Instructions for _SAITO FA-100/100GK (AAC) 4-St ‘We would like to expres our sincere thanks for your purchase of the SAITO FA 100/100GK engine, which i manafsctured by Saito Seisakusho, Lid. Please read our instwcionscaeflly and teat your engine with care. Should there bea manufacturing, defect, Saito Seiakusho, Lid will make necessary repairs at fee of ebarge. You will notice letter (A, A, C ele) stamped on the top of the sight mounting Wu This identifies the production version of your engine. If you ever need to order apart ox hve a question about your engine, speci long withthe part uraber you ced so We can beter handle your request ith completely ign Silio FA'IOO/100GK engines have been dssigned placing emphasis on the lightweight, high-pecfommance and excelent + finde nwnsTimns 1 the mons secre of cylinder Hed and finer wih vet ned chm. pled Taner sree Siitout sing cinder lines this engae” emplaszes voy wile le ffs lightened terion oplaution of 4 Stroke Cycle Eugine tre sue vith proved colng enc. so: su gh isn cit lad tn Sethe ps se onsrcton ile har s compreson ring ances ie Seewo’s eines. m “Crankstat: Made of slid chrome molybdenum ste, and spores | SAGQT| RE by two ball bearings. 4 + Cam gonna Our fiat outed com ear design cele n compat engine oS) ( com _Feanres hgh ups type high com Y) “Combustion chanberInceased combustion effieney with improved Ietmakestoke 2. Compression rks ‘endegtedenl shape 3. Expansion stoke 4. Exhaust stroke + Catan auHigh performance pe wih sow adusinent exhpped ne "= . — ‘The four-stroke engine consists of four individual piston rmovement eased above: “Sule” erm th he pion i + Dep nD at eg o preven al-f fr ety ‘ved fom he oper ead hte o hs lower esd ener ps + atm soe nRea pine exigent ound the fonrtste pian, as pte compat ere ere 1 Wightman Lightnt th aa PAAOVAONGK Technical Data Bow Pina da Sete 26mm ‘eke ate ‘wien Aeon 5 che nl (Apt: 0, w= Prt ee ‘Aprox. 2000~11,000 rm (Recommended highest seston he rod: 8 $00~10,000 rm) =e ae Approx. 40ce/minute (at full throttle, approx. 9300 rpm) ae a Fuel flow: ‘Fuel flow varies depends upon propeller load. More fucl flow ‘sit egerloe andl fel ow wih sole oe inact ight feel fw sme incre Fuel, ‘Synthetic oil with 10~20% nitromethane content f a » Sates Approx 2.72. 919300 pm with ARC Applian TRC Sn Aplne Se Aplus Sports Alla: of ye GO ar ad bey daw Spene for pet astngeetnnnnannnLeach Main pestle eeasion bet lech penmotea | Rrmtedelegscew ppemee (QI) ooscAeeh Mallen | Hexagonal spanner (weeach)(1.5,2.022.5)....leach PS glow plug. bi co cockManufacturing cde (engine bed op) ie ‘A. Fuel $205 eset cer dn pa Moe eee aN er aaeteuee nn Memeeoeeniee ‘Saito Fuel Filter“F-2" exhibits highest performance. B.£ueltank Pease select best fel tank avaiable fn the market referring to the data for the opacity: Sethe level of fel i the tank fo heb that of alt nipple of eorburctor Also, pt weigh othe fuel alt ata distance of approximately Sma fom the rear wall of th thet roughly the same wih " 3H Check: Sor the cack inthe alminum pipe and silicon tube inthe tak. Since Sato engine employs muler presse, careful atention fs required for tbe leakage, Also, be careful ot to make length piping icon tube unsecessrily long, (Web for possible crack) C.Plug Since ove explosion occurs every two rotons in 4 stroke agin, sclection of the plug is rica. Use of improper plus resus ina rouble of exgne Since ‘etorouce a he cagie varies eccovdig tothe matching wih the fe oft the season, we recommend testing Warous pes forthe tsi perforce Haaecsne yg of he ober manafactrer extbis good match with Saito engine. Also, performance ofthe plug deeirses afer many ght hours even tot broken reuent exchange ofthe plug with new one would be necessary) ise of SALTO ["SAL GPO17GER) Clow Plag i recommended. D.Propeller varies according to the body of atplne, however, standard sive ranges from 13°M9"~13"x11" and 14°N6"~ 14°10" (asst guilin). Pease selec the one avaible inthe nacket wih high reliability. (We recommend APC) ‘Thonough balancing must be earied out (Use balancing device is recommended) Use of unbalance proper creates excessive vl and is nngerous Ifyou fnd Naw etc, replace it with new one, a itis dangerous ing the cogine beyond 11,000 pen with ight load propeller on the ground and Below 8,500 rpm with lange load propeller ctherwisecranksal necing rods cam gears ete. may be damaged, ia, reduces performace ‘Use propeler tht tatches tothe airplane aad turns in good canton in the range of 8500-~10,000rpa on the ground i view ofthe characteristics of this cesiee Of propel sae isnot inthe stndad, ifs OK long a the spe is within this range) Speed vases depending upon te manufacturer amd als, in ‘me Testaacr, i occurs with the propellers in the some size those manufactured by the same manufacturer, We recommend testing vious propellers ‘E.Engine Mounting ‘Your cngine canbe mounted in any direction requted. However, we recommend using the vertical or horizontal poston i possible An verted ensine may be hmaged upon tuning and requires tht the glow plug be removed, withthe prop tured over several ies to remove any exces fue, afler each Nying session. ‘Use of Suto Engine Mount is recommended. “Topreveet loose engine mousting, application of small qzamty of rubber adhesive o he tp of Md cap sere is effective. ‘E.Proparation before Starting Engine. Engine must e mous to the sturdy test Bench with correct paralelism oro the body of sip. (Engi sot move?) (For the break-in on the bench, tse fuel tak with wsupacty between 400 and SOc. Fr aiplate body, use the one lead tbe firmly fie in lier ease so that does et (Foe the fue, se the one with sppreximately 15% nlte-content except ow ol conten. DF te propel, prepare APC 14°" propeller (around 9,300~9 400 rpm at standard) ‘3eTo fix propeller, tar dive ange iw forward dtection (counterclockwise) and when pressure is fl place propeller in horizontal posiion and flly gen doll nt to fix (Spine must also be attached 25 he starr wil be use) wooden propel, Would he compressed Catton:@since4-stoke engine doesnot clearly exhibit peak coun like 2-sroke engine, use twehoweter to prevent oversqueeze or overheating. @Attch silicon tube othe bree vpple to check the exhaust of breather (0 check ol Now). (DMuffler presse must be wsed without ail, (Make sure that oo leakage fs occuring from the tak.) BPrepare necessary materials and tools for plug bes (Drrepare he starter and battery, (Contin: Hany specitoris watching nash, please ask the one 19 move backward prior fo start the engine. Also, he arm iat holds sgplane must be Rept _avay fom the prop. Whee ihe eagite is started, move tthe back of srplae. Any operation Ike needle adjusten! must be ceed ou from the back of splane If airplane is oot ied, it x mafe task your assistat to old the irlane. Following procedure describes the colton i which engine is mounted to the body of sirplane. (A) Staring method witha starter (For your own safety, this method is recommended.) Firs tua on the switch of transmit. Next, tut onthe switch ofreeiver Unit o check hot ation and then, st thle stick atthe position fully closed, @open main needle by 440 5 tune (This sus guide) |®open shot valve 1/4 to 13 from fll lose position with thro sick (Str wth excessively opens @rum propeter in reverse diestion (clockwise) unl engine is compressed Brower he pve. ttle is dnogeroue a the spine jumps forward) forward direction, sit is dangerous. (8) Manual starting method (Forte safety, wear gloves and sey stick ete) (DFirst tua onthe switch of transmitter. Next ur onthe switeh of reciver unit to check thot action and then, st trot stick af the position fll closed. open visin needle by 41 S twas. (This isjust a gue) @ser those valveat fall open with tht tick, @ctose the est of the muller wil hand aad tra propeller 2 to tens ‘Caution, Excestive fel intake compresses fuel and may damage connecting rods ee. Crank 12 tums with hand sd eheck i 0 fuel compression bas svcurre, ‘Balter vote valve ix fully closed ooce with thvoile stick, open throtle valve 1/4 to 1/3 with thre stick. (Sta with excessively opened thot is dangerous asthe airplane jumps forward) @Pum propeller ie forward aiection (countetclockwis) to feel compression (propeller i horizon), (Dower the poe @Alier th plug is powered, wot fora few seconde nd, when the propeller forcibly cranked in clockwise direction, engine starts in forward diretion bythe explosion counteraction (Caution, In case of itoke engine, donot ry fo Sart engine manually in forward direction fom the poi where rhe engine is in compressed condition like in he case of? stoke engine, ae Your lager may be inured due o reverse action ofthe engine. Above staring method most be followed ‘wiht fi ‘As the break-in is (Dantr fue tanks ill up start the engine a described ia tbe above. Water opening of tote valve is set approximately 1/2 or less jus asa guide) with thre ck, adjust engine speed to stabilized condiion a approximately ‘6.000ep or less ich contin with main needle valve is opened § tras or more while carefully Watching tachometer and exhaust ol density an cischarge ‘densi from the beac un the engine in this condo for ‘also be employed [the case allows. important procedure to pull out maximum performance ofthe engin, it must be cautiously implemented Caution, Absolutly never sake fel mina ole condition in this stage Even if you d speed and rin the expe at lw speed, ‘Sizate would vecvcit the mintare is leat, Object ofthis breakin is initial alization Of connecting rods, gears moving pars aad so 08 the ‘sondtion mainly wih ich fuel miature (Neat st vote vadve a fll epenand ran the engine in ich condition for fll tank (In this stage, exhaust il density and discharge density frm the breather rust also be checked.) @Mce, vn the engine at just before 9,000 rpm for hall tak. Fall, run the engine at peak sped and less speed alternatively and ifthe engine runs at peak speed without unevenness, pound breakin bas completed for the time being, Thea, after tappet clearace Is adjusted according to the procedure described in Arile J and carburetor is also adjusted according to the following ariel, and alter around 10 Might alse speed, breakin wll be complete F Caution forthe fight For cary igs fyaigplane inthe windward and keep high aitude and distance so tht the airplane is abe return to the irl tvenf the engine hos sopped.f you fly amlane at low ate fom the begining, body of smplane sy be damaged at emergency i Tanding diet engine rouble Base steps forthe ajusiment of carburetor are fist obtaining peak speed (maximum speed) by adjusting main needle ad then, set idling. speed {Glow speed) using htt valve and slow needle. (Vice vers is nt possible, however) @DAMtr fot takes filed vp stat engine ws deseibed in Article G. Alte throne valve opening is set at fll open with thot ‘vith main nese while watching tachometer and listesing tothe exbavst nose 2, cautiously obtain peal speed F Canin: Excessive chsing of min needle very dangerous, asthe propeller ni besomes loose. In such oceasion, immediately tua the sin ase in counterclockwise to loosen {®t slowly close thie valve and eauouly adjust the speed sing a screwdriver for slow needle and thet stick fr trot valve opening so thatthe 28engine runs at aniling speed inthe ange of arousd 2,000~2,500 gpm in sabe condition. (See the gare Below) (@onee ing speed is set, slowly open the thot valve to ful pes, If he speed! becomes irepsar or suddenly increases this process, carefully make fine ‘djustnent wiih low needle so thatthe peed changes linearly [om the iling othe peak speed @W hen the above adjusiment has completed, quicky change he speed from idling to its peak. If the speed does nat reach at its peak sim ‘onaition of throttle valve fully pened, retura main needle by single knrl notch, Thea, quickly change the speed from idling to its peak again, Repeat this procedure cautiously unl you cas obtain good response. @When al covdtions are st, erm the adjustment by 2 to 3 knuelnot taneously withthe 1s (or about 300 pm slower). 300 rpm, seduce speed by 30 rpm to sett at 9,000 rpm, Its the Key for Tonge service lif 10 run the engine at & 2 When peak speed wih fll tank fuel ‘speed slower than speak by around 300 rpm and the bearings would huey get ‘ue standard values shown in the folowing figure asthe standard for carburetor needle opening ajusiment, hough light adjustment is equired according to the engine mounting postion, propeler type ue ype plug, weather condition, and so feth agioneeae Fuel nile Sedan aes Jre_, Title er Stow eee (Fruthiome ever (sew iver Forlani orrchmiste @o not openste your engine to lean at fll tote, a twill cause overheated engine, Adjust it silly slower than the peak (Teo Lean operation causes knocking, Soppage and negative iniluence on the connecting rods and cam gear) DTappet exp adjustment ‘Aller operating the engine fo one hour, you shoul! ages tappet gap (valve elearnce) because of inal wear. Adjustment of tppet sip mst be cari out ‘ve the engine is col. Tor the adjectneat of appet exp femove plag and rocker arm cover and when the propellers slowly timed in forward direction with hand, ocker arm stops IT ou tre the propeller fhe, pst reaches at ts top dead center of compression. Then, make adjusinent using attacked spanner and hexagonal wrench 30 Thos cates tatty closet aero while the compression exist atthe position, When the gap ts cheekeg, securly fasten (but not excessively) the locking ‘in cose of actual automobile eagige, small gp i provided by anticipating valve longaion. However, in the case of our engine, gap becomes lager daring charton as elongtfon of einer (lamina) is larger than tat of the vale, therefore, the gop must be st indefinitely lose to zero while te engine is ie ‘Alte his sdjstneat,appet gap mu be checked from time to time wit he above procedure. If attached gauge (limit gauge 1-0.) aa be inserted, 3p tetonne tex rgecand adjutneht must be made-Tapret gap isthe most important factor inthe maintenance of 4stoke engine. fhe engin is operated with exeesive gop it would esl rlormance ‘@ivien exhaust pipe i fixed tote cylinder and propeller uti fixed, apply sal quantity of silicon rubber (oot excessively onthe Head section and sew it in I prevent leakage and loseeing. @Asstiinal ighening of propeller nut and exhaust nt (hil is hos) mast be erred out fom tie i @Atier the Hight, ubvieste entre engine with spray type preserve lubricant through the carburetor or breather ir the esatac is aot operated for any Tonger period of tne, remove the plug, tear cover head cover ete. from the engine an clean them thorbuphy with alcchol Alter lubication, reassemble them othe original condition and pata plastic cover oni it the engine is stopped with mach mixture, bearings in the crankcase may get rus. Run your engine for about 10 seconds at maximum speed before itis stopped and cut of the uel 10 op. Bo prevem wear and sigue of rotating section and sliding surtce ofthe engine, necessary areas ae lubricated with back molybeoum ol. When the engine isin openton, black waste oli preduced from breather apple, nil, et, however, you can continue your operation i is normal. I eerurs in break sage {@Pision bearings. cam gear, ee are lubricated by the ol tha comes int crankcase through the gop between cylinder (Do discharge wast oil, connec silicon tube et. othe breather appl lested under the fon forthe dlscarge outside ofthe seplane (DSafety is the most important element when operaing model engines. Be careful motto cause trouble to others, ‘Denne for mode! snplane is wt toy. Handle twit extreme cre stow ‘K. Hints for Disassembly/Assembly Work Dimssembling aod assembling of your engine are not recommended, however, fllow the following insretions when necessary (DFor the dismmaitng, put beach marks on the parts by yourself (ase marking pen ete) while checking ereetion of pars in proper sequence. Als, clean cach part To putcular,carefl stein is required onthe valve ining, valve inet and exhaust, ston deetion, connecting od direction, aids forth DT he eyliner serews should be lovened lite by lie in ersscross pattern. If hey are loosened improper, you may distort the eyinr ag?(@Assennble it with te some crisscross method applying engi ul tthe ips af the eerews you tighten the screws without el, you may cause dunage tothe threaded areas. @assenbe the eum gear ising up the necessary marks perth digram. The crams! shoul be p ‘am gear should be positioned below. one atte op dead center, Then he eoneidence ofthe (Position the piston, connecting rod, rocker arm, pias, push rod, appel, ete in thee original position. Engine pris are mated afer vusing and they must be returned to heir origiaal positions. When you de assemble your engine, apply engine oi to cach past and reassemble them i proper sequence while cttuly ‘checking marks and directions without applying excessive frce when igen 1-1) Pot mars onail ports Thee pincplesofdisussenbly: _} 2) Make sure dizecions are core % 3) Loosen sorews evenly and digo 1) Keepall pats clean, | Thee principles of wssembiy: + 2) Labricate each part with engine ol. C5 Fasten sre fly ond evenly and do aot ove lighten, Marking atthe bation, Crest of gear eoth (@ovange in mounting direction of carburetor (See 1) Remove mouating cap screws so tbat the surburtorsan be moved 2) Tueathe carburetor about 90 degrees as showa in Fig. 2 using the section where Jotake pipe is inserted into epinder ae {bleram without removing carburetor and ace pipe 3) Turathe carbretorin opposite ditetion previous postion, 4) Return carburetor tothe mounsiog postion and mount i with mounting sap Sesevis. Corel stienton is required for ‘he Hightening torque of exp screws a8 excessive torque results ia poor ‘movement of thotle valve (rot) ® All specifications and modes ate subject ochange without notice SAITO SEISAKUSHO, CO. , LTD. 22-7, 3-chome, ‘Tokagi, Ichikawa, Chiba 272-002 Phone 047-378-4156 Fox 047-378-4155SAITO FA—~100, 100GK Peres List m0 Deseription we) [ae Deseription wy ot | eviinaee 1] [a2 [Recker orm scrow Wut (42-1, 42-2) tea 06 [Piston 1] [Tas [Recker are sin z ot_| Piston pin 1] [Tas [ave set in w Ba) 61 15-2) Taet 8 | Piston pin retainer 2] [#1 [alve spring & Keeper & Re zea, 03 | Piston ring 1 AT-1, 47-2, 48 10 | Connecting Fed 1] [at [ave retainer (otter [2 14 [Cylinder serow oot T1162) Tet] [Tao [Rocker ora cover 2 15 | Crankoase 1 02_| Intake manifold (Intake pipe) to TT Rear caver 1] [re [uettter Gen sipoie) 1 T0_[ Breather nipple 1] [Las [etter manifold set TET, 80. 160 inet 20_[ Front bearing 1] [Tao etter nut (to avttien 7 22 | Rear bearing 1] [Beet | corburetor complete inet 75_| Crankehefe 1] [68-1 [Corburetor body assenbly tae faper collet & Drive flange(i-1, 21-2 [iee. BAT egsTo2G2a|-Q.Og Tee TTB | zr Tap so aD) BETslathatse eal g ee 26 [Prop washer & Nut (281, 28-2) Te) EE - [[1_[[crankease seven sot (21-1, 31-2,31-3) Taet a a aT [Throttle barrel assenbly SP | Enotne sesket set + 2-1-5, 62-1-6, 621-8, 88, 89 ka 301, 30-0 92-3, 0-4, 1-5, TE 2 ae ; SES | [at Linrettte Taver(@,s0-1 ja aa 83 | Idle needle 1 35 D — 1) [er [Garburetor soron & sprive eet re : 2-1-6, 2-1-1, 82-1-8, 82-113, 90-1 ve a Test TT [Carburetor gasket set 38_| Tappet 2 Tet 50-4, 92-5, 80-6, 6221-3, TTA 38_| Pustred z TI Asti Tassening nuk 1 4G | Foshrod cover & Rubber oval WOn1, 40-2, 40-3) [ee.) Para Veseening me [Ta [Rocker arm z See eee FA=100 I | Carburetor Complete (2006. 5.