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SKY Engines Boxer 220s Instruction Manual

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BOXER 220s
INSTRUCTION MANUAL

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Summary of Contents for SKY Engines Boxer 220s

  • Page 1 BOXER 220s INSTRUCTION MANUAL...

  • Page 2: Table Of Contents

    CONTENT 1.0 INTRODUCTION 1.1 General warnings • 1.2 Recommendations for accident prevention • 2.0 INSTRUCTIONS FOR USE • 2.1 Fuel • 2.2 Running in • 2.3 Starting the engine 3.0 ENGINE TECHNICAL DATA • 3.1 Engine illustration • 3.2 Technical characteristics •...

  • Page 3: Introduction

    Sky Engines s.r.l. GENERAL WARNINGS: • SKY ENGINES shall not be directly 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.

  • Page 4: Recommendations For Accident Prevention

    • Any modifications made by the buyer to the engine or the removal of original parts can make use of the engine dangerous! • SKY ENGINES reserves the right to make changes to the model on sale and/or in the catalogue, without prior warning, at any time, without any obligation;...

  • Page 5: Instructions For Use

    2.1 FUEL BOXER 220s is a 2-stroke engine which CAUTION!!! needs a fuel mix of PETROL IS AN EXTREMELY petrol-oil.

  • Page 6: Running In

    2.2 RUNNING IN Good running in of the product ensures a long lasting engine and better performance of the components: For the first 3 hours of flight, use the engine with caution. do not use the engine at maximum power for a long time. do not keep the accelerator in the same position for more than a few seconds;...

  • Page 7: Engine Illustration

    3.1 ENGINE ILLUSTRATION 1: CYLINDERS SKYBO22005005A 13: LOWER EXHAUST SKYBO22006004C 2: RADIATOR CAP SKYBO22004032 14: IGNITION COIL SKYBO22001014 3: RADIATOR SKYBO22004014 15: RADIATOR TUBES SKYBO22004002-3- 4-29 16: EXPANSION 4: REED VALVE SKYBO22002002 SKYBO22004027 TANK 5: EXHAUST RUBBER SKYB022006007 17: RADIATOR SKYBO22004005 SECTIONS BRACKETS...

  • Page 8: Technical Characteristics

    PAY UTMOST ATTENTION TO THE ABOVE AND WE INVITE YOU TO COMPLY WITH THE MAXIMUM LIMITS STATED. SKY ENGINES CANNOT BE HELD IN ANY WAY LIABLE FOR DAMAGE CAUSED TO PROPERTY OR PEOPLE DUE TO LACK OF ATTENTION...

  • Page 9: Assembly Of The Secondary Components

    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 components with original SKY ENGINES spare parts to ensure more reliable operation. 3.3.2 RADIATOR (also see 3.3.3 SILENT BLOCK BRACKETS) Assemble the specific silent blocks on the radiator and then the brackets on the silent blocks (on both sides).

  • Page 10: Silent-Block Brackets

    Then assemble the tank as in the figure. Position the radiator on the upper head cover and insert the tubes in 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...
  • Page 11 Assemble the brackets on the silent block of the upper 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.

  • Page 12: Clutch

    3.3.4 CLUTCH Before assembling the clutch, ensure you have the following parts. Position the 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.
  • Page 13 Arrange everything 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: Overall Ignition Unit

    3.3.5 OVERALL IGNITION UNIT Take the flywheel and ensure 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.
  • Page 15 Position the threadlocker and the specific screw 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 specific compartment of the pulley, 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 Insert the cord in 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 Position 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: Exhaust

    Lastly, check everything is assembled correctly 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 Fasten the upper exhaust 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: Silencer

    3.3.7 SILENCER The silencer is supplied complete as in the photo below. 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: Reed Valve

    Slide the rubber sections to totally cover the slot between the silencer and the manifold of the exhaust. 3.3.8 REED 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”...
  • 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: Carburettor

    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 Open the cap by removing the spring and the guillotine. 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: Reduction

    Unscrew 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.

  • Page 29: Essential Cleaning

    REMEMBER THAT DAMAGE DUE TO POOR MAINTENANCE WILL NOT BE COVERED BY WARRANTY. 4.1 ESSENTIAL CLEANING The BOXER 220s engine does not need excessive cleaning, remember not to clean the external or internal engine parts with corrosive solvents. PAY UTMOST ATTENTION 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.
  • Page 30 ATTENTION!! THE REFRIGERANT LIQUID SHOULD ALWAYS BE SUPPLIED WITH THE ENGINE COLD !!! IF LACKING, POUR THE LIQUID IN THE RADIATOR NOT THE TRAY, SINCE THE LATTER HAS THE SOLE FUNCTION OF COLLECTING 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;...

  • Page 31: Adjustments

    VEL FOR REDUCTION SHOULD PERIODICALLY BE CHECKED USING THE BUSHING ON THE FRONT (with the engine in the vertical position, the correct level is under the lower line of the 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.

  • Page 32: Deadlines And Measures

    For correct adjustment, carry out the operations outlined below: ATTENTION!!! ADJUST CARBURATION WITHOUT THE PROPELLER PRESENT! A – MECHANICAL ADJUSTMENT OF AIR PASSAGE B – MECHANICAL ADJUSTMENT OF THE MINIMUM PETROL PASAGE FOR CORRECT CARBURATION, TURN SCREW “B” UNTIL YOU HAVE A SPEED OF 2400÷2600 RPM.
  • Page 33 Some components of the SKY BOXER 220s are subject to wear, therefore to avoid risking damage to the engine or to avoid malfunctions, please comply with the following deadlines: • Before flight, check all the safety devices applied to the exhaust, the silencer and the filter box (connect or check the steel cables);...
  • Page 34 MAINTENANCE SCHEDULE Deadline Check Replacement First 5 hours Overall check of nut and bolt and after 15 tightening hours Condition of exhaust silent Every 25 hours block and relevant fastening straps • Clutch shoe wear • reduction oil level • Spark plug •...

  • Page 35: Spare Parts

    5.0 SPARE PARTS We actively advise you to use SKY ENGINES spare 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.

  • Page 36: Warranty

    3) THE WARRANTY DOES NOT COVER: - malfunctions/breakages due to improper use of the product, or negligence - changes made to the engine not originating and not authorised by Sky Engines s.r.l. - normal wear of all items, parts and spare accessories...
  • Page 37 CERTIFICATE OF WARRANTY ENGINE CODE: …………………………………………………… MODEL AND COLOUR: ……………………………………………………. DEALER'S NAME …………………………………………………….. PURCHASE DATE: ……………………………………………………… PLACE OF PURCHASE: …………………………………………………… THIS CERTIFICATE GUARANTEES A 12-MONTH WARRANTY STARTING FROM THE PURCHASE DATE. READ THIS MANUAL CAREFULLY FOR CONDITIONS. FOR FURTHER INFORMATION, PLEASE CONTACT US BY TELEPHONE OR E- MAIL, OR VISIT THE SITE www.skyengines.com REMEMBER THAT FOR WARRANTY...
  • Page 38 CERTIFICATE OF WARRANTY ENGINE CODE: ……………………………………………………. MODEL AND COLOUR: ……………………………………………………... DEALER'S NAME ……………………………………………………… PURCHASE DATE: ………………………………………………………... PLACE OF PURCHASE: ……………………………………………………... THIS CERTIFICATE GUARANTEES A 12-MONTH WARRANTY STARTING FROM THE PURCHASE DATE. READ THIS MANUAL CAREFULLY FOR CONDITIONS. FOR FURTHER INFORMATION, PLEASE CONTACT US BY TELEPHONE OR E- MAIL, OR VISIT THE SITE www.skyengines.com REMEMBER THAT FOR WARRANTY...
  • Page 39 CERTIFICATE OF WARRANTY ENGINE CODE: …………………………………………………………. MODEL AND COLOUR: …………………………………………………………… DEALER'S NAME …………………………………………………………… PURCHASE DATE: …………………………………………………………….. PLACE OF PURCHASE: ………………………………………………………….. THIS CERTIFICATE GUARANTEES A 12-MONTH WARRANTY STARTING FROM THE PURCHASE DATE. READ THIS MANUAL CAREFULLY FOR CONDITIONS. FOR FURTHER INFORMATION, PLEASE CONTACT US BY TELEPHONE OR E-MAIL, OR VISIT THE SITE www.skyengines.com REMEMBER THAT FOR WARRANTY...

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