Rato RV170 Service Manual
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Rato RV170 Service Manual

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RV160 RV170
SERVICE MANUAL
Chongqing Rato Power Co., Ltd

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Summary of Contents for Rato RV170

  • Page 1 RV160 RV170 SERVICE MANUAL Chongqing Rato Power Co., Ltd...

  • Page 2: Table Of Contents

    CONTENT CONTENT 1. INTRODUCTION ........................ 1 1-1 Parts Description......................1 1-2 Specifications......................2 1-3 Service Limit RV160 ....................2 2. DIMENSION AND TORQUE ..................... 6 2-1 Dimension ........................6 2-2 The Position Of Installing Hole .................. 7 2-3 PTO Installing Drawing....................7 2-4 Torque Value ......................
  • Page 3 CONTENT 4-3 Dismounting Chart ....................26 4-4 Gasoline Engine ......................27 4-4-1Recoil starter / fan cover ................27 4-4-2 Muffler ......................30 4-4-3 Fuel Tank....................... 31 4-4-4 Air Cleaner ....................32 4-4-5 Governor......................34 4-4-6 Carburetor...................... 36 4-4-7 Flywheel ......................41 4-4-8 Cylinder Head / Valve ...................

  • Page 5: Introduction

    1. INTRODUCTION 1. INTRODUCTION 1-1 Parts Description START HANDLE OIL DIPSTICK SPARK PLUG MUFFLE AIR CLEANER FUEL TANK COVER...

  • Page 6: Specifications

    1. INTRODUCTION 1-2 Specifications MODEL RV160 RV170 ITEM L× W× H(not including 395× 348× 282(mm) 395× 348× 282(mm) crankshaft output terminal) Dry Weight 12.1Kg or 13.7kg 12.5Kg or 13.7Kg Engine Type Single Cylinder Horizontal,4-Stroke, OHV Displacement 163cc 173.2cc Bore × Stroke 68mm×...
  • Page 7 Spark Plug Cap Resistance 3.75-6.25kΩ 0.8-1.0Ω Resistance Primary coil 5.9-7.2kΩ Secondary coil Ignition Coil 0.4± 0.2 （at flywheel） Air Gap RV170 SERVICE PARTS ITEM STANDARD LIMIT Maximum Speed (No Load) 3400±100rpm Idle Speed Engine 1900±100rpm Cylinder Compression 1.38Mpa at 1200rpm...
  • Page 8 1. INTRODUCTION Cylinder Head Sleeve I.D 71.165 Cylinder Head Warpage 0.10 Skirt O.D. 69.985 69.845 Piston–to-Cylinder Clearance 0.015-0.050 0.12 Piston Piston Pin Bore I.D. 18.002-18.008 18.048 Piston Pin O.D 17.994-18.00 17.954 Piston Pin-to-Piston Pin Bore Clearance 0.002-0.014 0.08 Ring Side Clearance： second 0.030-0.065 0.15...
  • Page 9 1. INTRODUCTION Main Jet 13.7 Carburetor Float Height Pilot Screw Opening 2-5/8turns 0.7-0.8 Spark Plug 3.75-6.25kΩ Spark Plug Cap Resistance 0.8-1.0 Ω Resistance Primary coil 5.9-7.2 kΩ Secondary coil Ignition Coil 0.35~0.45mm （at flywheel） Air Gap...

  • Page 10: Dimension And Torque

    2. DIMENSION AND TORQUE 2. DIMENSION AND TORQUE 2-1 Dimension...

  • Page 11: The Position Of Installing Hole

    2. DIMENSION AND TORQUE 2-2 The Position Of Installing Hole 2-3 PTO Installing Drawing P1 Shaft P2 Shaft SEAT FACE SEAT FACE P1 Shaft P2轴...
  • Page 12 2. DIMENSION AND TORQUE P3 Shaft P26 Shaft SEAT FACE SEAT FACE P27 Schaft P28 Schaft SEAT FACE SEAT FACE...
  • Page 13 2. DIMENSION AND TORQUE P29 Shaft SEAT FACE...

  • Page 14: Torque Value

    2. DIMENSION AND TORQUE 2-4 Torque Value ITEMS FASTENERS TORQUE VALUE (N· m) Connection-Rod Bolt M7× 1.0 12± 1 Governor Gear Bolt M6× 12 10± 2 Crankcase Cover Bolt M8× 50 26± 1 Spark Plug M14-1.25 18± 2 Cylinder Head Bolt M8×...

  • Page 15: Standard Torque Value

    2. DIMENSION AND TORQUE 2-5 Standard Torque Value FASTENERS SPECIFICATION TORQUE VALUE(N· m) 5mm Bolt, Nut 4.5-6 6mm Bolt, Nut 8-12 8mm Bolt, Nut 18-25 10mm Bolt, Nut 29-34 12mm Bolt, Nut 49-59 4mm Screw 1.5-2.6 5mm Screw 3.5-5 Bolt, Nut 6mm Screw 7-11 5mm Flange Bolt...

  • Page 16: Maintenance

    2-stroke gasoline engine oil, because they haven’t enough lubrication, and may shorten the engines service life. ● Check the engine with it stopped on a level ground. ● Engine oil capacity: RV160 & RV170 0.6L Engine oil recommended: SAE 10W-30...
  • Page 17 3. MAINTENANCE When the temperature in your area is in the frame of the above chart, you can use other viscosity of engine oil. OIL DIPSTICK SEALING RING (Don’t Refuse) OIL UPPER LIMIT OIL LOWER LIMIT OIL HOLE CHECK METHOD 1.

  • Page 18: Air Cleaner

    3. MAINTENANCE 3-3 Air Cleaner BREATHE TUBE CASE AIR CLEANER ELEMENT COVER GASKET NUT M6 Wash the engine each 50 hrs (or 3 months). (Wash more frequently in dust area)  Remove the air cleaner cover and take the element out. ...

  • Page 19: Wash The Strainer

    3. MAINTENANCE 3-4 Wash The Strainer Don’t smoke or use fire near the flammable solvent. FUEL TANK a) Fill the fuel into the container b) Remove the fuel tube, screw the strainer bolt off. c) Check the strainer for damage and clean the strainer.

  • Page 20: Valve Clearance Adjustment

    3. MAINTENANCE e) To avoid cross-threading, first, screw in spark plug by hand, then tighten with a spark plug wrench to compress the gasket. If a new spark plug is used, more twist 1/2 turns after compressing the gasket. g) If reinstalling the used spark plug, just more twist 1/8-1/4 turns. Spark plug torque value：18±...
  • Page 21 3. MAINTENANCE After the cylinder head cover is removed, engine oilmay flow. Be sure to wipe up any flowed oil. b) Pull the starting rope lightly and set the piston at top dead center of the compression stroke (Insert a feeler gauge between the rocker arm and valve to measure the valve clearance).

  • Page 22: Governor

    3. MAINTENANCE Clearance too big: Intake and exhaust valve opening delay will shorten the intake and exhaust time, lower the opening height of the valve and change normal distributing phase to result in power lowering from the intake lack and exhaust uncompleted. Furthermore, also make vale train parts knock increasing and wearing quickly.

  • Page 23: Disassembling And Servicing

    3. MAINTENANCE 4. DISASSEMBLING AND SERVICING 4-1 Troubleshooting 4-1-1 Starting Difficult TROUBLE CAUSE REMEDY There is no enough fuel in fuel tank and Fill fuel, open fuel cock. fuel cock is closed. Air vent in the fuel filler cap is clogged Dredge air vent.
  • Page 24 TROUBLE CAUSE REMEDY Piston ring is worn to or even over its Replace wear limit Piston ring is broken. Replace Piston ring is sticking. Clear up carbon fouling. Spark plug is not installed tighten or Tighten with a gasket in. without a gasket.

  • Page 25: Power Lack

    3. MAINTENANCE  Turn the fuel cock to “OFF” position, and drain the gasoline of the carburetor.  Remove the spark plug and spark plug cap  Pull the recoil starter grip to drain the gas in the cylinder.  Install the spark plug cap.

  • Page 26: Speed Unstable

    4-1-3 Speed Unstable TROUBLE CAUSE REMEDY Piston, cylinder or piston ring is worn excessively. Replace the worn Piston pin and piston pin hole are worn excessively. Replace piston or piston pin Knocking Sound Tie rod small head is worn excessively. Replace tie rod Roller bearing for crankshaft main shaft is worn.

  • Page 27: Gasoline Engine Is Overheat

    3. MAINTENANCE 4-1-5 Gasoline Engine Is Overheat TROUBLE CAUSE REMEDY Oil insufficient in the gasoline Refill engine oil Exhaust pipe blocked up Clean exhaust pipe Shroud leaking Repair damaged part Cooling fins blocked by foreign matter Clear cooling fins Connection rod deformation to make piston and cylinder Replace connection rod bushing side wear Cylinder or piston or piston ring is worn to make hunting...

  • Page 28: Preparation Of Servicing

    4-2 Preparation Of Servicing 4-2-1 Safety Precautions Indicate a possibility of invalid warranty and personal or equipment damage if instructions are not followed. Please pay special attention to the following: 1. Strictly set the engine according to the regulated power on the nameplate. Do not overload, overrun the engine or run it with low load and at low speed in a long time.

  • Page 29: Special Tools

    3. MAINTENANCE 12. Safe warning label: Please carefully read warning label before operating. Our company will not assume any responsibility, for person hurt, or equipment damaged caused by disregarding this warning label. DON’T BREATH EXHAUST IN. DON’T OPERATE PLEASE READ THE PLEASE KEEP OWNER’S MANUAL...

  • Page 30: Dismounting Chart

    4-3 Dismounting Chart ENGINE CARBURETOR FLYWHEEL AIR CLEANER SHROUD RECOIL STARTER MUFFLER ENGINE HOUSING...

  • Page 31: Gasoline Engine

    3. MAINTENANCE 4-4 Gasoline Engine 4-4-1Recoil starter / fan cover Removal： RECOIL STARTER GRIP Bolt M5× 16 FUEL COVER ENGINE COVER CLIP NUT M6-8 RECOIL STARTER CASE RECOIL STARTER SPRING ROPE RETURN SPRING SPRING DRIVE CAM DRIVE GUIDE LOCKING Screw SHROUD STUD M6×...
  • Page 32 Wear gloves and eye protection during disassembly, and take care not to allow the return spring to come out. Installation Instruction ① Pass the recoil starter rope through the rope in the recoil starter pulley and make a figure-eight knot at the rope end. Check the rope foe wearing and broken before reassembling, then, install it.
  • Page 33 3. MAINTENANCE ⑥ Pass the recoil starter rope through the recoil starter case and recoil starter grip, and make a figure-eight knot at the rope end. ⑦ Pull the recoil starter rope lightly to check the drive cam for function.

  • Page 34: Muffler

    4-4-2 Muffler Removal / Installation ⑤MUFFLER GASKET ③Bolt M6× 80 (Don’t Reuse) ①Bolt M6× 12 ④ MUFFLER ASSY. ②MUFFLER COVER Disassemble the muffler as shown on the figure. The muffler can produce carbon deposits in the long time operation and seriously trouble the exhaust system.

  • Page 35: Fuel Tank

    3. MAINTENANCE 4-4-3 Fuel Tank a) Removal / Installation The fuel tank does not require general maintenance, but, sometimes the dusts and vapor will trouble the fuel system, so that, periodically washing it with lubrication oil and gasoline is required. ①...

  • Page 36: Air Cleaner

     Remove the fuel tube, screw the fuel strainer bolt off and remove the fuel tank.  Clean the fuel tank and dry it thoroughly.  After Cleaning, install the strainer on the fuel tank and connect the fuel tube. ...
  • Page 37 3. MAINTENANCE NOTICE  Check for damage of the air cleaner and install. AIR CLEANER  Note the installation direction, view from the air GASKET cleaner side.  Before installing the breather tube, check for deterioration or damage. Replace if necessary. Pay attention to connect the beveled end smaller to the air cleaner case and other end to the engine.

  • Page 38: Governor

    4-4-5 Governor Removal / Installation GOVERNOR Bolt M6× 12 PIN 8× 14 SHAFT HOLDER PLATE WASHER 6mm WASHER OIL BLOCK GOVERNOR SLIDER: Insert the governor slider into the governor shaft check slider moving smoothly. GOVERNOR CRANKCASE DRIVEN GEAR: GOVERNOR HOLDER SHAFT COVER Before Installing, (Align The Shaft Groove With...
  • Page 39 3. MAINTENANCE THROTTLE VALVE RETURN SPRING (Hook the left end hook into the hole of the throttle valve shaft. projection.) GOVERNOR LEVER THROTTLE （ Insert The Left End VALVE SHAFT GOVERNOR Into Vertical Hole Of The ASSY. Throttle Valve） FIXING BOLT CHOKE SHAFT CHOKE LEVER（Hook NUT M6...

  • Page 40: Carburetor

    4-4-6 Carburetor At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Output power will decrease, and fuel consumption will increase. Engine performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw. If you always operate the engine at altitudes higher than sea level 1000 meters over, have our authorized dealer perform this carburetor modification.
  • Page 41 3. MAINTENANCE THROTTLE VALVE THROTTLE SHAFT CHOKE SHAFT INSULATOR CHOKE GASKET (Don’t Reuse) CARBURETOR INSULATOR AIR CLEANER CARBURETOR GASKET (don’t CARBURETOR GASKET Gasket (Don’T reuse (Don’T Reuse) Reuse) Wash the carburetor in the clean place, first, clean the outside surface, and wash the inside the parts with special carburetor detergent or industrial gasoline.
  • Page 42 a) Carburetor disassembly： PILOT JET THROTTLE STOP SCREW O-RING PILOT SCREW CARBURETOR (Clean With Compressed Air Before Installation) FLOAT PIN FLOAT VALVE MAIN NOZZLE FLOAT （ After installation, MAIN JET check for operation by lightly pushing with a finger） FLOAT CHAMBER GASKET DRAIN BOLT FLOAT CHAMBER...
  • Page 43 3. MAINTENANCE  Check the float valve, float seat and float spring for wear. FLOAT VALVE Seat FLOAT VALVE WORN NORMAL  Clean with compressed air before installation. MAIN JET  Clean with compressed air before installation. MAIN NOZZLE O-RING ...
  • Page 44 b) After washing the carburetor, reset the pilot screw PILOT SCREW BROKEN back. Only repairing the carburetor can disassemble it.If the pilot screw is broken, replace with new one.  Disassemble the broken pilot screw from the PILOT SCREW carburetor. ...

  • Page 45: Flywheel

    3. MAINTENANCE 4-4-7 Flywheel ①Removal： a) Holding the flywheel with a commercially WHEEL PULLER (Commercial available strap wrench, remove the nut Available) （M14）. FLYWHEEL b) Disassemble the starter cut and impeller. c) Remove with a commercially available flywheel puller.  Do not hit the flywheel with a hammer.
  • Page 46 FLYWHEEL (CAST IRON) IMPELLER START ER Cup HOLE HOLE Flywheel（aluminum） FLYWHEEL d) Apply light coat of the oil to the threads and surface of the nut, and install the nut loosely. Torque：52N.m...

  • Page 47: Ignition Coil

    3. MAINTENANCE ③Ignition coil STARTI ×1.5 IMPELLER FLYWHEEL ASSY BOLT(M6×25) IGNITION COIL HIGH VOLTAGE IGNITION LINE (Check The Insulator For SPARK PLUG CAP Damage, If Damaged, Please Replace It) a) Remove the fuel tank, air cleaner, IGNITION COIL carburetor and recoil starter assy. b) Measure the clearance between the FLY WHEEL CLEARANCE...
  • Page 48 Check the ignition coil （primary side） Measure the resistance of the primary coil by attaching one ohmmeter lead to the ignition coil’s primary terminal while touching the other tester lead to the iron core Primary side resistance value：0.8-1.0Ω （Secondary side） Measure the resistance of the secondary side of the coil with the spark plug cap removed, touching one test lead to the high tension cord while touching the other tester lead to the...

  • Page 49: Cylinder Head / Valve

    3. MAINTENANCE 4-4-8 Cylinder Head / Valve VALVE GUIDE EXHAUS INTAKE Valve VALVE Valve SPRING GUIDE Head Seal RETAINER LIFTER PUSH ROD PUSH LOCKING Guide VALVE ADJUSTING BOLT ROCKER BOLT M6× 12 GASKET CYLINDER HEAD COVER 1) Removal / Installation ①...
  • Page 50 CYLINDER HEAD Installation ： Before installation, remove any carbon PIN（10× 14） deposits from the combustion chamber and inspect the valve seats. Measure the cylinder compression after reassembly. GASKET BOLT（Ｍ８×５０） Loosen and tighten the SPARK bolts crisscross PLUG pattern in 2 or 3 steps. TORQUE：26N.m CYLINDER HEAD COVER...
  • Page 51 3. MAINTENANCE INTAKE VALVE Reassembly： PUSH ROD Don’t interchange with the Reassembly： exhaust valve. Check both ends for wear and the rod IN：２５ｍｍ for straightness. CYLINDER Be sure the rod ends are firmly seated EX：２４ｍｍ HEAD in the lifters. Be careful not to damage the PUSH ROD GUIDE valve stem when installing.
  • Page 52 ⑤ Install the head cover gasket aligning the projection HEAD of the head cover gasket with the projection of the COVER cylinder head. GASKET PROJECTIONS ⑥ Valve spring retainer Push down on the valve spring and move the retainer to the side so that valve stem slips through the side hole.
  • Page 53 3. MAINTENANCE ② Valve spring free length Measure the free length of the valve Springs. If out of the standard or service limit. Please replace the spring. Standard Service limit 34.0mm 32.5mm ③ Valve guide Inspect： a) Inspect the valve guide for smooth, scratch and damaged in the inner surface, and matching between the valve guide and cylinder cover for fastness.
  • Page 54 VALVE GUIDE CLIP Be careful to avoid damaging the DRIVER cylinder head when driving out the valve guides. VALVE GUIDE INSTALLATION c) Install the new valve guides HEIGHT 11MM from the valve spring side of the cylinder head.  Exhaust side: Drive the exhaust valve guide until the clip is fully seated (as shown as fig.).
  • Page 55 3. MAINTENANCE e) Check the valve guide bore, it should be straight, 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 bent or damaged. Check the valve stem-to-guide clearance.
  • Page 56 Use the 32° -45° cutters to narrow and adjust the valve seat so that it contacts the middle of the valve face. The 32° cutter removes material from the top edge (contact too high). d) The 45° cutter removes material from the bottom edge (contact too low). Be sure that the width of the finished valve seat is within specification.

  • Page 57: Crankshaft / Piston

    3. MAINTENANCE 4-4-9 Crankshaft / Piston CONNECTION CRANKSHAFT Rod Cap Reassembly： Push in firmly until contact is made with the rearing surface. Be careful not to damage the oil seal. BEARING 6205 CRANKCASE PISTON PIN PISTON PISTON PIN CLIP SEAL 25× 38×7...
  • Page 58 ①Disassembly： 120° MARKER a) Piston Mark  Install with the maker mark facing upward as shown. Do not interchange the top ring and the SECOND second ring (top ring with “▽”MARK Ring chrome plated). OIL RING  After assembly, check for smooth movement of the piston ring.
  • Page 59 3. MAINTENANCE c) Bearing  Apply oil to the circumference of a new ball bearing.  Drive the ball bearing in the cylinder barrel using 6205 tool. DRIVER Tools： HANDLE RETAINER Driver handle Assembler Retainer assembler BEARING INNER 6205 Inner assembler RETAINER ASSEMBLER d) Oil seal：...
  • Page 60 defects, piston top for burn and cracks. If damaged, replace. Clean the carbon deposit Clean the deposit round the piston top and cylinder neck before checking, first soak the carbon deposit with kerosene, and then clean with meter scraper or metal brush. a) Piston skirt O.D Measure the piston skirt O.D with outside micrometer, if out of the service limit, replace it.
  • Page 61 3. MAINTENANCE Check with piston converting in the cylinder, and inserting feeler between piston skirt bearing face and wall, then pull the feeler out, if feeling resistance and smoothly out, the thickness of the feeler shall be considered as piston-cylinder clearance. Standard Service Limit 0.015-0.050mm...
  • Page 62 If connecting rod bending, twisting or big end shaft bush and small end outer ring movement or crack on one side, should be rejected and replaced with new one. a) Check small end diameter If out of the standard or exceed service limit, replace the connecting rod. Standard Service Limit 18.005-18.020mm...
  • Page 63 3. MAINTENANCE Standard Service limit 0.040-0.063mm 0.12mm  If the clearance exceeds the service limit, replace the connecting rod and recheck the clearance. ⑤Camshaft check The camshaft is main driving part of the train valve mechanism, which control the intake and exhaust valves opening and closing.
  • Page 64 Poor lubrication will result in camshaft abnormal wearing, such as, oil viscosity low, impurity too much, and recycling oil little can’t let the camshaft surface forming complete oil film to make the camshaft surface seriously worn in the high speed rubbing stat. Second, installing precision problem, when the matching clearance of the camshaft journal and camshaft seat or bearing is out of the service limit, camshaft rotation precision will lower and contacting with the relative part produce deviation face to make abnormal wearing.
  • Page 65 3. MAINTENANCE ALIGNMENT MARK CAMSHAFT GEAR CAMSHAFT GEAR Timing gear will be damaged in gear worn, gear face peeling off, and gear teeth broken. The engagement clearance is bigger due to gear wearing, the noise is bigger. If the timing gear is damaged, please replace with new one. Please replace the gear with a new set to ensure the engaging face completely engage in.

  • Page 66: Electric Diagrams

    c) Check： Camshaft handle inside diameter Standard Service limit 14.0mm 14.048mm CRANKCASE COVER 4-5 Electric Diagrams...

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