DLE-55

Operator’s Manual

Specifications
Displacement: 55.6 cc [3.4 cu. in.]
Performance: 5.5 HP / 7,500 rpm
Idle Speed: 1,350 rpm
Ignition Style: Electronic Ignition
Recommended Propellers: 22 u 8, 22 u 10, 23 u 8, 23 u 10
Sparkplug Type: CM6
(Gap) 0.018 in.– 0.020 in. [0.45 mm – 0.51mm]
Diameter × Stroke: 1.77 in. [45 mm] u1.38 in. [35 mm]
Compression Ratio: 7.6:1
Carburetor: Walbro with Manual Choke
Weight: Main Engine − 2.88 lb [1310 g]
Muffler − 3.5 oz [100 g]
Electronic Ignition − 4.2 oz [120 g]
Engine Mount Standoffs − 3.9 oz [110 g]
Fuel: 87− 93 Octane Gasoline with a 30:1
gas/2-stroke (2-cycle) oil mixture

1 © 2010 Hobbico®, Inc. DLEG0055 Mnl

 Parts List

(1) DLE-55cc Gas Engine w/carb

(1) CM6 Spark Plug with spare ignition wire spring
(1) Muffler w/gasket
(2) 5x20mm SHCS (muffler mounting)
(1) Electronic Ignition Module w/ additional tachometer lead
(4) Engine Mounting Standoffs
(4) 5x20mm SHCS with 5mm washers (mounting engine to standoffs)
(4) 5x40mm SHCS with 5mm lock washers & flat washers (propeller mounting)
(1) Silicone Pick-up Wire Cover / Ignition Wire Cover
(1) Throttle Arm Extension
(1) Red Three Pin Connector Lead w/ Pig Tail (ignition switch)
(2) Three Pin Connector Securing Clips
(3) DLE Decals

Safety Tips and Warnings

● This engine is not a toy. Please place your safety and the
safety of others paramount while operating. DLE will not be
held responsible for any safety issues or accidents involving
this engine.
● Operate the engine in a properly ventilated area.
● Before starting the engine, please make sure all components
including the propeller and the engine mount are secure and tight. It
is strongly recommended that a screw sealant is used (Great Planes®
Threadlocker GPMR6060) during engine installation.
● During the break-in period, it is recommended that the engine be
installed on the aircraft or a test stand with an appropriate shock
absorber. Otherwise it is probable that vibration could rebound
2
 back to the engine and serious damages may occur during the
break-in period.
● For your safety and the safety of others, please do not stand in front
of or in line with the propeller when the engine is running. Keep
onlookers away from the running engine, especially small children.
● Always use a balanced spinner and a balanced propeller. An
unbalanced spinner and propeller combination will cause high
levels of vibration and may cause the propeller shaft to break.
Always use a lightweight spinner on your engine. Lightweight
spinners are considered to be those with a cone wall of 1mm
or less. Heavy spinners could cause the propeller shaft to break.
Securely tighten the spinner and propeller on the engine to prevent
it from being thrown off the engine while running.
● Never use a propeller that has hit the ground. Even though it may
look good from the outside, it may be cracked on the inside which
may cause it to disintegrate while in use. Do not use a nicked,
cracked or split propeller.
● Keep foreign objects away from the propeller. Make sure that
nothing can be “sucked in” by the propeller.
● Never start the engine on loose gravel or sand.
● Do not attempt to stop the engine by throwing anything into the
path of the propeller.
● Make sure the fuel line is well-secured to the engine and to the fuel
tank so that it won’t come off in flight.
● Do not use silicone fuel line because it will be dissolved by the fuel.
Use gasoline approved vinyl or neoprene rubber fuel line. Always
secure the fuel line away from the cylinder head. The engine’s heat
can damage the fuel line.
● Never touch the engine immediately after a run. The engine will
be hot.
● Before transporting your model, remove all the fuel from the fuel
tank and fuel lines.
● Always use high-quality oil intended for 2-stroke (2-cycle) engines.
A high quality synthetic 2-cycle oil is recommended for optimum
performance and a longer engine life. Synthetic 2-cycle oils leave
fewer combustion byproducts than natural oil which can foul
the engine and exhaust ports, resulting in reduced performance.
Synthetic oils also better reduce friction and provide more fluidity
at low temperatures.
● Do not install your throttle servo or kill switch servo inside the
engine compartment. Doing so could cause radio interference.
3
 Install all electronic radio devices at least 305mm [12"] away from
the engine.
● The throttle and choke pushrods should be non-metallic.
● In case the engine is not to be used for more than a month, drain
the fuel tank and remove any fuel from inside the carburetor. Do
this by running the engine at idle until it quits by running out of fuel.
Keeping gasoline inside the carburetor over an extended period of
time will damage the diaphragm valve and clog passages inside
the carburetor. Because the carburetor is more complicated than
those used in glow engines, keep the fuel clean by using a fuel
filter. Use a filter intended to be used with gasoline engines. Metal
filters intended for glow engines are too coarse and will not screen
out finer particles.
● Always filter your fuel by using an appropriate filter before putting
it into the airplane’s fuel tank.
● Gasoline is extremely flammable. Keep it away from an open flame,
excessive heat or sources of sparks.
● Do not smoke near the engine or the fuel tank.
● This engine was designed for use in a model aircraft. Do not
attempt to use it for any other purpose.
● Always install an ignition system kill switch on the aircraft used.
● Caution: Running the engine with a lean gas mixture will cause
the engine to overheat and burn the electrode of the spark plug.
Pay close attention to the High-Speed Needle adjustment. Running
the engine with the proper gas mixture will make the spark plugs
appear yellow at the ignition point.
● For optimum performance please use fresh or recently purchased
87– 93 octane gasoline with a 30:1 gas /oil 2-stroke (2-cycle) mixture.
GAS/OIL Mixing Chart
1 Gallon Gasoline (128 fl oz/3.78L) / 2-Cycle Oil
(4.26 fl oz /125.68ml) = 30:1 ratio

● Excessive running of the engine at idle speed can result in a

seriously carbonized spark plug.
● Keep the surface of the engine clean to ensure proper heat
dissipation.
● To avoid permanent damage to the electronic ignition system,
NEVER rotate the propeller on your DLE engine with the
electronic ignition system switched on and the plug not installed
in the plug cap.

4
 Installation Instructions
Prepare the engine for installation
1. Check to see that all screws and bolts are tight. Check carefully
for any cracks, broken, or missing parts. Tighten or replace any
damaged or missing parts before proceeding.

2. Test fit the muffler and muffler gasket. Use two 5  20mm SHCS
and washers to hold it in place.

3. Install the silicone wire cover over the pick up lead coming from
the motor (cut the excess silicone wire cover) and connect the lead
to the pick–up lead from the Electronic Ignition Module. Secure
5 the connection with the included three pin connector securing clip.
 4. Connect the kill switch lead to the red connector from the
electronic ignition system using the lead from the kill switch or
with the included three pin connector with pig tail. Use one of the
included three pin securing clips to secure the connection.

5. Connect the ignition module battery to the kill switch. Any 4.8-
6.0V, 1000 mAh and above capacity battery will work well for this.
Use heat shrink tubing to secure this connection.

6. Install the remaining silicone wire cover over the ignition wire.

7. Install the spark plug into the engine head (7– 8 lbs torque).
6
 Switch
Charge Lead (Not included)

Battery Lead

Ignition Control
Switch Wire
(To On/Off Switch)

ELECTRONIC IGNITION

Tachometer
Ignition Wire Lead/
(To Spark Plug) RPM
Pick-Up
Signal
Sensor Wire
(To Sensor On Engine)
Out-Put

Optional
Tachometer
(Not included)

Installing the DLE-55 on Your Airplane

Note: The DLE-55 must be installed on at least a 9.5mm [3/8"]
thick 5-ply plywood firewall. The firewall must be securely glued to
the airplane. Use triangle stock and pin the firewall with hardwood
dowels to reinforce the firewall glue joints. Never install the DLE-
55 onto a firewall thinner than specified because it may fail due to
the power of the engine.

Note: The length of the engine from the back of the engine mount
stand offs to the propeller drive washer is 168 mm [6-5/8"].

1. Use the supplied template (on the back cover of this manual) to
7 drill the engine mounting bolt holes.
 2. Install the standoffs to the
firewall using (4) 5x20mm SHCS
with 5mm lock washers and
5mm washers (not included)
from the back side and through
the firewall into the standoffs.
Use some threadlocking compound, such as Great Planes® Pro™
Threadlocker (GPMR6060), on the screws. Next install the DLE-55
to the standoffs using the included (4) 5x20mm SHCS with 5mm
washers. Be sure to also use threadlocker when mounting the
engine to the standoffs.

3. Install the fuel tank in the airframe. Use only gasoline-safe fuel
lines and a gasoline safe fuel tank stopper. One line should go to
the carburetor and the other is to be used as a vent (a vent line is
simply an open ended fuel line from the fuel tank which exits the
engine compartment or the fuselage; most vent lines exit at the
bottom of the firewall).You can fill the tank by using the carburetor
line as fill line if you have access to it or install a third line to be
used as fill line. Installing a third line is the cleanest and easiest
way to add fuel. An alternative fueling set up is a 2-line system
with a T-fitting approved for gasoline use. Be sure to use a filler
plug with either a 2 line or 3 line set-up.

Fuel Tank Supply Line Make connection line

to T-Fitting between T-Fitting and
Carb
Carburetor as short
as possible.

Clunk Line
T-Fitting
Filler Cap
Fuel fill line or Plug (A)

Drain/Vent Pressure Relief Line

This line must be extended
Route to top-front of fuel tank interior,
to exit the bottom of the aircraft.
to prevent siphoning (2-Line Set-up)

4. Install the kill switch on the

aircraft so that it is easily accessible
from outside the plane.

5. Install the throttle servo at

least 305mm [12"] away from the
engine. Make sure that you get the
carburetor’s full range of rotation
with your servo travel. Be sure to
8 use a non-metallic linkage.
 6. Install the choke servo (optional) at least 305mm [12"] away
from the engine. Be sure to use a non-metallic linkage.
7. Install the ignition module securely in the airplane forward
area. It is recommended that a thin piece of foam rubber is placed
between the module and the mounting surface and that Velcro™ is
used to hold the module in place.
8. Secure any unsecure connection with heat shrink tubing. (Not
included.)

9
 9. Connect the ignition wire from ignition module to the spark plug.
10. Install the muffler onto the engine. Be sure to use threadlocker.
11. Cut all necessary clearance, carburetor adjustment, cooling, and
exhaust holes in the cowl.
12. Make sure the cowl is secured to the airplane and that the
spinner to cowl clearance is at least 3.2mm [1/8"].

Drill and Install the Propeller

The easiest way to drill the propeller to fit the hub is to use a drill
guide. If you do not have a drill guide, you can use the following
method to drill your propellers.

1. Remove the cowling from the aircraft. Use the included propeller
washer to mark the centering hole in the propeller.
2. Once the location is established, use a drill press with a #5 (.2055”
/ 5.21mm) drill bit as a pilot hole. Once the pilot hole is established,
use a 13/32” (.406/10.31mm) drill bit to finish the hole. In order to
achieve a clean opening on both sides of the propeller, drill only
half way through the propeller with the finishing drill bit. Then flip
10 the propeller over and drill completely through the hole.
 3. Next, set the engine at the beginning of the compression stroke.
Note the position of the ignition magnet with engine inverted.

4. Place the propeller on the crankshaft at the 1 o’clock position.

11
 5. Mark the location of one of the outer holes while the propeller is
in the top of the compression stroke position. Use a Dead Center
Hole Locator (GPMR8130) to center and start the hole.

6. Remove the propeller from the engine and drill the outer hole
on the drill press using a #35 drill bit as a pilot hole. Next use a
#5 (.2055” /5.21mm) drill bit to finish the hole. In order to achieve
a clean opening on both sides of the propeller, drill only half way
through the propeller with the finishing drill bit. Then flip the
propeller over and drill completely through the hole.

7. Use one of the 5x40mm SHCS with 5mm lock washers and 5mm
flat washers to align the propeller washer on the propeller and use
the Dead Center Hole Locator to mark position of the remaining holes.

8. Drill the remaining three holes in the propeller. In order to

achieve a clean opening on both sides of the propeller, drill only
half way through the propeller with the finishing drill bit. Then flip
the propeller over and drill completely through the hole.

9. Mount the propeller to the engine using the 5x40mm SHCS with
12 5mm lock washers and flat washers. Be sure to use threadlocker.
 Adjustment of the Engine
Each DLE Engine has been factory preset. However, elevation
changes will influence the performance of the carburetor. To obtain
optimum output of the engine, slight adjustment of the carburetor
maybe necessary.
Engine Functions and Adjustments
1. Choke Control
(the choke should
be used when the
engine is cold)
2. Throttle Stop
3. Idle Adjustment
Screw (adjust the
idle speed)
4. (L) Low-Speed
Needle (adjusts the
fuel/air mixture at
low speeds)
5. (H) High-Speed
Needle (adjusts the
fuel/air mixture at
high speeds)

Idle Adjustment
Turning the Idle Adjustment Screw (No.3) clockwise will increase
the idle speed. Turning the Idle Screw counter-clockwise will
decrease the idle speed.

Low Speed Needle Adjustment

Turning the Low-Speed Needle (No.4) clockwise will lean the
fuel/air mixture at low speeds. Turning the Low-Speed Needle
(No.4) counter-clockwise will richen the fuel/air mixture at low
speeds. (The default or factory setting of the Low-Speed Needle
is as follows; turn the needle to the fully stop/closed position and
13 then open the needle 1.25 turns.)
 High Speed Needle Adjustment
Turning the High-Speed Needle (No.5) clockwise will lean the
fuel/air mixture at high speeds. Turning the High-Speed Needle
(No.5) counter-clockwise will richen the fuel/air mixture at high
speeds. (The default or factory setting of the High-Speed Needle
is as follows; turn the needle to the fully stop/closed position and
then open the needle 1.5 turns). It is recommended that the High-
Speed Needle be adjusted by the use of a tachometer to obtain
maximum speed.
Smooth acceleration and deceleration is an indicator of proper
engine performance.
Ignition Timing Adjustment
The ignition timing is preset on the DLE-55 at 44° before Top Dead
Center (TDC). The ignition timing can be advanced or retarded by
loosening the (2) ignition sensor phillips head screws and sliding
the sensor to the full extent clockwise (45° advancing the ignition)
or counter clockwise (43° retarding the ignition). Be sure to retighten
the Phillips head screws after adjusting the ignition timing.

Advancing the timing causes combustion to occur earlier resulting in

higher performance of the engine. However, advancing the timing
also causes higher engine temperatures and can cause premature
wear of internal engine components.

Carburetor Adjustment Troubleshooting

Problem
1. The engine hesitates when accelerated rapidly.
2. The rpm increases at idling.
3. The engine stops when the throttle is moved from high to low.
Solution
The low-speed needle “L” is too lean. Open it about 1/8 of a turn
and try again.

Problem
The idle is not steady.
Solution
The low-speed needle “L” valve is too rich. Close it 1/8 of a turn
and try again.

14
 Problem
1. Engine stops at full throttle.
2. Engine hesitates when accelerated rapidly.
3. The engine will not come up to full rpm at full throttle.
Solution
The high-speed needle valve “H” is too lean. Open it 1/8 of a turn
and try again.

Problem
1. The engine does not reach full rpm.
2. Carbon build-ups appear consistently on your spark plug.
Solution
The high-speed needle valve “H” is too rich. Close it 1/8 turn and
try again.

Starting Procedures
If starting the engine the first time and during break-in it’s
recommended that you run the engine without the cowling. Also,
for safety reasons do not make adjustments to the carburetor
while the engine is running.

There are two recommended ways to start the DLE-55:

A. Manual Starting
Note: When hand starting the DLE-55, use a thick glove or a heavy
duty starter stick to protect your hand.

1. The propeller should be installed on the drive washer at the 1

o'clock position and at the beginning of the compression stroke so
that it's comfortable to flip it through compression.
2. Have someone help you hold the airplane while you start the
engine.
3. Make sure the ignition is OFF, close the choke on the carburetor
and open the throttle slightly from the idle position.
4. Rotate the propeller slowly about 4 to 8 times (more in cold
temperatures) until fuel begins to be drawn into the carburetor.
Another way to prime the engine is to rotate the propeller clockwise
from bottom dead center to top dead center (compression) and
then counterclockwise back to bottom dead center repeatedly.
15
 5. Switch the ignition to ON.
6. Flip the propeller counterclockwise several times briskly, until a
popping sound is heard. This indicates the engine is firing.
7. Move the choke lever to the OPEN position.

8. Set the throttle to a high idle. Set the propeller so that it is at the
beginning of the compression stroke. (1 o'clock position)

9. Flip the propeller through compression rapidly. If this is done

properly, the engine will start in just a few flips of the propeller.

10. After starting, let the engine idle for 30 to 45 seconds. Open and
close the throttle slowly until the engine runs smoothly at idle and
at full throttle. Acceleration should also be smooth. If acceleration
is not smooth, adjustments to the carburetor may be neccessary.
(See Adjustment of the Engine on page 13.)

11. If your engine does not start, repeat steps 1 through 10.

B. Electric Starter Starting

A 24V electric starter is recommended to start the DLE-55.

1. Make sure you use a good quality, lightweight aluminum spinner.

2. Have someone help you hold the airplane while you start it.

3. Make sure the ignition is OFF, close the choke plate on the
carburetor and open the throttle slightly from the idle position.

4. Use your electric starter to turn the engine over for several
seconds.

5. Switch the ignition to ON and open the choke.

6. Set the throttle to high idle and use your electric starter to turn
over the engine until it starts.

7. After starting, let the engine idle for 30 to 45 seconds. Open and
close the throttle slowly until the engine runs smoothly at idle and
at full throttle. Acceleration should also be smooth. If acceleration
is not smooth, adjustments to the carburetor may be neccessary.
(See Adjustment of the Engine on page 13.)

8. If your engine does not start, repeat steps 1 through 7.

16
 Engine Troubleshooting
If your engine fails to start after the preceding starting procedures
please check the following.

Symptom Diagnosis Fix

Ignition battery low Charge or

replace battery

Battery wires faulty Replace wires or

Re-connect/check
connections
Engine
does not
fire
Faulty spark plug Replace spark plug
or not firing or check for spark *

Engine flooded Remove plug,

rotate prop to
remove fuel

Fuel not reaching Check for:

Engine engine
starts, a) fuel in tank
then rpm b) fuel tubing
increases cut, blocked,
till engine or kinked
cuts out c) carburetor
clogged

* This can be done by removing the spark plug from head of the
engine and contacting the plug on the outside of the crank case.
Have an assistant turn the engine over while checking this and be
sure to have the spark plug firmly plugged into the ignition wire.
Warning the high voltage from the ignition can cause bodily harm,
especially when checking for spark in this manner.
17
 Optional Mini Tachometer
An optional mini tachometer
is available that can be
directly connected to the
ignition and display the
RPMs of the engine. This
unit can be installed on the
aircraft or used to spot check
the Engine RPMs. Do not
install or uninstall the DigitalTachometer while the engine is running.

Many of the DLE Ignition modules have an addition lead to plug

into the optional tachometer. If your ignition module does not have
this additional lead, the digital tachometer can still be used. Simply
used the included Y-harness (included with the Digital Tachometer)
to connect to the pick-up lead from the engine. Be sure to secure
all connections and to secure the Digital Tachometer or leads on
the aircraft used.

Engine Maintenance
Please clean the fuel filter in the Walbro Carburetor periodically.
Failure to do so may result in mis-calibration of the needle
adjustments. In order to do this it is necessary to remove the
phillips head screw which secures the carb filter cover and the
carb filter gasket. Use only carburetor cleaner to clean the opening
18 around the filter.
19
 Warranty Information
The DLE-55 has a two year limited warranty through Hobby Services
beginning at date of purchase.

Contact Us
Hobby Services
3002 N. Apollo Drive Suite #1 Ph: 217-398-0007
Champaign, Il 61822 Fax: 217-398-7721
E-mail: [email protected]
Web address: www.hobbyservices.com

2.64 in.
[67 mm]

3.15 in. [80 mm]

20
 4.84 in.
[123 mm]

6.50 in. [165 mm]

4.02 in. [102 mm]

6.69 in. [170 mm]

21
22
7 1

5
19
20 29

9
27

4
28
8
26 17
30
11
10 18
6 21
18
3
13 2 15
12
22
3
25
16
23
24
 Replacement Parts
Stock Key
No. No. Description
DLEG5501 1 Cylinder Head
DLEG5502 2 Crankshaft w/Connecting Rod,
22 Spacer
30 Woodruff Key
DLEG5503 3 Crankcase
DLEG5504 4 Piston
26 Needle Bearing
27 Piston Pin
28 Piston Retainer Clips (2)
DLEG5505 5 Piston Ring
DLEG5506 6 Electronic Ignition Module
13 Ignition Sensor
DLEG5507 7 Muffler
19 Muffler Gasket w/(2) 5x20mm Muffler Mounting Screws
DLEG5508 8 Carburetor Complete
DLEG5509 9 Engine Mounting Standoffs w/(4) 5x20mm Engine Mounting
Screws and (4) 5mm Washers
DLEG5510 10 Spark Plug #CM6
DLEG5511 11 Reed Valve
21 Reed Valve Spacer
29 Vacuum Tube
DLEG5512 12 Front Crankshaft Bearings
25 Rear Crankshaft Bearings
DLEG5515 15 Complete Screw and Washer Set
DLEG5516 16 Propeller Hub
23 Crank Shaft Extension
24 Propeller Flange
30 Woodruff Key
DLEG5514 17 Carburetor Gasket
18 Reed Valve Spacer Gaskets (2)
19 Muffler Gasket
20 Head Gasket
DLEG1113 29 Ignition Sensor w/Phillips Head Mounting Screws
DLEG5517 26 Needle Bearing
DLEG5518 30 Woodruff Key

Optional Parts
DLEG5525 Onboard Digital Tachometer
23
DLE 55 Mounting Pattern

3.15 in. [80 mm]

2.64 in.
[67 mm]