Rato R160 Service Manual Download Page 2

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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:

Company’s written permission.

Summary of Contents for R160

Page 1: ...GASOLINE ENGINE R100 R440 HORIZONTAL SHAFT SERVICE MANUAL CHONGQING RATO POWER MANUFACTURING CORPORATION...

Page 2: ...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 a...

Page 3: ...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...

Page 4: ...1 torque values 22 2 3 STANDARD Torque valueS 24 3 MAINTENANCE 25 3 1 Maintenance schedule 25 3 2 engine oil 26 3 3 Air cleaner 27 3 4 Cleaning of the fuel filter 27 3 5 spark plug cleaning and 28 adj...

Page 5: ...S OVERERHEATED 5 4 2 Preparation of servicing 6 4 2 1 Safety precautions 6 4 3 DisASSEMBLING chart 46 4 4 Engine 47 4 4 1 Recoil starter 48 4 4 2 Flywheel 50 4 4 3 Air cleaner 52 4 4 4 Carburetor 54 4...

Page 6: ......

Page 7: ...1 1 INTRODUCTION 1 1 PARTS DESCRIPTION Throttle grip Fuel tank Recoil starter Muffler Spark plug Choke lever Air cleaner Fuel tank cover Start handle Drain plug Oil dipstick...

Page 8: ...SP LD F7RTC F7TC Lubrication System Forced Splash PTO Shaft Rotation Counterclockwise Model items R180 R200 L W H 390 320 345mm 390 320 345mm Dry Weight 16kg 16kg Engine Type 4 stroke OHV single cylin...

Page 9: ...se Model items R270 R280 L W H 420 395 430mm 420 395 430mm Dry Weight 26kg 26kg Engine Type 4 stroke OHV single cylinder Displacement 270cm3 277cm3 Compression Ratio 8 2 1 Bore Stroke 77 58mm 78 58mm...

Page 10: ...Rotation Counterclockwise Model items R420 R440 L W H 465 415 440mm 465 415 440mm Dry Weight 28kg 28 5kg Engine Type 4 stroke OHV single cylinder Displacement 420cm3 438cm3 Compression Ratio 8 5 1 8 5...

Page 11: ...earance Top Second Ring Oil Ring Ring End Gap Top Second Ring Oil Ring Ring Width Top Second Oil Ring 0 03 0 07mm 0 15 0 3mm 0 1 0 6mm 1 5mm 2 5mm 0 15 1 1 1 37 2 37 Connecting Rod Small End I D Big E...

Page 12: ...002 0 014mm 67 845mm 0 12mm 18 048mm 17 954mm 0 06mm Piston Rings Ring Side Clearance Top Second Ring Oil Ring Ring End Gap Top Second Ring Oil Ring Ring Width Top Second Oil Ring 0 015 0 045mm 0 2 0...

Page 13: ...Gasoline Engine Maximum Speed No Load Cylinder Compression 3750 3810rpm 1 17Mpa 1400rpm Cylinder Cylinder Bore I D 70 0mm 70 165mm Cylinder Head Warpage 0 10mm Piston Skirt O D Piston to Cylinder Clea...

Page 14: ...mm 27 75mm 14 184mm 27 45mm 27 50mm 14 166mm Crankcase Cover Camshaft Holder I D 14 2mm 14 048mm Carburetor Main Jet Float Height Pilot Screw Opening 0 85 13 7 1 5mm 2 1 8 circle Spark Plug Gap 0 7 0...

Page 15: ...0 7mm 18 07mm 30 066mm 0 12mm 1 1mm Crankshaft Crankshaft pin O D 29 98mm 29 92mm Valve Valve Clearance Stem O D Guide I D Stem to Guide Clearance Seat Width Spring Free Length IN EX IN EX IN EX IN EX...

Page 16: ...0 08mm Piston rings Ring side clearance first second Oil Ring end gap first second Oil Ring width first second Oil 0 015 0 045mm 0 2 0 4mm 0 2 0 7mm 1 5mm 2 0mm 0 15mm 1 0mm 1 0mm 1 37mm 2 0mm Connect...

Page 17: ...Piston rings Ring side clearance first second Oil Ring end gap first second Oil Ring width first second Oil 0 02 0 06mm 0 20 0 40mm 0 2 0 7mm 3 4 3 6mm 2 75 3 15mm 0 15mm 1 0mm 1 0mm 1 37mm 2 0mm Con...

Page 18: ...mm 6 66mm 0 10mm 0 12mm 2 0mm 37 5mm camshaft Cam height Journal O D IN EX 6 045mm 5 766mm 16 166 16 184mm 5 95mm 5 65mm 16 12mm Crankcase cover Camshaft holder I D 16 2 16 218mm 16 248mm Carburetor M...

Page 19: ...end oil clearance Big end side clearance 15 011 15 022mm 33 025 33 039mm 0 013 0 03mm 0 25 0 65mm 15 27mm 33 07mm 0 12mm 1 0mm Crankshaft Crankshaft pin O D 32 975 32 985mm 32 92mm Valves Valve cleara...

Page 20: ...mm 20 002 20 008mm 19 994 20mm 0 002 0 014mm 87 85mm 0 12mm 20 042mm 19 95mm 0 08mm Piston rings Ring side clearance first second Oil Ring end gap first second Oil Ring width first second Oil 0 015 0...

Page 21: ...042mm 19 95mm 0 08mm Piston rings Ring side clearance first second Oil Ring end gap first second Oil 0 02 0 06mm 0 2 0 4 mm 0 2 0 7 mm 0 15mm 1 0mm 1 0mm Seat width Spring free length EX 0 05 0 077mm...

Page 22: ...0 mm 6 545 6 560 mm 6 6 6 615 mm 0015 0 055mm 0 015 0 055mm 0 65 0 95 38 8 39 2mm 6 44mm 6 4mm 6 66mm 0 11mm 0 13mm 2 0mm 37 5mm camshaft Cam height Journal O D IN EX 6 59 mm 6 07 mm 15 966 15 984 mm...

Page 23: ...ll end I D Big end I D Big end oil clearance Big end side clearance 20 011 20 022 mm 36 025 36 039 mm 0 25 0 65 mm 0 013 0 03 mm 20 07mm 36 07mm 0 12mm 1 0mm Crankshaft Crankshaft pin O D 35 975 35 98...

Page 24: ...18 Pilot screw opening Spark plug Gap 0 7 0 8mm Spark plug cap Resistance 9 5 10 5k Ignition coil Resistance Air gap Primary coil Secondary coil 0 6 0 9 5 6 6 9k 0 3 0 5mm...

Page 25: ...19 2 DIMENSIONS AND TORQUE 2 1 ENGINE DIMENSIONS 2 1 1 R100 2 1 2 R160 R180 R200 R210 R225...

Page 26: ...20 2 1 3 R270 R280 R300...

Page 27: ...21 2 1 4 R390 R420 R440...

Page 28: ...necting rod 4 Crankcase cover R100 R160 R225 M6 25 8 8 A M8 32 8 8 A 11 2 28 2 Crankcase cover crankcase gasket crankcase 5 Flywheel subassembly R100 R160 R225 R270 R440 M12 1 25 8 A M14 1 5 8 A M16 1...

Page 29: ...R270 R440 M6 8 8 8 A M6 8 8 8 A M6 8 8 8 A 10 2 Recoil starter shroud 16 Air cleaner R100 R440 M6 8 A 10 2 Air cleaner gasket carburetor 17 Throttle control subassembly R100 R160 R225 R270 R440 M6 8 8...

Page 30: ...R440 M6 30 8 8 A 2 3 STANDARD TORQUE VALUES Item Specifications Torque valve N m Kg m Standard torque 5mm bolt nut 5 5 0 55 6mm bolt nut 10 1 0 8mm bolt nut 21 2 4 10mm bolt nut 37 5 3 75 12mm bolt nu...

Page 31: ...y for keeping the generator in a good operating condition Perform the service and inspection at the intervals shown in the Maintenance Schedule below Time option Each use First month or 20 Hrs 3 Every...

Page 32: ...Recommended oil General oil SAE15W 40 SJ class or equivalent API classified SJ class SAE10W 30 oil In a low temperature range below 10 use oil with the grade higher than SAE10W 30 In a cold environmen...

Page 33: ...uch oil will jam the strainer holes Oil bath type 1 Clean the air cleaner case with cleaning oil and dry it 2 Add the clean oil to specified level and install the air cleaner case back 3 Clean the pol...

Page 34: ...TC BPR6ES NGK with anti wave interference ability F7RTC with anti wave interference ability 3 6 VALVE CLEARANCE ADJUSTMENT CAUTION Valve clearance adjustment must be per formed with the engine cold 1...

Page 35: ...ERNOR 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 extreme position 3 Turn the governor support right to extreme position g...

Page 36: ...nt in the fuel tank cover is clogged Unclog air vent Improper or clogged main jet Readjust or clean blow to get through Needle valve is not closed properly or start hole is clogged Dismantle needle va...

Page 37: ...ng is broken Replace Piston ring is sticking Clear up carbon fouling Spark plug is not installed tightly or is installed without a gasket Air leakage between cylinder block and cylinder head Tighten w...

Page 38: ...gnition system Fuel supply system Air in fuel line or fuel line is clogged Drain air or unclog fuel line Main jet is not adjusted properly Readjust In carburetor needle valve and main jet are clogged...

Page 39: ...piston pin hole are worn excessively Replace piston or piston pin Connecting rod small head is worn excessively Replace connecting rod Roller bearing for crankshaft main journal is worn Replace roller...

Page 40: ...d part 4 1 5 Exhaust gas color is abnormal TROUBLE CAUSE REMEDY Black smoke Piston cylinder or piston ring is worn excessively Replace the worn part Too much carbon deposit in combustion chamber Clear...

Page 41: ...nnect yellow lead of the engine and connect the engine to ground when the engine is running Be sure the alert lamp lights up and the engine stops 2 Disconnect oil level switch lead under the specified...

Page 42: ...ctly 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 2 Use prescribed grade of gas and di...

Page 43: ...ean it thoroughly before starting 10 Do not run the engine in airtight or poorly ventilated places 11 The exhaust muffler is very hot during running the engine even after the engine stops Never touch...

Page 44: ...8 4 Trademark label 5 Throttle control label 6 Air cleaner maintenance label 7 Choke lever fuel cock label 8 Oil grade label...

Page 45: ...9 9 Oil filling label...

Page 46: ...7 Diamond lap 320 8 Flywheel driver 9 Bearing extractor 10 Valve guide reamer Carburetor float level inspection Valve guide removal installation Assembling ball bearing Installing handle and bearing A...

Page 47: ......

Page 48: ...46 4 3 DISASSEMBLING CHART Engine Air cleaner Carburetor Recoil starter Shroud Flywheel Starter motor...

Page 49: ...ellow lead Gray lead Connect to charging coil lead Fan cover only used for automatic starter Disassembly reassembly Disassemble and reassemble with the recoil starter assembled Black white lead Connec...

Page 50: ...through the groove in the recoil starter reel and make a figure eight knot at the rope end Hang the side hook of the recoil starter spring to the groove of the recoil starter case set the recoil star...

Page 51: ...tall the return spring on the recoil starter reel while hooking it to the side of the driving cam Install the spring driving guide and fixing screw one after another Insert the recoil starter rope thr...

Page 52: ...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...

Page 53: ...ore Secondary side resistance value 5 7k 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 other test lea...

Page 54: ...e silencer only for silence Elbow seal Air cleaner elbow Disassembly reassembly remove and install with the choke lever and fuel valve in the ON position Clean the inside of the elbow with compressed...

Page 55: ...Collar Air cleaner case Oil capacity 60cc Reassembly After cleaning with solvent fill with clean oil and install Air cleaner elbow Disassembly reassembly Remove and install with the choke lever in ON...

Page 56: ...of its hole Reassembly After pulling fuel hose from the carburetor insert it into protruding shoulder of the choke handle preventing oil leakage Reassembly Blow out the passages with compressed air a...

Page 57: ...check for any sign of fuel leakage Reassembly Clean thoroughly with compressed air before installation reassembly Inspect for wear before installation Idle speed adjusting screw Idle speed mixed ratio...

Page 58: ...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 heigh...

Page 59: ...over gasket Cylinder head cover Valve adjusting bolt Cylinder head Installation Before installation remove any carbon deposits from the combustion chamber and inspect the valve seats Measure the cylin...

Page 60: ...der 2 Inspect service repair Valve stem outside diameter Inspect the valve stem outside diameter with the micrometer if it is found out of the standard or service limit or if it has visible burn and d...

Page 61: ...stness b Use the valve guide reamer ream the valve guides to remove any carbon deposits before measuring If the valve guide inside diameter is lower than standard or out of the service limit replace t...

Page 62: ...oid 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 cli...

Page 63: ...ight round and centered in the valve guide insert the valve and check operation If the valve does not operate smoothly the guide may have been bent during installation Replace the valve guide if it is...

Page 64: ...lockwise never counterclockwise d Continue turning the cutter as you lift it from the valve seat Tool Valve seat cutter Use the 32 45 cutters to narrow and adjust the valve seat so that it contacts th...

Page 65: ...mbly Push it in firmly until contact is made with the bearing surface Be careful not to damage the oil seal Bolt Crankcase Bearing Governor arm Bolt Crankcase cover Gasket Don t reuse Pin Oil seal Pin...

Page 66: ...when reassembling crankcase cover Pin Fix the governor arm with pin after installing Spacer Oil seal Connection rod Piston pin Piston pin clip Piston Crankcase Crankshaft Reassembly Push in firmly un...

Page 67: ...ng and the second ring first ring is chrome plated After assembly check for smooth movement of the piston rings Stagger the piston ring end gaps 120 apart Reassembly a Piston pin clip Install by setti...

Page 68: ...al brush 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 S...

Page 69: ...sening 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 rin...

Page 70: ...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 replace the connecting rod Standard Servi...

Page 71: ...ter will be badly rubbed from periodical impact and will be easily damaged So the camshaft shall be wearable and lubricated well Visually inspect camshaft face and camshaft height for damage and camsh...

Page 72: ...t camshaft rotation precision will lower and contacting with the relative part will produce deviation to make abnormal wearing Timing gear a Check timing gear for engagement clearance and align marks...

Page 73: ...71 4 4 7 Starting control box a Disassembly reassembly Only for starter 6 12mm 2 screw Control box Silicon rectifier Check 7 8 Blade type fuse 5A Reassembly Check for burn before installation...

Page 74: ...t Oil alert Check P 7 8 Reassembly Install by aligning with the hole of the control plate Control panel Resetting button 1A Reassembly Be careful not to install the left and right side plate reverse S...

Page 75: ...ter Check continuity between leads when switch is kept at each position Lead color Switch position Black red to grounding Black white White OFF ON START Check with fuse connected Oil alert lamp Connec...

Page 76: ...w battery Don t connect the positive and negative poles wrongly Don t use the battery with over 6V if so bulb will break Silicon rectifier Check continuity between the two terminals if it is continuou...

Page 77: ...75 control box starter motor starter relay charging coil...

Page 78: ...ing 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...

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