa 1200rpm Cylinder Head S
10. e Install the piston with the mark on the piston head toward the push rod hole side 3 Piston check Check the piston and cylinder for contacting and check the groove for DRIVER RETAINER BEARING INNER RETAINER ASSEMBLER Driver Handle RETAINER ASSEMBLE OIL SEAL 25x38 VW M ARK PISTON RING COMPRESSOR PUSH ROD COMMERCIALLY HOLE AVAILABLE 23 defects piston top for burn and cracks If damaged replace Clean the carbon deposit Clean the deposit round the piston top and cylinder neck before checking first soak the carbon deposit with kerosene and then clean with meter scraper or metal brush a Piston skirt O D Measure the piston skirt O D with outside micrometer if out of the service limit replace it 67 985mm 67 845mm b Piston pin bore to piston clearance Separately measure the piston pin bore I D and O D with inside micrometer and outside micrometer Then calculate clearance by measuring results c Piston cylinder clearance Difference between cylinder maximum diameter and piston skirt should be considered as piston cylinder clearance NOTICE This clearance must be checked before and after repairing 56 3 MAINTENANCE Check with piston converting in the cylinder and inserting feeler between piston skirt bearing face and wall then pull the feeler out if feeling resistance and smoothly out the thickness of the feeler shall be considered as piston cylinder clea
11. gauge on the crank pin connecting rod and bolt to specified torque Torque 12 N m NOTICE Place the plastic gauge axially PLASTIC GAUGE e Remove connecting rod and measure with plastic WITH SCALE PLASTIC GAUGE gauge 58 3 MAINTENANCE e Ifthe clearance exceeds the service limit replace the connecting rod and recheck the clearance 5 Camshaft check The camshaft is main driving part of the train valve mechanism which control the intake and exhaust valves opening and closing Feature The shaft is equipped with cam and journal which can control intake and exhaust When operating camshaft operating face and lifter will be badly rubbed from periodically impacting and easily be damaged So camshaft shall be wearable and lubrication well e Visually inspect camshaft face and camshaft height for damaged and camshaft and bearing for loosening and wearing replace as required e Check camshaft for height dimension if out of the service limit replace the camshaft 27 70mm IN 27 75mm EX 27 45mm IN 27 50mm EX Check outside diameter of the camshaft if less than the service limit replace the camshaft 13 966 13 984mm 13 916mm Camshaft wearing cause and to engine performance influence 59 Poor lubrication will result in camshaft abnormal wearing such as oil viscosity low impurity too much and recycling oil little can t let the camshaft surface forming complete oil
12. handle Inner retainer assembler Diamond lap 45 Diamond lap 327 Flywheel driver Bearing extractor l 2 di 4 5 7 8 9 Valve guide reamer Carburetor float level inspection Valve guide removal installation Assembling ball bearing Installing handle and bearing Assembling ball bearing and time Rectifying valve seat surface Rectifying valve seat surface Dismounting flywheel Dismounting flywheel Fine reaming the guide inner hole 25 4 3 Dismounting Chart 26 ENGINE CARBURETOR FLYWHEEL AIR CLEANER SHROUD RECOIL STARTER ENGINE HOUSING 3 MAINTENANCE 4 4 Gasoline Engine 4 4 1Recoil starter fan cover Removal Bolt M5x16 RECOIL STARTER GRIP ENGINE COVER NUT 6 8 SSE 4 RETURN SPRING o 5 4 DRIVE CAM STUD M6x88 27 NOTICE Wear gloves and eye protection during disassembly and take care not to allow the return spring to come out Installation Instruction 1 Pass the recoil starter rope through the rope in the recoil starter pulley and make a figure eight knot at the rope end NOTICE the rope foe wearing and broken before reassembling then install it 2 Hang the side hook of the recoil starter spring in the groove of the recoil starter case set the recoil starter CUTOUT spring into the case with counterclockwise rotating e starter spring REEL COVER GROOVE
13. never counterclockwise Continue to turn the cutter as you lift it from the valve seat Tool Valve seat cutter CUTTER HOLDER 51 Use the 32 45 cutters to narrow and adjust the valve seat so that it contacts the middle of the valve face The 32 cutter removes material from the top edge contact too high d The 45 cutter removes material from the bottom edge contact too low Be sure that the E 3 Y width of the finished valve seat 1s within specification e Make alight pass with the 45 cutter to remove any possible burrs at the edges of the seat f After resurfacing seat inspect for even valve seating width Apply colorant to the valve tapered face insert the valve and press it forcefully several times be sure the valve does not rotate on the seat The seating surface as shown by the transferred marking compound should have good contact all the way around Apply the abradant to the valve seat face suitable for running in when rotating valve seat with valve seat cutter VALVE LAPPING TOOL h After reassembling check the valve clearance 52 3 MAINTENANCE 4 4 9 Crankshaft Piston CONNECTION CRANKSHAFT Reassembly Push in firmly until contact is made with the rearing surface Be careful Se N N hi DIE _ 27 p e not to damage the oil seal BEARING 6205 2 5 x Z lt 2 2 2 2
14. 0 p NUT M6 the left end into upper 5S u 4 hole of the choke shaft Wi THROTTLE CONTROL BOLT BOLT M6x28 M5x16 GOVERNOR SPRING LEFT HOOK POSITION 35 4 4 6 Carburetor At high altitude the standard carburetor air fuel mixture will be excessively rich Output power will decrease and fuel consumption will increase Engine performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw If you always operate the engine at altitudes higher than sea level 1000 meters over have our authorized dealer perform this carburetor modification If not should lower load power in operating gasoline engine Even equipped with suitable carburetor engine horsepower will decrease approximately 3 5 for each 300 meter increase in altitude The effect of altitude on horsepower will be lowered greater than this if no carburetor modification is made If a carburetor suitable to high altitude 1s equipped with engine suitable to a lower altitude the lean air fuel mixture will make engine output power lowering over heat and seriously damage The gasoline enters into the carburetor from the fuel tank and fuel filter The fuel filter can filter the foreign matters in the gasoline and oxide out of the fuel tank If having quality defectiveness partly foreign matters will enter into the carburetor Otherwise the gasoline contains some co
15. 2 PD 5 5 ee SEAL 25 38 7 PISTON PIN CLIP 53 DDisassembly a Piston 120 MARKER Install with the maker mark facing upward as shown Do not interchange the top ring and the second ring top ring with chrome plated OIL RING e After assembly check for e s smooth movement of the piston 9 IK ring CONNECTION ROD Stagger the piston ring end gaps Reassembly 120 apart Make sure that the longer end marked is toward the piston head with the 2 Reassembly a Piston pin clip Install by setting front end of the clip in the piston groove holding the other end with long nosed pliers and rotating the clip in PISTON PIN CLIP Do not align the end gap of the clip with the cutout in the piston pin bore CUTOUT b Connecting rod cap ALIGNMENT MARKS Install by aligning the alignment marks on the connecting rod cap 54 c Bearing 3 MAINTENANCE e Apply oil to the circumference of a new ball bearing e Drive the ball bearing in the cylinder barrel using 6205 tool Tools Driver handle Retainer assembler Inner assembler d Oil seal e Apply oil to the circumference of a oil seal Drive the oil seal in the cylinder barrel using following tool Tools Driver handle Retainer assembler e Apply the lubrication oil on after reassembling e Piston e Apply oil to the piston and cylinder
16. R CLEANER ELEMENT 32 3 MAINTENANCE NOTICE Check for damage of the air cleaner and install AIR CLEANER _w e Note the installation direction view from air GASKET cleaner side Before installing breather tube check for deterioration or damage Replace if necessary Pay attention to connect the beveled end smaller to the air cleaner case and other end to the engine BREATHE TUBE e Don t wash the foam element with the gasoline acidity alkalic or organic solvent e Don t pull and wrest the sponge or it will be damaged A WARNING Don t start the engine without air cleaner or the engine will be quickly worn 33 4 4 5 Governor Removal Installation GOVERNOR Bolt M6x12 PIN 8x14 SHAFT HOLDER PLATE WASHER 6mm WASHER OIL BLOCK 6mm GOVERNOR SLIDER Insert the governor slider into the governor shaft and check for slider moving smoothly GOVERNOR CRANKCASE DRIVEN GEAR GOVERNOR HOLDER SHAFT COVER Before Installing Align The Shaft Groove With Check For Wear The Projection In Case 34 3 MAINTENANCE THROTTLE VALVE RETURN SPRING Hook the left end hook into the hole of the throttle valve shaft projection GOVERNOR LEVER THROTTLE VALVE SHAFT Insert The Left End GOVERNOR ASSY Into Vertical Hole Of The Throttle Valve kr SM MA a X E L M lt A eg f MD A y um CHOKE SHAFT a S
17. atch and damaged in the inner surface and matching between the valve guide and cylinder cover for fastness VALVE GUIDE b Using the valve guide reamer ream the valve guides to remove any carbon deposits before measuring If the valve guide inside diameter 15 lower than standard or out of the service limit replace the guide 5 500 5 512mm 5 562mm Replacement a Chill the replacement valve guides in the freezer section of a refrigerator for about an hour b Drive the valve guide out of the combustion chamber side using valve guide driver 49 VALVE GUIDE Be careful to avoid damaging the DRIVER cylinder head when driving out the valve guides VALVE GUIDE INSTALLATION HEIGHT 11MM c Install the new valve guides from the valve spring side of the cylinder head e Exhaust side Drive the exhaust valve guide until the clip is fully seated as shown as fig e Intake side Drive the intake valve guide to the specified height measured from the top of the valve guide to the cylinder cover as shown as fig VALVE GUIDE DRIVER d After installation inspect the valve guide for damage if damaged please replace Reamer For best results be sure the cylinder head 15 at room temperature before reaming valve guides a Coatthe reamer and valve guide with cutting oil b Rotate the reamer clockwise through the valve guide for the full length of the reamer c Continue to rotate the reame
18. ce Intake Valve 0 10 0 02mm Exhaust Valve 0 15 0 02mm Adjusting Nut Value Clearance 17 3 MAINTENANCE A CAUTION Clearance too big Intake and exhaust valve opening delay will shorten the intake and exhaust time lower the opening height of the valve and change normal distributing phase to result in power lowering from the intake lack and exhaust uncompleted Furthermore also make vale train parts knock increasing and wearing quickly Clearance too small After running engine parts will be heated to expand and push the valve open which will make the engine not closing tight and result in leaking power lowering serious carbon deposit or burn on the valve surface even valve impacting the piston 3 7 Governor Governor adjustment THROTTLE VALVE a Remove the air cleaner GOVERNOR SUPPORT b Loosen the nut M6 Be sure that the carburetor throttle valve is OI c Rotate the governor support shaft fully to the right governor fully closed position and tighten the nut TORQUE VALUE 10N m d Check to see that the governor support and throttle valve move freely e Check the maximum engine speed Maximum Speed Adjustment a Start the engine and allow it to warm up to normal operating temperature b Ifthe maximum speed not conforming to specified value adjust the adjusting bolt M5x30 Engine maximum speed 3400 100rpm Speed too big Turn the bolt counterclockwise Speed too small Turn t
19. e coil s iron core Secondary side resistance value 5 9 7 2 0 Spark plug cap Measure the resistance of the spark plug cap by attaching one ohmmeter lead to the wire end of the plug cap while touching the other tester lead to the spark plug end AS Resistance value 3 75 6 25 44 3 MAINTENANCE 4 4 8 Cylinder Head Valve VALVE GUIDE EXHAUS SPRING GUIDE VALVE A 3 RETAINER PUSH ROD e Sani CYLINDER 1 Removal Installation 1 Remove the muffler 2 Remove the air cleaner 3 Remove the recoil starter and shroud 4 Remove the carburetor and insulator 45 46 CYLINDER HEAD Installation Before installation remove any carbon deposits from the combustion chamber and inspect valve seats Measure the cylinder compression after reassembly BOLT M8x50 Loosen and tighten the bolts in crisscross Kaes nattern in 2 or 2 tens CYLINDER GASKET HEAD COVER BOLT M6x12 Apply oil to thread Loosen and tighten the bolts in a crisscross pattern especially tightening uniformly and gradually tighten finally to the specified torque aen a a ANT mm 3 MAINTENANCE INTAKE VALVE Reassembly PUSH ROD Don t interchange with the Reassembly exhaust valve Check both ends for wear and the rod IN 25mm for straightness CYLINDER HEAD EX 24mm Be sure the rod ends are firmly seated
20. el 4 FLYWHEEL CAST IRON IMPELLER LUG HOLE HOLE LUG Flywheel aluminum FLYWHEEL d Apply light coat of the oil to the threads and surface of the nut and install the nut loosely Torque 52N m 42 3 MAINTENANCE Ignition coil NUT ay STARTI vU af Am Ye FLYWHEEL Sf 77 BOLT M6x25 LI IGNITION C 5 HIGH VOLTAGE IGNITION SPARK PLUG CAP Xe LINE Check The Insulator For Damage If Damaged Please Replace It a Remove the fuel tank air cleaner IGNITION COIL b c d carburetor and recoil starter assy Measure the clearance between the FLY WHEEL ignition coil and flywheel with the feeler Adjust the clearance of the ignition and flywheel Adjusting method Loosen the bolt and move the ignition coil up and down for adjusting the clearance then screw down the bolt CLEARANCE 0 35 0 45mm 43 Check the ignition coil primary side Measure the resistance of the primary coil by attaching one EH iu TET Qa ohmmeter lead to the ignition coil s primary terminal while d 4 JE ng GN touching the other tester lead to the iron core N Primary side resistance value 0 8 1 00 Secondary side Measure the resistance of the secondary side of the coil with the spark plug cap removed touching one test lead to the high tension cord while touching the other tester lead to th
21. ement mE badly replace in time e Be careful to prevent dirt from entering the air duct that leads to the carburetor e Place the foam element over the paper element and cover the case cover on 14 3 MAINTENANCE 3 4 Wash The Strainer Don t smoke or use fire near the flammable solvent a b c d e clean the strainer FUEL TANK Fill the fuel into the container N Remove the fuel tube screw the strainer bolt off Check the strainer for damage and f Neu Om CLIP After Cleaning install the strainer on OIL TUBE STRAINER the fuel tank and connect the fuel tube Check for leaking 3 5 Spark Plug a b d Remove the spark plug cap Clear away dirt around SPARK PLUG SOCKET WRENCH the spark plug base Dismantle the spark plug with a spark plug wrench Visually check the spark plug Clean with a Steel brush If the insulator is damaged replace the spark plug instead Measure the spark plug clearance with a feeler The clearance should be 0 7 0 8mm If adjustment 15 necessary bend the side 0 70 0 80 electrode carefully SIDE ELECTRODE 3 MAINTENANCE e To avoid cross threading first screw in spark plug by hand then tighten with a spark plug wrench to compress the gasket f If a new spark plug is used more twist 1 2 turns after compressing the gasket If reinstalling the used spark plug just more twist 1 8 1 4 turns S
22. erheat Metal beating sound Too much carbon deposit in combusting chamber Clear away carbon deposit when abnormal Improper fuel brand Replace fuel combustion occurs mE Engine is overheat Find a cause and eliminate it Readjust valve clearance Improper valve clearance The other properly Fly wheel is not connected with crankshaft tightly Connect tightly 23 4 2 Preparation Of Servicing 4 2 Safety Precautions WARNING Indicate a possibility of invalid warranty and personal or equipment damage instructions are not followed Please pay special attention to the following 1 10 IRE 24 Strictly set the engine according to the regulated power on the nameplate Do not overload overrun the engine or run it with low load and at low speed in a long time Use regulated brand of gas and diesel The fuel should be fully deposited and filtrated before use Keep clean the fuel filler change the oil periodically Periodically check the installation connection and the degree of tightness of the fixed bolt Tighten it 1f necessary Periodically clean the element of the air cleaner change it when necessary The engine 15 air cooled so clean the radiator wind cover and fan in time in order to make the engine cool normally The operator should be familiar with the working principle and structure of the gasoline engine knowing how to make an emergent stop and the operation of all controlling parts A
23. film to make the camshaft surface seriously worn in the high speed rubbing stat Second installing precision problem when the matching clearance of the camshaft journal and camshaft seat or bearing 15 out of the service limit camshaft rotation precision will lower and contacting with the relative part produce deviation face to make abnormal wearing 6 Timing gear a Check timing gear for engagement clearance with aligning two side mark on the gear Bolt M8x50 Oil Seal 25 40 7 f SM Sa NM Crankcase Cover GASKET DON T REUSE IT GOVERNOR e Nu WASHER 6 2x15x0 6 IN INNER SIDE FIX WITH AG 224 AFTER SSEMBLING GOVERNOR OIL SEAL 6x11x4 60 3 MAINTENANCE ALIGNMENT MARK CAMSHAFT GEAR CAMSHAFT GEAR Timing gear will be damaged in gear worn gear face peeling off and gear teeth broken The engagement clearance 15 bigger due to gear wearing the noise 1s bigger If the timing gear 15 damaged please replace with new one NOTICE Please replace the gear with a new set to ensure the engaging face completely engage in b Reassembly ai LAP Oil seal RETAINER e Apply grease to new oil seal around ASSEMBLER Ki OIL SEAL Install the oil seal into the crankcase cover with special tools 25x40x7 e After installing apply special grease to the oil seal 61 c Check Camshaft handle inside diameter Inm CRANKCASE COVER
24. gasoline There is water in float chamber Spark improper spark plug electrodes clearance Lacking Something wrong with induced coil and so on Check and replace damaged parts 4 1 4 Unable Igniting Spark plug is punctured or DEM Replace spark plug short circuited by carbon deposit Side electrode of spark plug is dropped i B Replace spark plug and clean the cast ou Ignition coil is punctured or NL Replace ignition coil short circuited Parking wire is located on engine body Find out meeting and insulate Cylinder is seriously scored and valve Fuel Supply DI DI O c c Ignition System Repair or replace damaged parts dropped out The Other 22 3 MAINTENANCE 4 1 5 Gasoline Engine Is Overheat Connection rod deformation to make piston and cylinder Replace connection rod bushing side wear Cylinder or piston or piston ring is worn to make hunting Replace the worn parts between cylinder and crankcase Improper adjustment of engine governor to produce Readjust engine governor speed high Crankshaft main bearing burnt out Replace main bearing 4 1 6 Abnormal Sound TROUBLE CAUSE REMEDY Piston piston ring or cylinder is worn Replace the worn part Connection rod or piston pin and piston pin hole Replace the worn part Beating sound are worn Crankshaft main neck is worn Replace bearing Piston ring is broken Replace piston ring Gasoline Engine Is Ov
25. he bolt clockwise 18 3 MAINTENANCE 4 DISASSEMBLING AND SERVICING 4 1 Troubleshooting 4 1 1 Starting Difficult TROUBLE CAUSE REMEDY There is no enough fuel in fuel tank and Fill fuel open fuel cock fuel cock is closed Air vent in the fuel filler cap 15 clogged Readjust or clean blow to Improper or clogged main oil flow hole get through i Dismantle needle valve and Needle valve is not closed properly or repair clean blow to get start hole is clogged through Float is damaged or sticking Fuel is too filthy or deteriorated Drain extra fuel dry up spark Too much fuel in engine plug electrodes Select proper fuel brand Fuel supply is not smooth or no Normal spark plug spark D JD un gt an D D S gt DI c gt DI e vel S i N Wrong fuel brand corresponding with the Fuel supply is normal requirements Too much carbon deposit and dirt around Clear away electrodes Electrodes are burn damaged seriously i Replace spark plug or insulators damaged Abnormal gap between the ignition coil Adjust gap and flywheel Normal cylinder compression Normal high tension line Spark plug is in bad conditions Normal fuel supply system High tension line Normal spark 19 TROUBLE CAUSE REMEDY Piston ring is worn to or even over its MN Replace wear limit Piston ring is sticking Clear up carbon fouling Spar
26. k plug is not installed tighten or Tighten with a gasket in without a gasket Check cylinder gasket and the flatness of the surface by which cylinder block contacting with Air leakage between cylinder block Normal spark plug cylinder head and cylinder head Normal fuel supply system Tighten cylinder head bolts in stipulated order to Abnormal cylinder compression stipulated torque Check valve Clearance tightness repair if Air leakage in the valves necessary If still can t starting have the engine to our authorized dealer for repairing e Spark plug testing e Make sure there is no spilled fuel outside the engine and that the spark plug isn t dipped with fuel When testing the spark plug never hold the high tension line of the spark plug with wet hand prevent fire keep sparks far away from the spark plug mounting hole RECOIL STARTER GRIP SPARK PLUG SPARK PLUG CAP 20 3 MAINTENANCE Turn the fuel cock to OFF position and drain the gasoline of the carburetor e Remove the spark plug and spark plug e Pull the recoil starter grip to drain the gas in the cylinder e Install the spark plug cap e Put the control lever to low position Pass negative pole thread of the spark plug through cylinder cover to connect grounding and pull the recoil starter grip to observe the spark 4 1 2 Power Lack TROUBLE CAUSE REMEDY Ai
27. l End Side Clearance Crankshaft Pin O D Valve Clearance Stem O D Guide I D Stem Clearance Seat Width Spring Free Length Cam Height Journal O D Camshaft Bracket I D 0 015 0 050 18 002 18 008 17 994 18 00 0 002 0 014 0 030 0 065 0 2 0 4 1 5 18 005 18 020 30 020 30 033 0 040 0 063 0 1 0 7 29 970 29 980 0 15 0 02 0 20 0 02 5 468 5 480 5 435 5 450 5 500 5 512 0 020 0 044 0 050 0 077 0 8 34 0 27 70 27 75 13 966 13 984 1 INTRODUCTION Main Jet Carburetor Float Height 13 7 Pilot Screw Opening 2 5 8turns uu Resistance Primary coil 5 9 7 2 Ignition Coil Secondary coil i 0 35 0 45 Air Gap at flywheel mu 2 DIMENSION AND TORQUE 2 DIMENSION AND TORQUE 2 1 Dimension 2 DIMENSION AND TORQUE 2 2 The Position Of Installing Hole 2 3 PTO Installing Drawing Shaft P2 Shaft SEAT FACE SEAT FACE 0754238 191 d La AJ d P E a ap av ar av av caer am o n dr 2777777 2579 BI 2 DIMENSION AND TORQUE P26 Shaft P3 Shaft SEAT FACE SEAT FACE EZ C AZ P28 Schaft P27 Schaft SEAT FACE 3 8 24UNF 28 Gyre 2 855 SEAT FACE 3 8 24UNF 28 e K r ZZ
28. leeve I D 395g kw h Theoretical Maximum Power 3 0kW 3 600r min Skirt O D Piston to Cylinder Clearance 0 015 0 050 Piston Piston Pin Bore I D 18 002 18 008 Piston Pin O D 17 994 18 00 Piston Pin to Piston Pin Bore Clearance 0 002 0 014 Ring Side Clearance second 0 030 0 065 Piston Rings Ring Enc Gap second 0 2 0 4 Ring Width second Lo 1 INTRODUCTION Small End I D 18 005 18 020 Big End I D 30 020 30 033 Big Oil Clearance 0 040 0 063 Small End Side Clearance 0 1 0 7 Valve Clearance 0 10 0 02 0 15 0 02 Stem O D 5 468 5 480 5 435 5 450 Guide I D 5 500 5 512 Stem Clearance 0 020 0 044 0 050 0 077 Seat Width 0 8 Spring Free Length 34 0 Cam Height 27 70 Camshaft 27 15 Journal O D 13 966 13 984 Main Jet Carburetor Float Height 13 7 Connecting Rod Pilot Screw Opening 2 5 8turns Resistance Primary coil 0 8 1 00 Ignition Coil Secondary coil 5 9 7 2 0 at flywheel 0 40 2 RV170 SERVICE PARTS ITEM STANDARD LIMIT Maximum Speed No Load 3400 100rpm Idle Speed 1900 100rpm Cylinder Compression 1 38Mpa at 1200rpm 1 INTRODUCTION E Head Sleeve I D Connecting Rod Crankshaft Valve Camshaft Crankcase Cover Skirt O D Piston to Cylinder Clearance Piston Pin Bore I D Piston Pin O D Piston Pin to Piston Pin Bore Clearance Ring Side Clearance second Ring Enc Gap second Ring Width second Small End I D Big End ID Big Oil Clearance Smal
29. mposition which can form the colloid after long sediment and attach in the carburetor parts such as main jet oil path and float chamber surface The air enter into the carburetor Through air filter based on the intake can not be too much resistance and other factors to consider the filter can not be too dense and therefore part of the air in the tiny impurities will enter into the carburetor through the air cleaner 36 3 MAINTENANCE THROTTLE VALVE THROTTLE SHAFT CHOKE SHAFT INSULATOR d GASKET CHOKE Don t Reuse W CARBURETOR INSULATOR AIR CLEANER CARBURETOR Gasket Don T CARBURETOR GASKET Don T Reuse Reuse e 8 Wash the carburetor in the clean place first clean the outside surface and wash the inside the parts with special carburetor detergent or industrial gasoline Exception for washing impurities also wash the gasoline colloid on the part surface Blow the washed parts clean with compression air and don t use cloth and paper against recontaminating Don t use the steel wire and other hard material to open the blocked hole to prevent carburetor performance from changing holes diameter Use the gasoline and compression air to clean it 37 a Carburetor disassembly PILOT JET THROTILE STOP SCREW gt PILOT SCREW Qe Dy CARBURETOR Clean With Compressed Before Installation FLOAT PIN FLOAT VALVE MAIN NOZZLE MAIN JET FLOAT After installatio
30. n check for operation by lightly FLOAT CHAMBER pushing with a finger P_ Ag G GASKET Br DRAIN BOLT FLOAT CHAMBER SET BOLT Tighten The Bolt Install So That The Securely And Check For Drain Bolt Facing To Gasoline Leakage Choke Valve Loosen the drain bolt and completely drain the fuel out before installing carburetor No fire 38 3 MAINTENANCE e Check float valve float seat and float spring for wear FLOAT VALVE A WORN NORMAL FLOAT VALVE Clean with compressed air before installation MAIN JET e Clean with compressed air before installation MAIN NOZZLE e Clean with compressed air before installation Apply light coat of oil to the O ring to facilitate installation ae IDLE SPEED JET BODY 39 b After washing the carburetor reset the pilot screw PILOT SCREW BROKEN back Only repairing the carburetor can disassemble it If the pilot screw 1s broken replace with new one e Disassemble the broken pilot screw from the carburetor e Put the spring onto the replaced pilot screw and then install it onto the carburetor e Turn the pilot screw in until it is lightly seated the bottom of hole then turn the screw out the specified numbers of the turns Pilot Screw Standard Opening State 2 5 8 turns out c Inspection Float level height Place the carburetor the position as shown and measure the distance between the float top
31. ny one without training is forbidden to operate the engine Keep periodical maintenance Solve problems in time Do not run the engine in spite of malfunction Running the engine in a well ventilated place keep it at least one meter away from building walls or other equipments keep away from inflammables such as gasoline amtmatches and so on to avoid possibility of fire Refuel in a well ventilated area with the engine stopped and in places refueling or storing gasoline no smoking and any flames or sparks Refuel the fuel tank not too full so as to avoid fuel s spilling out If there 1s spilled fuel around be sure to clean it thoroughly before starting Do not run the engine in airtight or ill ventilated places The exhaust muffler is very hot during running the engine even after the engine stops Never touch it or you may get burns Transport or store the engine with it cooling down entirely 12 Safe warning label 3 MAINTENANCE Please carefully read warning label before operating Our company will not assume any responsibility for person hurt or equipment damaged caused by disregarding this warning label me PLEASE READ THE OWNER S MANUAL CAREFULLY BEFORE OPERATING 4 2 2 Special Tools DON T BREATH EXHAUST IN PLEASE KEEP DON T OPERATE THE FIRE FAR INDOORS AWAY TOOL NAME APPLICATION NOTE Float lever gauge Valve guide driver Retainer assembler Assembler
32. park plug torque value 18 2N m Spark Plug Type F7TC The spark plug must be tightened securely or it may become very hot to damage CAUTION i d i engine Only use recommended spark plug or the equivalent Incorrect heat range of the spark plug may damage the engine 3 6 Valve Clearance Adjustment CAUTION Measure the valve clearance in the cold of the engine state SPARK PLUG SPARK PLUG CAP a Remove the bolt M6x12 cylinder head cover gasket spark plug cap and spark plug AA A O YU 16 3 MAINTENANCE CAUTION After the cylinder head cover is removed engine oilmay flow Be sure to wipe up flowed oil b Pull the starting rope lightly and set the piston at top dead center of the compression stroke Insert a feeler gauge between the rocker arm and valve to measure the valve clearance c Measure the valve clearance with feeler FEELER AMO I E 2 d Valve clearance adjustment method Loose the locking nut turn the adjusting nut to get the correct E valve clearance Screw down the locking nut Torque value 10N m e Recheck the valve clearance f Set the new gasket with the projection of the cylinder head Install the cylinder head cover and tighten the four bolts to the specified torque Torque value 6N m Standard Valve Clearan
33. r clockwise while removing it from the valve guide Tools Valve guide reamer d Thoroughly clean the cylinder head to remove any cutting residue 50 X Ew 3 MAINTENANCE e Check the valve guide bore it should be straight round and centered in the valve guide insert the valve and check operation If the valve does not operate smoothly the guide may have been bent during installation Replace the valve guide if it is bent or damaged f Check the valve stem to guide clearance The valve stem to guide clearance The vale guide bore detract the valve stem outside diameter to get the clearance between the valve guide and valve stem h If the clearance is over the service limit judge a new guide if 1t can make the clearance Conforming to service limit if conforming to replace the guide and ream the guide refinish the valve when replacing the valve guide 4 Valve seat a Thoroughly clean the combustion chambers and valve seats to remove carbon deposits Apply a light coat of red lead powder or erasable color painting to the valve faces b Insert the valves and then press the valve Several times forcefully Be sure the valve does not rotate VALVE FACE on the seat The transferred marking compound will show any area of the seat that is not concentric c Using 45 cutter remove enough material to produce a smooth and concentric seat Turn cutter clockwise
34. r in fuel line or fuel line clogged Exhaust air or dredge fuel line Main oil flow hole is not adjusted properly In carburetor needle valve hole and main oil Clean and blow to get through flow hole clogged Fuel cock is clogged up Clean replace damaged part Too much carbon deposit in combusting Clear away chamber Too much car bon fouling in muffler and Clear away exhaust pipe Air cleaner is clogged up Clean air cleaner filter element Intake pipe is leaking Repair or replace Piston or cylinder or piston ring is worn Replace the worn Air leakage from the surface by which cylinder i Replace cylinder gasket block contacting with cylinder head Too big or too small valve clearance Drain the oil of the fuel tank out D N gt YN gt oF oF 5 O 5 N gt c When increasing the throttle speed increase slow or even decrease and stop running Poor Compression CYLINDER PRESSURE e Drain the gasoline by loosening the oil drain bolt of the carburetor Remove the spark plug cap and spark plug and install the cylinder pressure meter e Forcibly pull the recoil starter several times and measure compression force Compression Force 1 38Mpa 1200rpm 21 4 1 3 Speed Unstable Abnormal n Too much carbon deposit in combustion chamber Combustion Improper gasoline brand or low gasoline quality Replace with qualified
35. rance d Piston ring side clearance Check with placing each ring into each self groove The piston ring should be freely turned without loosening and sticking Then measure with inserting feeler into clearance of the ring and upper and lower face e Piston ring end gap PISTON RING Flatly place the piston into the cylinder with pushing the piston head to working position Measure the opening clearance with feeler that clearance not too big or not to small too big can result in cylinder sealing performance poor while too small can result in piston expanded from heating and blocked in the cylinder si thus causing piston broken and sticking If opening clearance is too small file the opening with fine flat file Often check in the cylinder when filing until the proper clearance is got 4 Check connecting rod 27 If connecting rod bending twisting or big end shaft bush and small end outer ring movement or crack on one side should be rejected and replaced with new one a Check small end diameter If out of the standard or exceed service limit replace the connecting rod 18 005 18 020mm 18 052mm b Check big end diameter If out of the standard or exceed service limit replace the connecting rod 30 020 30 033mm 30 066mm c Connecting rod big end oil clearance e Wipe oil off the crank pin and connecting rod bearing mating surface BOLT CQ B Set the plastic
36. se place the gasoline engine out touch of the passerby and children Don t place the flammable materials near the exhaust vent during operation 30 3 MAINTENANCE 4 4 3 Fuel Tank a Removal Installation The fuel tank does not require general maintenance but sometimes the dusts and vapor will trouble the fuel system so that periodically washing it with lubrication oil and gasoline 15 required BOLT 5 16 ENGINE HOUSING 9 FUEL TANK CAPACITY BOLT 6 14 CLIP FUEL TUBE 7 FUEL STRAINER Don t smoke and use fire near the flammable solvent b Clean Installation e Check the fuel tube for damage or leak e Hill the fuel into the proper container e Remove bolt M5x16 recoil starter grip fuel tank cover and engine housing 31 e Remove the fuel tube screw the fuel strainer bolt off and remove the fuel tank e Clean the fuel tank and dry it thoroughly e After Cleaning install the strainer on the fuel tank and connect the fuel tube Check fuel tank for leak e Install the engine housing fuel tank cover recoil starter grip and bolt M5x16 c Notice Check fuel tank cover vent foe blocked e Check the fuel strainer for clogged or broken e Check the fuel hose for aging or cracks e If finding trouble replace it in time before installation 4 4 4 Air Cleaner Removal Installation BREATHE TUBE COVER NUT M6 AI
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