HIRTH 3203 Carburated - 65 hp
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1 HIRTH 3203 Carburated - 65 hp Hp engine shown with fan cooling HIRTH s most popular engine. The 3203 produces more horsepower and torque per pound than any other engine in its power class. Hirth 3203 is the forerunner in power plants for the heaviest of ultralight trainers, gyrocopters and light experimentals today incorporates Al-Nikasil coated cylinders for superior performance and reliability. Al-Nikasil in simple terms is a nickel based material, applied in a paste form, when super heated it becomes part of the cylinder itself. Al-Nikasil provides for a super low coefficient of friction, reducing engine heat and wear. The pistons and cylinders expand at the same rate thus providing for a seizure resistant engine crankshaft is 4130 chromemolly steel. Heads, cylinders, rings, block casting, connecting rods and associated components are all of the highest grade alloys available today. Technical Data: Model: cycle, two cylinder in line Carburetion: Dual 38mm slide type or optional fuel injection fan cooled Fuel Pump: Auxiliary external pneumatic Bore: 2.99 [76 mm] Lubrication: Premix - 50:1 ratio or optional oil injection Stroke: 2.72 [69 mm] Rotation: Counter clockwise, viewed from output end Piston Diameter: [75.84mm] Ring Gap: [0.23mm] Cylinder Diameter: [75.97mm] Starter: 12 VDC electric, recoil or both/250 watt charging. Displacement: 625 cc Cooling: Optional - Axial fan or free air cooled by prop. Compression: 9.5 : 1 Ignition: Single CDI (Capacitive discharge Ignition) HP Output: 65hp [ rpm Weight: 82 lbs. fan cooled including Elec. Torque: 56ft. lbs. [ rpm start and exhaust. TBO 1000 Hrs. Rated at 75% power *Optional Plugs: NGK BR8HS Champion RL86C or #830 Engine HP FC Ign Carbureted 16 BTC Ign Fuel Injected 18 BTC Spark Plug Heat VI 280 Spark Plug Gap No. of Carburetors Two Carburetor ID # Dellorto PHBE 34 BD 8 Main Jet l60 : 155 & 158 Available Idle Jet 40 Jet Needle K 35 Needle Jet AB 268 Needle Position 1 Do not exceed RPM 6600 Peak HP RPM 6300 Peak RPM 65 Peak Torque RPM 6000 Peak Torque Ft. Lb. 55 Maximum CHT 535 F Maximum full power 1256 F Maximum cruise RPM 1330 F Spark Plug Denso W24 FSR - U10* Form rev2
2 f Tag Name This wiring diagram is to be considered as a proposal for wiring e Gezeichnet: Rögele General size of line wire: 1,5 mm 2 d Geprüft Rögele c Wiring diagram - single ignition PVL Size of line from/to E-Starter: 16 mm 2 b a Rectifier-regulator mount on cooling body (ca. 250x200x5mm) Tag Name * Minimum distance to other current wires: 100 mm (4 in.) Form 17700
3 part list Carburetor Engines Fuel Injected Engines 65 HP 3203 Crankcase 3203 Form 16952
4 Crankcase 3203 Fig. No. No. Designation Ref. No. Neoteric Part No Note 10 1 Crankcase, 320 DIU Incl. Pos complete 20 3 Cylinder screw DIN 912 M8x50 Md=23-25 Nm 30 4 Cylinder screw DIN 912 M6x Md=9-11 Nm 40 4 Washer DIN 125 B6, Threaded pin DIN 913 M8x8 Loctite 243 Grub Screw 60 8 Stud screw DIN 835 M8x85 Loctite Plug tip DIN x12 Loctite Cylinder screw DIN 912 M6x10 Carburetor engines 80 1 Cylinder screw DIN 912 M6x10 Fuel lnj. Engines without oil inj 80C 1 Oil injection nipple Oil inj. Engines with fuel inj Sealing ring, AL D7603 6,5x9,5x Not used - engines with FI &OI 100A 1 Pulse line nipple 270 K Carburetor engines only. 100B 1 Cylinder screw DIN 912 M6x10 Fuel Inj. Engines without oil inj. 100C 1 Oil injection nipple Oil inj. Engines with fuel inj. Form 17275
5 Crankshaft 3203 Description Fig. Qty. No. 1 1 Crankshaft, complete 2 1 Deep groove ball bearing 3 1 Deep groove ball bearing 4 1 Deep groove ball bearing 5 2 Circlip 6 2 Shaft sealing ring 7 1 Space ring 8 Remark / Notes Neoteric Part # 5449 Includes items Needle Bearing, Blue dot (#1) 7909 * Connecting Rods are Color-Coded with a Paint Dot on the Piston end. Needle Bearing, Yellow dot (#2) 6082 Needle Bearing, Red dot (#3) 6083 Engines built from 2010 onward also include a Number Code next to the Paint Dot. The coding corresponds to the correct Needle bearing size. (Approx " [0.008mm] graduation between each size) 5464 Blue (#1) is the smallest and Green (#5) is the largest. Connecting rods with a Red (#3) dot are most common. 2 Needle Bearing, White dot (#4) Needle Bearing, Green dot (#5) 7910 If the paint dot is missing and no number code can be found, all bearings must be tried for the best fit. Part rev2
6 Ignition lighting system single ignition 2703 Fig. No. Qty. Designation Part No. Neoteric Part No Remark 1 1 Hexagon head nut DIN 985 M16x1, Md= Nm 2 1 Washer 161 A6 3 1 Flywheel with gear ring /2 4 2 Cylinder screw DIN 912 M5x Washer 212 A Washer DIN 125 B5, Md=4-4,5 Nm 7 1 Stator plate complete / Flywheel alignment pin DIN 7 4m6x6 9 1 CDI - Box / Mounted with silicone 10 2 Coil Mounting Screw M6XP1X12 SHC SS 2469 Included in item Ignition coil /3/ Ignition cable, complete 274 BA10U Spark plug Denso W24 FSR - U VAPE R82 DC Regulator 14V 33 Magnet Support / Spark plug lead, short Spark plug lead, long Spark Plug lead set 5661 Includes plug boots Form 17683
7 2-Cylinder Fuel Injection Electrical System Fig.No Qty Description Red Computer Box Cable harness, Red Cable harness, Black 0-compensation plug Neoteric Part # Shrink tube Air Temp Sensor Engine Temp Sensor Throttle Pos. Sensor Black Computer Box Note Used on Early HoverTrek Models Harness for Red Computer Box Harness for Black Computer Box Used when optional manual enrichment device not used Place on plug with 3 wires (cable colors red, blue, black) 60 denotes length in mm Attached to Cylinder Head Used on Current HoverTrek Models Form rev3
8 Hirth Fuel System Fig. Qty. Description Neoteric Remark / No. Part # Notes 10 1 Fuel Line Screw/Band Hose Clamp Pinch Hose Clamp, Sm Electric Fuel Pump Pinch Hose Clamp, Lg Fuel Line Gapless Hose Clamp Fuel Filter Fuel Line Large Elbow Fuel Pump Holder Fuel Pump Connection Kit Fuel Pump Assy 6666 Includes Fig No Micro Fuel Filter Small Elbow 2438 Form rev2
9 Fuel Injection /Fuel mixture 3203 Form rev2
10 Fig. No. Hirth 2-Cylinder Fuel Injection /Fuel mixture No. Designation Ref. No. Neoteric Part # 10 2 Reed valve Intake manifold 327 A Hose clamp 063.6/ Gasket 327 A Cylinder screw D912 M6x Md=9, Nm, Loctite Washer D125 B6, Throttle manifold 277 EA1U 80 2 Clamp Cylinder screw D912 M6x Md=9, Nm, Loctite Washer D125 B6, Washer DIN9021 B6, Hexagon head nut D934 M Hexagon head nut, self. D985 M Ground cable 277 EA7U Air filter Injector 277 EA Bosch Injector Holding plate 277 EA Washer D125 B3, Cylinder screw D912 M3x12 Loctite Pressure regulator (Regulates to 3 bar -41PSI) Pressure regulator holder, complete 277 EA11U Cylinder screw D912 M6x Md=9, Nm, Loctite Washer D125 B6, Cylinder screw D912 M5x35 Loctite Washer D125 B5, Hexagon head nut D985 M Washer D433 5, Cylinder screw D912 M5x Washer D125 B5, Bushing 264 H Note Form rev2
11 Exhaust system Fig. No. Quantity Designation Part No. Neoteric Part No Remark 1 2 Exhaust gasket 268 A Cylinder screw DIN 912 M8x Md = Nm 3 1 Exhaust manifold 278 A1U 5548 Prepared for temperature meas. 4 4 Exhaust Spring M8x1x10 SHCS 6934 Removed from EGT Holes (not in sketch) Form 17120
12 Cylinder single ignition Fig. No. Quart. Designation Part No. Neoteric Part No Remark 1 2 Cylinder 322 A1 Can be substitute for 322E1 1 2 Cylinder 322 E Motor Cylinder base gasket 322 A Cylinder head 322 B Cylinder head 322 H Cylinder head F332E2 free air 6 16 Cylinder screw DIN 912 M6x Md = Nm 7 16 Washer 212 AS Washer 322 A Hexagon head nut DIN 934 M Md = 9,6-11 Nm 10 2 Piston set * * Keystone ring(top) Piston ring (down) / Piston pin / Retaining ring (cir clip) / Assy Form 17276
13 Start device 3203 Fig. No. Quantity Designation Part No. Neoteric Part No Remark 1 3 Cylinder screw DIN 912 M6x Md = 9, Nm 2 3 Spring ring DIN Starter, mounted 265 A1U Cylinder screw DIN 6912 M8x35 Md = Nm 5 3 Tab washer 053.8/ * Driving dog with starter, Flat 6189 *Used up to model year 2008 (Engine # & Lower) 6 1 Driving dog with starter, Poly-V 275 AB3U 6389 Currently used, from 2008 onward (Engine # & Higher) 7 2 Cylinder screw DIN 912 M8x Md = Nm - 2 Cylinder screw 275 L1 With starter mounted 8 2 Tab washer 058.8/ E-starter Solenoid starter Starter-relay Form rev2
14 Carburetor / Fuel mixture 3203 Fig No. No. Designation Ref. No. Neoteric Part No Note 1 2 Reed valve Gasket 327 A Intake manifold/carb 327 A flange 4 2 Hose clamp 063.6/ Rubber 056.7/150.9mm 6 8 Cylinder screw D912 M6x40 Md=9, Nm, Loctite Washer D125 B6, Carburetor PHBE34BD3 BD Dellorto 9 2 Protective stopper Not shown 10 Rubber cap/nipple cover Not shown Form 17286
15 Hirth HT4 Air Box Assembly Cutouts on FI Air Boxes Only; Carbureted Air Boxes have no Cutouts Fig. No. Qty Designation Neoteric Part # Remark 1 2 Rivet Fiberglass Air Box, Carbureted Fiberglass Air Box, FI Air Filter 6622 Includes item Hose Clamp Large Washer Small Washer Air Box Assembly, Carbureted 5583 Includes item 1-6 as shown above - - Air Box Assembly, FI 7765 Includes item 1-6 as shown above Form rev2
16 Fan cooling system 3203 Flat Belt Cooling Fan (Old Style) Flat Belt (Old Style) Poly V Belt Cooling Fan (Current) Poly V Belt (Current) Form rev3
17 Fan cooling system 3203 Fig. No. Qty. Designation Ref. No. Neoteric Part No Note 1 1 Fan housing, Includes Fig No. 273 EA1U complete 4, 5, 6, 10*, 12, 19, 20, Alignment sleeve DIN x Cylinder screw DIN 912 M6x Md = 9, Nm 4 1 Hexagon head nut DIN 985 M12x1,5 Md = Nm 5 1 Washer DIN 125 B13-St 7* 1 Flat belt 043.4/ *Used up to model year 2008 (Engine # & Lower) 7 1 Poly Flex belt 6390 Currently used, from 2008 onward (Engine # & Higher) 8 2 Locking ring DIN 472, J32 x 1,2 9 2 Deep groove ball DIN bearing 2RZ/C * Fan wheel Assy, Flat belt Fan wheel Assy, Poly V 273 AB1U 323 C1U (5879 modified) Incl. Pos. 8, 9, 10, 11 *Used up to model year 2008 (Engine # & Lower) Incl. Pos. 8, 9, 10, 11 Currently used, from 2008 onward (Engine # & Higher) 11 1 Bushing 263 A Eccentric shaft 263 A B 1 Air guide cowl - SI 323 G5U 5324 Single ignition 14 2 Thread screw 050.8/ Cylinder screw DIN 912 M6x Md = 9, Nm 16 2 Washer DIN 125 B6, Spring ring DIN 127 B Metal plate 323 A Hexagon head nut DIN 985 M Washer DIN 125 B4, Screw DIN963 M4x A 2 Rubber grommet 273 R1 For dual ignition engines 23-B 2 Rubber grommet 273 R15 For single ignition engines 24 1 Cylinder screw DIN 912 M6* Md=9, Nm Air guide mounting R block 26 1 Sheet 323 A7 Not on Sketch Form rev2
18 Carburetor (Dellorto) PHBE 34 Form 16975
19 Bild Nr. Fig. No. Fig. No. Stückzahl Benennung Quant. No. Designation Designation Carburetor (Dellorto) F 33 A (PHBE 34 BD 6832) Bestell- Neoteric Part No Bemerkung Nr. Remark Part No. Note Ref. No. 1 1 Throttle slide Jet needle K Needle jet AB , Main jet 079.4/ , 5544, 5863, 5864, Idle jet 079.5/ Cold start jet Float valve Float Rubber cap Adjusting screw Nut Screw Screw Choke system plate Sealing for choke system pl. - Included in Pos Spring for choke valve Choke valve Spring for throttle slide Bracket plate O-ring carburetor plate - Included in Pos Adjusting screw for idle Spring for adjusting screw Washer Scaling for adjusting screw for - Included in pos. 59 idle 26 1 Screw for idle rpm Spring for screw for idle rpm Washer for screw for idle rpm O-ring for screw for idle rpm - Included in Pos Fuel filter O-ring - Included in Pos Screw O-ring - Included in Pos O-ring - Included in Pos Main jet holding screw Pin Sealing for float chamber - Included in Pos Float chamber Sealing for float chamber - Included in Pos. 59 holding screw 41 1 Float chamber holding screw Connecting nipple for fuel line mm 58 1 Carburetor plate Scaling set 5468 Includes Pos. 16,21,25,29,32,34,35,38,40, it's only complete delivered 17755rev2
20 HIRTH ELECTRICAL COMPONENT RESISTANCE VALUES Volt Meter Terminal 1 Volt Meter Terminal 2 (Red Lead) (Black Lead) Value Unit Part Notes Yellow Wire Yellow Wire Ohm /65Hp Stator Coil Yellow Wire Mount Plate Ohm (Magneto) Primary 1 Primary Ohm Primary Secondary Ohm Secondary 1 Secondary Ohm /65Hp Ignition Coil See Figure "A" Black & Green Wire Black & White Wire Ohm Yellow & Brown Wire Black & White Wire Ohm Black & Blue Wire Black & White Wire Ohm Ground Black & White Wire Ohm Secondary 1 Ground Ohm Secondary 2 Ground Ohm Secondary 3 Ground Ohm Yellow Wire Yellow Wire Ohm Hp Ignition Coil Hp Stator Coil (Magneto) See Figure "B" Black Red Volts (DC) Red Black > Volts (DC) Yellow Yellow Volts (DC) Hirth Voltage Regulator * Must have a multi-meter with a diode test to diagnose voltage regulator
21 Hirth 65HP Engine Fan Curve Form 16920
22 Form 706
HIRTH 3203 Carburated - 65 hp
HIRTH 3203 Carburated - 65 hp 2706-65Hp engine shown with fan cooling HIRTH s most popular engine. The 3203 produces more horsepower and torque per pound than any other engine in its power class. Hirth
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