Manual-Service - Green Sky Adventures, Inc.
Contents
1. LD of journal mm p 44 000 44 008 944009 44 016 9 40 988 40 993 Color of bearing BROWN Color mark BLUE Effectivity HKS700E after S N 100600 44 nil oa Service Manual 6 2 Crankshaft bearing Front Journal No on 01 02 I D of journal mm No on J1 J2 O D of journal mm Color of bearing BROWN BLACK Color mark BLUE Grading of cylinder and piston Grading letter A B C is marked as illustrated Use same grading of cylinder or piston when replacing Cylinder Bore mm Piston O D mm A 84 995 85 005 q 84 980 84 990 C 85 006 85 015 q 84 991 85 000 Effectivity HKS700E after S N 100600 45 mab ax Service Manual 8 Wear limits Designation _ OfdmPstn p SePma Pstnpn Psonpn 000 Psonpnboe 2000 0008 Clearance pinin piston 0002 0002 Conrod bore smalend 20007 20012 Clearance pninconrod ous Denge Rhggoowdemame 0050 0085 Fingend gap 0100 0200 Rhggoowdexmame 0025 000 Fingend gap 0150 0250 Ofdehed _ Wwegudeboe 600 6091 iN 1890 595 EX 590595 _ msn 5 0 025 0 049 Seaingtace with Nvave ao _ Sealing face width EXvave ao Valve stem 7 Valve spring free mm Rekeramboe 1202 _ C Rekeramshat 11902. 4 8 Driven gear and Starter idler gear reassembly 4 9 Rear cover reassembly 4 9 1 Stator 4 9 2 Oil pump 4 9 3 Pressure regulator 4 9 4 Oil filter 4 10 Front cover reassembly 4 10 1 Atype ratio2 58 4 10 2 B type ratio3 47 4 11 Gearbox reassembly 4 11 1 Atype ratio2 58 4 11 2 B type ratio3 47 Effectivity HKS700E after S N 100600 mab ax Service 4 12 Electric starter reassembly 4 13 Spark plug reassembly 4 14 Intake manifolds reassembly 4 15 Carburetors reassembly 4 15 1 Upper type 4 15 2 Horizon type 5 Table for torque values 6 Selection of metal bearing 6 1 Connecting rod bearing 6 2 Crankshaft bearing Grading of cylinder and piston 8 Wear limits Effectivity HKS700E after S N 100600 Service Manual WARNING This is a non certified aircraft engine the possibility of engine failure exists at all times Do not operate this engine over densely populated areas Do not operate this engine over terrain where a safe power off landing cannot be performed The operating and maintenance instructions supplied with this engine must be followed at all times Flying any aircraft involves the risk of injury or death building and maintaining your own aircraft requires great personal responsibility Effectivity HKS700E after S N 100600 mab ax Service Manual 1 Introduction Effectivity HKS700E after S N 100600 HKS Service Manual 2 General informatio
3. e Attach spacer e Attach 12 spring washers on the shaft as illustrated e Attach hub dog e Attach gear so the knuckle joint is engaged to new face of hub dog Effectivity HKS700E after S N 100600 38 Service Manual e Attach retainer e Compress gear using ST 07 and attach half rings with the flat side out e Set inner race with ST 09 Press ST 07 to insert inner race ST 09 e Fitcirclip in the groove Effectivity HKS700E after S N 100600 39 HK 5 Service Manual e Clean and remove oil from contact surface of front cover and gearbox e Place new gasket to front cover e Place 2 pipe knock pins 6 e Apply motor oil to roller bearing and gear tooth e Place gearbox on front cover 4 11 1 Atype ratio2 58 e Tighten gearbox with 4 bolts 6 25 4 bolts M6 45 and washers evenly to 1 2 kgfm applying LOCTITE 243 4 11 2 B type ratio3 47 e Tighten gearbox with 4 bolts M6 25 6 bolts M6 45 and washers evenly to 1 2 kgfm applying LOCTITE 243 Effectivity HKS700E after S N 100600 40 Service Manual 4 12 Electric starter reassembly e Apply motor oil to gear tooth and installation bore Fit electric starter into crankcase e Tighten electric starter with 2 bolts M6 35 and washers to m 1 2 kgfm applying LOCTITE 243 4 13 Spark plug reassembly e Insert spark plug with LOCTITE
4. 03 e Remove woodruff key D Effectivity HKS700E after S N 100600 14 5 Service Manual 3 9 Starter idler gear and Driven gear removal e Remove idler gear idler shaft and 2 thrust washers e Remove driven gear by turning clockwise left D 3 10 Flywheel removal e Block crankshaft same as 1 8 e Remove 6 bolts M8 e Shift to remove flywheel Effectivity HKS700E after S N 100600 15 mo Service Manual 3 11 Cylinder head removal e Remove 5 bolts 5 and cylinder head cover e Remove head cover gasket CAUTION Do not damage contact surface e Rotate crankshaft to set piston to bottom dead center position e Remove bolt M5 and 2 M6 e Remove 4nuts e Shift to remove rocker arm compartment e Lift out push rods stop oil dripping by sealing with finger NOTE Identify both push rods to IN EX e Shift to remove cylinder head e Remove gasket Effectivity HKS700E after S N 100600 oa kad Service Manual 3 11 1 Cylinder head disassembly e Remove bolt M5 and banjo bolt M10 e Remove oil jet pipe e Compress valve spring with valve spring mounting device and clamp or similar tool e Remove valve cotters and release valve spring e Remove valve spring retainer valve springs and valve NOTE To prevent damage to valve guide trim out burrs which may be present on valve stems prior to the removal of val
5. 07 Inner race will move to upward by spring washers If three ST 08s are inserted go to STEP 4 else go to STEP 1 STEP 4 Remove ST 08s and ST 07 Remove Inner race Press Release e Remove spacer e Press PTO shaft to remove from gearbox Effectivity HKS700E after S N 100600 ais Service Manual 3 6 Front cover removal 3 6 1 Drive gear removal e Block crankshaft with ST 02 e Remove nut M25 and washer e Shift to remove drive gear e Remove 12 bolts MO e Shift to remove front cover Effectivity HKS700E after S N 100600 11 Service Manual 3 7 Rear cover removal and disassembly e Remove oil filter with oil filter wrench 1 e Remove 10 bolts MO e Shift to remove rear cover NOTE Do not lose the thrust washer 3 7 1 Oil pump disassembly e Remove bolt e Remove spring and valve e Remove 5 bolts M6 e Remove oil pump cover e Remove inner rotor 25mm e Remove woodruff key e Shift to remove pump body 25mm Effectivity HKS700E after S N 100600 ND Service Manual e Remove inner rotor 15mm e Remove woodruff key 2 e Shift to remove pump body 15mm e Shift to remove inner feed rotor Assy D Effectivity HKS700E after S N 100600 oa kad Service Manual 3 8 Stator removal e Block crankshaft with ST 02 e Remove bolts M10 e Remove stator with tightening ST
6. 91 Service Manual 4 Assembly 4 1 Connecting rod reassembly e Clean all parts e Fit connecting rod bearings Apply motor oil to metal surface e Assemble connecting rod Apply motor oil to bolt and thread e Tighten connecting rod cap end evenly with 2 connecting rod bolts Tightening torque is 3 8 kgfm e Swing connecting rod to check for ease movement CHANGE PARTS AT OVERHAUL Connecting rod bearing See para 6 1 Effectivity HKS700E after S N 100600 22 oa kad Service Manual 4 2 Crankcase reassembly 4 2 1 Crankshaft bearing and Thrust bearing e Clean bearing seat and remove oll e Visually check the metal bearing surface Remove oil from back of metal bearing e Place metal bearing into both crankcases e Place thrust bearing to crankcase with applying grease to back side of thrust bearing d d NOTE There are two kinds of bearings Bearing with a lug is attached to a RH side crankcase Flat side of bearing is assembled to the crankcase side CHANGE PARTS OVERHAUL Crankshaft bearing and thrust bearing See para 6 2 4 2 2 Crankshaft e Apply motor oil to bearing surface e Place crankshaft to RH crankcase with care Effectivity HKS700E after S N 100600 oleae Service Manual 4 2 3 Camshaft e Apply motor oil to camshaft journal and all teeth of drive and driven gear e Place camshaft to RH crankcase while uniting punch marks 424 Oil strainer e
7. ANTISEIZE and tighten to 2 3 kgfm CHANGE PARTS AT OVERHAUL Spark plug Replace every 200Hr 4 14 Intake manifolds reassembly e Clean and remove oil from contact surface of cylinder head and intake manifold e Place new gasket The seal spreading side is assembled to manifold side e Tighten intake manifold with 2 bolts M8 20 to 2 4 kgfm applying LOCTITE 243 Effectivity HKS700E after S N 100600 44 oa kad Service Manual 4 15 Carburetors reassembly e Attach carburetor by turning action and tighten clamp screw OF CHANGE PARTS AT OVERHAUL Insulator rubber 4 15 1 Upper type e Tighten2 nuts M6 4 15 2 Horizon type e Hook tension spring Effectivity HKS700E after S N 100600 42 mab ax Service Manual 5 Table for torque values Designation Size Torquelkgfm Remark LOCTITE 243 Drive gear nut ws us Crankcase Engine oil IEEE Leen LOCTITE 243 Oil jet pipe Cylinder head M10 Banjo n es Engine oi Cylinder head Cylinder os LOCTITE243 Gyinderheag cover 08 _ Engine oi Union rear cover Stud bolt Exhaust por LOCTITE 243 sae o Effectivity HKS700E after S N 100600 43 mab ax Service Manual 6 Selection of metal bearing 6 1 Connecting rod bearing Rear PIN Front PIN No on P1 P2 O D of pin mm
8. Fitnew O ring to oil strainer with applying motor oil e Place oil strainer to RH crankcase and tighten bolt M6 20 temporary Effectivity HKS700E after S N 100600 24 HKS Service Manual 4 2 5 LH crankcase e Clean and remove oil from both contact surface of crankcase e Apply LOCTITE 5699 on contact surface of RH crankcase e Place 2 pipe knock pins 8 and 2 pipe knock pins 2 15 e Place LH crankcase RH crankcase e Fit washer and new O ring to 2 bolts M10 with applying motor oil e Attach LH crankcase on RH crankcase with 2 bolts M10 both upper side 2 bolts M10 with O ring both lower side and 2 bolts M8 applying motor oil to thread e Tighten 4 bolts M10 both side evenly to 4 8 kgfm e Tighten 2 bolts 8 evenly to 2 4 kgfm e Tighten 7 bolts M6 25 and 1 bolt M6 45 evenly to 1 2 kgfm with LOCTITE 243 and washers e Attach drain bolt with motor oil and new copper washer Tighten to 1 2 kgfm NOTE The crankshaft and camshaft must turn freely Effectivity HKS700E after S N 100600 25 Service Manual e Wipe off the protruding LOCTITE e Fix oil strainer with 2 bolts M6 20 with applying LOCTITE 243 Tighten to 1 2 kgfm Effectivity HKS700E after S N 100600 26 HK 5 Service Manual 4 3 Piston reassembly 4 3 1 Piston ring e Fit Top and Second rings using piston ring pliers with the dot mark towards pis
9. evenly to 1 2 kgfm applying LOCTITE 243 4 9 4 Oil filter e Lubricate the rubber seal of oil filter e Screw new oil filter by hand until it stops at the oil filter housing e Tighten by an extra 3 4 turn Effectivity HKS700E after S N 100600 36 HKS Service Manual 4 10 Front cover reassembly e Clean and remove oil from contact surface of crankcase and y a front cover 2 e Place new gasket D to crankcase e Place 2 pipe knock pins 6 e Apply motor oil to bearing bush of front cover and crankshaft e Place front cover on crankcase 4 10 1 Atype ratio2 58 e Tighten front cover with 12 bolts M6 30 and washers evenly to 1 2 kgfm applying LOCTITE 243 4 10 2 B type ratio3 47 e Tighten front cover with 2 bolts M6 45 8 bolts M6 35 2 bolts M6 30 and washers evenly to 1 2 kgfm applying LOCTITE 243 e Attach drive gear and washer to crankshaft e lighten nut M25 to 10 0 kgfm applying LOCTITE 243 Pay attention for the Bere p 16 AEA LT direction of the washer Effectivity HKS700E after S N 100600 97 c 4 11 Gearbox reassembly Service Manual e Insert new oil seal from the inside using insertion jig Add seat PTO shaft with rounded side towards oil seal Heat up gearbox in oven to approx 120 C Press in ball bearing and fit circlip in the groove e Apply grease to sealing lips e Press PTO shaft from outside into gearbox
10. 1200 Rocker arm racial dere 0004 008 _ Rocker arm axial clearance 0100 0450 _ Grankshan SePma 7 7 7 0 200 0 390 MEE Effectivity HKS700E after S N 100600 46 mab a Service Manual Designation New mm Wearlmi mm Crankease ll See Para 6 2 o o Uerhoeboe Propeller gearbox Il Propflange axialoutofiue J NT Weardepthofdogs 020 Camshaft ll Plunger axial clearance 0 030 0 070 0 120 Out of round 0 0 0 1 Effectivity HKS700E after S N 100600 SATE mab ax Service Manual Effectivity HKS700E after S N 100600 48
11. HKS OOE Service Manual 9 2005 November Ver 2 01 HKS CO LTD 7181 KITAYAMA FUJINOMIYA SHIZUOKA JAPAN 418 0192 TEL 81 0 544 54 1781 FAX 81 0 544 54 1410 hks_aviation hks power co jp http www hks power co jp hks aviation mab ax Service Manual CONTENTS PG1 3 1 Introduction 2 General information 2 1 Special tools 3 Disassembly 3 1 Carburetor disassembly 3 1 1 Upper type 3 1 2 Horizon type 3 2 Intake manifolds removal 3 3 Electric starter removal 3 4 Spark plug removal 3 5 Gearbox removal and disassembly 3 5 1 Atype ratio 2 58 3 5 2 B type ratio 3 47 3 6 Front cover removal 3 6 1 Drive gear removal 3 7 Rear cover removal and disassembly 3 7 1 Oil pump disassembly 3 8 Stator removal 3 9 Starter idler gear and Driven gear removal 3 10 Flywheel removal 3 11 Cylinder head removal 3 11 1 Cylinder head disassembly 3 12 Cylinder and Piston disassembly 3 13 Crankcase disassembly 3 14 Crankshaft disassembly Effectivity HKS700E after S N 100600 mab ax Service Manual 4 Assembly 4 1 Connecting rod reassembly 4 2 Crankcase reassembly 4 2 1 Crankshaft Bearing and Thrust bearing 4 2 2 Crankshaft 4 2 3 Camshaft 4 2 4 Oil strainer 4 2 5 LH crankcase 4 3 Piston reassembly 4 3 1 Piston ring 4 4 Cylinder reassembly 4 4 1 Hydraulic lifter 4 5 Cylinder heads reassembly 4 5 1 Push 4 5 2 Rocker arm compartment 4 6 Cylinder head cover reassembly 4 7 Flywheel reassembly
12. and stator hub e Fit stator hub and washer Apply LOCTITE 243 to bolt M10 50 and tighten to 5 0 kgfm Effectivity HKS700E after S N 100600 ce a K oa kad Service Manual 4 9 2 Oil pump e Attach inner feed rotor Assy and outer rotor in rear cover e Fit4 new O rings e Attach 2 knock pins 4 e Attach pump body 15mm e Attach woodruff key e Attach inner rotor 15mm e Attach outer rotor 15mm e Fit2new O rings e Attach 2 knock pins e Attach pump body 25mm e Attach woodruff key Effectivity HKS700E after S N 100600 34 mo Service Manual e Attach inner rotor 25mm e Attach outer rotor 25mm e Fit2new O rings e Attach oil pump cover e Tighten oil pump with bolt M6 60 4 bolts M6 110 and washers evenly to 1 2 kgfm applying LOCTITE243 4 9 3 Pressure regulator e Insert valve and spring applying motor oil e Attach bolt with new copper washer Tighten to 2 5 kgfm e Clean and remove oil from contact surface of crankcase and rear cover e Apply LOCTITE 5699 on red circle area Effectivity HKS700E after S N 100600 35 Service Manual e Place new gasket D to crankcase e Place 2 pipe knock pins 6 e Turn oil pump shaft into a position to align with groove of camshaft e Place rear cover on crankcase e Tighten rear cover with 10 bolts M6 20 and washers
13. bolt M6 20 to 1 2 kgfm and bolt M5 20 to 0 8 kgfm with LOCTITE 243 and washers NOTE The valve must move freely when turning the crankshaft e Repeat same procedure from 2 3 on the opposite side Effectivity HKS700E after S N 100600 STET Service Mawd 4 6 Cylinder head cover reassembly e Clean and remove oil from contact surface of cylinder head and cylinder head cover e Place new gasket D to cylinder head e Attach cylinder head cover to cylinder head with 5 bolts M5 25 with LOCTITE 243 and washers Tighten evenly to 0 8 kgfm 4 7 Flywheel reassembly e Block crankshaft same as 1 8 09 e Attach flywheel to crankshaft with 6 bolts M8 13 wih 2 A LOCTITE 243 Tighten evenly to 2 4 kgfm se CHANGE PARTS AT OVERHAUL M8 13 bolt Effectivity HKS700E after S N 100600 82 oa kad Service Manual 4 8 Driven gear and Starter idler gear reassembly e Attach driven gear to crankshaft by turning to left Apply motor oil over the whole of one way clutch bush bearing and gear tooth NOTE The driven gear must engaged on crankshaft when turning clockwise right looking from rear side and turn freely when turning counter clockwise left e Attach idler gear idler shaft and 2 thrust washers applying motor oil 4 9 Rear cover reassembly 4 9 1 Stator e Attach woodruff key in crankshaft e Check for tight fit and degrease tapers of crankshaft
14. k towards upper side CHANGE PARTS AT OVERHAUL IN and EX valve e Compress valve springs with valve spring mounting tool Insert valve cotters and release springs NOTE Check correct positioning of valve cotters e Push piston of banjo bolt to check for ease movement e Attach oil jet pipe to cylinder head with banjo bolt amp applying motor oil to thread Tighten to 2 4 kgfm e Insert bolt 5 10 with LOCTITE 243 and tighten to 0 8 kgfm Effectivity HKS700E after S N 100600 99 HK 5 Service Manual e Clean and remove oil from contact surface of cylinder and cylinder head e Place new gasket D to cylinder e Place 2 pipe knock pins 10 e Place cylinder head 4 5 1 Push rod e Place push rod on hydraulic lifter NOTE Coloring side is turned to cylinder head side I 8 1F3 Color mark e Check proper position of push rod Effectivity HKS700E after S N 100600 30 HK 5 Service Manual 4 5 2 Rocker arm compartment e Rotate crankshaft to set both lifters to bottom position e Place 2 pipe knock pins 10 e Attach rocker arm component to cylinder head with 4 nuts and 4 washers applying motor oil to thread Tighten evenly to 2 0 kgfm e Tighten more 90 deg NOTE Pay attention the direction of nut and washer Dull side ca A CHANGE PARTS AT OVERHAUL nut e Tighten
15. n 2 1 Special tools ST 04 ST 06 T 03 ST 05 ST 07 ST 09 In addition to this service manual please refer to the following 1 HKS 700E Installation instruction Manual 2 HKS 700E Operations Manual 3 HKS 700E Parts List Effectivity HKS700E after S N 100600 mo Service Manual 3 Disassembly 3 1 Carburetors removal NOTE Identify both carburetors to RH LH cylinders 3 1 1 Upper type e Remove 2 nuts M6 3 1 2 Horizon type e Remove tension spring e Loosen clamp screw and remove carburetor by turning action 3 2 Intake manifolds removal e Remove 2 bolts M8 and intake manifold e Remove intake gasket Effectivity HKS700E after S N 100600 oa kad Service Manual 3 3 Electric starter removal e Remove 2 bolts M6 e Shift to remove electric starter 3 4 Spark plug removal e Remove 4 spark plugs Effectivity HKS700E after S N 100600 ot mad Service Manual 3 5 Gearbox removal and disassembly 3 5 1 Atype ratio2 58 e Remove 8 bolts M6 3 5 2 B type ratio3 47 e Remove 10 bolts M6 e Shift to remove gearbox QD e Remove circlip e Set ST 07 as shown e Compress gear and remove half rings Effectivity HKS700E after S N 100600 Service Manual e Remove Inner race following below instruction STEP 1 Compress ST 07 to make clearance between Inner race and Retainer STEP 2 Insert one ST 08 STEP 3 Decompress ST
16. ton crown e Insert new piston pin circlip in groove of FRONT MARK front marked triangular sign side e Apply motor oil over the whole of the piston pin the bore in connecting rod and the bore in piston e Insert piston pin e Insert new piston pin in another groove CHANGE PARTS AT OVERHAUL Piston piston pin piston rings and piston pin circlip See para 7 Effectivity HKS700E after S N 100600 97 oa kad Service Manual 4 4 Cylinder reassembly 4 4 1 Hydraulic lifter e Fill hydraulic lifter with motor oil e Insert hydraulic lifter into crankcase with applying motor oil and MOLYPASTE e Clean and remove oil from contact surface of crankcase and cylinder e Place new gasket D to crankcase e Top Ring gt P Second Ring gt m Oil Ring upper side lt Oil Ring expander Oil Ring lower side M e Place pipe knock pin 6 e Lubricate piston and cylinder with motor oil Compress rings with piston ring spanner and mount cylinder with care CAUTION Use piston ring spanner to avoid ring breakage Effectivity HKS700E after S N 100600 28 HK 5 Service Manual Apply MOLYPASTE 4 5 Cylinder heads reassembly e Place valve spring seat on valve guide Insert valve with MOLYPASTE place valve spring and spring retainer in position NOTE Place valve spring with the color mar
17. ves e Remove valve spring seat Effectivity HKS700E after S N 100600 BS b i HK 5 Service Manual 3 12 Cylinder and Piston disassembly NOTE Identify both cylinders and pistons to RH LH e Rotate crankshaft to set piston to top dead center position e Shift to remove cylinder Support piston by hand to avoid damaging piston and piston rings e Remove gasket e Remove piston pin circlip using the specially shaped screwdriver e Pull out to remove piston pin e Remove piston CAUTION Make sure to install rings in initial position e Remove piston rings using the piston ring pliers e Pull to remove hydraulic lifters from crankcase Effectivity HKS700E after S N 100600 18 oa kad Service Manual 3 13 Crankcase disassembly e Remove 2 bolt M6 e Remove 8 bolts MO e Remove 2 bolts 2 8 e Remove 4 bolts M10 e Setcrankcase ST 01 e Attach ST 04 at mounting boss ST 04 e Split crankcase with tightening bolt Effectivity HKS700E after S N 100600 19 Service Manual e Remove oil strainer e Remove camshaft e Remove crankshaft e Remove 4 thrust bearing e Remove 4 main bearing Effectivity HKS700E after S N 100600 20 3 14 Crankshaft disassembly e Remove 4 connecting rod bolts e Remove connecting rod cap end e Remove connecting rod bearing Effectivity HKS700E after S N 100600 Service Manual
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