Zenoah | G231PUM | Instruction manual | Zenoah G231PUM Instruction manual

®
ENGINE INSTRUCTION MANUAL
4
3
5
2
7
1
6
G26 Air
G26/G231 Marine
G26/G231 Heli
G38
G62
GT80 Twin
G45
1
2
3
4
5
6
7
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Break In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting the Engine, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting the Engine, Heli & Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Servicing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting Guide for Gasoline Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Propeller Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exploded Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
G26/G231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
G38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
G45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GT80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Non-Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Registration Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Very Important
Failure to read and follow these instructions before you proceed may result in engine
damage and the voiding of your warranty!
Introduction
Congratulations on purchasing a Zenoah® engine. Cared
for properly, these high-quality, finely crafted engines will
offer many years of reliability.
This instruction manual has been developed to ensure
optimum performance from the Zenoah engine you have
purchased. It’s important that the instructions are read
thoroughly prior to mounting and running the engine.
Safety Instructions
This manual describes the engine’s features and functions. For specific information on mounting, see the instruction
manual included with the model airplane, helicopter or
boat in which you intend to install the engine. This model engine will give you considerable pleasure,
satisfaction and performance if you strictly follow these
safety instructions and take heed of the warnings as to the
engine’s safe and proper use. This engine has more than
enough power to cause harm if misused or if the safety
precautions are not observed.
Always
1. Use genuine parts for replacement.
2. Check the propeller, rotor (helicopter) or screw propeller (boat) prior to each time the engine is used. If nicked, scratched, cracked or damaged in any way,
replace it with a new one.
3. Use the correct size and pitch of propeller for your
engine; refer to the propeller chart in this manual.
4. It is extremely important to balance the propeller prior
to installation of the engine. Failure to do so may cause
damage to the Zenoah engine and/or the airframe. Securely
tighten the propeller nut against the washer and propeller.
5. Inspect the tightness of the propeller nut prior to each flight.
6. Keep your face and body away from the path of the
propeller blades when starting or running your engine.
8. Make all carburetor adjustments from behind the propeller.
9. To stop the engine, the black lead wire from the coil should be grounded to the engine body, or use the
throttle linkage to shut off the air by closing the throttle
valve completely.
Do not use hands, fingers or any other part of
the body to stop the propeller. Do not throw
any object into a propeller to stop it!
10. Ensure that all spectators, especially children, are at
least 20 feet away when you start running the engine.
11. Make sure your fuel is kept in a safe place well away
from sparks, heat or anything that could ignite the fuel.
Recommendations
1. Use safety glasses or goggles when starting and running your engine.
2. Do not run the engine in the vicinity of loose gravel
or sand. The propeller may throw such materials into
your eyes. The engine could also ingest these harmful
materials.
3. Avoid loose clothing when operating your model
engine, as it could become entangled in the propeller,
creating the possibility of bodily harm. All loose objects
(screwdrivers, pencils, nickel cadmium glow drivers, etc.)
should be removed from your pockets so that they do not
fall into the propeller.
7. Use a thickly padded glove when hand starting the engine.
Safety Instructions (continued)
Caution
Disassembly
1. Model engines get very hot while running. Do not
attempt to handle them until they have cooled.
The Zenoah engine can be disassembled or reassembled
without any specific difficulties. Refer to the Engine
Maintenance Section for specific instructions on these
procedures. If you need service to your Zenoah engine,
please send it to the authorized service center at the .
following address:
2. Always run your model engines in a well-ventilated
area. Similar to automotive engines, model engines
produce harmful carbon monoxide fumes.
3. Never modify the flywheel.
4. Check the flywheel. If it’s damaged, replace it with a
new one.
5. When mixing the fuel or operating the engine, do so in a well-ventilated area 6. Remember that model engines produce a substantial
amount of power, more than enough to seriously
injure people and/or do considerable damage to
property. Always use common sense, skill and constant
observance of safety precautions.
®
Horizon Hobby, Inc.
Attention: Zenoah Service
4105 Fieldstone Road
Champaign, IL 61822
Phone: (217) 355-9511
Engine Parts Identification
It’s important to be able to identify the parts of your
Zenoah engines. Inside this manual you will find an
exploded view of Zenoah engines, as well as a chart
including part numbers and descriptions. This will assist
you in easily and rapidly identifying the respective parts
of your Zenoah engine.
Support Equipment
The following items are not included with your Zenoah
engine but are necessary for operation.
Fuel—Mix gasoline and 2-stroke gas compatible oil at a
mixing ratio of 25–40:1. Note: Be sure to use a gasoline-resistant fuel tubing (do not use any silicone rubber tube). Never use any alcohol fuel or alcohol-added fuel as this will damage the rubber part of the carburetor. Propeller—Refer to the Propeller Selection Chart located
on Page 8 to determine the best initial propeller for your
particular application.
Manual or Electric Starter—For manual starts, a chicken
stick is highly recommended. Never use your fingers to
start any model engine as you could be injured. If you
must hand-start a gasoline engine, be sure to protect
your hand with a heavily padded glove. There are a
variety of heavy-duty electric starters on the market that
can be used.
Evolution Oil
EVOX1001Q
Mounting the Engine
Make sure the engine is mounted on the aircraft using
aircraft grade plywood that’s at least 6mm in thickness
for the G26 engine, and 10mm in thickness for the G38
through GT80 twin, or a mount of equivalent strength. Make sure it’s firmly mounted with 4 bolts.
1. Be sure to set flat washers or a metal plate on the
reverse side of the mount to prevent the bolts from
sinking into the mount. Periodically check the engine
mount for loose bolts.
2. Since the engine is equipped with a floatless carburetor
with a diaphragm pump, the direction of the cylinder and
position of the fuel tank can be freely selected.
3. If the engine is mounted on a shock (rubber) mount
placed between the engine and the firewall for antivibration, check the hardness of the rubber, making sure
it’s not too soft, in order to avoid excessive vibration
during engine operating rpms. Note carefully if the engine
is vibrating at idle, as excessive vibration can result in
erratic engine operation due to overflow at the carburetor.
4. It is suggested that the bolts for the muffler be coated
with threadlock when mounting the muffler to the engine. Operation
Break In
Coil
No specific break in is required. The engine is gradually
broken in as it is used, and the output power increases
gradually as the engine breaks in.
Starting the Engine—Aircraft
Before attempting to start the engine, be sure to read through
all the steps for starting the engine as outlined below:
Zenoah engines are equipped with the ultra compact
C.D.I. type flywheel magneto ignition system and should
be started according to the following procedure:
Note: The magneto system is timed in such a way
that when the compression stroke starts (refer
to Figure 1-A) sparks are never produced on the
spark plug, no matter how fast the propeller is
flipped. The correct starting procedure is to quickly
flip the propeller when the edge of the magnet on
the rotor is approaching the coil (Figure 1-B). This
means that the propeller should be quickly flipped
at about 90 degrees in crank angle before the compression stroke is about to start.
Magnet
Fig 1-A
Fig 1-B
1. Make sure the spark (glow) plug(s) are installed and
tightened. Check the condition of the plug cap for cracks
or breaks.
2. Be sure the propeller is properly secured.
3. Make sure the fuel tank line(s) are properly connected. The main line should be connected to the carburetor
spray bar.
4. Be certain the mufflers are installed properly.
5. Fill the fuel tank.
6. Choke the engine and turn the propeller through a few times until the fuel appears at the carburetor.
7. Set the throttle valve at the idle position or at the position slightly open from idle.
Operation (continued)
8. Quickly flip the propeller in a counterclockwise direction. (See note on previous page)
We recommend the Zenoah ZEN20000 Kill Switch. Refer
to the example shown in the following diagram.
9. The engine should start after a few flips of the propeller.
10. Be sure to open the choke when the initial firing of the engine is heard.
Red Lead
11. When the choke is opened, be sure to close the
throttle valve to a position near the idle position before
the next flipping of the propeller is attempted.
Black Lead
CAUTION: If the engine is started when the throttle is wide open, a great thrusting force will be
generated, which can be very dangerous.
12. If you do not use a chicken stick to start the
engine, be sure to wear a thick glove when flipping
the propeller and use all fingers, except the thumb, for
the flipping operation.
13. Do not over-rev the engine. These engines are
designed to develop maximum output with the standard
muffler and the recommended propeller size. Please refer
to the propeller chart on page 10 to confirm the proper
propeller for the applicable Zenoah engine.
®
Kill Switch
Engine
Body
Ground
Carburetor Adjustment
The carburetor is provided with three adjustment screws,
which are factory set to the best (approximate) positions. They may need minor adjustment, depending upon
the temperature, humidity, atmospheric pressure (altitude), etc., of the area where the engine is being used.
Starting the Engine—Helicopter and Boat
1. Fill the tank with fuel.
High-Speed Needle
Low-Speed Needle
2. Push the priming bulb located on the carburetor until
fuel appears in the priming bulb (for helicopter).
3. Choke the engine and open the throttle valve approximately 1/3–1/2 of the full open position.
4. Quickly pull the starter cord until the initial firing of
the engine is heard.
5. When the initial firing is heard, open the choke, set
the throttle valve at the idle position or at the position
slightly open from the idle position and quickly pull the
starter cord a few more times until the engine starts.
6. For helicopter operation, you should adjust the rotorpitch to obtain a 9,000 to 10,000 rpm of the engine at
full throttle operation.
Stopping the Engine
The ability to shut down the engine in an emergency is
extremely important. For stopping the engine, the black
lead wire from the coil should be grounded to the engine
body, or the throttle valve should be closed completely. Installation of a “stop” or “kill” switch is recommended. Idle Screw
1. Start the engine without making any adjustments.
2. Make adjustments only when the engine shows signs
of inefficient operation.
3. Standard settings of each needle is as follows:
a. Low-Speed Needle: 11/8 plus/minus 1/4
b. High-Speed Needle: 13/8 plus/minus 1/4
Idle Screw: Turning this screw clockwise increases the
idling rpm. Turning it counterclockwise decreases the
idling rpm.
Low-Speed Needle: This is the fuel adjust screw (not
the air screw). Turning this needle clockwise makes
the gas mixture leaner, and turning it counterclockwise
makes it richer.
Operation (continued)
High-Speed Needle: Turning this needle clockwise makes
the gas mixture leaner, and turning it counterclockwise
makes it richer. Set this needle at a position which is 1/4
open from the maximum rpm position while the aircraft is
on the ground.
When the engine has just started and is not warm
enough, there may be insufficient acceleration and
the engine may die. Be sure to allow the engine to
warm up at idle for a few minutes before conducting
normal operation.
Note: Do not tighten the high and low speed .
needles too tightly.
Engine Care and Maintenance
Recommendations
• Engine oil
To extend the life of your Zenoah® engine, the following
is recommended:
• Washing gasoline
1. Use an Evolution quality 2-stroke oil mixed at 32 to 1.
• Scraper
2. Use the recommended spark plugs.
• Cloth
3. Use the proper propeller size and balance the .
propeller prior to use.
The engine can be disassembled or reassembled without
any specific difficulties, but note the following:
4. Always adjust the engine to a slightly rich setting.
For disassembling, the special tools shown in the parts
list are required (stopper, puller assembly), in addition to general tools. Be sure to use a new gasket when the
crankcase and cylinder have been disassembled.
5. For long-term storage, make sure there is no fuel
left in the tank or the engine. Remove the spark plug(s)
and apply several drops of high-quality oil (e.g., Marvel
Air Tool Oil) to the top of the engine and into the spark
plug hole. Rotate the crankshaft several times. Store the
engine in the box it came in or on the airplane with the
nose down in order to keep oil in the bearings.
• Brush
Note: Because the crankshaft is of the assembly type, do not disassemble, hit or twist its end.
Disassembly
Servicing the Engine
1. Dismount the engine from the model.
Required Tools
2. Remove the carburetor and insulator carefully without
damaging the gasket.
• Regular screwdriver
• Phillips screwdriver
• Hexagonal wrench (4mm/5/32")
• Open wrench (19mm/3/4")
• Plastic hammer
• Thickness gauge
3. Remove the muffler.
4. Remove the spark plug and ignition module. 5. Remove the propeller hub.
6. Remove the rotor (flywheel). If it cannot be detached,
use a plastic hammer and tap the part lightly.
• Threadlock (Blue Threadlock Z-42 or equivalent)
a. Screw the stopper in place of the spark plug,
then turn the rotor counterclockwise until the piston
touches the stopper. Take care, as it can cause damage to the piston or connecting rod if the stopper is
not screwed into the bottom.
• Lithium grease
b. Loosen and remove the rotor securing nut.
• Tapered round rod
• Liquid gasket (Permatex or equivalent)
Engine Care and Maintenance (continued)
c. Remove the rotor by using the puller. Do not hit
the crankshaft with the plastic hammer, as this can
increase the runout of the shaft.
7. Remove the mounting plate.
8. Remove the four bolts from the crankcase.
9. Tap around the case fitting side gently with the plastic
hammer and slowly separate the crankcase from the
cylinder block.
10. Pull out the crankshaft with the piston, bearings, and
other parts attached.
8. Put the piston in the cylinder, with the piston’s arrow
facing in the exhaust port direction. Set the crankshaft to the cylinder block. Then, fit the oil seal to the cylinder
block. The snap ring joint should be set vertically to the cylinder.
9. Fit the crankcase to the cylinder block and tighten the bolts.
11. Remove the Woodruff key from the crankshaft.
10. Check that the crankshaft can be smoothly turned by hand.
12. Remove the oil seal, snap ring and bearings.
11. Put back the Woodruff key.
13. Remove the circlip and pull out the piston pin.
12. Replace the rotor (flywheel), fitting it to the Woodruff
key. Tighten the hub nut after having applied threadlock
(Blue Threadlock Z-42 or equivalent) to the threads. 14. Remove the thrust washers and needle bearing from
the smaller end of the connecting rod (G38).
15. Remove the piston ring.
16. Wash each part. Check for abrasion and damage, and
replace any part that is defective.
Assembly (G38)
1. Apply engine oil (SAE #30) to the inside of the cylinder and to the needle bearings on the larger end of the connecting rod.
2. Fit the piston ring to the piston.
3. Mount the needle bearing and thrust washer (with its oil slot facing inside) to the smaller end of the
connecting rod and apply engine oil (SAE #30).
4. With the arrow on the top of the piston facing the
straight side (opposite side to the propeller) of the
crankshaft, fit the piston to the top of the connecting rod and insert the piston pin with its blank end to the
exhaust port side.
5. Fit the circlip.
6. Fit the bearings, snap ring and oil seal to the
crankshaft. (Apply lithium grease to the lip area of the oil
seal and fit it, paying attention to its direction.)
7. Wipe the contact surfaces of the cylinder block and crankcase, and apply liquid gasket (Permatex or equivalent).
13. Apply threadlock (Blue Threadlock Z-42) to the
muffler bolts and mount the muffler. 14. Apply threadlock (Blue Threadlock Z-42) to the
ignition module setscrews and fix the coil temporarily.
15. Set the rotor (flywheel) so that the magnet is located
on the opposite side of the module (G38). Place a
thickness gauge between the core of the module and rotor
(flywheel) and adjust the clearance to 0.25 ^ 0.35 mm
(0.01 ^ 0.014 in). Then tighten the setscrews after having
applied threadlock (Blue Threadlock Z-42) to them. 16. Using a new gasket, fix the insulator with screws to
which threadlock (Blue Threadlock Z-42) has been applied.
17. Using a new gasket, mount the carburetor with
screws, paying attention to its mounting direction. 18. Tighten the mounting plate, using screws with
threadlock (Blue Threadlock Z-42) applied.
19. Install the spark plug.
Note: Disassembly and assembly steps were written using a G38 engine as an example, but
they apply to all engines.
Engine Care and Maintenance (continued)
Maintenance Chart
Items
Before Use Every 25 hours Every 100 hours
Leakage,
Damage/Crack
Losing Speed
Check/Adjust
Air-cleaner (PUH)
Check/Cleaning
Spark Plug (gap)
Check/Adjust
Cylinder (barrel)
Check/Cleaning Piston, Ring
Check/Cleaning Muffler & Bolt
Check/Cleaning
Bearings
Check/Cleaning Crankshaft
Rotor
Action
Check
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
Check/Alignment Check
Propeller Hub (PU)
Check/Alignment Water Jacket (PUM)
Check/Leakage
P
P
P
P
P
P
P
P
P
P
P
P
P
Note
Replace if necessary
ì
ì
ì
ì
ì
ì
ì
ì
ì
Specifications & Technical Data
Items
Unit
G260PU
G260PUM
G260PUH
G231PUM
G231PUH
Type
––
Air Cooled
Water Cooled
Air Cooled
Water Cooled
Air Cooled
Bore x Stroke
mm
34 x 28
Displacement
3
cm
Effective
Compression Ratio
Carburetor
25.4
ë
ë
ë
ë
––
8.4
ë
ë
Type (Walbro)
WT-645
Venturi (mm)
12.7
Air Cleaner
WT-644
ë
WT-677
ë
22.5
ë
ë
ë
ë
32 x 28
WT-644
ë
WT-677
ë
––
––
­­––
Hand Flipping or
Electric Motor
Recoil Starter
Type
CDI
BTDC/rpm
28/7000
STD
RZ7C
Option
––
CMR8H/7H
––
CMR6H/7H
––
Idle Speed
rpm
1800
APC 18 x 8
3500
3000
3500
3000
Max. Power
rpm
1.62/12000
2.16/12000
1.71/13000
2.09/12000
1.58/13000
Min. Torque
rpm
1.48/9000
1.94/9500
1.42/9500
1.79/10000
1.34/9000
760
720
700
1.77 (*1.57)
1.55
1.78 (*1.58)
Starting
Ignition
Spark Plug
ë
30/7000
ë
Fuel Consumption
cc
790
710
Weight
kg
1.69 (* 1.52)
1.54
Dry Type
––
Dry Type
ë
ë
ë
ë
ë
ë
ë
ë
ë
ë
ë
ë
Engine Care and Maintenance (continued)
Maintenance Specifications
Items
Standard
Limit
Standard
Limit
Measuring Device
Bore (mm)
ø34
Plating damaged
ø32
Plating damaged
Eye Checking
Diameter (mm)
ø33.97
ø33.87
ø31.97
ø31.87
Micro Meter
Piston Ring
Groove Width (mm)
1.01
1.11
1.01
1.11
Thickness Gauge
Piston Ring Hole (mm)
ø8.01
ø8.05
ø8.01
ø8.05
Cylinder Gauge
Clearance Between Piston
and Cylinder (mm)
0.03–0.05
0.15
0.03–0.05
0.15
Micro Meter
Cylinder Gauge
Clearance Between Groove
and Piston Ring (mm)
0.02–0.04
0.1
0.02–0.04
0.1
Thickness Gauge
End Gap (mm)
0.05–0.25
0.5
0.05–0.25
0.5
Thickness Gauge
Width (mm)
0.98
0.93
0.98
0.93
Micro Meter
Piston Pin Diameter (mm)
ø8
ø7.98
ø8
ø7.98
Micro Meter
Connecting Rod, Small End (mm)
ø11
ø11.05
ø11
ø11.05
Cylinder Gauge
Crankshaft Dia. at Main Bearing (mm)
ø12
ø11.98
ø12
ø11.98
Micro Meter
Eccentricity (mm)
––
0.07
––
0.07
Dial Gauge
Axial Play (mm)
––
0.5
––
0.5
Thickness Gauge
Main Bearing
––
Gritty or
Has Flat Spot
––
Gritty or
Has Flat Spot
––
Cylinder
Piston
Piston
Ring
10
Remarks
At the skirt end and
the right angle to
the piston pin
When inserted in a
new cylinder
Troubleshooting Guide for Gasoline Engines
Generally speaking, there are very few things that will
keep today’s modern engines from starting. Use good
quality “fresh” fuel and make sure that good plugs are
installed. Should the engine fail to start after these items
are verified, refer to the charts on the following page.
a) The engine does not start.
The crankshaft
does not rotate
Seizure, intrusion of a foreign substance
The crankshaft
rotates
The fuel has not been fed to
the carburetor
Disassemble and repair
Clogging inside the
carburetor
Disassemble and clean
Clogging of the fuel
piping
Clean
The fuel has been fed to the
carburetor
No compression
(normally 7 kg/cm2
99.5 psi or more)
Compression adequate
The spark plug does not spark
Loosened
Tighten further
spark plug
Replace
Abrasion or damage of
the cylinder, piston, or
piston ring
The spark plug does spark
Remove the spark
plug and dry it
The carburetor has
not been properly
Readjust
adjusted
The fuel is not
Replace
suitable
The Stop switch has
Turn on
been turned off
Wiring is disconnected
Repair
The spark plug is defective
Replace
The ignition module is defective Replace
The air gap is too large
Adjust
Adjust
The spark plug gap is too large
Wet plug
b) The engine stops by itself
It suddenly stops
The crankshaft does not rotate
or is abnormally heavy
The crankshaft
rotates
See a)
The plug cap has come off
Wiring disconnection
Put back
Spark plug bridge
Use a standard plug
Use clean fuel
The Stop switch has
been turned off
It slows down and stops
Out of fuel
Not out of fuel
Repair
Turn on
Refuel
The fuel is not fed to the carburetor
Water is mixed in the fuel
See a)
Replace
c) Lower power output
Overheating
The carburetor has not beeen properly adjusted
Air suction from a carburetor joint or oil seal
Abrasion of the piston ring
The fuel is not suitable
Clogging of the muffler or exhaust port due to carbon
The spark plug heat range is not proper
Readjust
Repair
Replace
Replace
Clean
Replace
d) The engine does not stop
Overheating
The Stop switch is defective
Switch wiring is disconnected
See c)
Repair
Repair
11
Troubleshooting Guide for Gasoline Engines
(continued)
In the event that none of the above procedures result .
in the engine running properly, contact our service
department for suggestions at:
Horizon Hobby, Inc.
4105 Fieldstone Road
Champaign, IL 61822
Phone: 217-355-9511 (M–F 8:00–5:00 CST)
Propeller Chart
This chart enables you to select the best propeller for
initial setup of your Zenoah engine.
Remember, it’s imperative to balance each propeller
prior to installation onto your Zenoah engine. Failure to
do so may cause unwanted vibration in your aircraft.
EnginePropeller
G26A
16x8 @ 8,700
G231 Heli
G26 Heli
Adjust pitch of rotor to obtain .
9,000–10,000 rpm of the .
engine at full throttle
G26 Marine
12
G231 Marine
Diameter = 65–75mm Pitch ratio 1.9–1.4mm
G38 Gas
18x10 @ 7,300
G45 Gas
20x10 @ 7,200
G62 Gas
22x10 @ 7,200
GT80 Gas
22x12 @ 7,200
24x10 @ 7,200
Note: All recommendations are based on engines using
APC brand props.
Engine Specifications
Outside Dimensions (mm)
Items
Length
Width
Height
Operating
RPM
Optional
Mufflers
G26A
139mm
105mm
181mm
2,000–10,000
BIS07123
G26M
139mm
105mm
181mm
2,000–10,000
G26H
139mm
105mm
181mm
2,000–10,000
—
—
G231 HELI
142mm
105mm
181mm
3,000–11,000
G231 MARINE
142mm
105mm
181mm
3,500–15,000
G38
—
—
170mm
130mm
215mm
2,000–9,000
BIS07138
G45
152mm
130mm
185mm
2,000–10,000
BIS07145
G62
162.5mm
140mm
185mm
2,000–10,000
BIS07163
GT80
191.5mm
257mm
190mm
1,800–10,000
BIS07445/6
Specifications
Displacement
(cu in)
Bore
(in)
Stroke
(in)
Weight
(oz)
K
(ISO)
HP
(H/M)
Carb
(Walbro)
G26A/M/H
1.55
1.41
1.1
54/57
M8x1.25/6x1
2.4
WT645/WT644/WT677
G231M/H
1.4
1.3
1.1
54
M8x1.25
2.2
WT644/WT643
G38
2.3
1.5
1.3
67
M10x1.25
2.2
WT338/WTA-6A
G45
2.74
1.69
1.22
74
8x1
3.3
HDA-48D
G62
3.8
1.9
1.4
73
10x1
4.75
HDA-48D
GT80
4.8
1.60
1.22
126
10x1.25
6
WJ-64
* w/spring starter
13
Exploded Illustration
G26/G231
14
New Zen
Key #Part #
14
1-1
1- 2
2-1
2-2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Out of Date
Part #
ZENT207512110 ZEN2601
ZENT207012111 ZEN2301RCA
ZENT207612110 ZEN2601M
ZENT207812110 ZEN23102M
ZENT207612210 ZEN2603M
ZEN0785100515 ZEN2304M
ZEN0700013040 ZEN23105M
ZENT207612320 ZEN23106M
ZEN116012330 ZEN2307M
ZENT207513120 ZEN23108
ZEN331012281 ZEN2309
ZENT207513150 ZEN2305RC
ZEN114813162 ZEN23111
ZENT207514120 ZEN23112
ZENT207521100 ZEN23114
ZEN262921130 ZEN6213
ZENT207521140 ZEN23116
ZEN216921210 ZEN3828
ZEN33301412 ZEN2318
ZEN0406502812 ZEN2319
ZEN0603406001 ZEN2320
ZEN185021220 ZEN2321M
Quantity Per Unit
G260G260G260G231G231
DescriptionPUPUMPUHPUMPUH
CYLINDER
CYLINDER
CYLINDER
CYLINDER
JACKET
JOINT
O-RING 3 x 40
O-RING 1.5 x 15.5
BOLT M3 x 8
GASKET, CYLINDER
BOLT M5X20
GASKET, INSULATOR
INSULATOR
GASKET, CARBURETOR
CRANKCASE, COMPLETE
CRANKCASE, REAR
CRANKCASE, FRONT
PIN
GASKET
SEAL, 12 x 22 x 7
BEARING
Snap Ring
BEARING
SEAL, 12 x 28 x 7
1
–
–
–
–
–
–
–
–
1
6
1
1
1
1
1
1
3
1
1
2
1
1
–
–
–
1
–
1
2
1
1
2
1
6
1
1
1
1
1
1
3
1
1
2
1
–
1
1
–
–
–
–
–
–
–
–
1
6
1
1
2
1
1
1
3
1
1
2
1
1
–
–
–
–
1
1
2
1
1
2
1
6
1
1
1
1
1
1
3
1
1
2
1
–
1
–
1
–
–
–
–
–
–
–
1
6
1
1
2
1
1
1
3
1
1
2
1
1
–
Exploded Illustration
G26/G231 continued
Quantity Per Unit
New ZenOut of Date G260G260G260G231G231
Key #Part #
Part #
DescriptionPUPUMPUHPUMPUH
22
23-1
23-2
24-1
24-2
25-1
25-2
26
27
28
29
30
31
32
33
34
35
36
37
38-1
38-2
39
40
41
42
43
44
45
46
47
48
49
50
51-1
51-2
51- 3
52
53
54
55
56
57-1
57-2
58-1
58-2
59-1
59-2
60
61
62
ZEN0125230530 ZEN2322
ZENT208841110 ZEN2623
ZENT207041110 ZEN2320RC
ZENT208841210 ZEN2624
ZENT207041210 ZEN2321RC
ZEN2625
ZEN160041310
ZEN2322RC
ZEN110141310
ZEN2323RC
ZEN126041320
ZEN550041410
ZEN2324RC
ZEN110141340
ZEN2325RC
ZENT207542000 ZEN23129
ZEN2330
ZEN115574110
ZEN2331
ZEN026210516
ZEN2327RC
ZEN165043230
ZEN116075210
ZEN2333M
ZEN2634
ZEN186175101
ZEN2341
ZEN026330414
ZEN100043240
ZEN2328RC
ZEN114043250
ZEN2337
ZEN6236
ZEN262971210
ZEN2339M
ZEN116071211
ZEN115571110
ZEN2354
ZEN6241
ZEN026030422
ZEN2341
ZEN026330414
ZENT207572210 ZEN2638
ZEN190072120
ZEN6239
ZEN262971311
ZEN6237
ZENT207073110 ZEN26451
ZEN2667M
ZEN369991975
ZEN2648
ZEN026330555
ZEN2647
ZEN114283110
ZEN848ES08300 ZEN2649A
ZENT207782000 ZEN23150H
ZEN2650
ZEN2650
ZENT207581000 ZEN2651
ZENT207681000 ZEN23151
ZENT207781000 ZEN23152
ZEN115243260
ZEN2359
ZEN115243281
ZEN2360
ZEN115243290
ZEN2361
ZEN2362
ZEN335053410
ZEN23156
ZEN114013141
ZEN0125230550 ZEN2357
ZEN0125230560 ZEN2357H
ZEN2358
ZEN026330408
ZEN2358H
ZEN026390416
ZENT207515110 ZEN2655
ZEN114808010
ZEN2355
ZEN2366
ZEN114515412
ZEN115815420
ZEN2367
ZENT303991310 ZEN23124RC
ZEN20010
ZEN20010
ZEN20005 ZEN20005
BOLT, M5 x 30 PISTON
PISTON
RING
RING
PISTON PIN PISTON PIN SNAP RING BEARING
WASHER
CRANKSHAFT, COMPLETE
MOUNT, PLATE
SCREW, M5 x 16
NUT, M8
PULLEY
RECOIL ASSEMBLY
SCREW, M4 x 14
KEY
SHIM
COIL, (GREY) COIL, (RED) ROTOR
SCREW M4 x 22
SCREW M4 x 14
PLUG CAP
SPRING
COIL
SPARK PLUG RZ7C
SPARK PLUG MARINE ONLY
SCREW, M5 x 55
SPACER, 5 x 10 x 1.6
AIR TUNNEL (VENTURI)
CLEANER ASSEMBLY
TUBE
CARBURETOR ASSY WT-645
CARBURETOR ASSY WT-644
CARBURETOR ASSY WT-643
HUB
STUD
WASHER
NUT, M8
GASKET, MUFFLER
BOLT, M5 x 502
BOLT, M5 x 60
SCREW, M4 x 8
SCREW, M4 x 16
MUFFLER
MUFFLER
SPACER SPACER
SOCKET
piston stopper, option for G260PUA/M/H
Piston Stopper
4
1
–
1
–
1
–
2
1
2
1
1
3
1
–
–
–
1
1
1
–
1
2
2
1
1
1
1
–
2
2
1
–
1
1
–
–
1
1
1
1
1
–
–
1
–
1
–
–
–
1
1
4
1
–
1
–
1
–
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
1
1
2
2
1
–
1
–
1
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1
1
4
1
–
1
–
1
–
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
1
–
2
–
–
1
–
–
–
1
–
–
–
–
2
–
2
–
1
–
1
1
1
1
1
4
–
1
–
1
–
1
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
1
1
2
2
1
–
1
–
1
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1
1
4
–
1
–
1
–
1
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
1
–
2
–
–
1
–
–
–
1
–
–
–
–
2
2
–
1
–
1
1
1
1
1
15
Exploded Illustration
(Standard Accessory for G380PU)
G38
Index
No.
1
2
3
4
5
6
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
16
New ZEN
Part No.
ZEN337812111
ZEN333014111
ZEN333014121
ZEN026020520
ZEN333014132
ZEN337815000
ZEN284115210
ZEN333015220
ZEN337821110
ZEN0125230540
ZEN029220510
ZEN312013510
ZEN313013520
ZEN334041113
ZEN334041211
ZEN330441310
ZEN331041320
ZEN165041510
ZEN331041410
ZEN337842000
ZEN603006201
ZEN165021220
ZEN0406503212
ZEN216921210
ZEN126043240
ZEN165043230
ZEN029020820
ZEN0164120812
ZEN260951110
ZEN354411510
ZEN114543290
Out of Date
Part No.
ZEN3801
ZEN3802
ZEN3803
ZEN3804
ZEN3805
ZEN3806
ZEN3811
ZEN3812
ZEN3813
ZEN3814
ZEN3815
ZEN3816
ZEN3817
ZEN3818
ZEN3819
ZEN3820
ZEN3821
ZEN3822
ZEN3823
ZEN3824
ZEN3825
ZEN3826
ZEN3827
ZEN3828
ZEN3829
ZEN2327RC
ZEN3831
ZEN3832
ZEN3833
ZEN6232
ZEN3835
Description
cylinder
insulator
carb gasket
insulator screw
insulator gasket
muffler assembly
muffler gasket
muffler bolt
crankcase
case bolt
case washer
case plug
plug gasket
piston
piston ring
piston pin
pin retainer
conrod spacer
conrod bearing
crankshaft
crankshaft bearing
front oil seal
snap ring
rear oil seal
key
rotor nut
lock washer
rotor washer
prop hub (new)
hub bolt
prop washer (new)
Qty/
unit
1
1
1
2
1
1
1
2
1
4
4
1
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
1
2
1
Index
No.
New
Part No.
36 ZEN260951411
37 ZEN337871110
38 ZEN260971210
39 ZEN126071261
40 ZEN262972210
41 ZEN190072120
42 ZEN6242
43 ZEN3843
44-1 ZEN3844
45 ZEN026010540
46 ZEN337885111
47 ZEN026000512
ZEN337806040
ZEN20005
Out of Date
Part No.
ZEN3836
ZEN3837
ZEN3838
ZEN3839
ZEN6238
ZEN6239
ZEN6242
ZEN3843
ZEN3844
ZEN3845
ZEN3846
ZEN3847
ZEN3871
ZEN20005
Qty/
unit
Description
prop bolt (new)
module
rotor (new)
spacer (module)
plug cap (black)
cap spring
spark plug, c859
module bolt
carb ass’y (ht-338)w/choke
carb screw
mount
mounting bolt
screw/nut set
piston stopper
}
for g380pu
2
1
1
3
1
1
1
3
1
2
1
4
1
1
Exploded Illustration
G45
Index
No.
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
New
Part No.
ZEN281712111
ZEN281714110
ZEN281714121
ZEN48013180
ZEN848C9014C2
ZEN267014211
ZEN48013180
ZEN262951111
ZEN335615210
ZEN335615220
ZEN285015230
ZEN281721101
ZEN262921130
ZEN0406503515
ZENT401221240
ZEN152021220
ZEN140021220
ZEN267021250
ZEN281721311
ZEN48013180
ZEN281722210
ZEN267041114
ZEN267041211
ZEN335041310
ZEN335041320
ZEN140041410
ZEN267041510
ZEN281742001
ZEN130042410
ZEN100043240
ZEN140043230
Out of Date
Part No.
ZEN4501
ZEN4502
ZEN4503
ZEN4504
ZEN6204
ZEN4506
ZEN4504
ZEN6207
ZEN6208
ZEN6209A
ZEN6210
ZEN4513
ZEN6213
ZEN6214
ZEN6215
ZEN6216
ZEN6217
ZEN6276
ZEN4520
ZEN4504
ZEN4522
ZEN4523
ZEN4524
ZEN4525
ZEN6223
ZEN6224
ZEN4528
ZEN4529
ZEN6228
ZEN6227
ZEN6229
Description
cylinder
insulator
insulator gasket
bolt
carburetor gasket
cylinder gasket
bolt
muffler
muffler gasket
muffler bolt
muffler nut
crankcase comp.
case pin
snap ring
bearing
rear oil seal
front oil seal
elbow fuel nipple
case gasket
bolt
pipe
piston
piston ring
piston pin
pin retainer
conrod bearing
washer
crankshaft comp.
shim
key
flywheel nut
Qty/
unit
1
1
1
2
1
1
4
1
1
2
2
1
3
1
2
1
1
1
1
4
1
1
2
1
2
1
2
1
0-2
1
1
Index
No.
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
New
Part No.
ZEN262951110
ZEN354411510
ZEN262951310
ZEN262951410
ZEN6257
ZEN149071110
ZEN262971210
ZEN262971311
ZEN262972210
ZEN90072120
ZEN026330416
ZEN26030422
ZEN6242
ZEN6243
ZEN0125230550
ZEN6245
ZEN0160120513
ZEN262991510
ZEN262891110
ZEN0125230614
ZEN029020615
ZEN149096101
ZEN20005
ZEN6253
DISCONTINUED
Out of Date
Part No.
ZEN6230
ZEN6232
ZEN6233
ZEN6234
ZEN6257
ZEN6235
ZEN6236
ZEN6237
ZEN6238
ZEN6239
ZEN4543
ZEN6241
ZEN6242
ZEN6243
ZEN4547
ZEN6245
ZEN6246
ZEN6247
ZEN6248
ZEN6249
ZEN6250
ZEN6251
ZEN20005
ZEN6253
ZEN4557
Description
prop hub
hub bolt
washer
prop bolt
magneto assembly
rotor
source coil
ignition coil
plug cap (black)
cap spring
source coil screw
coil screw
spark plug
carburetor assembly
bolt
washer
washer
bolt
mount
bolt
washer
}
*for g450pu
puller assembly
stopper (optional)
guide (optional)
wrench (optional)
Qty/
unit
1
2
1
1
1
1
1
1
1
1
2
2
1
1
2
2
2
1
1
4
4
1
1
1
1
17
Exploded Illustration
G62
* (Accessory for G620PU-1)
Index
No.
1
2
3
4
5
6
7
8
9
10
11,12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
New ZEN
Part No.
ZEN336612116
ZEN848C9014B3
ZEN261814120
ZEN848C9014C2
ZEN261614211
ZEN331012281
ZEN262951111
ZEN335615210
ZEN335615220
ZEN285015230
ZEN262921100
ZEN262921130
ZEN0406503515
ZENT401221240
ZEN152021220
ZEN140021220
ZEN262921311
ZEN335021320
ZEN261841112
ZEN261841210
ZEN336641310
ZEN335041320
ZEN140041410
ZEN261641510
ZEN262942002
ZEN100043240
ZEN130042410
ZEN140043230
ZEN262951110
Out of Date
Part No.
ZEN6201
ZEN6202
ZEN6203
ZEN6204
ZEN6205
ZEN2309
ZEN6207
ZEN6208
ZEN6209
ZEN6210
ZEN6211
ZEN6213
ZEN6214
ZEN6215
ZEN6216
ZEN6217
ZEN6218
ZEN6219
ZEN6220
ZEN6221
ZEN6222
ZEN6223
ZEN6224
ZEN6225
ZEN6226
ZEN6227
ZEN6228
ZEN6229
ZEN6230
Description
cylinder
insulator gasket
insulator
carburetor gasket
cylinder base gasket
cylinder bolt
muffler
muffler gasket
muffler bolt
muffler nut
crankcase comp.
case pin
snap ring
bearing
rear oil seal
front oil seal
crankcase gasket
case assembly bolt
piston
piston ring
piston pin
pin retainer
needle bearing
connecting rod spacer
crankshaft comp.
key
shim
flywheel nut
hub, propeller comp.
for g620pu-1
18
Qty/
unit
Index
No.
1
1
1
1
1
4
1
1
2
2
1
3
1
2
1
1
1
4
1
4
1
1
2
1
2
1
2
1
0-2
1
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
New ZEN
Part No.
ZEN0402500312
ZEN354411510
ZEN262951310
ZEN262951410
ZEN149071110
ZEN262971210
ZEN262971311
ZEN262972210
ZEN190072120
ZEN026330416
ZEN026030422
ZEN6242
ZEN6243
ZEN262982210
ZEN6245
ZEN016020513
ZEN262991510
ZEN262891110
ZEN0125230614
ZEN029020615
ZEN149096101
ZEN20005
ZEN6253
ZEN6200
ZEN6258
ZEN262981420
ZEN6257
Out of Date
Part No.
ZEN6231
ZEN6232
ZEN6233
ZEN6234
ZEN6235
ZEN6236
ZEN6237
ZEN6238
ZEN6239
ZEN6240
ZEN6241
ZEN6242
ZEN6243
ZEN6244
ZEN6245
ZEN6246
ZEN6247
ZEN6248
ZEN6249
ZEN6250
ZEN6251
ZEN20005
ZEN6253
ZEN6200
ZEN6255
ZEN6256
ZEN6257
Description
pin for g620pu-1
hub bolt
prop washer
prop bolt
rotor
source coil
ignition coil
plug cap (black)
plug cap spring
ignition coil screw
source coil screw
spark plug, c859
carburetor assembly
carb mount screw
carb washer
washer
tap prop bolt
mount
bolt
washer
}
*for g62pu
puller assembly
stopper (optional)
piston pin guide
spring starter
high-speed needle
low-speed needle
magneto assembly
Qty/
unit
1
2
1
1
1
1
1
1
1
2
2
1
1
2
2
2
1
1
4
4
1
1
1
1
1
1
1
Exploded Illustration
GT80
Index
No.
Index
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
New ZEN
Part No.
ZEN289812111
ZEN289814111
ZEN285014123
discontinued
ZEN289881000
ZEN289814131
ZEN0125230550
ZEN289814210
ZEN0215230520
ZEN289821001
ZEN202921130
ZENT401221240
ZEN0406503515
ZEN0603406202
ZEN140021220
ZEN267021250
ZEN106581100
ZEN289821310
ZEN0215230520
ZEN285041110
ZEN285041210
ZEN285041310
ZEN130041320
ZEN44524
ZEN44525
ZEN289842000
ZEN130042410
ZEN100043240
ZEN140043230
ZEN149071110
ZEN262971210
Out of Date
Part No.
ZEN44501
ZEN44502
ZEN44503
ZEN3848
ZEN44505
ZEN44506
ZEN2357
ZEN44508
ZEN44509
ZEN44510
ZEN6213
ZEN6215
ZEN6214
ZEN44514
ZEN6217
ZEN6276
ZEN44517
ZEN44518
ZEN44509
ZEN44520
ZEN44521
ZEN44522
ZEN44523
ZEN44524
ZEN44525
ZEN44526
ZEN6228
ZEN6227
ZEN6229
ZEN6235
ZEN6236
Description
cylinder
manifold
manifold gasket
manifold bolt
carburetor ass’y
carburetor gasket
carb bolt
cylinder gasket
bolt
crankcase ass’y
pin
bearing
snap ring
bearing
front oil seal
fuel nipple elbow
pipe
crankcase gasket
bolt
piston
piston ring
piston pin
pin retainer
bearing
thrust washer
crankshaft comp
shim
key
nut
rotor
source coil
Qty/
unit
2
1
2
4
1
1
2
2
8
1
4
2
2
1
1
1
1
1
4
2
4
2
4
2
4
1
0-2
1
1
1
1
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
New ZEN
Part No.
ZEN262972210
ZEN289871510
ZEN262922210
ZEN190072120
ZEN6242
ZEN026330414
ZEN026030422
ZEN289815110
ZENT210015210
ZEN335615220
ZEN285015230
ZEN289874110
ZEN0125230614
ZEN269975110
ZEN269975200
ZEN269975310
ZEN268975320
ZEN331071150
ZEN0125230625
ZEN269975410
ZEN262851101
ZEN0402500312
ZEN354411510
ZEN262951310
ZEN262951410
ZEN262991510
ZEN111091320
ZEN149096101
ZEN20005
ZEN289881410
ZEN289881420
Out of Date
Part No.
ZEN6238
ZEN44533
ZEN6238
ZEN6239
ZEN6242
ZEN44537
ZEN44538
ZEN44539
ZEN44540
ZEN6209
ZEN44542
ZEN44543
ZEN44544
ZEN44545
ZEN44546
ZEN44547
ZEN44548
ZEN44549
ZEN44550
ZEN44551
ZEN44552
ZEN44553
ZEN6232
ZEN6233
ZEN6234
ZEN6247
ZEN44555
ZEN6251
ZEN44554
ZEN44556
ZEN44557
Description
ignition coil
cord
plug cap (black)
cap spring
spark plug, c859
screw
screw
muffler
muffler gaslet
muffler bolt
nut
mount
bolt
boss
clutch comp
spring
collar
washer
bolt
pad
hub. propeller comp
pin
hub bolt
hub washer
prop bolt
tap prop bolt
socket
puller ass’y (optional)
stopper (optional)
high-speed needle
low-speed needle
Qty/
unit
2
1
2
2
2
4
2
2
2
4
4
1
3
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
G80A
Index
No.
01
02
20
21
40
New ZEN
Part No.
ZEN286912110
ZENT208014110
ZENT200241110
ZEN266041211
ZEN20006
Out of Date
Part No.
ZEN8001
ZEN8002
ZEN8020
ZEN8021
ZEN20006
Description
cylinder
intake manifold (black)
piston
piston ring
carburetor insulator
Qty/
unit
2
1
2
2
1
19
Warranty Information
Warranty Repairs
Exclusive Warranty- Horizon Hobby, Inc., (Horizon) warranties that the
Products purchased (the "Product") will be free from defects in materials and
workmanship for a period of 3 years from the date of purchase by the Purchaser.
you must contact Horizon directly. This will enable Horizon to better answer
your questions and service you in the event that you may need any assistance. For questions or assistance, please direct your email to .
productsupport@horizonhobby.com, or call 877.504.0233 toll free to speak to a
service technician.
Limited Warranty
Inspection or Repairs
(a) This warranty is limited to the original Purchaser ("Purchaser") and is
not transferable. REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS
WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER. This
warranty covers only those Products purchased from an authorized Horizon
dealer. Third party transactions are not covered by this warranty. Proof of
purchase is required for warranty claims. Further, Horizon reserves the right
to change or modify this warranty without notice and disclaims all other
warranties, express or implied. If this Product needs to be inspected or repaired, please call for a Return
Merchandise Authorization (RMA). Pack the Product securely using a shipping
carton. Please note that original boxes may be included, but are not designed to
withstand the rigors of shipping without additional protection. Ship via a carrier
that provides tracking and insurance for lost or damaged parcels, as Horizon is
not responsible for merchandise until it arrives and is accepted at our facility. A
Service Repair Request is available at www.horizonhobby.com on the “Support”
tab. If you do not have internet access, please include a letter with your
complete name, street address, email address and phone number where you
can be reached during business days, your RMA number, a list of the included
items, method of payment for any non-warranty expenses and a brief summary
of the problem. Your original sales receipt must also be included for warranty
consideration. Be sure your name, address, and RMA number are clearly written
on the outside of the shipping carton.
(b) Limitations- HORIZON MAKES NO WARRANTY OR
REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NONINFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE OF THE PRODUCT. THE PURCHASER ACKNOWLEDGES THAT
THEY ALONE HAVE DETERMINED THAT THE PRODUCT WILL SUITABLY
MEET THE REQUIREMENTS OF THE PURCHASER’S INTENDED USE. (c) Purchaser Remedy- Horizon's sole obligation hereunder shall be that
Horizon will, at its option, (i) repair or (ii) replace, any Product determined
by Horizon to be defective. In the event of a defect, these are the Purchaser's
exclusive remedies. Horizon reserves the right to inspect any and all equipment
involved in a warranty claim. Repair or replacement decisions are at the sole
discretion of Horizon. This warranty does not cover cosmetic damage or
damage due to acts of God, accident, misuse, abuse, negligence, commercial
use, or modification of or to any part of the Product. This warranty does
not cover damage due to improper installation, operation, maintenance, or
attempted repair by anyone other than Horizon. Return of any goods by
Purchaser must be approved in writing by Horizon before shipment.
Damage Limits
HORIZON SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT OR
CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR
COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCT,
WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE,
OR STRICT LIABILITY. Further, in no event shall the liability of Horizon exceed
the individual price of the Product on which liability is asserted. As Horizon has
no control over use, setup, final assembly, modification or misuse, no liability
shall be assumed nor accepted for any resulting damage or injury. By the act
of use, setup or assembly, the user accepts all resulting liability.
If you as the Purchaser or user are not prepared to accept the liability
associated with the use of this Product, you are advised to return this Product
immediately in new and unused condition to the place of purchase.
Law: These Terms are governed by Illinois law (without regard to conflict of
law principals). Safety Precautions
This is a sophisticated hobby Product and not a toy. It must be operated with
caution and common sense and requires some basic mechanical ability. Failure
to operate this Product in a safe and responsible manner could result in injury
or damage to the Product or other property. This Product is not intended for
use by children without direct adult supervision. The Product manual contains
instructions for safety, operation and maintenance. It is essential to read and
follow all the instructions and warnings in the manual, prior to assembly, setup
or use, in order to operate correctly and avoid damage or injury.
Questions, Assistance, and Repairs
20
Your local hobby store and/or place of purchase cannot provide warranty
support or repair. Once assembly, setup or use of the Product has been started,
Warranty Inspection and Repairs
To receive warranty service, you must include your original sales receipt
verifying the proof-of-purchase date. Provided warranty conditions have
been met, your Product will be repaired or replaced free of charge. Repair or
replacement decisions are at the sole discretion of Horizon Hobby. Non-Warranty Repairs
Should your repair not be covered by warranty the repair will be completed and
payment will be required without notification or estimate of the expense unless
the expense exceeds 50% of the retail purchase cost. By submitting the item
for repair you are agreeing to payment of the repair without notification. Repair
estimates are available upon request. You must include this request with your
repair. Non-warranty repair estimates will be billed a minimum of ½ hour of
labor. In addition you will be billed for return freight. Please advise us of your
preferred method of payment. Horizon accepts money orders and cashiers
checks, as well as Visa, MasterCard, American Express, and Discover cards. If you choose to pay by credit card, please include your credit card number
and expiration date. Any repair left unpaid or unclaimed after 90 days will be
considered abandoned and will be disposed of accordingly. Please note: nonwarranty repair is only available on electronics and model engines.
Electronics and engines requiring inspection or repair should be shipped to the
following address:
Horizon Service Center
4105 Fieldstone Road
Champaign, Illinois 61822
All other Products requiring warranty inspection or repair should be shipped to
the following address:
Horizon Product Support
4105 Fieldstone Road
Champaign, Illinois 61822
Please call 877-504-0233 with any questions or concerns regarding
this product or warranty.
Warranty Information (continued)
Registration Form
Fill in and mail this form along with your dated sales
receipt (send a copy, keep the original for your files)
within 10 days of purchase to:
Horizon Service Center
Attn: Zenoah Warranty Dept.
4105 Fieldstone Road
Champaign, IL 61822
Engine Type: _ _________________________________________________________________________________
Date of Purchase: _______________________________________________________________________________
Owner’s Name: _ _______________________________________________________________________________
Street Address: _ _______________________________________________________________________________
City/State/Zip: _ ________________________________________________________________________________
Daytime Phone Number: __________________________________________________________________________
Purchased From: ________________________________________________________________________________
Dealer’s Name: _________________________________________________________________________________
Street Address: _ _______________________________________________________________________________
City/State/Zip: __________________________________________________________________________________
Please cut on dotted line.
21
22
23
© Copyright 2007, Horizon Hobby, Inc. www.horizonhobby.com
ZZPZ200
6135.2
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