FL-70

FOUR CYCLE ENGINE

OWNER'S INSTRUCTION MANUAL
It is of vital importance, before attempting to
operate your engine, to read the general
SAFETY INSTRUCTIONS AND WARNINGS'
section on pages 2-6 of this booklet and to strictly
adhere to the advice contained therein.
Also, please study the entire contents of this
instruction manual, so as to familiarize yourself
with the controls and other features of the
engine.
Keep these instructions in a safe place so that
you may readily refer to them whenever
necessary.
It is suggested that any instructions supplied
with the aircraft, radio control equipment, etc.,
are accessible for checking at the same time.
CONTENTS
SAFETY INSTRUCTIONS AND WARNINGS
ABOUT YOUR O.S. ENGINE ---------------- 2-6 TYPE 60W CARBURETOR, STARTING -------- 25-27

ENGINE CONSTRUCTION - - - - - - - - - - - - - - - - - - - - - - - - 7 RUNNING -IN, CARBURETOR -------------------- 27-30

NOTES WHEN APPLYING AN ELECTTRIC STARTER ---- 8 CARBURETOR AIR-BLEED ADJUSTMENT - - - - - - - - 31

INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - 9 TROUBLE SHOOTING WHEN THE

ENGINE FAILS TO START----------------------- 32-33
BEFORE STARTING - - - - - - - - - - - - - - - - - - - - - - 10-13
VALVE ADJUSTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
ENGINE PARTS NAME--------------------------------------14
HOW TO SET THE CAMSHAFT TIMING --------- 35
INSTALLATION ------------------------------------------------ 15-16
CARE AND MAINTENANCE ----------------------- 36-37
SILENCER & EXHAUST HEADER PIPE INSTALLATION ------- 17
ENGINE EXPLODED VIEWS & PARTS LIST -------- 38-39
FUEL TANK & LINES -------------------------------- 18-20
CARBURETOR EXPLODED VIEWS
& PARTS LIST ---------------------------------------- 40-41
THROTTLE LINKAGE, NEEDLE-VALVE EXTENSION ------ 21
GENUINE PARTS & ACCESSORIES -------42-43
PROPELLER & SPINNER ATTACHMENT ---- 22-23
THREE VIEW DRAWING --------------------------------- 44
GLOWPLUG ------------------------------------------- 2 4

1
 SAFETY INSTRUCTIONS AND WARNINGS ABOUTYOUR O.S. ENGINE
Remember that your engine is not a "toy", but a highly efficient internal-
combustion machine whose power is capable of harming you, or others, if it is
misused.
As owner, you, alone, are responsible for the safe operation of your engine, so act
with discretion and care at all times.
If at some future date, your O.S. engine is acquired by another person, we would
respectfully request that these instructions are also passed on to its new owner.
The advice which follows is grouped under two headings according to the
degree of damage or danger which might arise through misuse or neglect.

WARNINGS NOTES
These cover events which These cover the many other
might involve serious (in possibilities, generally less obvious
extreme circumstances, even sources of danger, but which, under
fatal) injury. certain circumstances, may also
cause damage or injury.

2
 WARNINGS
Never touch, or allow any object to come Model engine fuel is also highly
into contact with, the rotating flammable. Keep it away from open flame,
propeller and do not crouch excessive heat, sources of sparks, or
over the engine when it is anything else which might
running. ignite it. Do not smoke or allow
anyone else to smoke, near to it.
A weakened or loose propeller may
disintegrate or be thrown off and, since Never operate your engine in an en-
propeller tip speeds with powerful closed space. Model engines, like auto-
engines may exceed 600 feet(180 metres) mobile engines, exhaust deadly carbon-
per second, it will be understood that monoxide. Run your engine only in an
such a failure could result in serious open area.
injury, (see 'NOTES' section relating to Model engines generate considerable
propeller safety). heat. Do not touch any part of your
Model engine fuel is poisonous. Do not engine until it has cooled. Contact with
allow it to come into contact with the eyes the muffler (silencer),
or mouth. Always store it in a cylinder head or exhaust
clearly marked container and header pipe, in particular,
out of the reach of children. may result in a serious burn.

3
 NOTES
This engine was designed for model If you remove the glowplug from the engine
aircraft. Do not attempt to use it for any and check its condition by connecting the
other purpose. battery leads to it, do not hold the plug with
bare fingers.Use an appropriate tool or a
Mount the engine in your model securely,
folded piece of cloth.
following the manufacturers' recommenda-
tions, using appropriate screws and lock- Install a top-quality propeller of the
nuts. diameter and pitch specified for the engine
Be sure to use the silencer (muffler) and aircraft. Locate the propeller on the
supplied with the engine. Frequent shaft so that the curved face of the blades
exposure to an open exhaust may faces forward-i.e. in the direction of flight.
eventually impair your hearing. Firmly tighten the propeller nut, using the
Such noise is also likely to cause correct size wrench.
annoyance to others over a wide area.

4
 NOTES
Always check the tightness of the propeller Discard any propeller which has become
nut and retighten it, if necessary, before split, cracked, nicked or otherwise rendered
restarting the engine, particularly in the unsafe. Never attempt to repair such a
case of four-stroke-cycle engines. If a propeller: destroy it. Do not modify a propeller
safety locknut assembly is provided with in any way, unless you are highly experienced
your engine, always use it. This will prevent in tuning propellers for specialized
the propeller from flying off in the event of a competition work such as pylon-racing.
"backfire", even if it loosens. Also, check Take care that the glow plug clip or battery
the tightness of all the screws and nuts leads do not come into contact with the
before restarting the engine.
propeller. Also check the linkage to the
If you install a spinner, make sure that it is throttle arm. A disconnected linkage could
a precision made product and that the also foul the propeller.
slots for the propeller blades do not cut into
After starting the engine, carry out any
the blade roots and weaken them.
needle-valve readjustments from a safe
Preferably, use an electric starter. The position behind the rotating propeller. Stop
wearing of safety glasses is also strongly the engine before attempting to make other
recommended. adjustments to the carburetor.

5
 NOTES
Adjust the throttle linkage so that the engine For their safety, keep all onlookers
stops when the throttle stick and trim lever (especially small children) well back (at
on the transmitter are fully retarded. least 20 feet or 6 meters) when preparing
Alternatively, the engine may be stopped by your model for flight. If you have to carry
cutting off the fuel supply. Never try to stop the model to the take-off point with the
the engine physically. engine running, be especially cautious.
Take care that loose clothing (ties, shirt Keep the propeller pointed away from you
sleeves, scarves, etc.)do not come into and walk well clear of spectators.
contact with the propeller. Do not carry loose Warning! Immediately after a glowplug-
objects (such as pencils, screwdrivers, etc.) ignition engine has been run and is still
in a shirt pocket from where they could fall warm, conditions sometimes exist whereby
through the propeller arc. it is just possible for the engine to abruptly
Do not start your engine in an area restart if the propeller is casually flipped
containing loose gravel or sand. over compression WITHOUT the glowplug
The propeller may throw such material in battery being reconnected. Remember this
your face and eyes and cause injury. if you wish to avoid the risk of a painfully
rapped knuckle!

6
 ENGINE CONSTRUCTION

With this engine, the piston will

feel tight at the top of its stroke
Piston
(TDC) when the engine is cold.
Cylinder Liner
This is normal.
The cylinder bore Is a little
tapered.
Crankshaft
The piston and cylinder are
designed to achieve a perfect A little tapered
running clearance when they
reach their running temperatures.

When the engine is cold. When the engine is hot

 NOTES WHEN APPLYING
AN ELECTRIC STARTER

Do not over-prime. This could

cause hydraulic lock and damage
the engine on application of the
electric starter.

If over-primed, remove glowplug,

close needle-valve and apply
starter to pump out surplus fuel.
Cover the head with waste to
prevent pumped out fuel coming
into your eyes.

8
INTRODUCTION STANDARD ACCESSOIES

The FL-70 is an air-cooled, overhead-

Glow Plug Type F
valve four stroke engine for model aircraft (fitted with the engine)
use. This engine is suitable for trainer,
sport and scale models.
This engine reduces maintenance by
incorporating the first O.S. ringless F-4030 Silencer Assembly
piston/liner assembly. Also, a sealed front
bearing prevents oil leaks. The engine is
fitted with the new easy-to use O.S. 60W
airbleed carburetor. This engine is
designed so that more R/0 pilots, from
hobby beginners to skilled Sunday fliers
may enjoy the performance advantages
of four stroke engines - greater fuel
economy, higher torque, lower noise and
realistic sund. T Nipple

9
BEFORE STARTING FUEL
Tools, accessories, etc.The following items are The FL-70 should be operated on a methanol
necessary for operating the engine. based fuel containing not less than 20%
(volumetric) castor oil, or a top quality synthetic
Items necessary for starting lubricant (or a mixture of both), plus a small
GLOW PLUG percentage (5-15%) of nitromethane for improved
O.S. Type F glowplug is installed in the flexibility and power. (The carburetor is adjusted at
engine. the factory for a fuel containing 20% lubricant and
15% nitromethane.) Some commercial fuels also
GLOWPLUG IGNITER contain coloring additives as an aid to fuel level
Commercialy available handy visibility. In some cases, these additives have
glowplug heater in which the indicated slightly negative effects o performance.
glowplug battery and battery We would suggest that you use such fuels only if
leads are integrated. you are satisfied that they do not adversely affect
running qualities when compared with familiar
standard fuels. When changing to a fuel brand or
FUEL PUMP
formula that is different from the one
Alternatively, one of the
to which you are accustomed, it is a
purpose-made manual or
wise precaution to temporarily revert
electric fuel pumps may be used
to in-flight running-in procedures,
to transfer fuel directly from your
until you are sure that the engine is
fuel container to the fuel tank.
running entirely satisfactorily.
10
Reminder! O.S. Non-Bubble Weight
Model engine fuel is poisonous. Do not To prevent the pickup from adhering to
allow it to come into contact with the eyes or the tank wall under suction and
mouth. Always store it in a clearly marked restricting fuel flow, slots may be filed
container and out of the reach of children.
I the end of the weight. Alternatively,
Model engine fuel is also highly flammable. O.S. Non-Bubble Weight is available
Keep it away from open flame, excessive
as an optional extra.
heat, sources of sparks, or anything else
which might ignite it. Do not smoke, or allow
anyone else to smoke, near to it. Fuel Filter
It is recommended to fit a good
Electric Starter and in-line filter between the fuel tank
Starter Battery and carburetor to prevent entry of
foreign matter into the carburetor.
Required when starting
the engine. 12- Volt lead-acid battery Fuel Tank
Electric Starter A fuel tank of approximately
O.S. Super Filter (Fuel Can Filter) 300cc capacity is suggested.
Fit a filter to the outlet tube of your This allows around 10 minutes
refueling container to prevent entry of flying time, dependent upon the
foreign matter into fuel tank. O.S. type of fuel used, the size of propeller and on
'Super Filters' (large and small) are the proportion of full-throttle to part-throttle
available as optional extras. operation throughout the flight.

11
Spinner than those shown in the table may be used,
Since the FL-70 is intended to be but remember that the propeller noise will
started with an electric starter, the increase if blade tip is raised, due to higher
addition of a spinner assembly for rpm or if a larger-diameter/lower-pitched prop
centering the starter sleeve is desirable. Use a is used.
heavy-duty, well balanced spinner either of
metal or plastic. Sport & Aerobatic 12X7, 12.5X6, 13X6
Trainer & Scale 12.5X6, 13X6-7
SILICONE FUEL LINE
Heatproof silicone tubing of
approx. 5mm o.d. and 2.5mm Warning:
i.d. is required for the Make sure that the propeller is well
connection between the fuel balanced. An unbalanced propeller and/or
tank and engine. spinner can cause serious vibration which
Propellers may weaken parts of the airframe or affect
the safety of the radio-controlled system.
The choice of propeller depends on the design
DO NOT forget the WARNINGS and NOTES
and weight of the aircraft and o the type of
on propeller and spinner safety given on
flying in which you will be engaged. Determine
front pages.
the best size and type after practical
experimentation. As a starting point, refer to Reminder!
Never touch, or allow any object to come Into
the props listed in the accompanying table. contact with, the rotating propeller and do not
Slightly larger, or even slightly smaller, props crouch over the engine when it Is running.

12
 TOOLS LONG SOCKET WRENCH WITH PLUG GRIP
Recommended for easy removal and
HEX WRENCH replacement of the angled and recessed
Necessary for engine installation. glowplug, the O.S.Long Socket Wrench
1.5mm, 2mm, 2.5mm, 3mm opposite side incorporates a special grip.

8mm

Plus Threaded Drivers

No.1,No.2,etc.
Spanners
8mm, 13mm, 14mm, etc.
SCREWDRIVER
Necessary for carburetor adjustments.
No.1,No.2,etc

Nipper
Box Wrenches
5.5mm, 7mm, 8mm opposite side

13
Engine Parts Name
F-4030 Silencer Assembly
Rocker Cover Exhaust Header Pipe
Nipple No.1
Glow Plug (Larger hole)
Lock Nut Set Nipple No.5
(Smaller hole)
Lock Nut

Silencer Body

Propeller Washer

Drive Hub Rotor Guide Screw

Crankcase
Carburetor Needle
Type 60W Beam Mount
Throttle Lever
Cover Plate
Airbleed Screw

14
INSTALLATION
Because the FL-70 is a powerful, large-displacement, single-cylinder four-stroke-cycle engine, it is
essential to use very substantial engine mounting. Conventional wooden mounting beams should be
of rigid hardwood and of at least 15mm or 5/8-in square section.
Make sure that the mounting beams are parallel and that their
top surfaces are in the same plane.

CORRECT INCORRECT

Front view Side view Top surfaces are not

Top surfaces are in the same plane. in the same plane. Opposite beam
Top surfaces are not in the
same plane.
Re-align the surfaces Engine does not rest firmly.
as necessary

15
How to fasten the mounting screws. Make sure that these mounting beams are
Hardwood mounting beams accurately aligned and firmly integrated with
Tighten second nut the airframe, reinforcing the adjacent
3mm steel nuts firmlydown onto first nut. structure to absorb vibration. Use 3mm or
Tighten this nut first. larger steel screws, preferably Allen type
Spring washer or hexagon socket head cap screws, with
lock washer washers and locknuts, for bolting the engine
to the bearers.
15mm min Hardwood such as
cherry or maple. INSTALLING THE GLOWPLUG
Steel washer
Install washer on glowplug and
15mm min. 3mm steel screw insert carefully into cylinder-head,
making sure that it is not cross-
threaded before tightening firmly.
Radial motor mount
(cast aluminum) 3mm steel Allen screw
Glow plug
Spring washer Washer

16
SILENCER & EXHAUST HEADER PIPE INSTALLATION
Screw the header pipe into the cylinder head
until it "bottoms" , then unscrew sufficiently to Lock Nut
achieve the desired exhaust angle and tighten
the lock nut securely with a 14mm wrench.
Screw the silencer onto the outer end of the
header pipe and tighten the other locknut.
The application of a heatproof silicone sealant
to the threads of the exhaust system is Exhaust Header Pipe
recommended to reduce the risk of joints
loosening and the leakage of exhaust gasses
and oil residue.

Reminder:
Model engines generate considerable heat
and contact with the header pipe or silencer
may result in a serious burn.
If you need to tighten the silencer joints,
which may loosen when they are hot, use a
thick folded cloth for protection. Apply silicone sealant.

17
FUEL TANK & LINES
Make sure that the tank is well rinsed out Piping suitable for acrobatic flights
with methanol or glow fuel before installation With the general piping, the fuel in the tank
and that the pickup weight is well clear of the may flow into the silencer when the throttle is
bottom of the tank when held vertically. set to slow during upside-down flight or
Connect between pressure nipple on the vertical dive, which may result in engine stop
silencer (larger hole one) and the tank to due to mixture change at low speed. Piping
apply muffler pressurized fuel feed system shown in the Fig 2 prevents fuel flowing into
which deliver the fuel stably reducing fuel the silencer, and engine stop at slow running
level negative effect. during maneuvers. Also, this piping allows to
set the idling r.p.m. a little lower and longer
Connect between breather nipple on the flight by preventing excess fuel flowing out.
cover plate and silencer breather nipple
(smaller hole one). When the tank is filled (when the fuel level is
higher than the carburetor center line.),
General Piping
prevent the fuel flowing into the carburetor
Make connections as shown in the Fig.1. with a commercially commercially available
An airbleed type carburetor is required to set fuel stopper, etc. Release the stopper before
idling r.p.m. a little higher to prevent engine starting the engine.
cutting.

18
 Note: When cutting silicone tubing,
Fig. 1 General Piping use knife or razor blade.

No.5 Nipple (smaller hole)

Silicone Tubing Do not use wire cutter
No.1 Nipple (larger hole) or pliers.
If you should need to clean out silicone
tubes, use methanol or glow fuel, not
gasoline or kerosene.

Fuel Fitter (commercially available)

Fuel Stopper (commercially available)

Carburetor
Center Line

Refueling Fuel Tank Center Line

T Nipple (supplied)
tubing
Approx. 10mm
Plug (commercially available)

19
Fig. 2 Piping suitable for acrobatic flights

No.5 Nipple (smaller hole)

No.1 Nipple (larger hole) Install the fuel tank so that carburetor
center line and fuel tank center line may
come to as much close as possible.

Fuel Filter
(commercially available) T Nipple (supplied)

Fuel Stopper
(commercially Refueling T Nipple
available) tubing Approx. 10mm
(commercially available)
Plug (commercially available)

20
THROTTLE LINKAGE NEEDLE-VALVE EXTENSION
Before connecting the throttle to its servo, The needle-valve supplied with this engine is
make sure that the throttle arm and linkage designed to incorporate an extension so that,
safely clear any adjacent part of the airframe when the engine is enclosed within the
structure, etc., as the throttle is opened and fuselage, the needle-valve may be adjusted
closed. from the outside. Cut a commercially available
Connect the linkage so that the throttle is fully rod to the required length, bend one end to an
closed when the transmitter throttle stick and L shape, insert it into needle's center hole and
its trim lever are at their lowest settings and secure it by tightening the set-screw in the
fully open when the throttle stick is in its fully- needle-valve knob with 1.5mm Allen key.
open position.. Needle Valve Extension Cable Set (Code No.
Carefully align the appropriate holes in the 72200080) is available from O.S. as an
throttle arm and servo horn so that they move optional part.
symmetrically and smoothly through their full 1.5mm Allen key.
travel.

Needle Valve Extension Cable Set

21
PROPELLER & SPINNER ATTACHMENT
There is a risk, particularly with powerful four- 3. Add the specially tapered and slotted
stroke engines, of the propeller flying off if the locknut and secure with a 10mm wrench
prop nut loosens due to detonation while holding the prop nut with the 13mm
("knocking") in the combustion chamber when wrench.
the engine is operated too lean, or under an
excessively heavy load.
Obviously, this can be very hazardous. To
eliminate such dangers, the O.S. Safety Propeller Washer
Locknut Assembly was devised.

1. Ream the propeller shaft hole to 6.4-6.5mm Lock Nut

bore with an appropriate reamer, checking
that the hole is exactly centered.
Propeller Nut
2. Install the prop to the engine shaft, followed
by retaining washer and prop nut lightly.
Turn the prop counter-clockwise slowly to 4. Fit a spinner assembly to start the engine
locate the position where compression is with an electric starter.
felt. At this position, fit the prop horizontally
and tighten firmly the prop nut with a 13mm
wrench.
22
Note:
Some spinners which are fixed at the top of
the cone cannot be used with the prop
locknut supplied with the engine. In this
case, optional locknut sets are available
from O.S. - Propeller Locknut Set for
Spinner (Code No.45810200) and Propeller
Locknut Set for Tru Turn Spinner (Code
No.145810300).

IMPORTANT
Regardless of the type of propeller fixing
used, make a habit of always checking the
tightness of the propeller before starting
the engine. Remember that, especially with
wooden propellers, there is a tendency for
the material to shrink, or for it to be
reduced by the serrated face of the drive
hub.

23
GLOWPLUG
The FL-70 supplied with an O.S. Type F glowplug, Install a plug suitable for the engine.
specially designed for O.S. four-stroke engines. Use fuel containing a moderate percentage of
nitromethane unless more is essential for racing
The role of the glowplug events.
With a glowplug engine, ignition is initiated by the
Do not run the engine too lean and do not leave the
application of a 1.5-volt power source. When the battery
battery connected while adjusting the needle.
is disconnected, the heat retained within the combustion
chamber remains sufficient to keep the plug filament When to replace the glowplug
glowing, thereby continuing to keep the engine running.
Apart from when actually burned out, a plug may
Ignition timing is 'automatic' : under reduced load,
need to be replaced because it no longer delivers its
allowing higher rpm, the plug becomes hotter and,
best performance, such as when:
appropriately, fires the fuel/air charge earlier;
conversely, at reduced rpm, the plug become cooler and Filament surface has roughened and turned white.
ignition is retarded. Filament coil has become distorted.
Foreign matter has adhered to filament or plug
Glowplug life body has corroded.
Particularly in the case of very high performance Engine tends to cut out when idling.
engines, glowplugs must be regarded as expendable Starting qualities deteriorate.
However, plug life can be extended and engine
performance maintained by careful use, i.e.:

24
TYPE 60W CARBURETTOR STARTING
Two adjustable controls are provided on this The FL-70 is not equipped with manual
carburettor. choke controls, as it is intended for use
They are as follows: with an electric starter only.
The Needle Valve A high-torque electric starter not only
Needle Valve makes starting the engine easier, it
This is used to establish the
fuel/air mixture strength dispenses with the need for a choke valve
required for full power when by turning the engine over fast enough to
the throttle is fully open. cause the fuel pump to prime the cylinder
Airbleed Screw automatically.
The Airbleed Screw Starting procedure is as follows:
This is used to establish the mixture strength
required tor steady idling and a smooth 1.Fill the fuel tank with fuel. When filled,
transition to medium speeds. (The varying prevent fuel flowing into the carburetor with
mixture strength required between part- a commercially available fuel stopper, etc.
throttle and full-throttle running is Release the stopper before starting the
automatically adjusted by coupled movement engine.
of the throttle.)
The sequence in which these controls are 2. Make sure that plug element glows red, and
adjusted is explained in the succeeding fit the plug to the cylinder head.
sections, under Starting, Running-in and Idling
Adjustment.
25
 Element glows when energized. 3. Check that the current to the glowplug is
Pliers switched off.
4. To close the needle-valve, turn it Close
clockwise, while to open the
Open
needle-valve, turn it counter-
Replace the plug when the clockwise. Turn the needle-valve
Close
element does not glow or is clockwise slowly until it stops.
burnt out. This is the fully closed position.
Fully opened
5.0pen the needle-valve 2-2.5 position
turns from the fully closed
Glow Plug Igniter position and set the throttle in
the fully open position.
WARNING 6. Apply the starter and press the starter switch
When checking the plug with energizing it, for 5-6 seconds to prime the engine.
hold the plug with tools, such as pliers, etc.
Do not bring your face close to the plug or 7. Position the throttle stick at 2-3 scales
the boiled fuel remaining in the filament will advanced from the fully pulled down position.
Turn the prop "backwards" (clockwise) by
burn you.
hand until it is arrested by compression. This
is to enable the kinetic energy of the prop to
subsequently assist the starter through the
compression stroke to start the engine.

26
8. Make sure that the rotating direction of the
electric starter is correct. Energize the RUNNING-IN ("Breaking-in")
glowplug and apply the starter. For long life and peak performance, every
9. When the engine starts, slowly open the engine needs special treatment when new,
throttle to the mid speed position. Then, know as "running-in" or "breaking-in". This is a
disconnect current to the glowplug. If at this procedure during which the engine is operated
pint the engine stalls, it is probable that the under strictly controlled conditions at the
mixture is excessively rich. Close the beginning of its life, in order to avoid the risk of
needle-valve a little and restart the engine. immediate damage to certain components
through becoming overheated or stressed and
10. Now close the needle-valve gradually so to help working surfaces to become smoothed
that revolutions are increased. and aligned for maximum mechanical
How to stop the engine efficiency thereafter. With some engines, this
Pull down the throttle lever and trim lever on can require a tediously protracted period of
the transmitter fully. bench running, but, as O.S. engines are
manufactured to fine tolerances and from the
Note: finest quality materials, a relatively brief
Make sure that the throttle running-in period is sufficient and can be
Close
linkage is made so that the completed with the engine installed in the
throttle is fully closed when aircraft. Prolonged running with too rich
the throttle lever as well as mixture and/or low speed will not complete the
trim lever on the transmitter proper running-in.
are fully pulled down.
27
On the contrary, prolonged low speed running 5. Repeat this process, alternately running the
may cause the oil in the fuel gelled, which may engine fast and slow by means of the
result in seizure of the piston and cylinder liner. needle-valve, while keeping the throttle fully
The recommended procedure is as follows: open, then begin to extend the short
periods of high-speed operation until two
1. Use the same fuel and prop as you intend
tanks of fuel have been consumed.
for flying your model.
WARNING:
2. Open the needle-valve 2.5 turns from the
When ground running the engine, avoid
fully closed position and start the engine.
dusty or sandy locations. If dust or grit is
3. Open the throttle slowly to the mid speed drawn into the engine, this can be a
position, and disconnect the current to the ruinous effect, drastically shortening
glowplug. engine life ion a matter of minutes.
6. Following the initial running-in session,
4. Now open the throttle slowly to the fully
check for any looseness in the installation
opened position and run the engine for no
due to vibration, then allow the engine a
more than 5 seconds with the needle-valve
period of moderately rich operation in flight.
tuned to produced near maximum r.p.m.,
then, immediately, slow the engine down 7. For the first flight, have the needle-valve set
again by opening the needle-valve on the rich side and adjust the throttle trim
approximately one turn. The rich mixture, so on the transmitter so that the engine does
induced, will cool the engine, at the same not stop when the throttle is closed to the
time providing increased lubrication. idle setting.
28
8. With each successive flight, close the CARBURETOR
needle-valve very slightly until, at the end of
about 10 flights, the needle is set for full These engines are equipped with a throttle
power. Do not "over-lean" the mixture in an type car-buretor which provides a wide range
attempt to extract more power. of engine speed control. With the throttle lever
linked to a suitable servo in the model,
If overheating should be suspected at any movement of the throttle control on the
time during flight (i.e.if the engine begins to transmitter will enable engine to be varied,
"labor") reduce power by partially closing proportionally, from idling speed to full power.
the throttle and land the aircraft to enable The carburetor of your engine has been factory
the needle-valve to be readjusted to a set for the approximate best results and no
richer setting. adjustment (except to the needle-valve) should
be required provided that the fuel tank is
correctly located, as previously described.
After the engine has been run-in, check the
operation of the throttle according to the
following chart. Re-adjust the controls only
when necessary.

29
 Start the engine

Make sure that the throttle is

fullyopen

Adjust the neede-valve. 20-30' open from maximum

rp.m setting.

Close the throttle gradually

The position where the lowest

Find the idling position. possible r p m .with steady
running, is obtained.

Fix the idling position. Set the throttle opening by

means of the throttle trim on
the transmitter so that the lowest
practical speed, without risk of
Re-set theidling position at the engne stoppingis obtained.
alittle higherr.p.m.

Open the throttle fully.

Does the engine

Engine stops. regain full power?

Yes.
Continue running at high speed
lor 10 seconds

Close the throttle.

Run at idling speed lor 5 seconds.

Engine stops. Does the engine slop?

No.

Apply full throttle

Does the engine

Engine stops. regain full power
immediately'?
Yes.
Refer to the CARBURETOR OK
AIR-BLEED ADJUSTMENT
section on page 31
CARBURETOR AIR-BLEED ADJUSTMENT
Pre-Flight Check
Start engine and adjust needle-
valve as previouslv described.

Close the throttle gradually.

Find the idling position.

approx
15 degrees

Hold the model.

Hold model level, then slowly raise the nose.

If rpm increases. If engine runs unevenly or stops.

Stop the engine.

approx
Note: Stop engine by 15 degrees
pinching fuel line
Do not touch
needle-vatve. Immediatety point
nose down. so that
These adjuslments can be engine runs steadily
made without stopping again
the engine.
However, it is advisable for
beginners to slop the engine
for safety reasons. Stop the engine.

Open air bleed Close air-bleed

screw. screw.

Half turn at a Half turn at a

time. time.

Attention: Do not leave the glowplug connected to the

battery while adjusting the carburetor throttle.
TROUBLE SHOOTING WHEN THE ENGINE FAILS TO START
Four key points
For quick, reliable starting, the following four conditions are required.
(1.) Good compression. (2.) Adequate "glow" at glowplug. (3.) Correct mixture.
(4) Sufficient electric starter rotating speed.
If the engine fails to start, or does not keep running after being started, check symptoms against the
following chart and take necessary corrective action.
Note: The most common causes of trouble are marked with three asterisks, the less common problems
with one or two asterisks.

Symptom Factor Cause Corrective action

Sluggish rotation . . . . . . Recharge the electric starter battery.

Engine falls
to fire. Glowplug battery . . . . . . Recharge lead-acid cell or replace dry battery. (Note: An unused, or almost
discharged, unused, dry battery may sometimes be of insufficient capacity if it is "old
stock".)
Glowplug element Is Replace glowplug. Check that applied voltage Is not too high.
burned out
Something wrong with . . Check glowplug heating using other leads
battery leads.
Engine "flooded" due to Close needle-valve fully and remove glowplug, then Hip propeller to pump
excessive priming, out excess fuel. (Invert engine, if possible, white pumping out excess). Re-
start engine. (Priming is not necessary at this lime.)

Insufficient priming. . . . . . Repeat priming procedure referring to Priming.

32
 Symptom Factor Cause Corrective action

Incorrect heating of . . . . . Voltage too high or too low. Re-check and readjust referring to "BEFORE
Engine fires glowplug. STARTING".
Intermittently but Over priming. . . Continue applying an electric starter. II the engine does not start after more
does not run. than 4 tries, disconnect the current to the glowplug and leave for a few
minutes., then re-energize plug and apply starter. If the engine still does not
start, remove glowplug and pump out excess fuel by applying the starter.

Sluggish rotation. Then re-start. (Priming is not necessary.)

Recharge the electric starter battery.

Glowplug battery Recharge lead-add cell or replace dry battery.

Engine fires once discharged. (Note: An unused, or almost unused, dry battery may sometimes be of
or twice, then insufficient capacity it it is "old stock".)
tails to lire.
Insufficient priming. Repeat priming procedure referring to Priming.
Engine starts but
rpm decreases Mixture too rich. Close needle valve hall turn (180") and wait for several minutes then re-
and engine eventually start (Priming is not necessary.)
stops.
Engine starts. Fuel not reaching the Make sure that tank is filled with fuel. Check that there Is not something
rpm increases engine, wrong with the fuel line (kinked or split). Check that carburettor is not
and engine cuts clogged with dirt.
out.
Mixture too rich. . . . . . . . Close the needle-valve a little before disconnecting current to the glowplug.
Engine stops when
the current to the
Mismatch of glow plug and- Change fuel or glowplug.
glowplug is discon-
nected after starting

33
VALVE ADJUSTING
Valve clearances are correctly set before any
O.S. engine leaves the factory and, in normal
use, will seldom require adjustment. However,
if, after a very considerable amount of running
time has been consumed, a loss of power is
detected, or if he engine has been
disassembled for repair, these clearances
should be checked and reset as necessary.
For checking and adjusting the valve
clearances, VALVE ADJUSTING TOOL KIT is
available as an optional accessory.

The kit comes in a plastic case and includes:

(Code No.72200060)
Feeler gauge 0.04mm
Feeler gauge 0.1 mm
Hex. key 1.5mm
Wrench 5mm

34
HOW TO SET THE CAMSHAFT TIMING
When replacing the camshaft, set the timing as The relation of position between ' ' mark of
follows. the gear and teeth may differ from the sketch,
1. Secure propeller. by each model.
NOTE: crankcase
If propeller is not secured, crankshaft may center line
move backward and correct timing cannot
be set.
mark T mark on
2. Turn the crankshaft so that T mark on the the drive hub
drive hub may match crankcase center line.
(This is engine T.D.C. position)
3. Push the camshaft into camshaft housing camshaft
until it stops. Locate ' ' mark on the side of
Fig.2
camshaft gear in line with the push rod. in line with
4. Rotate crankshaft right and left a little and the push rod
make sure that the ' ' mark on the gear is in
line with the push rod when the ' T ' mark on
the drive hub matches the crankcase center
line. mark of the
5. Secure cam cover with screws. camshaft gear

35
CARE AND MAINTENANCE
Please pay attention to the matters Fit an in-line fuel filter between the tank and
described below to ensure that your engine carburetor to prevent dist and dust in the
serves you well in regard to performance, tank entering the carburetor.
reliability and long life.
Clean these filters periodically.
As previously mentioned, it is vitally important
to avoid operating the engine in conditions If these precautions are neglected, restriction
where dust, disturbed by the propeller, may of fuel flow may cause the engine to cut out,
be deposited on the engine and enter its or the fuel/air mixture to become too lean
working parts. causing the engine to overheat.

Remember to keep your fuel container The use of modern high-performance alcohol
closed to prevent foreign matter from based model engine fuels, while promoting
contaminating the fuel. cooler running, improved anti-detonation
combustion and increased power, has the
Fit a fuel can filter to prevent dirt and dust in disadvantage of causing bottom end
the fuel container entering the fuel tank. corrosion in a four-stroke engine. This is due
O.S. Super Filters (L) and (S) are available to the acidic by products of combustion that
as optional extra. accumulates in the engine's crankcase and
are not flushed out by fresh air/fuel mixture
as in the case of a two-stroke engine.

36
 The use of nitromethane in the fuel can also When the engine is not to be used for some
contribute to the problem. As a primary months (for example, as between flying
defense, users are advised to avoid running seasons), a worthwhile precaution is to
the engine on too lean a mixture - i.e. do not remove it from the airframe and, after
close the needle-valve and the airbleed washing off the exterior with alcohol (not
screw too much. gasoline nor kerosene), remove carefully the
carburetor with intake pipe, glow plug and all
Do not leave unused fuel in the engine at the silicone tubing and put them safely aside.
conclusion of a day's flying. Accepted Then, immerse the engine in a container of
practice is to cut off the fuel supply while the alcohol. Rotate the crankshaft while the
engine is still running at full throttle, then engine is immersed. If foreign matter is
expel as much fuel residue as possible by visible in the alcohol, rinse the engine again
turning the engine over 5-10 seconds with in clean alcohol. Finally, shake off and dry
the electric starter. Finally, inject some after- the alcohol ,and inject some after-run oil from
run oil through the glowplug hole and turn the glowplug hold and rotate the crankshaft
engine over several times by hand. several times by hand. Re-fit the carburetor
with intake pipe and glowplug with the engine
and keep it dry place after putting in a vinyl
bag.

37
ENGINE EXPLODED VIEW

*Type of screw
C Cap Screw B..Binding Head Screw M.. Oval Fillister-Head Screw
F...Flat Head Screw N. .Round Head Screw S...Set Screw
 No. Code No Description
1 44404200 Rocker Cover
2 45961400 Rocker Support Assembly
2-1 45961410 Rocker Support
2-2 45761600 Rocker Arm Retainer (2pcs.)
3 44753000 Rocker Arm Assembly (1pair)
3-1 44753100 Rocker Arm (1pc.)
3-2 45761200 Tappet Adjusting Screw
4 44460000 Intake Valve Assembly (1 pair)
4-1 44460100 Intake Valve (1pc.)
4-2 45960210 Valve Spring (1pc.)
4-3 45060309 Valve Spring Seal (1pc.)
4-4 46160400 Valve Spring Retainer (2ps.)
5 44461000 Exhaust Valve Assembly (1pair)
5-1 44461100 Exhaust Valve(1pc.)
5-2 45960210 Valve Spring (1pc.)
5-3 45060309 Valve Spring Seat (1pc.)
5-4 46160400 Valve Spring Retainer (2ps.)
6 44404100 Cylinder Head(W/Gasket)
7 44404000 Cylinder Head (W/Gasket and Valve Assembly)
8 44481000 Carburetor Complete (60W)
9 44714100 Head Gasket
10 44403000 Cylinder & Piston Assembly
11 45906000 Piston Pin
12 44405000 Connecting Rod
13 44407009 Cover Plate Retaining Screw
14 44407000 Cover Plate
15 44402000 Crankshaft
16 44408100 Drive Pin
17 44430000 Crankshaft Ball Bearing (Rear)
18 44401000 Crankcase
19 44462000 Camshaft
20 44401100 Cam Cover
21 44701109 Cam Cover Retaining Screw
22 44766000 Push Rod (2pcs.)
23 44766100 Push Rod Cover Assembly (2pcs.)
23-1 44766110 Push Rod Cover (1 pcs.)
23-2 24881824 Push Rod Cover "0" Ring (2pcs.)
24 45664000 Cam Follower (2pcs,)
25 44731000 Crankshaft Ball Bearing (Front)
26 44408000 Drive Hub
27 23209003 Propeller Washer
28 44410000 Lock Nut Set
29 44425000 F-4030 Silencer Assembly
29-1 44425100 Silencer Body
29-2 45926100 Exhaust Header Pipe Assembly
29-3 45626030 Manifold Nut (M11)( 1pc.)
71615009 Glow Plug Type F
29084610 T Nipple (1pc.)
Specifications are subject to alteration for improvement without notice.
CARBURETOR EXPLODED VIEW

* Type of screw
C Cap Screw B Binding Head Screw M Oval Fillister-Head Screw
F...Flat Head Screw N . Round Head Screw S .Set Screw

40
CARBURETTOR PARTS LIST

No. Code No. Description

1 22081408 Throttle Lever Assembly
1-1 22081313 Throttle Lever Retaining Screw
2 44481200 Carburetor Rotor
3 44481100 Carburetor Body
4 45915000 Carburetor Rubber Gasket
5 22681980 Needle-valve Assembly
5-1 24981837 "0" Ring (2pcs.)
5-2 26381501 Set Screw
6 44481960 Nozzle Assembly
6-1 26711305 Ratchet Spring
6-2 45281920 Nozzle Retaining Screw (2pcs.)
6-3 22681953 Fuel Inlet (No.1)
7 44481310 Air-bleed Screw
Specifications are subject to alteration for improvement without notice.

41
O.S. GENUINE PARTS & ACCESSORIES
O.S.GLOW PLUG BOOSTER CABLE SET BOOSTER PROPELLER
TYPEF (72200110) TERMINAL KIT LOCKNUT SET
(71615009) (72200130) (45810100)

0 (45810200 For Spinner)

Needle Valve Extension
Cable Set _
(72200080)

PROPELLER LOCKNUT SET FLEXIBLE EXHAUST PIPES EXHAUST HEADER PIPES

FOR TRU-TURN SPINNER
(72109500) (72109600)
1/4"-M5 (45810300)

Code.No. Type Length (mm)

72108100 1111A 120
72108110 HUB 240
Inside Outside
72108120 1111C 170
72108130 1111D 330

42
NON-BUBBLE WEIGHT LONG SOCKET WRENCH VALVE ADJUSTING
(71531000) WITH PLUG GRIP TOOL LIT
(71521000) (72200060)

SUPER FILTER (L)

(72403050)

LOCK WASHER BLIND NUT (10pcs./sets) CAP SCREW SETS (10pcs./sets)

(10sets)
M2.6x8 (79871025)
M3 (55500002) M3 (79870030) M2.6x10(79871030)
M3.5x12(79871080)
M3.5x20(79871100)

The specifications are subject to alteration (or improvement without notice.

43
THREE VIEW DRAWING Dimension(mm)
Specification
Displacement 11.45cc(0.698cu.in.)
Bore 27.7mm (1.090 in.)
Stroke 19.0mm (0.748 in.)
Practical R.P.M. 2.300-12.000 r.p.m.
Power output 1.1ps/ 11.000 r.p.m.
Weight 467g (16.480Z.)
(Silencer including 51.5g(1.8oz.)
exhaust header pipe)

44
 6-15 3-Chome Imagawa Higashisumiyoshi-ku
Osaka 546-0003. Japan TEL. (06) 6702-0225
FAX. (06) 6704-2722
URL: http://www.os-engines.co.jp

(C) Copyright 2004 by O.S.Engines Mfg. Co.. Ltd. All rights reserved. Printed in Japan. 60091500 050400