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 3203 is the forerunner in power plants for the heaviest of ultralight trainers, gyrocopters and light experimentals today. 3203 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. 3203 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: 3203 2 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: 2.986 [75.84mm] Ring Gap: 0.009 [0.23mm] Cylinder Diameter: 2.991 [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 [48.5 kw] @ 6300 rpm Weight: 82 lbs. fan cooled including Elec. Torque: 56ft. lbs. [76 Nm] @ 5700 rpm start and exhaust. TBO 1000 Hrs. Rated at 75% power *Optional Plugs: NGK BR8HS Champion RL86C or #830 Engine 3203-65 HP FC Ign. Timing @ 2000 Carbureted 16 BTC Ign. Timing @ 2000 Fuel Injected 18 BTC Spark Plug Heat VI 280 Spark Plug Gap.020-.024 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 HP @ Peak RPM 65 Peak Torque RPM 6000 Peak Torque Ft. Lb. 55 Maximum CHT 535 F Maximum EGT @ full power 1256 F Maximum EGT @ cruise RPM 1330 F Spark Plug Denso W24 FSR - U10* Form 16013 rev2
f Tag Name This wiring diagram is to be considered as a proposal for wiring e Gezeichnet: 04.07.00 Rögele General size of line wire: 1,5 mm 2 d Geprüft 04.07.00 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
part list Carburetor Engines Fuel Injected Engines 65 HP 3203 Crankcase 3203 Form 16952
Crankcase 3203 Fig. No. No. Designation Ref. No. Neoteric Part No Note 10 1 Crankcase, 320 DIU Incl. Pos. 60 + 70 complete 20 3 Cylinder screw DIN 912 M8x50 Md=23-25 Nm 30 4 Cylinder screw DIN 912 M6x30 2289 Md=9-11 Nm 40 4 Washer DIN 125 B6,4 6916 50 4 Threaded pin DIN 913 M8x8 Loctite 243 Grub Screw 60 8 Stud screw DIN 835 M8x85 Loctite 243 70 2 Plug tip DIN 1474 5x12 Loctite 586 80 2 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 045.12 5490 Oil inj. Engines with fuel inj. 90 2 Sealing ring, AL D7603 6,5x9,5x2 5629 Not used - engines with FI &OI 100A 1 Pulse line nipple 270 K4 5630 Carburetor engines only. 100B 1 Cylinder screw DIN 912 M6x10 Fuel Inj. Engines without oil inj. 100C 1 Oil injection nipple 045.12 5490 Oil inj. Engines with fuel inj. Form 17275
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 2-7 5460 5461 5462 7912 5453 7913 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 0.0003" [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 17756 rev2
Ignition lighting system single ignition 2703 Fig. No. Qty. Designation Part No. Neoteric Part No Remark 1 1 Hexagon head nut DIN 985 M16x1,5 6939 Md=140-150 Nm 2 1 Washer 161 A6 3 1 Flywheel with gear ring 021.43/2 4 2 Cylinder screw DIN 912 M5x20 5 4 Washer 212 A5 5994 6 1 Washer DIN 125 B5,3 6936 Md=4-4,5 Nm 7 1 Stator plate complete 021.43/1 5591 8 1 Flywheel alignment pin DIN 7 4m6x6 9 1 CDI - Box 021.43/6 5664 Mounted with silicone 10 2 Coil Mounting Screw M6XP1X12 SHC SS 2469 Included in item 15 15 2 Ignition coil 021.41/3/2 5682 30 2 Ignition cable, complete 274 BA10U 5827 31 1 Spark plug Denso 023.29 5668 W24 FSR - U10 32 1 VAPE R82 DC 029.8 5338 5641 Regulator 14V 33 Magnet Support 021.41/20 5724 34 1 Spark plug lead, short 5666 34 1 Spark plug lead, long 5665 34 1 Spark Plug lead set 5661 Includes plug boots Form 17683
2-Cylinder Fuel Injection Electrical System Fig.No. 1 2 2 3 Qty 1 1 1 1 Description Red Computer Box Cable harness, Red Cable harness, Black 0-compensation plug Neoteric Part # 5328 6235 6237 7205 4 1 Shrink tube 3192 5 6 7 8 1 1 1 1 Air Temp Sensor Engine Temp Sensor Throttle Pos. Sensor Black Computer Box 7525 7526 7567 6382 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 16959 rev3
Hirth Fuel System 130 150 10 40 50 70 80 90 100 20 30 60 120 110 140 Fig. Qty. Description Neoteric Remark / No. Part # Notes 10 1 Fuel Line 6335 20 3 Screw/Band Hose Clamp 2203 30 1 Pinch Hose Clamp, Sm 5993 40 1 Electric Fuel Pump 6414 50 1 Pinch Hose Clamp, Lg 5986 60 1 Fuel Line 6334 70 1 Gapless Hose Clamp 6943 80 1 Fuel Filter 5372 90 3 Fuel Line 3193 100 1 Large Elbow 2674 110 1 Fuel Pump Holder 6336 120 1 Fuel Pump Connection Kit 6628 130 - Fuel Pump Assy 6666 Includes Fig No. 10-120 140 1 Micro Fuel Filter 5373 150 1 Small Elbow 2438 Form 17698 rev2
Fuel Injection /Fuel mixture 3203 Form 16021 rev2
Fig. No. Hirth 2-Cylinder Fuel Injection /Fuel mixture No. Designation Ref. No. Neoteric Part # 10 2 Reed valve 058.9 7203 20 2 Intake manifold 327 A2 6568 30 2 Hose clamp 063.6/5 40 2 Gasket 327 A3 5463 50 8 Cylinder screw D912 M6x20 2292 Md=9,6...11 Nm, Loctite 243 60 8 Washer D125 B6,4 6916 70 1 Throttle manifold 277 EA1U 80 2 Clamp 063.22 6929 90 1 Cylinder screw D912 M6x25 6901 Md=9,6... 11 Nm, Loctite 243 100 3 Washer D125 B6,4 6916 110 1 Washer DIN9021 B6,4 5996 120 1 Hexagon head nut D934 M6 130 1 Hexagon head nut, self. D985 M6 5572 140 1 Ground cable 277 EA7U 6454 150 2 Air filter 066.16 6622 160 2 Injector 277 EA3 6903 Bosch 170 2 Injector Holding plate 277 EA15 180 2 Washer D125 B3,2 190 2 Cylinder screw D912 M3x12 Loctite 243 200 1 Pressure regulator 072.3 7188 (Regulates to 3 bar -41PSI) 210 1 Pressure regulator holder, complete 277 EA11U 220 2 Cylinder screw D912 M6x14 7189 Md=9,6...11 Nm, Loctite 243 230 2 Washer D125 B6,4 6916 240 2 Cylinder screw D912 M5x35 Loctite 243 250 2 Washer D125 B5,3 6936 260 2 Hexagon head nut D985 M5 270 2 Washer D433 5,3 280 1 Cylinder screw D912 M5x35 290 1 Washer D125 B5,3 6936 300 1 Bushing 264 H4 6935 Note Form 16022 rev2
Exhaust system 2703 4 Fig. No. Quantity Designation Part No. Neoteric Part No Remark 1 2 Exhaust gasket 268 A4 5245 2 4 Cylinder screw DIN 912 M8x20 2288 Md = 23...26 Nm 3 1 Exhaust manifold 278 A1U 5548 Prepared for temperature meas. 4 4 Exhaust Spring 054.1 5421-2 M8x1x10 SHCS 6934 Removed from EGT Holes (not in sketch) Form 17120
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 E1 6099 Motor 3203 2 2 Cylinder base gasket 322 A4 5455 3 1 Cylinder head 322 B2 5457 3203 4 1 Cylinder head 322 H3 5458 3203 4 2 Cylinder head F332E2 free air 6 16 Cylinder screw DIN 912 M6x35 12.9 6322 Md = 23-28 Nm 7 16 Washer 212 AS 5994 8 8 Washer 322 A5 6234 9 8 Hexagon head nut DIN 934 M8 6233 Md = 9,6-11 Nm 10 2 Piston set * 014.81 5450 11 * Keystone ring(top) 014.7711 5452 12 Piston ring (down) 014.74/1 5451 13 Piston pin 014.77/4 5972 14 Retaining ring (cir clip) 014.72/5 6301 Assy 17312 Form 17276
Start device 3203 Fig. No. Quantity Designation Part No. Neoteric Part No Remark 1 3 Cylinder screw DIN 912 M6x35 6911 Md = 9,6...11 Nm 2 3 Spring ring DIN 7980 6 6940 3 1 Starter, mounted 265 A1U 5267 4 3 Cylinder screw DIN 6912 M8x35 Md = 23...28 Nm 5 3 Tab washer 053.8/8 5995 6* Driving dog with starter, Flat 6189 *Used up to model year 2008 (Engine #901105 & Lower) 6 1 Driving dog with starter, Poly-V 275 AB3U 6389 Currently used, from 2008 onward (Engine #901106 & Higher) 7 2 Cylinder screw DIN 912 M8x30 2348 Md = 23...28 Nm - 2 Cylinder screw 275 L1 With starter 028.12 mounted 8 2 Tab washer 058.8/8 5995 9 1 E-starter 028.10 6498-1 Solenoid starter 028.12 5417 10 1 Starter-relay 032.20 6522 Form 17282 rev2
Carburetor / Fuel mixture 3203 Fig No. No. Designation Ref. No. Neoteric Part No Note 1 2 Reed valve 058.9 2 2 Gasket 327 A3 5463 3 2 Intake manifold/carb 327 A2 6568 flange 4 2 Hose clamp 063.6/10 5 8 Rubber 056.7/150.9mm 6 8 Cylinder screw D912 M6x40 Md=9,6...11 Nm, Loctite 243 7 2 Washer D125 B6,4 6916 8 2 Carburetor PHBE34BD3 BD8 5355 Dellorto 9 2 Protective stopper 083.8 Not shown 10 Rubber cap/nipple cover 083.18 Not shown Form 17286
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 2156 2 1 Fiberglass Air Box, Carbureted 5584 2 1 Fiberglass Air Box, FI 7764 3 2 Air Filter 6622 Includes item 4 4 2 Hose Clamp 2201 5 2 Large Washer 2516 6 2 Small Washer 2352 - - 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 16619 rev2
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 17752 rev3
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, 21 2 3 Alignment sleeve DIN 7346 8x10 3 4 Cylinder screw DIN 912 M6x45 3258 Md = 9,6...11 Nm 4 1 Hexagon head nut DIN 985 M12x1,5 Md = 27...30 Nm 5 1 Washer DIN 125 B13-St 7* 1 Flat belt 043.4/4 3407 *Used up to model year 2008 (Engine #901105 & Lower) 7 1 Poly Flex belt 6390 Currently used, from 2008 onward (Engine #901106 & Higher) 8 2 Locking ring DIN 472, J32 x 1,2 9 2 Deep groove ball DIN 625 6002 bearing 2RZ/C3 6887 10* 1 10 1 Fan wheel Assy, Flat belt Fan wheel Assy, Poly V 273 AB1U 323 C1U 6391 3408 (5879 modified) Incl. Pos. 8, 9, 10, 11 *Used up to model year 2008 (Engine #901105 & Lower) Incl. Pos. 8, 9, 10, 11 Currently used, from 2008 onward (Engine #901106 & Higher) 11 1 Bushing 263 A6 12 1 Eccentric shaft 263 A7 6857 13-B 1 Air guide cowl - SI 323 G5U 5324 Single ignition 14 2 Thread screw 050.8/2 5997 15 1 Cylinder screw DIN 912 M6x25 6901 Md = 9,6...11 Nm 16 2 Washer DIN 125 B6,4 6916 17 2 Spring ring DIN 127 B6 5999 19 1 Metal plate 323 A7 6183 20 2 Hexagon head nut DIN 985 M4 2694 21 2 Washer DIN 125 B4,3 22 2 Screw DIN963 M4x10 2693 23-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*18 5998 Md=9,6... 11 Nm Air guide mounting 25 1 273 R9 6928 block 26 1 Sheet 323 A7 Not on Sketch Form 17753 rev2
Carburetor (Dellorto) PHBE 34 Form 16975
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 079.1 2 1 Jet needle K 079.2 6563 3 1 Needle jet AB 079.3 5760, 6194 4 1 Main jet 079.4/... 5543, 5544, 5863, 5864, 6193 5 1 Idle jet 079.5/... 6 1 Cold start jet 079.6 7788 7 1 Float valve 079.7 8 1 Float 079.8 6909 9 2 Rubber cap 079.9 6113 10 1 Adjusting screw 079.10 11 1 Nut 079.11 12 2 Screw 079.12 14 1 Screw 079.14 15 1 Choke system plate 079.15 16 1 Sealing for choke system pl. - Included in Pos. 59 17 1 Spring for choke valve 079.17 18 1 Choke valve 079.18 5901 19 1 Spring for throttle slide 079.19 20 1 Bracket plate 079.20 21 1 O-ring carburetor plate - Included in Pos. 59 22 1 Adjusting screw for idle 079.22 23 1 Spring for adjusting screw 079.23 24 1 Washer 079.24 25 1 Scaling for adjusting screw for - Included in pos. 59 idle 26 1 Screw for idle rpm 079.26 27 1 Spring for screw for idle rpm 029.27 28 1 Washer for screw for idle rpm 079.28 29 1 O-ring for screw for idle rpm - Included in Pos. 59 30 1 Fuel filter 079.30 32 1 O-ring - Included in Pos. 59 33 1 Screw 079.33 34 1 O-ring - Included in Pos. 59 35 1 O-ring - Included in Pos. 59 36 1 Main jet holding screw 079.36 37 1 Pin 079.37 38 1 Sealing for float chamber - Included in Pos. 59 39 1 Float chamber 079.39 40 1 Sealing for float chamber - Included in Pos. 59 holding screw 41 1 Float chamber holding screw 079.41 42 1 Connecting nipple for fuel line 079.42 6114 6 mm 58 1 Carburetor plate 079.58 59 1 Scaling set 5468 Includes Pos. 16,21,25,29,32,34,35,38,40, it's only complete delivered 17755rev2
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 0.080 Ohm 5591-55/65Hp Stator Coil Yellow Wire Mount Plate 450000000-550000000 Ohm (Magneto) Primary 1 Primary 2 0.351-0.429 Ohm Primary Secondary 450000000-550000000 Ohm Secondary 1 Secondary 2 2699.1-3298.9 Ohm 5682-55/65Hp Ignition Coil See Figure "A" Black & Green Wire Black & White Wire 0.396-0.484 Ohm Yellow & Brown Wire Black & White Wire 0.405-0.495 Ohm Black & Blue Wire Black & White Wire 0.387-0.473 Ohm Ground Black & White Wire 450000000-550000000 Ohm Secondary 1 Ground 1385.1-1747.9 Ohm Secondary 2 Ground 1386-1694 Ohm Secondary 3 Ground 1386-1694 Ohm Yellow Wire Yellow Wire 0.100 Ohm 6097-100Hp Ignition Coil 6564-100Hp Stator Coil (Magneto) See Figure "B" Black Red 2.950 Volts (DC) Red Black > 5.000 Volts (DC) Yellow Yellow 2.300 Volts (DC) 5338 - Hirth Voltage Regulator * Must have a multi-meter with a diode test to diagnose voltage regulator
Hirth 65HP Engine Fan Curve Form 16920
Form 706