SKY Engines Boxer 220s Instruction Manual Download Page 34

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MAINTENANCE SCHEDULE

Deadline

Check

Replacement

First 5 hours

and after 15
hours

Overall check of nut and bolt

tightening

Every 25 hours

Condition of exhaust silent

block and relevant
fastening straps

Every 50 hours

•

Clutch shoe wear

•

reduction oil level

•

coolant level

•

condition of

exhaust silent
block, engine,
spider

•

Spark plug

•

Glass wool in

silencer
(optional)

Every 100 hours

or each year

(even if engine is

not used)

•

All silent blocks

•

Petrol tubing

•

Reduction oil

Every 150 hours

Descaling combustion

chamber and piston
crown

•

Elastic bands

•

Piston roller cage

•

Propeller screws

Every 200 hours

Check wear on the main

bearings and the engine
shaft clearance

Engine shaft seals

Summary of Contents for Boxer 220s

Page 1: ...BOXER 220s INSTRUCTION MANUAL ...

Page 2: ... Technical characteristics 3 3 Assembly of the secondary components 3 3 1 Special warnings on assembly 3 3 2 Radiator 3 3 3 Silent block brackets 3 3 4 Clutch 3 3 5 Overall ignition unit 3 3 6 Exhaust 3 3 7 Silencer 3 3 8 Reed valve 3 3 9 Carburettor 3 3 10 Reduction 4 0 MAINTENANCE AND CLEANING Essential cleaning Liquid top up Adjustments Deadlines and measures 5 0 SPARE PARTS 6 0 WARRANTY Requir...

Page 3: ...tly or indirectly liable for the use of its engine especially if it has been modified or tampered with by third parties MAINTENANCE IS FUNDAMENTAL to avoid serious damage to the engine please read chapter 4 0 of this manual carefully and strictly follow all the points For spare parts to replace damaged parts consult paragraph 3 3 where all the assembly procedures are illustrated of the secondary p...

Page 4: ... ACCIDENT PREVENTION Use of this engine is high risk therefore you have to pay utmost attention during before and after flight to avoid very serious accidents You are therefore invited to follow the general measures illustrated here to avoid damage or accidents The engine cannot resolve all flight problems therefore you have to avoid unsafe situations one of the most common errors is to fly very l...

Page 5: ...ATTENTION STORED KEEP OUT OF CHILDREN S MIX PETROL AND OIL IN REACH A RATIO OF 3 USING TOP QUALITY SYNTHETIC OIL FOR 2 STROKE ENGINES Pay attention to the excess quantity of oil CAUTION and lack of it IN BOTH CASES NEVER MIX DIFFERENT OILS IT COULD DAMAGE THE ENGINE TOGETHER You are advised to use 100 synthetic oil BARDAL KITS already tested by our mechanics PERIOD PERCENTAGE OF OIL RUNNING IN 3 S...

Page 6: ...ENGINE IS RAN IN 2 3 STARTING THE ENGINE The BOXER220S engine starts via the pull EASY START with self winding cord which must be strongly pulled to avoid the engine flooding Thanks to this type of ignition the engine is easily started CAUTION Engine exhaust gas contains carbon monoxide which is lethal for the body DO NOT START THE ENGINE IN ENCLOSED LOCATIONS BUT OUTDOORS AND WELL VENTILATED PLAC...

Page 7: ...R BRACKETS SKYBO22004005 6 HEADS SKYBO22005001 18 CASING SKYBO22007004 5 7 CARBURETTOR SKYB022002005 19 SPIDER SKYBO22007003 8 UPPER EXHAUST MANIFOLD SKYBO22005016 20 EASY START IGNITION SKYBO22001 9 REDUCTION SKYBO22008 21 SILENT BLOCK SKYBO22007011 10 SILENCER SKYBO22006001 22 FILTER CASING SKYBO22002004 11 UPPER EXHAUST SKYBO22006004B 23 LOWER HEAD COVER SKYBO22005004 12 UPPER HEAD COVER SKYB02...

Page 8: ... CARBURETTOR KEIHIN 38 TOTAL WEIGHT WITH LIQUIDS 20 Kg EGT 680 C CHT 170 C COOLANT 95 C DRY CENTRIFUGAL CLUTCH Tests carried out in optimal conditions at sea level with the engine ran in CAUTION The recommendations in the technical characteristics are very important to avoid serious damage to the engine and your safety PAY UTMOST ATTENTION TO THE ABOVE AND WE INVITE YOU TO COMPLY WITH THE MAXIMUM ...

Page 9: ...yone without the skills and ability to carry out assembly operations NOT TO TOUCH THE ENGINE UNLESS FOR UNAVOIDABLE MAINTENANCE OPERATIONS IN THIS CASE WE ASK YOU TO FOLLOW THE INSTRUCTIONS OUTLINED STEP BY STEP WITHOUT IMPROVISING OR MAKING CHANGES THAT COULD CREATE SERIOUS DAMAGE FOR THE ENGINE NOT COVERED BY WARRANTY Modifications to the engine can make it extremely unsafe Replace the engine co...

Page 10: ...n the respective openings as in the figures below Check the positions of the joints and insert the tube tightening clamps as in the photo 3 3 3 SILENT BLOCK BRACKETS Assemble the Teflon disc and then the silent block on the upper head cover as in the figure to the side Then assemble the head cover dissipator ...

Page 11: ...er head cover and the silent blocks on the brackets Position the tank on the bracket and avoid using the nut without tightening it to see the tip of the screw exiting as in the figure to the side Lastly assemble the radiator on the specific silent blocks ...

Page 12: ...e spring in the specific compartment of the shoe and position the clutch body as demonstrated in the figures Before positioning the shoes and screwing in the screw affix a drop of Loctite to block the thread in the specific hole This process should also be carried out for the other 3 shoes ...

Page 13: ...verything on a vice aiding fastening with a cylindrical body ensuring the holes of the shoe and the clutch body match and insert the pin as in the following figure Lastly assemble the clutch in the engine casing ...

Page 14: ...nsure everything needed is present i e ratchets screws and springs Ensure the parts in question are clean Position the spring in the specific hole and in the flywheel guide as in the photo to the side Rest the ratchet and ensure it fits with the spring ...

Page 15: ...ew provided tighten and ensure the ratchet remains free to rotate as in the 2 following photos Grease the spring carefully Couple the serrated pin with the spring fitting the latter in the specific slot Position the spring serrated pin unit in the ...

Page 16: ...y also here fitting the spring in the specific slot of the pulley Then screw in the grid as shown in the figures below Insert the small spring from the other side of the pulley As before fit the spring well in the specific compartment ...

Page 17: ... the hole of the pawl tighten the grub screw on the cord then insert it in the hole of the pulley Lastly fit the pawl in the specific hole on the pulley and wind the cord 8 rotations in the pulley as shown in the figures ...

Page 18: ... the rope in the specific hole of the cup Insert the ignition unit assembled in the cup and connect the end of the small spring to the cup Insert the bushing as in the figure and tighten it to the serrated pin ...

Page 19: ... by pulling 3 3 6 EXHAUST Insert the manifold of the upper exhaust in the respective receptacle of the upper cylinder Then assemble the springs with the help of the specific hook Repeat the same operation for the lower exhaust as shown in the photo ...

Page 20: ...haust to the two upper silent blocks as shown in the figure Repeat the same procedure for the lower exhaust Lastly for the lower exhaust adjust the correct inclination by tightening the screw as circled in the image below ...

Page 21: ...Lastly insert the steel cable between the hooks letting it pass inside the springs and tie it to the side of the manifold as in the figure below ...

Page 22: ...low Before inserting the silencer ensure you have positioned the rubber sections on the manifolds of the exhausts as the first operation Insert the silencer in the manifold of the lower exhaust The first side to insert will therefore be that circled in the image below ...

Page 23: ...Then insert the silencer on the manifold of the upper exhaust as in the figure Screw in the silencer on the specific hooks on the exhausts without forgetting the aluminium shim ...

Page 24: ... VALVE Apply and evenly distribute a non excessive quantity of Motorsil on the internal flange avoiding dripping along the entire duct Position the specific paper gasket and distribute another layer of Motorsil the same as the first as in the following figures Place a drop of red Loctite in the holes for the screws ...

Page 25: ...Position the reed valve in its compartment in the casing position the rubber collector and screw in the 4 screws as in the figure below ...

Page 26: ...Position the clamp on the manifold assemble the carburettor and tighten the clamp 3 3 9 CARBURETTOR Unscrew the screws and proceed to replace the accelerator cable ...

Page 27: ...tine Hold the spring as in the figure releasing the cable from its compartment in the guillotine Proceed to replace the cable ensuring you have correctly fitted the end of the cable in the compartment of the guillotine as displayed in the figure below ...

Page 28: ...ew the cap of the reduction unit and proceed to change the oil after 100 hours of use Having accurately emptied the reduction body of consumed oil proceed to replace with new oil Add 30 35 ml of oil SKY Engines s r l recommends using Klüberoil GEM 1 150N oil Alternatively use thick synthetic oil 4 MAINTENANCE ...

Page 29: ... TO KEEP THE INNER PART OF THE ENGINE COMPLETELY CLEAN TO AVOID RESIDUE GOING INSIDE THE CYLINDER OR WORSE INSIDE THE CASING STALLING THE ENGINE 4 2 LIQUID TOP UP The only liquids to check are Coolant liquid Reduction oil COOLANT LIQUID SHOULD BE CHECKED EVERY 50 HOURS OF FLIGHT BY CARRYING OUT THE FOLLOWING OPERATIONS 1 Unscrew the CAP OF THE RADIATOR 2 Check the liquid inside the radiator reache...

Page 30: ...LECTING THE EXCESS LIQUID IN THE RADIATOR AND NOT FILLING IT THE EXCESS LIQUID IN THE TANK MAY FLOW OUT AND IF LEAKS ARE NOTED FIRSTLY CHECK THIS IT MUST NOT EXCEED THE LEVEL INDICATED THE TANK IS FILLED TO THE LEVEL INDICATED BY THE BLACK MAX WRITING LOCATED ON THE OUTER PART AS IN THE PHOTO REMEMBER THAT IT SHOULD NEVER BE COMPLETELY FILLED AS THIS WOULD CAUSE LIQUID TO FLOW OUT ...

Page 31: ...e bushing it must be completely visible AFTER APPROX 100 HOURS OR HAVING NOTED A CONSIDERABLE REDUCTION REPLACE THE OIL INSIDE To do so open the bushing carefully drain all the exhausted oil and insert 30 35 ml of synthetic oil for transmissions W150 We recommend Kluberoil GEM 1 150N 4 3 ADJUSTMENTS The only adjustment which could be necessary is air petrol passage in the carburettor ...

Page 32: ...RBURATION ONLY WITH THE ENGINE HOT AND AFTER OBVIOUS CLIMATIC CHANGES WHEN THE ENGINE IS COLD IT COULD SWITCH OFF OUR ADJUSTMENT IS AS FOLLOWS HAVING COMPLETELY SCREWED IN SCREW b UNSCREW BY A ROTATION AND A HALF 4 4 DEADLINES AND MEASURES This paragraph provides measures deriving from various tests carried out by our mechanics and recommendations from clients we invite anyone who finds faults or ...

Page 33: ...ent blocks of the spider and the exhaust they should be checked every 50 hours and replaced after 100 hours of flight or after one year Approx every 50 hours of EFFECTIVE flight check the clutch shoes to dismantle them read chapter 3 0 carefully in the paragraph on assembly of the secondary components take offs increase wear on the shoes an excess number risks reducing the hours of effective fligh...

Page 34: ...eduction oil level coolant level condition of exhaust silent block engine spider Spark plug Glass wool in silencer optional Every 100 hours or each year even if engine is not used All silent blocks Petrol tubing Reduction oil Every 150 hours Descaling combustion chamber and piston crown Elastic bands Piston roller cage Propeller screws Every 200 hours Check wear on the main bearings and the engine...

Page 35: ...parts only The spare parts catalogue can be found on our website www skyengines it To order parts contact us directly by telephone or e mail or contact your local dealer Further information can be found on replacement of parts under warranty in the following chapter ...

Page 36: ... l normal wear of all items parts and spare accessories damage due to omission of accurate maintenance damage due to engine operation without the propeller damage due to erosion damage due to use of petrol without added lubricant causing stalling use of the parts not designed by Sky Engines use of propellers that exceed the rotation limitations as specified by Sky Engines s r l loss of parts in fl...

Page 37: ...URTHER INFORMATION PLEASE CONTACT US BY TELEPHONE OR E MAIL OR VISIT THE SITE www skyengines com REMEMBER THAT FOR WARRANTY VALIDITY PURPOSES YOU MUST ALWAYS RETURN THE CERTIFICATE COMPILED AND SIGNED TOGETHER WITH THE REQUEST DATE DEALER S SIGNATURE Return of the compiled form certifies the user accepts the warranty and safety conditions indicated in this manual C da San Rustico snc 63038 Ripatra...

Page 38: ...URTHER INFORMATION PLEASE CONTACT US BY TELEPHONE OR E MAIL OR VISIT THE SITE www skyengines com REMEMBER THAT FOR WARRANTY VALIDITY PURPOSES YOU MUST ALWAYS RETURN THE CERTIFICATE COMPILED AND SIGNED TOGETHER WITH THE REQUEST DATE DEALER S SIGNATURE Return of the compiled form certifies the user accepts the warranty and safety conditions indicated in this manual C da San Rustico snc 63038 Ripatra...

Page 39: ...URTHER INFORMATION PLEASE CONTACT US BY TELEPHONE OR E MAIL OR VISIT THE SITE www skyengines com REMEMBER THAT FOR WARRANTY VALIDITY PURPOSES YOU MUST ALWAYS RETURN THE CERTIFICATE COMPILED AND SIGNED TOGETHER WITH THE REQUEST DATE DEALER S SIGNATURE Return of the compiled form certifies the user accepts the warranty and safety conditions indicated in this manual C da San Rustico snc 63038 Ripatra...

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SKY Engines Boxer 220s, Instruction Manual

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