HKS 700E. Service Manual June Ver. 2.04
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- Rodney Emil Daniels
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1 HKS 700E Service Manual 009 June Ver..04 HKS CO.,LTD 78 KITAYAMA FUJINOMIYA SHIZUOKA JAPAN TEL +8(0) FAX +8(0)
2 CONTENTS Introduction General information. Special tools PG-3 3 Disassembly 3. Carburetor disassembly 3.. Upper type 3.. Horizon type 3. Intake manifolds removal 3.3 Electric starter removal 3.4 Spark plug removal 3.5 Gearbox removal and disassembly 3.5. A type (ratio.58) 3.5. B type (ratio 3.47) 3.6 Front cover removal 3.6. Drive gear removal 3.7 Rear cover removal and disassembly 3.7. Oil pump disassembly 3.8 Stator removal 3.9 Starter idler gear and Driven gear removal 3.0 Flywheel removal 3. Cylinder head removal 3.. Cylinder head disassembly 3. Cylinder and Piston disassembly 3.3 Crankcase disassembly 3.4 Crankshaft disassembly Effectivity: HKS700E after S/N
3 4 Assembly 4. Connecting rod reassembly 4. Crankcase reassembly 4.. Crankshaft Bearing and Thrust bearing 4.. Crankshaft 4..3 Camshaft 4..4 Oil strainer 4..5 LH crankcase 4.3 Piston reassembly 4.3. Piston ring 4.4 Cylinder reassembly 4.4. Hydraulic lifter 4.5 Cylinder heads reassembly 4.5. Push rod 4.5. Rocker arm compartment 4.6 Cylinder head cover reassembly 4.7 Flywheel reassembly 4.8 Driven gear and Starter idler gear reassembly 4.9 Rear cover reassembly 4.9. Stator 4.9. Oil pump Pressure regulator Oil filter 4.0 Front cover reassembly 4.0. A type (ratio.58) 4.0. B type (ratio3.47) 4. Gearbox reassembly 4.. A type (ratio.58) 4.. B type (ratio3.47) Effectivity: HKS700E after S/N
4 4. Electric starter reassembly 4.3 Spark plug reassembly 4.4 Intake manifolds reassembly 4.5 Carburetors reassembly 4.5. Upper type 4.5. Horizon type 5 Table for torque values 6 Selection of metal bearing 6. Connecting rod bearing 6. Crankshaft bearing 7 Grading of cylinder and piston 8 Wear limits Effectivity: HKS700E after S/N
5 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
6 Introduction Effectivity: HKS700E after S/N
7 General information. Special tools ST-04 ST-0 ST-0 ST-03 ST-05 ST-06 ST-07 ST-08 ST-0 ST- ST- collar ST-09 In addition to this service manual, please refer to the following. () HKS 700E Installation instruction Manual () HKS 700E Operations Manual (3) HKS 700E Parts List Effectivity: HKS700E after S/N
8 3 Disassembly 3. Carburetors removal NOTE: Identify both carburetors to RH/LH cylinders. 3.. Upper type Remove nuts M Horizon type Remove tension spring. Loosen clamp screw and remove carburetor by turning action. 3. Intake manifolds removal Remove bolts M8 and intake manifold. Remove intake gasket. Effectivity: HKS700E after S/N
9 3.3 Electric starter removal Remove bolts M6. Shift to remove electric starter. 3.4 Spark plug removal Remove 4 spark plugs. Effectivity: HKS700E after S/N
10 3.5 Gearbox removal and disassembly 3.5. A type (ratio.58) Remove 8 bolts M B type (ratio3.47) Remove 0 bolts M6. Shift to remove gearbox. Remove circlip. Set ST-07 as shown. ST-07 Compress gear and remove half rings. Effectivity: HKS700E after S/N
11 Remove Inner race following below instruction.. STEP : Compress ST-07 to make clearance between Inner race and Retainer. STEP : Insert one ST-08. STEP 3: Decompress ST-07. Inner race will move to upward by spring washers. If three ST-08s are inserted, go to STEP 4 else go to STEP. STEP 4: Remove ST-08s and ST-07. Remove Inner race. Press ST-08 Release 3 ST-08s? Yes STEP STEP 3 No STEP 4 STEP Remove retainer. Remove gear, hub dog and spring washer 3. 3 Remove spacer. Press PTO shaft to remove from gearbox. Effectivity: HKS700E after S/N
12 3.6 Front cover removal 3.6. Drive gear removal Block crankshaft with ST-0. ST-0 Remove nut M5 and washer. Shift to remove drive gear 3. 3 Remove bolts M6. Shift to remove front cover. Effectivity: HKS700E after S/N
13 3.7 Rear cover removal and disassembly Remove oil filter with oil filter wrench. Remove 0 bolts M6. Shift to remove rear cover. NOTE: Do not lose the thrust washer Oil pump disassembly Remove bolt. Remove spring and valve. Remove 5 bolts M6. Remove oil pump cover. Remove inner rotor (5mm). Remove woodruff key. Shift to remove pump body 3 (5mm). 3 Effectivity: HKS700E after S/N
14 Remove inner rotor (5mm). Remove woodruff key. Shift to remove pump body 3 (5mm). 3 Shift to remove inner feed rotor Assy. Effectivity: HKS700E after S/N
15 3.8 Stator removal Block crankshaft with ST-0. ST-0 Remove bolts M0. Remove stator with tightening ST-03 (M6 x P.5). ST-03 Remove woodruff key. Effectivity: HKS700E after S/N
16 3.9 Starter idler gear and Driven gear removal Remove idler gear, idler shaft and thrust washers 3. 3 Remove driven gear by turning clockwise (left). 3.0 Flywheel removal Block crankshaft same as.8 Remove 6 bolts M8. Shift to remove flywheel. Effectivity: HKS700E after S/N
17 3. Cylinder head removal Remove 5 bolts M5 and cylinder head cover. Remove head cover gasket. CAUTION: Do not damage contact surface! Rotate crankshaft to set piston to bottom dead center position. Remove bolt M5. Remove bolt M6. CAUTION: Do not remove M6 first! Remove 4 nuts M8. Shift to remove rocker arm compartment. Lift out push rods; stop oil dripping by sealing with finger. EX IN NOTE: Identify both push rods to IN / EX. Shift to remove cylinder head. Remove gasket. Effectivity: HKS700E after S/N
18 3.. Cylinder head disassembly Remove bolt M5 and banjo bolt M0. Remove oil jet pipe 3. 3 Compress valve spring with valve spring mounting device and clamp or similar tool. Remove valve cotters and release valve spring. 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 valves. Remove valve spring seat. Effectivity: HKS700E after S/N
19 3. Cylinder and Piston disassembly NOTE: Identify both cylinders and pistons to RH/LH. Rotate crankshaft to set piston to top dead center position. Shift to remove cylinder. Support piston by hand to avoid damaging piston and piston rings. Remove gasket. Remove piston pin circlip using the specially shaped screwdriver. Pull out to remove piston pin. Remove piston. CAUTION: Make sure to install rings in initial position. Remove piston rings using the piston ring pliers. Pull to remove hydraulic lifters from crankcase. Soak the hydraulic lifters in cup of oil. Effectivity: HKS700E after S/N
20 3.3 Crankcase disassembly Remove bolt M6. Remove 8 bolts M6. Remove bolts M8. Remove 4 bolts 3 M0. 3 Set crankcase on ST-0. Attach ST-04 at mounting boss. ST-0 Split crankcase with tightening bolt. ST-04 Effectivity: HKS700E after S/N
21 Remove oil strainer. Remove camshaft. Remove crankshaft. Remove 4 thrust bearing. Remove 4 main bearing. Effectivity: HKS700E after S/N
22 3.4 Crankshaft disassembly Remove 4 connecting rod bolts. Remove connecting rod cap end. Remove connecting rod bearing 3. 3 Effectivity: HKS700E after S/N
23 4 Assembly 4. Connecting rod reassembly Clean all parts. Fit connecting rod bearings. Apply motor oil to metal surface. NOTE: Confirm the turn stop of bearing entered the ditch. Assemble connecting rod. Apply motor oil to bolt and thread. Tighten connecting rod cap end evenly with connecting rod bolts. Tightening torque is 3.8 [kgfm]. Swing connecting rod to check for ease movement. CHANGE PARTS AT OVERHAUL: Connecting rod bearing (See para 6.) Effectivity: HKS700E after S/N
24 4. Crankcase reassembly 4.. Crankshaft bearing and Thrust bearing Clean bearing seat and remove oil. Visually check the metal bearing surface. Remove oil from back of metal bearing. Place metal bearing into both crankcases. Place thrust bearing to crankcase with applying grease to back side of thrust bearing. LH RH 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 AT OVERHAUL: Crankshaft bearing and thrust bearing (See para 6.) 4.. Crankshaft Apply motor oil to bearing surface. Place crankshaft to RH crankcase with care. Effectivity: HKS700E after S/N
25 4..3 Camshaft Apply motor oil to camshaft journal and all teeth of drive and driven gear. Place camshaft to RH crankcase while uniting punch marks Oil strainer Fit new O-ring to oil strainer with applying motor oil. Place oil strainer to RH crankcase and tighten bolt M6-0 temporary. Effectivity: HKS700E after S/N
![bolts 3 M8 applying motor oil to thread. 3 Tighten 4 bolts M0 (both side) evenly to 4.8 [kgfm]. Tighten bolts M8 evenly to.4 [kgfm].](/docs-images/89/98846955/images/26-3.jpg "Tighten 7 bolts M6-5 and bolt 3 M6-45 evenly to. [kgfm] with LOCTITE 43 and washers.")
26 4..5 LH crankcase Clean and remove oil from both contact surface of crankcase. Apply LOCTITE 5699 on contact surface of RH crankcase. Place pipe knock-pins φ8 and pipe knock-pins φ5. Place LH crankcase on RH crankcase. Fit washer and new O-ring to bolts M0 with applying motor oil. Around the thread boss Attach LH crankcase on RH crankcase with bolts M0 (both upper side), bolts M0 with O-ring (both lower side) and bolts 3 M8 applying motor oil to thread. 3 Tighten 4 bolts M0 (both side) evenly to 4.8 [kgfm]. Tighten bolts M8 evenly to.4 [kgfm]. Tighten 7 bolts M6-5 and bolt 3 M6-45 evenly to. [kgfm] with LOCTITE 43 and washers. Attach drain bolt 4 with motor oil and new copper washer. Tighten to. [kgfm]. NOTE: The crankshaft and camshaft must turn freely. Effectivity: HKS700E after S/N
27 Wipe off the protruding LOCTITE. Fix oil strainer with bolts M6-0 with applying LOCTITE 43. Tighten to. [kgfm]. Effectivity: HKS700E after S/N
28 4.3 Piston reassembly 4.3. Piston ring Fit Top and Second rings using piston ring pliers, with the dot mark towards piston crown. Insert new piston pin circlip in groove of front marked (triangular sign) side. FRONT MARK Apply motor oil over the whole of the piston pin, the bore in connecting rod and the bore in piston. Insert piston pin. Insert new piston pin circlip in another groove. CHANGE PARTS AT OVERHAUL: Piston, piston pin, piston rings and piston pin circlip (See para 7) Effectivity: HKS700E after S/N
29 4.4 Cylinder reassembly 4.4. Hydraulic lifter Fill hydraulic lifter with motor oil. Insert hydraulic lifter into crankcase with applying motor oil and. Clean and remove oil from contact surface of crankcase and cylinder. Place new gasket to crankcase. Top Ring Second Ring Oil Ring, upper side Oil Ring, expander Oil Ring, lower side Place pipe knock-pin φ6. 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
30 4.5 Cylinder heads reassembly Place valve spring seat on valve guide. Insert valve with gear oil, place valve spring 3 and spring retainer 4 in position. 3 Service Manual 4 Apply gear oil Color mark NOTE: Place valve spring with the color mark towards upper side. CHANGE PARTS AT OVERHAUL: IN and EX valve Compress valve springs with valve spring mounting tool. Insert valve cotters and release springs. NOTE: Check correct positioning of valve cotters. Push piston of banjo bolt to check for ease movement. Attach oil jet pipe to cylinder head with banjo bolt applying motor oil to thread. Tighten to.4 [kgfm]. Insert bolt M5-0 with LOCTITE 43 and tighten to 0.8 [kgfm]. Effectivity: HKS700E after S/N
31 Clean and remove oil from contact surface of cylinder and cylinder head. Place new gasket to cylinder. Place pipe knock-pins φ0. Place cylinder head Push rod Place push rod on hydraulic lifter. NOTE: Coloring side is turned to cylinder head side. Check proper position of push rod. Color mark Effectivity: HKS700E after S/N
32 4.5. Rocker arm compartment Rotate crankshaft to set both lifters to bottom position. Place pipe knock-pins φ0. Attach rocker arm component to cylinder head with 4 nuts M8 and 4 washers 3 applying motor oil to thread. Tighten evenly to.0 [kgfm]. Tighten more 90 deg. 3 NOTE: Pay attention the direction of nut and washer. Chamfering side Sharp side down CHANGE PARTS AT OVERHAUL: M8 nut Tighten bolt M6-0 to.0 [kgfm] and bolt M5-0 to 0.6 [kgfm] with LOCTITE 43 and washers. NOTE: The valve must move freely when turning the crankshaft. Repeat same procedure from.3 on the opposite side. Effectivity: HKS700E after S/N
33 4.6 Cylinder head cover reassembly Clean and remove oil from contact surface of cylinder head and cylinder head cover. Place new gasket to cylinder head. Attach cylinder head cover to cylinder head with 5 bolts M5-5 with LOCTITE 43 and washers. Tighten evenly to 0.8 [kgfm]. 4.7 Flywheel reassembly Block crankshaft same as.8. Attach flywheel to crankshaft with 6 bolts M8-3 with LOCTITE 43. Tighten evenly to.4 [kgfm]. CHANGE PARTS AT OVERHAUL: M8-3 bolt Effectivity: HKS700E after S/N
34 4.8 Driven gear and Starter idler gear reassembly 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). Attach idler gear, idler shaft and thrust washers 3 applying motor oil Rear cover reassembly 4.9. Stator Attach woodruff key in crankshaft. Check for tight fit and degrease tapers of crankshaft and stator hub. Fit stator hub and washer Apply LOCTITE 43. to bolt M0-50 and tighten to 5.0 [kgfm]. Effectivity: HKS700E after S/N
35 4.9. Oil pump Attach inner feed rotor Assy and outer rotor in rear cover. Fit 4 new O-rings 3. Attach knock-pins Attach pump body (5mm). Attach woodruff key. Attach inner rotor (5mm). Attach outer rotor (5mm). Fit new O-rings 3. Attach knock-pins Attach pump body (5mm). Attach woodruff key. Effectivity: HKS700E after S/N
![Attach bolt 3 with new copper washer. Tighten to.5 [kgfm].](/docs-images/89/98846955/images/36-3.jpg "3 Clean and remove oil from contact surface of crankcase and rear")
36 Attach inner rotor (5mm). Attach outer rotor (5mm). Fit new O-rings 3. Attach oil pump cover. 3 Tighten oil pump with bolt M6-60, 4 bolts M6-0 and washers evenly to. [kgfm] applying LOCTITE43. NOTE: The oil pump must rotate freely when turning by hand Pressure regulator Insert valve and spring applying motor oil. Attach bolt 3 with new copper washer. Tighten to.5 [kgfm]. 3 Clean and remove oil from contact surface of crankcase and rear cover. Apply LOCTITE 5699 on red circle area. Effectivity: HKS700E after S/N
![Tighten rear cover with 0 bolts M6-0 and washers evenly to. [kgfm] applying LOCTITE 43. 4.9.](/docs-images/89/98846955/images/37-1.jpg "4 Oil filter Lubricate the rubber seal of oil filter.")
37 Place new gasket to crankcase. Place pipe knock-pins φ6. Turn oil pump shaft into a position to align with groove of camshaft. Place rear cover on crankcase. Tighten rear cover with 0 bolts M6-0 and washers evenly to. [kgfm] applying LOCTITE Oil filter Lubricate the rubber seal of oil filter. Screw new oil filter by hand until it stops at the oil filter housing. Tighten by an extra 3/4 turn. Effectivity: HKS700E after S/N
![47) Tighten front cover with bolts M6-45, 8 bolts M6-35, bolts 3 M6-30 and washers evenly to. [kgfm] applying LOCTITE 43.](/docs-images/89/98846955/images/38-5.jpg "3 Attach drive gear and washer to crankshaft. Tighten nut M5 to 0.0 [kgfm] applying LOCTITE 43.")
38 4.0 Front cover reassembly Clean and remove oil from contact surface of crankcase and front cover. Place new gasket to crankcase. Place pipe knock-pins φ6. Apply motor oil to bearing bush of front cover and crankshaft. Place front cover on crankcase A type (ratio.58) Tighten front cover with bolts M6-30 and washers evenly to. [kgfm] applying LOCTITE B type (ratio3.47) Tighten front cover with bolts M6-45, 8 bolts M6-35, bolts 3 M6-30 and washers evenly to. [kgfm] applying LOCTITE Attach drive gear and washer to crankshaft. Tighten nut M5 to 0.0 [kgfm] applying LOCTITE 43. CHANGE PARTS AT OVERHAUL: M5 nut and washer Pay attention for the direction of the washer. Effectivity: HKS700E after S/N
39 4. Gearbox reassembly 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. 0. Press in ball bearing and fit circlip in the groove. Apply grease to sealing lips. Press PTO shaft from outside into gearbox. Attach spacer. Attach spring washers on the shaft as illustrated. Attach hub dog. Attach gear so the knuckle joint is engaged to new face of hub dog. Effectivity: HKS700E after S/N
40 Attach retainer. Compress gear using ST-07 and attach half rings with the flat side out. ST-07 Press Set inner race with ST-09. Press ST-07 to insert inner race. ST-09 Fit circlip in the groove. Effectivity: HKS700E after S/N
41 Clean and remove oil from contact surface of front cover and gearbox. Place new gasket to front cover. Place pipe knock-pins φ6. Apply motor oil to roller bearing and gear tooth. Place gearbox on front cover. 4.. A type (ratio.58) Tighten gearbox with 4 bolts M6-5, 4 bolts M6-45 and washers evenly to. [kgfm] applying LOCTITE B type (ratio3.47) Tighten gearbox with 4 bolts M6-5, 6 bolts M6-45 and washers evenly to. [kgfm] applying LOCTITE 43. Effectivity: HKS700E after S/N
![. 4.3 Spark plug reassembly Insert spark plug with LOCTITE SILVER GRADE ANTISEIZE 7673 and tighten to -3 [kgfm].](/docs-images/89/98846955/images/42-2.jpg "CHANGE PARTS AT OVERHAUL: Spark plug (Replace every 00Hr) 4.4 Intake manifolds reassembly Clean and remove oil from contact surface of cylinder head and intake manifold.")
42 4. Electric starter reassembly Apply motor oil to gear tooth and installation bore. Fit electric starter into crankcase. Tighten electric starter with bolts M6-35 and washers to. [kgfm] applying LOCTITE Spark plug reassembly Insert spark plug with LOCTITE SILVER GRADE ANTISEIZE 7673 and tighten to -3 [kgfm]. CHANGE PARTS AT OVERHAUL: Spark plug (Replace every 00Hr) 4.4 Intake manifolds reassembly Clean and remove oil from contact surface of cylinder head and intake manifold. Place new gasket. The seal spreading side is assembled to manifold side. Tighten intake manifold with bolts M8-0 to.4 [kgfm] applying LOCTITE 43. Effectivity: HKS700E after S/N
43 4.5 Carburetors reassembly Attach carburetor by turning action and tighten clamp screw. CHANGE PARTS AT OVERHAUL: Insulator rubber 4.5. Upper type Tighten nuts M Horizon type Hook tension spring. Effectivity: HKS700E after S/N
44 5 Table for torque values Designation Size Torque [kgfm] Remark Connecting rod M8 3.8 Engine oil Flywheel M8.4 LOCTITE 43 Drive gear (nut) M5 0.0 Crankcase M0 4.8 Engine oil M8.4 M6. LOCTITE 43 Cylinder - Crankcase M6.0 Oil jet pipe - Cylinder head M0 (Banjo).4 M5 0.8 Stud bolt - Crankcase M8.0 Engine oil Rocker arm component (nut) M [deg] Cylinder head - Cylinder M5 0.6 LOCTITE 43 Cylinder head cover M5 0.8 Front cover M6. Gear box M6. Starter motor M6. Stator hub M0 5.0 Oil strainer M6. Adapter M4 (rear cover) M4 3.0 Engine oil Drain bolt M0. Union (rear cover) M8 3.0 Rear cover M6. LOCTITE 43 Regulator bolt M8.5 Engine oil Oil pump M6. LOCTITE 43 Stud bolt (Exhaust port) M8.0 LOCTITE 7 Spark plug M LOCTITE ANTISEIZE Intake manifold M8.4 LOCTITE 43 Insulator rubber M8.4 Effectivity: HKS700E after S/N
45 6 Selection of metal bearing 6. Connecting rod bearing Rear PIN No. on P/P O.D of pin [mm] Wear limit No. on con-rod I.D of journal [mm] [mm] φ ~ φ4.000 φ ~ φ N Front PIN φ ~ φ N φ ~ φ44.06 N+N Color of bearing BROWN 3 BLACK 4 BLUE Color mark New [mm] Wear limit [mm] Axial clearance Effectivity: HKS700E after S/N
46 6. Crankshaft bearing Rear Journal Front Journal No. on D/D I.D of journal [mm] No. on J/J O.D of journal [mm] Wear limit [mm] φ ~ φ φ ~ φ N φ ~ φ49.0 N φ ~ φ N+N Color of bearing BROWN 3 BLACK 4 BLUE Color mark New [mm] Wear limit [mm] Axial clearance Grading of cylinder and piston Grading letter (A, B, C) is marked as illustrated. Use same grading of cylinder or piston when replacing. Grading Cylinder Bore [mm] Piston O.D [mm] A φ ~ φ φ ~ φ B φ ~ φ φ ~ φ C φ ~ φ85.05 φ84.99 ~ φ Effectivity: HKS700E after S/N
47 8 Wear limits Designation New [mm] Wear limit [mm] Remark Cylinder/Piston Piston O.D & Cylinder bore See Para 7 Clearance Piston pin Piston pin Piston pin bore Clearance, pin in piston Con-rod bore, small end Clearance, pin in con-rod Piston rings Top ring Ring/groove clearance Ring end gap Second ring Ring/groove clearance Ring end gap Cylinder head Wear on valve seat Valve guide bore Valve stem IN EX Stem clearance IN EX Sealing face width, IN valve.40 Sealing face width, EX valve.40 Out-of-true on valve head Valve spring, free length Rocker arm bore Rocker arm shaft Rocker arm, radial clearance Rocker arm, axial clearance Crankshaft Pin & journal See Para 6 Effectivity: HKS700E after S/N
48 Designation New [mm] Wear limit [mm] Remark Crankcase Crankshaft bearing See Para 6. Lifter hole bore - S/N S/N Camshaft bore Hydraulic lifter Lifter O.D Radial - S/N clearance S/N Propeller gearbox Prop flange, axial out-of-true Wear depth of dogs 0.0 Disk spring, free length Camshaft Camshaft journal Axial clearance Radial clearance Height of cam shaft lobe IN EX Oil pump Plunger, axial clearance Push rod Out of round 0.3 See FIG. FIG. Effectivity: HKS700E after S/N
49 Effectivity: HKS700E after S/N
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