Gemini Industries FT-160 manual

It is of vital impor tance, bef ore attempting to operate y our engine, to read the general 'SAFETY INSTRUCTIONS AND W ARNINGS' section on pages 2-4 of this booklet and to strictly adhere to the advice contained therein. Also , please study the entire contents of this instruction manual, so as to f amiliar ize yourself with the controls a[...]

2 Remember that your engine is not a " toy ", but a highly efficient internal-combustion machine whose power is capable of harming you, or others, if it is misused or abused. As owner, you, alone, are responsible for the safe operation of your engine, so act with discretion and care at all times. If at some future date, your O.S. engine i[...]

4 Take care that the glow plug clip or battery leads do not come into contact with the propeller. Also check the linkage to the throttle arm. A disconnected linkage could also foul the propeller. After starting the engine, carry out any needle-valve readjustments from a safe position behind the rotating propeller. Stop the engine before attempting [...]

6 ENGINE P AR TS NAME Rock er Cover Glow Plug Lock Nut Drive Hub Propeller W asher Crankcase Carburetor Exhaust Pipe Propeller Nut Cylinder Head Left (No .1) Cylinder Right (No .2) Cylinder Photo . 2 Aluminum tube Aluminum tube is not supplied with the engine. 7 Push Rod Cov er Choke V alve Intake Pipe (Left) Photo . 3 Fuel Inlet Intake Pipe (Right[...]

8  It is essential that the firewall is strong and rigid (e.g. at least 15mm thick) and firmly integrated with the structure of the aircraft. INSTALLATION In the interests of scale appearance, the engine should be installed with the carburetor below the crankcase so that the exhaust pipes point downwards. Centre mark M5 Blind nut Centre mark Fir[...]

10 16x8, 18x6-8, 20x6 Carburetor The needle-valve and throttle lever locations are interchangeable by reversing the carburetor. This can be done as follows: Remove the carburetor carefully by unscrewing the two screws which secure both carburetor and choke valve. After reversing the carburetor, re-insert it into the intake manifold, taking care not[...]

12  GLOWPLUGS The role of the glo wplug Glowplug life Particularly in the case of very high performance engines, glowplugs must be regarded as expendable items. Install a plug suitable for the engine. Use fuel containing a moderate percentage of nitromethane unless more is essential for racing events. Do not run the engine too lean and do not le[...]

14 Glowplug leads Fig.12 Switch should have sufficient capacity. The plug leads are fitted with special snap-on connectors that ensure firm contact with O.S. plug. They are a "click" fit and are not suitable for use with most other makes of glowplug. The earth (ground) lead is fitted with a plug terminal which should be connected to the e[...]

16 Make sure that glowplugs are not connected to the battery. Do not heat the glowplugs while priming. (Fig.15). 2. Fig.15 Do not connect the battery to the glowplugs while priming. Open the throttle valve fully, close the choke valve and turn the propeller counter-clockwise through three revolutions. (Fig.16 & 17) 3. Fig.16 Fig.17 Open the thr[...]

18 Adjust the needle-valve 10. Abrupt adjustment of the needle-valve may cause the engine to stop, especially when it is new and insufficiently run-in. As the speed of the engine does not instantly change with needle-valve readjustment, small movements, with pauses between, are necessary to arrive at the optimum setting. Practical best (optimum) ne[...]

20 Start the engine. open the throttle fully . Adjust the neede-valve. Close the throttle gradually. Find the idling position. Fix the idling position. Open the throttle fully. Does the engine regain full power? Continue running at high speed for 5 seconds. Close the throttle. Run at idling speed for 5 seconds. Does the engine stop? Apply full thro[...]

21 + Adjusting the mixture control v alve If the engine hesitates, puffing out a good deal of smoke, before picking up to full speed, it is probable that the idling mixture is too rich. 1. Fig.25 Mixture Control Screw Screwdriver Turn 30 In this case, it will be necessary to turn the Mixture Control Screw in the reverse direction from the + mark (i[...]

23 VALVE CLEARANCE ADJUSTMENT Remove the rocker cover from each cylinder head by unscrewing two socket-head cap-screws from the rocker box on top of the cylinder head with Allen key supplied. ALL O.S. four-stroke engines have their valve (tappet) clearances correctly set before they leave the factory. However, if, after many hours of running time h[...]

25 Remove 0.04mm feeler, rotate prop through two revolutions and recheck gap. 5. If clearance is correct, loosen the locknut on the other rocker-arm and repeat steps 1 to 5 above. Finally, replace rocker box cover. 6. Remember: Excessive valve clearance will cause loss of power, due to valve (s) not opening sufficiently. On the other hand, a total [...]

26 EXPLODED VIEW Type of screw C...Cap Screw M...Oval Fillister-Head Screw F...Flat Head Screw N...Round Head Screw S...Set Screw M3 C.M2.6x7 C.M3.5x20 C.M3.5x15 C.M3x15 C.M3.5x10 C.M3.5x12 C.M3x16 C.M4x22 C.M3x8 N.+M3x22 28 30 29 31 32 29-1 12-2 12-1 12 14 9-2 9-1 9-3 9 10 11 9-2 13 33 13-1 13-2 24 23 22 21 20 17 16 16-1 16-2 16-3 15 1 18 19 5 5-2[...]

28 26381501 24981405 26381501 46481320 22781800 46481330 26381501 46481200 46281340 46481310 22781800 46481100 46281900 29081952 24981837 26381501 46181940 46181941 46181950 26711305 26781619 26681305 26681803 45581700 1 2 2-1 3 3-1 4 4-1 5 6 7 7-1 8 9 9-1 9-2 9-3 9-4 9-5 9-6 9-7 10 10-1 10-2 11 Description Code No. No. Set-screw Throttle Lever Ass[...]

30 13.26cc x 2 / 1.218cu.in. x 2 27.7mm / 1.091in. 22.0mm / 0.866in. 2.000-10.000r.p.m. 1,100g / 38.8oz. 23.5 50.5 63.5 4 -5.2 56.5 196 54 68 120 76 THREE VIEW DRAWING Dimensions(mm) Specifications Displacement Bore Stroke PracticalR.P.M. Output Weight C Copyright 2004 by O.S.Engines Mfg. Co., Ltd. All rights reserved. Printed in Japan. 60090531 04[...]