gasoline engine r80-r440 horizontal shaft service manual
Contents
1. 312 10000000 Il a LTU gt 35 Bea NLD AJ LU 1 LJ KA Cc Cc A c AJ DID zz 2 1 3 R270 R280 R300 DO ee am H H KE CI EF I om Ch EE NN a AG 422 2 1 4 R390 R420 R440 BO PLA 20 JU E2. db NS T a RE Da CN FT FIN AVY LE z At VV ILE GN AN mes gt 3 NS NE EE gt y EE DUDU 4 U VU il TTS NN GL ES N FT ID LXMB 6H 7 2 2 TORQUE VALUES Ser Part description and Torque no specifications value R100 M10x1 5x15 8 8 A TE R160 R225 M1Ox1 5x15 8 8 A 22 2 Oil drain plug flat 1 Oil drain plug 7 i E washer crankcase R270 R440 M12x1 5x18 8 8 A R100 M6x14 8 8 A R160 R225 M6x14 8 8 A
3. RATO GASOLINE ENGINE R50 R440 HORIZONTAL SHAFT SERVICE MANUAL CHONGQING RATO POWER MANUFACTURING CORPORATION This manual contains information about how to perform routine maintenance and how to do troubleshooting Keep this manual handy so you can refer to it at any time This service manual describes correct methods for maintaining this equipment If any personal casualty or equipment damage is caused due to disregard of our rules our company does not assume any responsibility NOTICE Copyright is reserved and no part of this publication may be reproduced without RATO Company s written permission SAFETY MESSAGES Your safety and the safety of others are very important We have provided important safety messages in this manual and on the generator Please read these messages carefully A safety message alerts you to potential hazards that could injure you or others Each safety message is preceded by a safety alert symbol and one of three words DANGER WARNING or CAUTION These messages mean You WILL be KILLED or SERIOUSLY INJURED if you don t follow ADANGER instructions A WARNING You CAN be KILLED or SERIOUSLY INJURED if you don t follow instructions PG Ne You CAN be INJURED if you don t follow instructions NOTICE Your generator or other property could be damaged if you don t follow instructions CONTENTS LNR ODINS 1 121 PARTS DEEP TN 1 Ferske me SR beeidende vand Re Lt
4. Check continuity between leads when switch is kept at each position BEA ve e Oil alert lamp Connect the black and yellow leads to 6V battery or dry cell check the alert lamp for lighting up Black battery Yellow battery Don t connect the positive and negative poles wrongly X Don t use the battery with over 6V if so bulb will break Black red lead e Connect the black red and yellow leads to 6V battery or dry cell check whether the alert lamp lights up ou A Black battery Yellow battery Don t connect the positive and negative poles wrongly X Don t use the battery with over 6V if so bulb will break e Silicon rectifier 0 Check continuity between the two terminals if it is continuous in the forward direction and uncontinuous in the reverse direction it shall be considered as normal e Resetting button Check the two terminals for continuity with resetting button turned to ON position 57 ELECTRIC DIAGRAM k switch combination starter motor Ap SS ignition coil a e in gt Lits re JR 5 a i e starter relay charging spark coil plug re 58 BEA ve Chongqing Rato Power Manufacturing Corporation Add No 99 Jiujiang Road Shuangfu District Chongqing China service hotline 400 681 9981 fox 023 85553450 postcode 402247 URL www rato cc E mail ratoservice rato cc consultation customer servic
5. Standard Standard I 8 Check connecting rod If connecting rod is bent or twisted or its big end shaft hole and small end hole have apparent grooves or have cracks on one side the connecting rod should be rejected and replaced with a new one a Check small end diameter If it is out of the standard or exceeds service limit replace the connecting rod Standard Service limit See 1 3Maintenance Standard See 1 3Maintenance Standard b Check big end diameter If it is out of the standard or exceeds service limit ERA replace the connecting rod G i R See 1 3Maintenance Standard See 1 3Maintenance Standard 51 c Connecting rod big end oil clearance e Wipe oil off the crank pin and connecting rod bearing mating surface e Set the plastic gauge on the crank pin then install connecting rod and fasten bolts to specified torque Torque See 1 3Maintenance Standard NOTICE Place the plastic gauge axially e Remove connecting rod and measure with plastic gauge e If the clearance exceeds the service limit replace the connecting rod and recheck the clearance PLASTIC GAUGE ITH SCALE PLASTIC GAUGE K SN See 1 3Maintenance Standard See 1 3Maintenance Standard 4 Camshaft check The camshaft is main driving part of the valve timing mechanism gren which controls the intake and exhaust valves opening and closing GF Feature The shaft is equipped with a cam and journal w
6. 0 087mm 0 12mm Seat Width 0 7 0 9 mm 2 0mm Spring Free Length 30 0 mm 28 5mm Camshaft Cam Height IN 27 500 27 900mm 27 450mm EX 27 547 7 947mm 27 500mm Journal O D 13 966 13 984mm 13 916mm Crankcase Camshaft Holder I D 14 14 018mm 14 048mm Cover Main Jet 0 85 Carburetor Float Height 13 7 1 5mm Pilot Screw Opening 2 1 8 circle Spark Plug Gap 0 7 0 8mm Spark Plug Resistance 7 5 12 5kQ Cap Resistance Primary Coil 0 8 1 0Q Ignition Coil Secondary Coil 5 9 7 1kQ Air gap 0 4 0 6mm 1 3 2 R420 Parts Item Standard Service limit Maximum speed No load 3750 3850rpm Engine Cylinder compression 1 2Mpa 1400rpm Cylinder Sleeve I D 90 90 015mm 90 17mm head Cylinder Warpage 0 10mm head Skirt O D 89 96 89 97 mm 89 85mm Piston to cylinder clearance 0 03 0 055 mm 0 27mm Piston Piston pin bore I D 20 002 20 008 mm 20 042mm Piston pin O D 19 992 19 998 mm 19 950mm Piston pin to piston pin bore clearance 0 004 0 016 mm 0 08mm Ring side clearance first second 0 02 0 06mm 0 15mm Oil a En Piston rings Ring end gap first second 0 2 0 4 mm 1 0mm Oil 0 2 0 7 mm 1 0mm Ring width first second 1 960 1 990mm 1 940mm Oil 1 960 1 975 mm 1 940mm Connecting Small end I D 20 011 20 022 mm 20 07mm rod Big end I D 36 025 30 039 mm 36 07mm Big end oil clearance 0 25 0 65 mm 0 12mm Big
7. 390x320x345mm 390x320x345mm DE Forced Air cooled Spark Plug BPR6ES NGK NHSP LD F7RTC F7TC Lubrication System Forced Splash p eg ae EE Displacement 420cm3 Compression Ratio Se Bowie wem Cooling System Forced Air cooled 1 3 SERVICE LIMIT 1 3 1 R210 Parts Item Standard Value Service Limit Gasoline Maximum Speed No Load 3750 38 10rpm Engine Cylinder Compression 1 17Mpa 1400rpm 7 Cylinder Cylinder Bore I D 70 0 70 015 mm 70 165mm SAB Warpage 0 10mm Head Skirt O D 69 965 69 985 mm 69 845mm Piston to Cylinder Clearance 0 015 0 050mm 0 12mm Piston Piston Pin Bore I D 18 002 18 008 mm 18 048mm Piston Pin O D 18 0 17 994 mm 17 954mm Piston Pin to Piston Pin Bore Clearance 0 002 0 0 14mm 0 06mm Ring Side Clearance Top Second Ring 0 035 0 070mm 0 15mm Oil Ring Piston Rings Ring End Gap Top Second Ring 0 2 0 35mm 1 0mm Oil Ring 0 2 0 7mm 1 0mm Ring Width Top Second Oil Ring 1 5 1 450 mm 1 37mm 2 5 2 450 mm 2 37mm Small End I D 18 005 18 020mm 18 07mm Connecting Big End I D 30 020 30 033mm 30 066mm Rod Big End Oil Clearance 0 040 0 063mm 0 12mm Big End Side Clearance 0 1 0 7mm 1 1mm Crankshaft Crankshaft pin O D 29 970 29 980mm 29 920mm Valve Clearance IN 0 15 0 02mm EX 0 20 0 02mm Stem O D IN 5 468 5 48mm 5 318mm EX 5 425 5 44mm 5 275mm Valve Guide I D IN EX 5 50 5 512 mm 5 572mm Stem to Guide Clearance IN 0 02 0 044mm 0 1mm EX 0 06
8. R 2 SERVICE LIMIE OO ROG WN AGE 3 2 DIMENSIONS AND TORQUE sees 6 OT ENGINE DIMENSIONS sentent 6 pe EG A Kr DE 6 BD PO RER ISO R200 PR 7 HIAR PAD E g HAA RSOORADOIRAAO ENE T 9 2 2 TORQUE VALUES seen 10 2 3 STANDARD Torque valueS 12 X MAINTENANCE Sn mine ne Di a cia cag aha Sedna tage ot ent 13 KE ee din A tn den 13 3 2 engine oil 14 EE EEE 15 3 4 Cleaning of the fuel filter 15 3 5 spark plug cleaning and adjusting 16 3 6 valve clearance adjustment 16 EOS WO 17 A DIS ASSEMBILINGAND SER 18 4 1 Troubleshooting 18 4 1 1 Hard starting 18 4 1 2 Engine lacks power 20 4 1 3 Speed is unstable tee 21 ANG Sunabl NJ JJ 21 4 1 5 Exhaust gas color is abnormal 59 4 1 6 Unable to ignite 29 4 1 7 Oil alert system malfunction Teese V E NNN 23 4 1 8GASOLINE ENGINE IS OVERERHEATED sr 23 4 2 Preparation of servicing 24 4 2 1 Safety precautions e 24 4 2 2 Special tools 38 AES TIS AS SE MBI Nr 29 4 4 Enginee 30 AAV Recoil EE EE 31 4 4 2 Flywheel tree 35 AA EX EE anno E EN E Acc 35 AA GE E 37 4 4 5 Cylinder head valve tea 40 4 4 6 Crankshaft piston eren eenen ennen enen enenenenenennnnnnnennnnnnennnnnenenenenenenenenenenenenenenens 46 4 4 7 Starting control box EE EE Eege E E Ree oes 5 5 1 INTRODUCTION 1 1 PARTS DESCRIPTION Fuel tank cover d Fi f F Fuel tank Air cleaner Muffler Throttle grip Recoil starter Start handle 1 2 SPECIFICATION
9. in the fig 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 in the fig d After installation inspect the valve guide for damage 1f it is damaged please replace Reamer 43 For best results be sure the cylinder head is at room temperature before reaming valve guides a Coat the reamer and valve guide with cutting oil b Rotate the reamer clockwise through the valve guide for the full length of the reamer Continue to rotate VALVE the reamer clockwise while removing it from the GUIDE valve guide SAD c Thoroughly clean the cylinder head to remove any cutting residue d Check the valve guide bore it should be straight round and centered in the valve guide insert the O 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 X EO e Check the valve stem to guide clearance f The valve stem to guide clearance g Deduct the valve stem outside diameter from the vale CORRECT INCORRECT guide bore to get the clearance between the valve guide and valve stem h If the clearance is over the service limit judge whether new guide can make the clearance conform to service limit if it can replace the guide and ream the guide refinish the valve when replacing the valve guide 4 Valve seat 44 NIF a
10. pressure meter e Forcibly pull the recoil starter several times and measure compression force gt 0 4MPa 20 NIF 4 1 3 Speed is unstable TROUBLE CAUSE REMEDY iston cylinder or piston ring is worn Replace the worn part excessively Piston pin and piston pin hole are worn Replace piston or piston pin l excessively Knocking sound l Connecting rod small head is worn l Replace connecting rod excessively Roller bearing for crankshaft main journal is Replace roller bearing orn Too much carbon deposit in combustion Clear away Abnormal combustion chamber Improper gasoline grade or low gasoline ne E S gt Replace with qualified gasoline quality There is water in float chamber Improper clearance between spark plug and Adjust Lack of spark electrodes Something wrong with induced coil and so ene Check and replace damaged parts on 4 1 4 Motor is unable to start TROUBLE CAUSE REMEDY 1 Check the battery Improper connection Correct the connection connection Wrong gasoline engine or battery is charged SE Check or replace rectification circuit insufficiently battery is stored long without 2 Check battery gt charge the battery with a special being used and pole plate s sulphation is De charger or replace the battery eroded Check and eliminate starting 3 Starter motor Motor and relay are in trouble connection is ma appliance circuit troubl
11. 8 2 R270 R440 M6x16 8 8 A R100 R160 R225 M10x1 5 8 A 71 R270 R440 R100 M6x25 10 9 A R160 R210 M7x32 10 9 A 2 Oil sensor Oil sensor crankcase Connecting rod 3 Connecting rod R225 M5x32 10 9 A cover crankcase connecting R270 R420 M8x35 10 9 A rod R440 M8x35 10 9 A Crankcase R100 M6x25 8 8 A Crankcase cover crankcase cover R160 R420 M8x32 8 8 A gasket crankcase R100 MI2x1 25 R160 R225 MI4x1 5 Starter Flywheel pulley impeller flywheel subassembly R270 R300 MI6x1 5 subassembly crankcase R390 R440 MI6x1 5 R100 M6x20 8 8 A Ignition coil RI60 R225 M6x25 8 8 A EA Ignition coil crankcase R270 R440 M6x28 8 8 A assy R100 M6x20 10 9 A 3242 Cylinder head Cylinder head R160 R225 M8x32 10 9 A 30 2 subassembly gasket bassembl gt R270 R440 M8x35 10 9 A 4043 crankcase Cylinder head cover R100 M8 1 25 8 8 A Rocker shaft p160 R225 M8x1 258 8 A 242 Rocker shaft bolt cylinder bolt head subassembly R270 R440 M8x1 25 8 8 A R100 M6x12 8 8 A Cylinder head 10 1 cover 10 subassembly cylinder subassembly R160 R225 M6x12 8 8 A head subassembly R270 R440 10 Spark plug R100 R440 M14x1 25 3044 Spark plug cylinder head subassembly R100 M6x10 8 8 A T R160 R210 M6x8 88 A 10 2 Cylinder shroud cylinder R270 R4440 M6x12 8 8 A BEE R100 12 Lower shield R160 R225 10 2 Lower shield crankcase R270 R440 R100 13 Oil protector R160 R225 8 2 Oil pr
12. Primary side resistance value 1 0 1 502 recommended value 33 Secondary side Measure the resistance of the secondary side of the coil with the spark plug cap removed touch one test lead to the high tension cord while touching the other test lead to the coil s iron core Secondary side resistance value 5 7kO recommended value Measure the resistance of the spark plug cap by attaching one ohmmeter lead to the wire end of the plug cap while touching the fe other test lead to the spark plug end Pa Resistance value 5kQ 5 10kQ 5 recommended value Flywheel cast iron e Assemble by aligning the four small holes in the flywheel e Assemble by aligning the lug on the rear side of the starter pulley with the small hole at the center of the flywheel FLYWHHL CAST IRON IMPELLER STARTER CUP NUT LUG 34 BEA LF 4 4 3 Air cleaner Wing nut Air cleaner cover Reassembly after reassembling the element and grid i e cover install the cover to the body W ei pl I A I a z UE Air cleaner element polyurethane I I Elbow seal e i Noise silencer only ATH for silence W L G RI WV ir cleaner element Air cleaner element paper Air cleaner elbow r7 Disassembly reassembly remove and install with the choke lever and fuel valve in the ON position Clean the inside of the elbow with compressed air be
13. Thoroughly clean the combustion chambers and valve seats to remove carbon deposits Apply a a light coat of red lead powder or erasable color a painting to the valve faces Insert the valves and then press the valve several times forcefully Be sure the valve does not rotate CUTTER on the seat HOLDER The transferred marking compound will show any area of the seat that is not concentric b Using 45 cutter remove enough material to L 7 produce a smooth and concentric seat IN valve 32 c Turn cutter clockwise never counterclockwise s EN valve 329 d Continue turning the cutter as you lift it from the valve seat i IN valve 45 EX valve 45 Tool Valve seat cutter 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 The 45 cutter removes material from the bottom edge contact too low Be sure that the width of the finished valve seat is within specification K See 1 3Maintenance Standard See 1 3Maintenance Standard S d Make a light pass with the 45 cutter to remove any possible burrs at the edges of the seat 45 4 4 6 Crankshaft piston Oil seal e Don Pin Fix the governor arm with e Apply oil to lip of the oil seal pin after installing Washer in Install it inside the seat LD Pin Crankcase cover Bo
14. a AU Sy a Sp SS Al NM Turn the fuel cock to OFF EN and drain the gasoline of the carburetor Remove the spark plug and spark plug cap Pull the recoil start handle to drive off the gas out of the cylinder Install the spark plug cap Put the control lever to low position 19 e Put negative pole thread of the spark plug through cylinder cover to connect to ground and pull the recoil start handle to observe the spark 4 1 2 Engine lacks power TROUBLE CAUSE REMEDY Air in fuel line or fuel line is Drain air or unclog fuel line clogged Main jet is not adjusted properly Ignition In carburetor needle valve and Clean and blow to get through system main jet are clogged Fuel supply Fuel cock is clogged Clean replace damaged part throttle opening speed increases Clean air cleaner filter element slowly or even Repair or replace decreases and stops nr Repair or replace running Piston cylinder or piston ring is Replace the worn part worn Air leakage from the surface along compression which cylinder block contacts with Replace cylinder gasket cylinder head Too big or too small valve Readjust clearance Compression pressure check Cylinder Ty RELA Se pressure 5 L gi P Ji e Drain the oil of the fuel tank meter KA e Drain the gasoline by loosening the fuel drain plug e of the carburetor e Remove the spark plug cap and spark plug and install the cylinder
15. badly tension Replace spark plug poor or insulators are damaged cord spark a conditions Improper electrode gap Adjust to proper value Replace damaged Ignition coil is damaged Magneto loses magnetism Abnormal gap between the NE Adjust gap ignition coil and flywheel 18 TROUBLE CAUSE REMEDY Piston ring is worn too much Replace or even over its service limit Piston ring is sticking Clear up carbon fouling Abnormal Normal Spark plug is not installed Tighten with a gasket in ignition kightly or is installed without a system gasket cylinder Check cylinder gasket and the flatness of the surface by which cylinder block Air leakage between cylinder contacting with cylinder head block and cylinder head Tighten cylinder head cover bolts in stipulated order to stipulated torque value Check valve clearance and tightness repair Air leakage in the valves if necessary If engine still can t start take the engine to our authorized dealer to repair it Spark plug testing WARNING When testing the spark plug never hold the high tension cord of the spark plug with wet hand Make sure there is no spilled fuel outside the engine and that the spark plug isn t dipped with fuel To prevent fire keep sparks far away from the spark plug mounting hole KA A gt Oa i Ge gn JM M RE ee f Ds A A
16. d be fully deposited and filtered before being used Keep the fuel filler clean change the fuel 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 1t when necessary The engine is air cooled so clean the radiator wind cover and fan in time in order to ensure the engine can cool normally The operator should be familiar with the working principle and structure of the gasoline engine know how to make an emergency stop and the operation of all controlling parts Any one without training is forbidden to operate the engine Keep periodical maintenance Solve problems in time Do not run the engine when it has malfunction Run the engine in a well ventilated place keep it at least one meter away from building walls or other equipment keep away from inflammables such as gasoline matches 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 much 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 poorly 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 s
17. e I 59
18. e and after repairing Check with piston upside down in the cylinder and inserting feeler between piston skirt bearing face and wall then pull the feeler out if feeling resistance and moving smoothly out the thickness of the feeler shall be considered as piston to cylinder clearance Standard Service limit See 1 3Maintenance Standard See 1 3Maintenance Standard d Piston ring side clearance Check by placing each ring into its groove The piston ring should be freely turned without loosening and sticking Then measure by inserting the feeler into clearance of the ring and upper and lower face Standard Service limit See 1 3Maintenance Standard See 1 3Maintenance Standard e Piston ring end gap Flatly place the piston into the cylinder by pushing the piston head to working position Measure the opening clearance with a feeler that clearance should not be too big or too small if it is too big can cylinder sealing performance will be poor if it is too small piston expanded by heat will be blocked in the cylinder 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 50 BEA SCF Piston ring See 1 3Maintenance See 1 3Maintenance P First ring second ring aerer i Standard Standard e mm z Oi ri See 1 3Maintenance See 1 3Maintenance PAD 1 ring i CG AE zz mmm
19. e micrometer if it is found out of the standard or service limit or if it has visible burn and damage on the valve face please replace it with new one 2 Valve spring free length Measure the free length of the valve Springs If out of the standard or service limit please replace the spring See 1 3Maintenance Standard See 1 3Maintenance Standard GI Valve guide 41 Inspect a Inspect the valve guide for smoothness scratch and damage in the inner surface and matching between the valve guide and cylinder cover for fastness VALVE GUIDE b Use the valve guide reamer ream REAMER the valve guides to remove any carbon deposits before measuring gt If the valve guide inside diameter is lower than standard or out of the service limit replace the guide See 1 3Maintenance Standard See 1 3Maintenance Standard VALVE GUIDE DRIVER Replacement 42 NIF 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 VALVE GUIDE p o DRIVER Valve guide Installation height NOTICE Be careful to avoid damaging the cylinder head when driving out the valve guides c Install the new valve guides from the valve spring side of the cylinder head Exhaust side Drive the exhaust valve guide until the clip is fully seated as shown
20. e or replace running is abnormal loose falling off and switch is damaged damaged part 21 4 1 5 Exhaust gas color is abnormal TROUBLE CAUSE REMEDY Piston cylinder or piston ring is worn Replace the worn part excessively Too much carbon deposit in combustion Clear away chamber Too much carbon deposit in combustion Black smoke Clear away chamber Improper gasoline grade or low gasoline p S S S S Replace with qualified gasoline quality Air Air cleaner is clogged IS Air cleaner is clogged Clean air cleaner filter element 4 1 6 Unable to ignite TROUBLE CAUSE REMEDY Carburetor is clogged Check fuel line and unclog it Fuel supply system Dismantle float chamber and Needle valve 1s stuck SE em eliminate the sticking Spark plug is punctured or short circuited by carbon Replace spark plug deposit nr Side electrode of spark plu Unable to ignite pe Replace spark plug has dropped out Ignition system High tension cord has Weld it on dropped out Ignition coil is punctured or von Replace ignition coil short circuited Stop engine wire Is located Find out the meeting position on engine body separate them and insulate Cylinder is seriously scored Others Repair or replace damaged parts and valves have dropped out 22 NIF 4 1 7 Oil alert system malfunction Check the oil alert system with the following method 1 Disconnect yellow lead of the engine and connect the engine to ground w
21. e severely Upper limit Lower limit 3 3 AIR CLEANER Dual element type Nut 1 Remove the nut air cleaner cover and wing nut Remove polyurethane and paper Air cleaner elements cover 2 Clean polyurethane with detergent then blow it dry with compressed air or Squeeze it dry Dip the element in clean det an oil then forcefully squeeze it dry and install it back Paper el 3 Tap the element lightly several times on EE a hard surface to remove excess dirt or blow compressed air lightly from the inside out If it is dirty replace it in time CAUTION Polyurethane element containing too much oil will jam the strainer holes Oil bath type Nut 1 Clean the air cleaner case with cleaning Air cleaner oil and dry it SAONA SE 2 Add the clean oil to specified level and install the air cleaner case back Polyurethane 3 element 3 Clean the polyurethane element with cleaning oil then blow with compressed air or squeeze Air cleaner case gt een Dip the element in clean oil then forcefully squeeze and install it back O ring 3 4 CLEANING OF THE FUEL FILTER Caution Don t smoke when washing Be sure there is no fuel leakage after tightening Turn the fuel cock to OFF position and tighten filter cup Torque 7N m Fuel strainer cup 15 3 5 SPARK PLUG CLEANING AND ADJUSTING 0 70 0 80 mm 1 Remove carbon or other deposits with a stiff wire br
22. ed Periodic maintenance and adjustment are necessary for keeping the generator in a good operating condition Perform the service and inspection at the intervals shown in the Maintenance Schedule below First month Every year or option Each use or 20 Hrs months or 50 months or 100 300 Hrs 3 3 para A Jf Air cleaner element Check Air cleaner element Clean Fuel strainer Clean nm Spark plug Clean Adjust Valve gap Check Adjust Fuel tank fuel element Clean Fuel tube Check Every 2 years 2 Replace Every 4 years 4 X Clean the air cleaner once every 10 hours or once every day when engine is used in dusty areas 13 3 2 ENGINE OIL e Oil change 1 Dismount the oil filler cap and oil ie Es drain bolt to drain dirty oil EN 2 Tighten the oil drain plug il p See 2 2 1Maintenance Standard Oil drain plug Oil drain hole 3 Add the clean oil from the filler neck R100 Oil capacity 0 35L General oil SAE15W 40 SJ class or equivalent API classified SJ class SAE10W 30 oil In a low temperature range below 10 C use oil with the Recommended oil grade higher than SAE10W 30 X In a cold environment temperature is below 15 C use SAESW 30 or equivalent API classified SJ class SAE5W 30 oil 4 After filling check oil level If the oil is insufficient add the oil to the upper limit CAUTION Run with insufficient engine oil may damage the engin
23. end side clearance 0 1 0 4 mm 1 0mm Crankshaft Crankshaft pin O D 35 975 35 985 mm 35 92mm Valve clearance IN 0 15 0 02 EX Stem O D IN en 6 44mm Valves Guide I D IN EX Sr 6 66mm Stem clearance IN 6 6 6 615 mm 0 11mm EX 0010 0 040mm 0 13 0 050 0 080mm WB Seat width 0 65 0 95 2 0mm 38 5 39 5 Spring free length a 37 5mm Cam height IN 32 59mm 32 54mm camshaft EX 32 07 32 02mm Journal O D 15 966 15 984 mm 15 92mm Crankcase Camshaft holder I D 16 000 16 018 16 050mm cover Main jet D1 1 s Carburetor Float height 13 2 1 5 mm Pilot screw opening 2 1 4 e Spark plug Gap 0 7 0 8mm Spark pl pre Resistance 7 5 12 5kQ cap Resistance Primary coil 0 6 0 90 Ignition coil Secondary coil 5 6 6 9kQ Air gap 0 3 0 5mm 2 DIMENSIONS AND TORQUE 2 1 ENGINE DIMENSIONS 2 1 1 R100 R80 2 1 2 R160 R180 R200 R210 R225 att 000000000N AI o c on oy gt a lo CS a ES O Z DD 00000000 NA I aooo
24. fore installation 35 Oil bath type ee Wing nut Air cleaner cover Air cleaner element polyurethane Air cleaner case Oil capacity 60cc Reassembly After cleaning with solvent fill with clean oil and install Elbow packing Air cleaner elbow Disassembly reassembly Remove and install with the choke lever in ON position and fuel cock in OFF position Clean the inside of the elbow with compressed air before installation 36 BEA LF 4 4 4 Carburetor Carburetor insulator a Disassembly reassembly Reassembly Blow out the passages with compressed air and install noting Governor rod Throttle return installation direction After 4 spring installation connect the high tension cord and fuel hose to the ground Carburetor gasket oN Choke handle B T fz A IT Insulator gasket Carburetor assy Disassembly Unhook the throttle return spring Pull the carburetor forward to a point where the groove in the governor rod lines up with the governor rod and lift the rod out of its hole Reassembly After pulling fuel hose from the carburetor insert it into protruding shoulder of the choke handle preventing oil leakage 37 b Disassembly reassembly Remove the drain plug and drain the carburetor before disassembling Prohibit fire Idle speed mixed ratio adjusting screw reassembly Choke lever Ins
25. hen the engine is running Be sure the alert lamp lights up and the engine stops 2 Disconnect oil level switch lead under the specified condition with the engine stopped and check the continuity of the yellow and green leads uncontinuity between yellow and green leads is normal 3 Disconnect oil level switch lead after draining oil out with the engine stopped and check the continuity of the yellow and green leads continuity between yellow and green leads is normal 4 1 8 GASOLINE ENGINE IS OVERERHEATED Gasoline engine is Cooling fan is loose and malfunctioning Reinstall it well ove Connecting rod deformation to make piston Replace connecting rod and cylinder bushing side wear Cylinder piston or piston ring is worn causing Replace the worn parts hunting between cylinder and crankcase Improper adjustment of engine governor cause Readjust engine governor 23 high speed Crankshaft main bearing is burnt out Replace main bearing 4 2 PREPARATION OF SERVICING 4 2 1 Safety precautions WARNING Indicate the possibility of invalid warranty and personal injury or equipment damage if instructions are not followed Please pay special attention to the following l 10 Els Strictly set the engine according to the regulated power on the nameplate Do not overload overrun the engine or run it with a low load and at low speed for a long time Use prescribed grade of gas and diesel The fuel shoul
26. hich can Ji control intake and exhaust When operating camshaft operating face and lifter will be badly rubbed from periodical impact and will be easily damaged So the camshaft shall be wearable and lubricated well e Visually inspect camshaft face and camshaft height for damage and camshaft and bearing for loosening and wear replace if necessary e Check camshaft for height If it is out of the service limit replace the camshaft 32 NIF ma emm IN lifter See 1 3Maintenance Standard See 1 3Maintenance Standard EX lifter See 1 3Maintenance Standard See 1 3Maintenance Standard e Check outside diameter of the camshaft if it is less than the service limit replace the camshaft ES See 1 3Maintenance Standard See 1 3Maintenance Standard ph A Bee n s S l JB AG Camshaft wearing cause and its influence on engine performance Poor lubrication caused by factors such as low oil viscosity too many impurities and little recycling oil will result in camshaft abnormal wearing making it hard for the camshaft surface to have a complete oil film causing the camshaft surface seriously worn in the state of high speed rubbing installing precision problem is also a factor that can cause lubrication problem when the matching clearance of the camshaft journal and camshaft seat or bearing is out of the service limit camshaft rotation precision will lower and contacting with the relative part will pr
27. lead i to side plate to ignition coil Charging coil lead white lead 6X12mmi5 Black red lead Black lead og To ignition coil lead Connect to ignition coil lead Yellow lead Engine switch Connect to oil level Engine equipped with oil alert device switch yellow lead Yellow lead Fan cover Recoil starter Gray lead Connect to oil Black white lead level switch Connect to charging Connect to starter coil lead lead el cad harness method only used for engine with a starter After connecting leads fix them with zipper jacket cable with collar and clip as shown as following 30 NIF 4 4 Recoil starter Driving guide Guide tray screw Spring Drive cam Starter coil spring Returning spring Starter reel NOTICE Wear gloves and eye protection during disassembling and take care not to allow the return spring to come out 1 Insert the recoil starter rope through the groove in the recoil starter reel and make a figure eight knot at the rope end 2 Hang the side hook of the recoil starter spring to the groove of the recoil starter case set the recoil starter spring into the case while counterclockwise rotating starter spring 31 3 Set the recoil starter coil spring s outside hook to the groove of the recoil starter reel Groove Groove 4 Set the starter drive cam on the recoil starter reel and install the return spring on
28. lt Governor arm Gasket Don t reuse Oil seal Crankcase KE Oil seal kr V KL Piston i Bearing Bearing SAN VS v Ze i gt 7 Ai Balancing NN shaft Bolt d gt Piston pin Piston pin Co LG clip CD 19 d _ VD kN 4 Camshaft gt Crankshaft 7 iw 7 D Reassembly Oil sensor Push it in firmly until contact is made with the bearing surface Be careful not to damage the oil seal HEA SC Bearing gasket Don t reuse Pin Crankcase cover Oil filter cap SO Oil dipstick Sealing ring Seal ring nd SO DD Oil seal Bolt Don t damage the edge of the oil seal when reassembling crankcase cover Pin Fix the governor arm With pin after Piston installing Oil seal pin clip Piston Piston pin Connection rod 7 Crankcase j d gt seg Pd 3 ie nj E d V ME l J Q Crankshaft Reassembly Push in firmly until contact is made with the bearing surface Be careful not to damage the oil seal 1 Disassembly 47 a Piston Install with the marker marking facing upward as shown Do not interchange the first ring and the second ring first ring is chrome plated e After assembly check for smooth movement of the piston rings Stagger the piston ring end gaps 120 apart Oilring Manufacturertag Connectingrod Reassembly a Piston pin clip Install by setting front end of the clip in
29. lts in a crisscross pattern especially Bolt Breathertibe when tightening all bolts should be tightened gradually and evenly up to specified torque Assembly disassembly Loosen and tighten the bolts in a crisscross pattern in 2 or 3 steps Exhaust valve Guide seal Reassembly Before installation remove carbon deposits and inspect the valve Retainer Spring Valve rotator Valve adjusting bolt Intake valve Reassembly Don t interchange with the exhaust valve Be careful not to damage the valve stem when installing Lifter Valve tappet Reassembly Check both Cylinder head Valve rocker Lifter stopper gt nds for wear Installation Reassembly Before plate assembly and the rod for Before installation remove installing check for straightness any carbon deposits from the wear on the 3e sure the rod combustion chamber and surfaces which ends are firmly inspect the valve seats contact the valve seated in the Measure the cylinder adjusting bolt the lifters compression after reassembly push rod and the 40 BEA ve 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 1s installed to the cylinder or the valves will drop into the cylinder 2 Inspect service repair Valve stem outside diameter Inspect the valve stem outside diameter with th
30. me position 3 Turn the governor support right to extreme position governor fully close position Tighten the bolt and nut 4 Check the governor support and throttle to ensure free moving 5 Assembling fuel tank d KI ge ee gt A gen Tom P FO FE i i AU CI s Pie d Di sg hd DES i L i Nei Sen A z e p ag MPE Pe Ch AM o d LiMY RARE D S Ke Start the engine rotate the throttle lever llmiting screw to adjust the maximum speed 17 4 DISASSEMBLING AND SERVICING 4 1 TROUBLESHOOTING 4 1 1 Hard starting TROUBLE CAUSE REMEDY There is no enough fuel in fuel dd fuel open fuel cock tank and fuel cock is closed Air vent in the fuel tank nclog air vent Fuel supply Cover is clogged is not Improper or clogged main Readjust or clean blow to smooth or jet get through there is no Needle valve is not closed Dismantle needle valve fuel supply properly or start hole is and repair clean blow to ormal Something clogged get through spark wrong with TEN P oat 1s damaged or sticking system Fuel is too filthy or Replace deteriorated Fuel cylinder Drain extra fuel dry up supply is Too much fuel in engine compression SE spark plug electrodes Select proper fuel grade Wrong fuel grade corresponding with the requirements Too much carbon deposit Clear away Spark and dirt around electrodes oes plug is in Electrodes are burned
31. oduce deviation to make abnormal wearing 53 6 Timing gear a Check timing gear for engagement clearance and align marks of the gears on two sides Timing gear will be damaged if gear is worn gear face peels off and gear teeth are broken The engagement clearance 1s bigger due to gear wearing the noise is bigger If the timing gear is damaged please replace it with new one NOTICE Please replace the gear with new set to ensure the engaging face completely engages in Crankshaft and Camshaft Alignment Alignment marks NT OR m gear NG p Camshaft gear 54 NIF 4 4 7 Starting control box a Disassembly reassembly Only for starter 6x12mm 2 s e screw Control box en oo Blade type fuse SA a Reassembly Check for burn before installation Oil alert Check P 7 8 Reassembly Install by aligning with the hole of the control plate Control panel Box installation bracket Switch Check Reassembly Install with the tab of the thread aligning Resetting button 1A with notch of the control panel Reassembly Be careful not to install the left and right side plate reverse ENGINE sw ON P 55 b Check e Engine switch Check the continuity between lead and fan cover Switch position Continuity NN ere e Engine switch with oil alert Black lead Check the continuity between black lead and engine switch x A Switch position ee e Switch with starter
32. otector crankcase R270 R440 R100 14 Shroud R160 R225 10 2 Shroud crankcase R270 R440 R100 M6x8 NSA 15 Recoil starter R160 R225 M6x8 8 8 A 10 2 Recoil starter shroud R270 R440 M6x8 NSA Cylinder shroud Air cleaner R100 R440 M6 8 A 1042 Air cleaner gasket carburetor PY BOR lea Throttle control R160 R225 M6x12 8 8 A 10 2 subassembly crankcase R270 R440 M6x12 8 8 A cylinder head subassembly Governor support Throttle control subassembly Governor R100 R400 M6 3 Q subassembly Governor support arm governor support b bl subassembly subassembly R100 e R160 R225 M6x28 10 2 Charging coil subassembly crankcase R270 R440 M6x32 R100 R160 R225 M6x10 8 8 A 10 22 Charging coil clamp crankcase R270 R440 M6x10 8 8 A R100 Starter motor 11 1 Starter motor subassembly 11 Charging coil subassembly Charging coil clamp subassembly RI60 R225 M6x35 8 8 A crankcase R270 R440 M6x30 8 8 A 2 3 STANDARD TORQUE VALUES Torque valve Specifications Nm Kem mm WA a a a 3 MAINTENANCE 3 1 MAINTENANCE SCHEDULE Good maintenance is essential for safe economical and trouble free operation It will also help reduce air pollution Exhaust gas contains poisonous carbon monoxide Shut off the WARNING engine before performing any maintenance If the engine must be running during maintenance make sure the area is well ventilat
33. pect for wear before installation Idle speed adjusting screw Main nozzle Float spring Reassembly Clean thoroughly with compressed air before installation Reassembly Check for top wear or spring wear before installation TN Fitting oil needle alve Main jet Reassembly Clean passage thoroughly with compressed air before installation Main jet P 2 4 Float pin Float ort Q Check the moving by finger after installation Oil cup bolt Oil cup drain bolt After assembly check for any sign of fuel leakage g 38 EA MF Inspection e Float level height Place the carburetor in the position as shown and push the float in by finger and measure the distance between the float top and carburetor body float height Specified float height See 1 3Maintenance Standard If the float height is out of specification replace the float valve and recheck the float height Float level gauge 39 4 4 5 Cylinder head valve 1 Removal installation 1 Remove the fuel tank 2 Remove the air cleaner 3 Remove the recoil starter and shroud 4 Remove the carburetor and insulator Spark plug Clean and adjust spark plug before installation Stud EX valve guide Cylinder head Cylinder head gasket cover gasket anr IND V Pin Cylinder head cover T QI a Z Stud P o IN valve guide Cp Guide circlip Apply oil to thread Loosen and tighten the bo
34. the piston groove holding the other end with long nosed Pisten pin collar pliers and rotating the clip in Do not align the end gap of the clip with the cutout in the piston pin bore c Connecting rod cap Install by aligning the alignment marks on the connecting rod cap Alignment marks 2 Piston check 48 BEA SCF Check the piston and cylinder for contacting and check the groove for defects piston top for burn and cracks If any of them is damaged replace it Clean the carbon deposit Clean the deposit round the piston top and cylinder neck before checking first soak the carbon deposit with kerosene then clean with a metal scraper or metal brush eel a Piston skirt O D Measure the piston skirt O D with an outside micrometer if it is out of the service limit replace it Standard Service limit See 1 3Maintenance Standard See 1 3Maintenance Standard 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 If out of the service limit replace the piston pin and piston as necessary Standard Service limit See 1 3Maintenance Standard See 1 3Maintenance Standard c Piston to cylinder clearance 49 Difference between cylinder maximum diameter and piston skirt should be considered as piston to cylinder clearance NOTICE This clearance must be checked befor
35. the recoil starter reel V H gt f d lt A 7 W Hi YAN WM 5 5 5583 3 d N A NN 858555 as gt N y while hooking it to the side of the driving cam Cr SE OR Ki SEN SES IN CY Install the spring driving guide and fixing screw one after another 6 Insert the recoil starter rope through the recoil 4 AN He SN S ASD N SE SAD f starter case and recoil start handle and make a 24 figure eight knot at the rope end Pull the recoil starter rope lightly to check the drive cam s function 32 ENST 4 4 2 Flywheel High tension cord check Flywheel the insulation for chap and Spark plug cap damage replace if necessary Starter pulley Nut CO z Impeller Ignition coil Bolt a Remove the fuel tank air cleaner carburetor and recoil starter assy b Measure the clearance between the ignition coil and flywheel with the feeler weg c Adjust the clearance of the ignition and flywheel d Adjusting method Loosen the bolt and move the ignition coil up and down for adjusting the clearance then screw down the bolt Check the ignition coil Primary side Measure the resistance of the primary coil by attaching one ohmmeter lead to the ignition coil s primary lead while touching the other test lead to the iron core
36. tore the engine with 1t cooled down entirely 24 BEA ve 12 Safety warning labels 13 Please carefully read warning labels before operating Our company will not assume any responsibility for person injury or equipment damage caused by disregarding warning labels Applique labels are shown as follows 1 Fuel label Check that there is not any fuel spilling or fuel leakage Filling before stalling engine is foroidden 2 Warning label Please read the user s manual carefully before operating the engine 3 Displacement label m 4 Trademark label RATO 25 5 Throttle control label g 6 Air cleaner maintenance label MAINTAIN AIR CLEANER Clean up in cleansing solvent and dry up once every 50 hours every 10 hours in unusually dusty circumstances and then immerse in clean engine oil until saturated squeeze out excessive oil 7 Choke lever fuel cock label NW 8 Oil grade label 26 9 Oil filling label BEA LA eujB
37. ue sur Bupesedo siojeq neen BNUB een au peel GSBEJd Check that there Is not any fuel spilling or fuel leakage Filing fuel before storting engine 27 4 2 2 Special tools Float level gauge Carburetor float level inspection Valve guide driver Valve guide removal installation Retainer assembler Assembling ball bearing Assembler handle Installing handle and bearing Inner retainer assembler Assembling ball bearing and time gear Diamond lap 45 Reconditioning valve seat surface Diamond lap 32 Reconditioning valve seat surface Flywheel driver Detaching flywheel l PA gt 4 6 de 8 9 Bearing extractor Detaching flywheel 10 Valve guide reamer Fine reaming the guide inner hole 28 BEA ve 4 3 DISASSEMBLING CHART Carburetor Flywheel Starter motor Recoil stats 4 4 ENGINE a Disassembly reassembly Fan cover only used for automatic starter Control box only used for automatic Lead support 2 Disassembly reassembly Disassemble and reassemble with the recoil starter Assembling Insert it into fan cover starter assembled Ignition coil lead black Engine switch Starter relay lead Disassembly Detach the clip with a screwdriver IW White lead LA cr e Wet Oil level switch lead ANT iY yellow Sed Oil level switch lead green Black
38. ush Check gasket for damage 2 Measure plug gap between center electrode and side electrode with a spark plug feeler If necessary adjust the gap by bending the side electrode Clean carbon deposit here Spark plug gap 0 7 0 8 mm BP6ES NGK Standard spark F7TC plug BPR6ES NGK with anti wave interference ability with anti wave interference ability 3 6 VALVE CLEARANCE ADJUSTMENT Cylinder head CAUTION Bolt cover gasket Valve clearance adjustment must be per formed with the engine cold 1 Remove the cylinder head cover bolt head cover and gasket CAUTION Cylinder head cover Be careful to avoid oil leaking when removing cylinder head cover Rocker arm Valve 2 Set the piston at top dead center of the Dy ch compression stroke MOROA 3 Insert a feeler gauge between the rocker arm and valve to measure valve clearance IN 0 15 0 02 mm Valve clearance EX 0 20 0 02 mm Use feeler gauge to a Valve lock nut alve check clearance 4 If adjustment is necessary proceed as follows a Hold the rocker arm pivot and loosen the valve lock nut b Turn the rocker arm pivot to obtain the specified clearance c Fix the rocker arm pivot with a spanner then tighten the lock nut d Recheck valve clearance after tightening the valve lock nut 3 7 governor 1 Remove the fuel tank 2 Loosen the nut on the governor arm Check the throttle to ensure it is fully open turn to left to extre
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