KAVAN AP09 - Instruction Manual

Introduction

The KAVAN AP09 is an ABC two-stroke design with a dual-ball bearing supported crankshaft, rear exhaust, and a directional muffler utilizing the highest small engine technology for long life, light weight, high power output and ease of use. The AP09 features a simple to operate single needle valve carburettor.

Becoming Familiar with the KAVAN AP09

1. Spinner Nut
2. Thrust Plate
3. Retaining Post and Nut
4. Needle Valve
5. Fuel Nipple
6. Position for Glow Plug
7. Head
8. Back Plate
9. Muffler Pressure Tap
10. Muffler
11. Head Bolts
12. Idle Stop Screw
13. Carburettor
14. Throttle Arm
15. Engine Case
16. Mounting Lug

Specifications

Displacement	1.47 ccm (0.09 cu inch)
Bore	12.5 mm
Stroke	12 mm
Power	0.35 kW/16,000 R.P.M.
Practical R.P.M	3,000 - 17,000
Weight (w/Muffler)	165 g

Dimensions (mm)

	A	B	C	D	E	F	G	H
AP06A	24	10	45	M4	38.5	33
AP09A	30	11	58	M5	43.5	41
S15AII	31.5	11	62	M5	49.8	42.8
S32AII	38	15	74.9	1/4”–28	56.7	53.2
S36AII	38	15	74.9	1/4”–28	56.7	53.2
S40AII	44	17.5	84.3	1/4”–28	70.2	60.3
S46AII	44	17.5	85	1/4”–28	70	60
S52AII	44	17.5	85.8	1/4”–28	70.9	60.7
S61AII	52	25	97.8	5/16”–24	80.3	68.5
S91A	52	25	97.5	5/16”–24	84.7	67
108A	58	25	105.3	3/8”–24	90	73.7
180AR	68	36.5	133.7	3/8”–24	108	96.6
FS-30AR	36	14	64.7	1/4”–28	71	46.8
FS-52AR	44	17.5	80.6	1/4”–28	82.4	59.2
FS-70AR	50	21	89	5/16”–24	97.4	65.3
FS-80AR	50	21	90	5/16”–24	98.3	65.3
FS-91AR	52	25	90	5/16”–24	100	65.3
FS-120AR	58	25	106	5/16”–24	116.3	78.3
FS-180AR	58	25	111.8	3/8”–24	120	80.8
FT-160AR	80	68	120	5/16”–24	195.3	69.5	56.5	56.5
FS-400AR		Ø122	160.5	3/8”–24	Ø227	78

Safety Notes

Important: Before attempting to operate your engine, please read through these instructions to familiarize yourself with the operations and features of this technical, fully operational two-stroke engine. The AP09 engine is designed for new and experienced modellers alike. Please read through the entire manual before operating this engine. Pay particular attention to the Safety Instructions and Warnings section of the manual.

Your new KAVAN AP09 Engine will give you dependable performance and will be a source of satisfaction and pleasure if you follow these instructions as to the engine‘s proper and safe use. Do not let pleasure turn into injury and/or tragedy! You alone are responsible for the safe operation of your engine, so act sensibly and with care at all times. This engine is a precision built machine whose power is capable of causing harm to you and others if abused, misused, or if you fail to observe proper safety precautions.

• Keep spectators, especially small children, who can be hurt when the engine is running at least twenty feet away from the operating engine.
• Mount the engine securely in the plane, or on a proper engine test stand. Follow the mounting recommendations on the airplane‘s plan and/or instruction manual, or in the test stand described in the directions. DO NOT clamp this engine into a vice!
• Use the correct size propeller and follow the recommended mounting procedures. Use a proper wrench to tighten the propeller nut. Do NOT use pliers.
• Inspect the propeller and propeller nut regularly for nicks, breaks, and loosening.
• To stop the AP09 engine, adjust the throttle linkage to close the carburettor barrel and cut off the air supply. NEVER use your hands or any other foreign object, like a towel, to stop the engine.
• Stand behind the engine when performing adjustments. NEVER reach over or around the propeller. NEVER lean toward the engine. Keep your face, body, and any objects or spectators away from the path of the propeller when starting and running the engine.
• If you decide to carry your model while the engine is running, be very cautious. Be aware of the propeller and keep it away from you and all others.
• Do not have tight fitting cowlings or oversized spinners, as they will impede airflow to the engine. Reduced airflow will cause damage to the engine due to overheating.
• Do not fly your model near or under power lines.

Engine Installation

1. Engine Orientation.

The AP09 can be oriented in any position. However, when fully inverted, carburettor adjustments may need to be set differently and the tank may need to be lowered.

2. Engine Bolts and Firewall Requirements.

For aircraft with a flat firewall, we suggest the use a suitable plastic (glass filled) motor mount. If the aircraft provides wood mounting beams, please make sure the beams are level. We suggest mounting the engine with M3 socket cap screws, washers and locknuts to the motor mount. If using a glass filled mount, the firewall in the airplane should be aircraft grade plywood no less than 3 mm (1/8”) thick. The firewall should also be reinforced to meet the torque and power of the engine.

3. Muffler Installation and Exhaust Pipe Direction Adjustment.

The muffler threads into the rear of the engine case. Simply thread the pieces together. Be careful not to cross thread the parts. The position of the exhaust tube can be changed by using the spacers provided between the muffler and the engine case.

4. Tank Size and Orientation to Carburettor.

Ideally, the tank stopper should be level with the needle valve assembly. However, most models will require the tank to be positioned higher than the ideal location. A high positioned tank will pose no problems but can be troublesome for extreme aerobatic flight. The size tank used should be 30 to 110 ml (1 to 4 ounces) according to the model and length of flights desired. A 1 ounce tank should provide between 4 and 5 minutes of run time at full throttle. The fuel pickup inside the tank should be connected to the carburettor’s fuel nipple. The vent for the tank should be connected to the muffler‘s pressure fitting.

5. Needle Valve Position.

The high speed needle valve is angled back to give some distance between it and the propeller. The nut at the base of the needle valve assembly can be loosened slightly to allow the needle valve to be changed at different angles. Be sure to tighten the nut once you have decided on a position.

6. Idle Stop Screw and Throttle Arm

The idle stop screw limits the travel of the carburettor barrel. By adjusting the screw (turn the screw in to open, out to close), the barrel‘s ability to close will be limited. The opening in the barrel controls how slow the engine idles. When the barrel closes completely, the engine will stop running. For most applications, it is advised to adjust the screw so that the barrel will close completely. The radio can then be setup to control the carburettor barrel closure via the throttle arm.

7. Carburettor Installation

The carburettor is held in position by a cinch bolt and nut. Slide the carburettor into the engine case. Lightly press against the carburettor to slightly compress the O-ring around the base of the carburettor. Tighten the nut on the cinch bolt to hold the carburettor in place. Do NOT over tighten the nut, as this will crush the carburettor base.

8. Propeller Installation

The propeller fits onto the engine‘s crankshaft. If it does not fit, use a propeller reamer, tapered reamer to open the hole slightly. Do NOT oversize the hole. Once the propeller has been positioned on the shaft, use the spinner nut to retain the propeller. To tighten the nut, slide a screwdriver or other device through the hole in the end of the nut.

Note: The crankshaft size is 5 mm.

Propeller, Glow Plug and Fuel

Recommended propeller

Optimal diameter and pitch of the propeller needed depends on the model. The weight, or rather the wing loading and the aerodynamic clarity of the model play a role. Different requirements apply to slow high-wing aircraft (Piper – larger propeller with lower pitch) and to aerobatic "speedsters" (smaller diameter, higher pitch). It is likely that you will have to experiment a little to achieve a complete satisfaction. Using a propeller that is too small will force the engine to run at too high RPM. A propeller that is too large will "choke" the engine – the RPM will be too low. In both cases, this will lead to difficult carburettor adjustment and excessive engine wear with the risk of failure.

For operation, select only one of the following propellers: 6×4", 6×5", 7×3", 7×3.5", 7×4". Use a 7×4" propeller for breaking-in.

Recommended glow plug

Use a hot glow plug intended for two-stroke engines. Do NOT use long reach plugs as they will damage the piston. Suitable glow plugs are: O.S. Engine No.6 (former A3), KAVAN PRO K1 etc.

Recommended fuel

The quality and type of fuel used greatly affects the performance and service life of the engine. We recommend two basic types for operating the AP09 engine: the fuel for breaking-in must contain no less than 20 % castor oil and no more than 15 % nitromethane. Using fuel with a higher nitromethane content or synthetic oil will cause the engine to run at too high a temperature, resulting in excessive wear and damage to the engine in a very short time. For proper break-in, the fuel must contain castor oil to ensure lower operating temperatures. Once the engine is properly broken-in (after about 45 minutes according to the procedure described below with the recommended break-in fuel), you can use fuel containing up to 25 % nitromethane and no less than 16 % castor oil, and fuel with a mixture of castor and synthetic oil can be used.

Note: We do not recommend using fuel with synthetic oil only. Synthetic lubricants have a lower flash point, i.e., the temperature at which the oil stops lubricating and ignites. Using fuel with castor oil only or a mixture of castor and synthetic oil causes the engine to run at a lower temperature, thus extending its service life. Also remember that the higher the nitromethane content in the fuel, the higher the operating temperature of the engine. This is another reason to use fuel with a lubricant that is effective at higher temperatures.

Needle valve

The needle valve determines the fuel/air ratio in the fuel mixture. Turning the needle clockwise will lean the mixture, turning it counterclockwise will enrich it. When starting the engine for the first time, screw the main needle completely in and then open it by two and a half turns. For subsequent starts, leave the needle in the same position as it was during the previous run.

Starting Procedure

The AP09 can be started with an electric starter or can be “hand-cranked”. For safety reasons, especially with new engines, we recommend using an electric starter. Proceed the two following steps without powering the glow plugs.

Hand-cranked start

When hand cranking, always protect your hand with a sturdy leather glove or a special rubber sleeve available from model shops. Never start with your bare hand – you risk serious injury. Starting is easier if you pre-fill the engine with fuel. Open the carburettor fully and block the exhaust outlet with your finger. Quickly turn the engine 2–3 times with the propeller to draw fuel into the engine. Don’t overdo it– excessive fuel intake will flood the engine. Remove your finger and turn the engine once to make sure it is not blocked due to flooding. Do not attempt to start a flooded engine – there is a risk of serious engine damage.

Electric start

When using the electric starter, preliminary fuel filling is not necessary. The starter is capable of turning the engine fast enough to easily draw in enough fuel on its own. Therefore, never block the exhaust outlet or carburettor intake with your hand, as this could cause excessive fuel to be drawn in, resulting in flooding. Blocking the engine while it is being turned by the electric starter can lead to a broken connecting rod or twisted crankshaft. Before using the electric starter, always turn the engine at least once by hand to make sure it is not blocked due to flooding.

1. Disconnect the power to the glow plug and install a 7×4“ propeller.
2. Fully close the needle valve and then open it by 2.5 turns. Fully closed is when the high-speed needle valve is screwed clockwise all the way into the assembly. Unscrewing the needle valve enriches the fuel mixture.
3. If you are using an electric starter, follow the steps mentioned in the paragraph above. If you are hand cranking, follow the respective guide mentioned above.
4. Set the carburettor to approximately ¼ throttle. Connect the power to the glow plug. If you are using a Power panel, set the glow plug current to 3–4 Amps.
5. Turn the engine once by hand or with an electric starter. If hand cranking, repeatedly turn the propeller through the top dead center several times with a sharp swing before the engine will start.
6. Once the engine starts, open the throttle to full, and immediately start closing the valve needle (leaning the mixture) by small steps (max. ¼ of a turn), until the engine runs smoothly without stalling. At this stage, thick white smoke will come out of the exhaust and the engine will sound as if it is running heavily (four-stroke sound). This is a good setting for a rich mixture.
7. After running the engine for 20 to 40 seconds, disconnect the the glow plug power. If this is a first run of the engine, please follow the steps in „Breaking-in“.
8. If restarting the engine while warm, simply connect the power to the glow plug and turn the engine once. If the engine is very hot, it may need to be re-primed. Only commence in re-priming the engine if it does not fire. A too hot engine can sometimes burn the prime prematurely. If the engine is that hot, let it cool for a few minutes before restarting. You may also wish to re-evaluate your needle valve setting, because the mixture may be set too lean.

Breaking-in

Note: Since the piston of this engine is not equipped with a ring but is machined to move tightly in the cylinder liner (type ABC - Aluminium piston - Brass sleeve - Chrome plated/Aluminium piston in chrome-plated brass sleeve), you will feel considerable resistance when turning the engine. This is normal. Once the engine has warmed up to operating temperature and is properly broken-in, this resistance will decrease and the correct backlash for operation will be achieved. Under no circumstances should you attempt to disassemble the engine or modify the friction surfaces of the piston in any way. This will only void the warranty. Simply follow the break-in procedure described below.

1. The break-in process allows the engine parts to perfectly fit to each other and properly protect the parts against unnecessary wear. The fuel used for break-in must not contain more than 15 % nitromethane and no less than 20 % castor oil. Do not use fuels containing synthetic oil during breaking-in. For break-in, we recommend installing the engine in the model in which it will be operated in the future. This will allow you to test and adjust not only the engine, but also the entire fuel system and RC throttle control. If the model has an engine cover, it should be removed for breaking-in.
2. Refer to the Recommended propeller section and select the correct propeller (7x4“ is recommended).
3. Start the engine as described in the Starting procedure section.
4. Once the engine starts and is running, open the throttle fully and open the needle valve to a very rich mixture (unscrewing the needle enriches the mixture). Let the engine run for two to three minutes. Then turn it off.
5. Once the engine cools down, restart the engine. Set the mixture to a slightly leaner setting. Let the engine run for a few minutes and then let it cool for 10 minutes.
6. Repeat this process while slowly leaning the mixture for each run.
7. In total, you should let the engine run for about 30–40 minutes. The engine is fully broken in when it maintains maximum RPM at full throttle for 5 minutes without fluctuations or overheating. After completing this break-in procedure, the engine is ready for flight.
8. Fly the model with the engine set to as rich mixture as possible and with an adequate power.
9. After each flight, lean the mixture slightly. Continue to do this, until the engine is holding a normal needle valve setting after 10 flights. Remember, do not over-lean the mixture.

Warning: Do not run the engine with a mixture that is too lean, and always allow it to cool down after flight. This will prevent premature wear or damage to the piston and sleeve.

Setting the Fuel Mixture Ratio

Now that the engine is fully broken in, you can adjust the needle valve to achieve optimum performance.

Note: Avoid setting the mixture too lean in an attempt to achieve maximum rpm. Remember that the lubricant is dissolved in the fuel. If you lean the mixture too much, you will not only reduce the fuel content in the mixture, but also the amount of oil entering the engine. Less lubricant means a greater risk of overheating and possible engine damage – seizure.)

Due to the single-needle design of the carburettor, the idle speed will be relatively high, up to around 6000 rpm before a proper break-in. After breaking-in, the main needle can be closed more to set a leaner mixture. This will also be reflected in a drop in idle speed to somewhere between 4,000 and 5,000 rpm.

Needle valve adjustment

1. Start the engine and disconnect the glow plug. Wait about 1 minute for the engine to warm up.
2. After the engine has warmed up, give full throttle and slowly close the needle valve until the engine reaches maximum speed. Then slowly open the needle valve, until the speed drops audibly. If you have a tachometer, this is a drop of 200–300 rpm.
3. With the engine running at full throttle, carefully raise the nose of the model to an angle of about 60 degrees. The mixture shouldn‘t get too lean, but you should hear a slight increase in speed. This is normal. If the engine stalls or loses speed when the model is nose up, the mixture is too lean and the needle valve needs to be opened slightly. The engine must always emit a clear trail of gray smoke when running.

Note: The engine speed will increase by about 10–30% during flight. This is because the engine is moving and more air is being sucked into the carburettor at a higher pressure, which enriches the mixture. In addition, as the fuel level in the tank drops, it becomes more difficult for the engine to draw fuel, especially during aerobatics, which further enriches the mixture. It is therefore necessary to set the mixture slightly richer on the ground to compensate for this leaning of the mixture in flight. Always monitor the exhaust gases during flight. The engine must always leave a visible trail of white smoke. If you do not see smoke, the mixture is too lean. You should land immediately and set a richer mixture.)

Lubrication

When the engine is properly set, the fuel provides plenty of lubrication while the engine is running. After the last run of the day, the engine should be run dry of fuel and an after run engine oil should be applied to the engine‘s internal parts through the carburettor and glow plug openings. This will protect the engine‘s moving parts from rust and other deterioration.

Care and Maintenance

To ensure that you obtain long life and peak performance from your engine, observe the following:

1. Avoid running the engine under dusty conditions.
2. Clean the fuel tank with fuel before installation.
3. Install a fuel filter between the fuel tank and the fuel inlet.
4. Clean the filters periodically.
5. At the end of the flying session, do not leave raw fuel in the tank or in the engine. Use an after run oil in the engine once the fuel has been expelled.
6. Clean the outside of the engine with a soft, dry cloth to prevent debris from discolouring the engine.
7. Do not take the engine apart without a reason. If you experience difficulties whilst not having any previous experience with model internal combustion engines you should consider contacting the KAVAN service centre.

Spare Parts List

To order replacement parts, visit your nearest KAVAN Europe s.r.o. dealer.

Spare parts are supplied in the sets listed below.

Part #	Description
09102+09101	Crankcase and back plate
09103	Cylinder Head
09210	Crankshaft
09238(09218+09219)+09108	Prop Drive, 2× Washer, Nut
09601(09604+09606+12114)	Silencer Complete
12804P+12816	Carberettor Complete with O-Ring
09124(09119+40118)	Carberettor Pinch Clamp
12110+12109	Bearing set (front/rear)
09203	Piston and Liner set
09204	Conrod
09213(09207+09208)	Gudgen Pin and Cap
40845+12816	O ring set (Carb body, high and low speed needle)
09111+09609(3)+09112(2)	Gasket set (exhaust, cylinder head, backplate)
09123B(4)	Engine Bolt set (4pcs)

What to do in the event of a failure?

Warranty Conditions

Since this engine, which requires regular maintenance and care, is intended for operation by the modeller under conditions of much higher performance and load on the model than those to which toys in the ordinary sense of the word are exposed, we cannot assume (and it cannot be supposed) any guarantee relating to how long it takes before individual parts need to be replaced due to wear. Engine parts wear out and require replacement over time. If any part of the engine appears to be damaged, defective or incorrectly installed when the engine is new – before the first start – this part will be repaired or replaced free of charge. Engines are only protected by the warranty against manufacturing defects in material, workmanship or assembly when new (before use).

If any part is found to be defective, incorrectly manufactured or incorrectly assembled during the statutory warranty period, it will be repaired or replaced by the importer free of charge. If you believe that the defect in material, workmanship or assembly was not apparent when the model was new and only became apparent after the product was used, then please contact KAVAN Europe s.r.o. (e-mail: info@kavanrc.com, tel. +420 446 260 133). We firmly believe in the quality of the products we sell and will do our utmost to ensure that you are satisfied with them.

Warranty Limitations

This warranty does not cover damage caused by improper or rough handling, negligence, accidents, water or excessive humidity, damage caused by chemicals, improper or negligent maintenance, neglect of maintenance, accidents and acts of God, unauthorized changes or modifications, use of incorrect fuel. The warranty does not cover engine parts that are considered consumables (spark plugs, oils, etc.). KAVAN Europe s.r.o. does not cover the costs of transporting defective parts from the user. Role of the Model Shop The shop where you have purchased the engine is the first place where you should apply for a warranty repair or complaint. The dealer can help with identifying a possible defect and communicating with the importer. Only if for some reason it is not possible to use the services of the shop where the model has been purchased, contact KAVAN Europe s.r.o. directly.

Limitation of Liability

KAVAN Europe s.r.o. does not provide - nor can it be assumed to provide - any other warranties. KAVAN Europe s.r.o. is not responsible for any special, incidental or consequential damages arising from the assembly or use of its products, accessories or chemicals required for the use of its products. The moment the product is used or operated, the user assumes all liability arising therefrom. In no event shall KAVAN Europe s.r.o.‘s liability exceed the actual sales price paid for the product.

How to send products for warranty or non-warranty service?

First, email or call the importer or service centre. It often happens that a product may appear defective or malfunctioning simply because it has not been used correctly or requires only simple adjustment. One email or phone call to our experienced service technicians can solve everything quickly and easily! When sending your product for service check/repair, please remember to include:

• A copy of your proof of purchase
• A return address
• A telephone number where you can be reached during business hours
• Your email address
• A detailed description of the problem

Preparing Your Motor for Service

The guidelines below will help you save on postage and assist our service technicians in carrying out repairs and returning products.

• Clean the engine before shipping to avoid paying an additional cleaning fee.
• Do not send fuel, batteries, accumulators, chargers, glow plug clips and glow plug heating devices, operating instructions or other accessories that you use when operating your engine (unless the service technician requests that you send one of these items). You will save on postage and avoid the risk of loss during transportation. KAVAN Europe s.r.o. is not responsible for the loss of unwanted accessories during transportation to the service or repair.
• When sending the product to the service, insure the product for the price corresponding to the newly purchased product. KAVAN Europe s.r.o. is in no way responsible for the loss of the product during transportation to the service.
• Pack the product thoroughly and securely in a hard cardboard box of appropriate dimensions. A freely moving engine in a large box can only cause additional damage.
• If possible, avoid using shredded paper or foam padding. If this cannot be avoided, place the padding or motor in a sealed plastic bag(s).
• Include all documentation needed to repair the motor, along with as detailed and concise a description of the fault or problem as possible.
• Include a telephone number where you can be reached during the business day and an email address so that the service technician can contact you with additional questions about the repair.
• Include a note with your address. It is surprising how often this is forgotten.