APC Zenoah Switch User Manual

®
ENGINE INSTRUCTION MANUAL
4
3
5
2
7
1
6
G26 Air
G26/231 Marine
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
Troubleshooting Guide for Gasoline Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Propeller Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exploded Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
G26/G231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
G38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
G45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
GT80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Non-Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Registration Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2
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.
7. Use a thickly padded glove when hand starting
the 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.
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.
11. Make sure your fuel is kept in a safe place well away
from sparks, heat or anything that could ignite the fuel.
3. Use the correct size and pitch of propeller for your
engine; refer to the propeller chart in this manual.
1. Use safety glasses or goggles when starting and
running your engine.
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.
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.
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.
Recommendations
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.
3
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 your engine 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 observation 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. Attached 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, which are not included with your
Zenoah engine, are necessary in order to operate the
model engine.
Fuel—Mix gasoline and 2-stroke 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 get
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.
4
Zenoah Oil
ZEN20001
Zenoah Start Kit
ZEN20002
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 anti-vibration, check the hardness of the rubber, making sure it’s
not too soft, in order to avoid excessive vibration during
engine operating rpms. It’s suggested you 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 you coat the bolts for the muffler 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.
5
Operation (continued)
8. Quickly flip the propeller in a counterclockwise
direction according to the procedure described in
the note above.
9. The engine should start after a few flips of the
propeller.
body, or the throttle valve should be closed completely.
Installation of a “stop” or “kill” switch is recommended.
Red Lead
Black Lead
10. Be sure to open the choke when the initial firing
of the engine is heard.
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.
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.
Starting the Engine— Helicopter and
Boat
Kill Switch
Engine
Body
Ground
Refer to the example shown in the following diagram.
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.
High-Speed Needle
Low-Speed Needle
1. Fill the tank with fuel.
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
6
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 a Zenoah 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.
Servicing the Engine
Required Tools
• Brush
Note: Because the crankshaft is of the assembly type,
do not disassemble, hit or twist its end.
Disassembly
1. Dismount the engine from the model.
• Regular screwdriver
2. Remove the carburetor and insulator carefully without
damaging the gasket.
• Phillips screwdriver
3. Remove the muffler.
• Hexagonal wrench (4mm/5/32")
4. Remove the spark plug and ignition module.
• Open wrench (19mm/3/4")
5. Remove the propeller hub.
• Plastic hammer
6. Remove the rotor (flywheel). If it cannot be detached,
use a plastic hammer and hit the part lightly.
• Thickness gauge
• Thread lock (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 in to the bottom.
• Lithium grease
b. Loosen and remove the rotor securing nut.
• Tapered round rod
• Liquid gasket (Permatex or equivalent)
7
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.
7. Wipe the contact surfaces of the cylinder block
and crankcase, and apply liquid gasket (Permatex
or equivalent).
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 con rod (G38).
15. Remove the piston ring.
16. Wash each part. Check for abrasion and damage, and
replace any part that is defective.
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 set screws and fix the coil temporarily.
2. Fit the piston ring to the piston.
15. Set the rotor (flywheel) so that the magnet is located
on the opposite side of the module (G-38). 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 set screws after
having applied threadlock (Blue Threadlock Z-42)
to them.
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).
16. Using a new gasket, fix the insulator with screws
to which threadlock (Blue Threadlock Z-42) has been
applied.
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.
17. Using a new gasket, mount the carburetor with
screws, paying attention to its mounting direction.
5. Fit the circlip.
19. Install the spark plug.
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.
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.)
18. Tighten the mounting plate, using screws with
threadlock (Blue Threadlock Z-42) applied.
Note: Disassembly and assembly steps were
written using a G38 engine as an example, but
they apply to all engines.
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
8
installed. Should the engine fail to start after these items
are verified, refer to the charts on the following page.
Troubleshooting Guide for Gasoline Engines
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
The spark plug gap is too large
Adjust
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
9
Troubleshooting Guide for Gasoline Engines
(continued)
In the event that none of the above procedures results
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 set-up 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.
ENGINE
PROPELLER
G26A
16x8 @ 8,700
G231 Heli
Adjust pitch of rotor to obtain
9,000–10,000 rpm of the
engine at full throttle
G26 Marine
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
10
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
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
1800–10,000
BIS07445/6
SPECIFICATIONS
Displacement
(cu in)
Bore
(in)
Stroke
(in)
Weight
(oz)
K
(ISO)
HP
(H/M)
Carb
(Walboro)
G26A/M
1.55
1.41
1.1
54
M8x1.25/6x1
2.4
WT645/WT644
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
1.59x2
1.22x2
126
—
6
WJ-64
* w/spring starter
11
Exploded Illustration
G26/G231
Index
No.
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
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
12
Q’ty per unit
Part No.
ZEN2601
ZEN2301RC
ZEN2601M
ZEN23102M
ZEN23103M
ZEN2304M
ZEN23105M
ZEN23106M
ZEN23107M
ZEN23108
ZEN2309
ZEN23110
ZEN23111
ZEN23112
ZEN23114
Description
CYLINDER
CYLINDER
CYLINDER
CYLINDER
JACKET
JOINT
O-RING 3X40
O-RING 1.5X15.5
BOLT M3X8
GASKET, CYLINDER
BOLT M5X20
GASKET, INSULATOR
INSULATOR
GASKET, CARBURETOR
CRANKCASE, COMP.
CRANKCASE, (R)
ZEN6213
ZEN23116
ZEN2317
ZEN2318
ZEN2319
ZEN2320
ZEN2321M
ZEN2322
ZEN2623
ZEN2320RC
ZEN2624
ZEN2321RC
ZEN2625
ZEN2325
ZEN2326
ZEN2327
ZEN2328
ZEN23129
ZEN2330
ZEN2331
ZEN2332
ZEN2333M
ZEN2634
ZEN2431
ZEN6227
ZEN2337
ZEN6236
ZEN2339M
ZEN2354
ZEN6241
ZEN2341
ZEN2638
ZEN6239
ZEN6237
ZEN26451
ZEN2648
ZEN2647
ZEN2649
ZEN23150H
ZEN2650
CRANKCASE, (F)
PIN
GASKET
SEAL 12X22X7
BEARING
SNAPRING
BEARING
SEAL 12X28X7
BOLT M5X30
PISTON
PISTON
RING
RING
PISTON RING
PISTON RING
SNAP RING
BEARING
WASHER
CRANKSHAFT, COMP.
MOUNT, PLATE
SCREW M5X16
NUT M8
PULLEY
RECIL ASSY
SCREW M4X14
KEY
SHIM
COIL, (GREY)
COIL, (RED)
ROTOR
SCREW M4X22
SCREW M4X14
PLUG CAP
SPRING
COIL
SPARK PLUG RZ7C
SCREW M5X55
SPACER 5X10X1.6
AIR-FUNNEL
CLEANER ASSEMBLY
TUBE
G260
G260
G231
G2301
1
–
–
–
–
–
–
–
–
1
6
1
1
1
1
1
1
3
1
1
2
1
1
–
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
2
1
1
2
1
6
1
1
1
1
1
1
3
1
1
2
1
–
1
4
1
–
1
–
1
–
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
–
2
2
1
–
1
–
1
–
–
–
–
–
–
–
1
6
1
1
2
1
1
1
3
1
1
2
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
1
2
1
1
2
1
6
1
1
1
1
1
1
3
1
1
2
1
–
1
4
–
1
–
1
–
1
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
–
2
2
1
–
1
PU PUM PUH PUM
Index
No.
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
Q’ty per unit
Part No.
ZEN2651
ZEN23151
ZEN23152
ZEN2359
ZEN2360
ZEN2361
ZEN2362
ZEN23156
ZEN2357
ZEN2357H
ZEN2358
ZEN2358H/RC
ZEN2655
ZEN2355
ZEN2366
ZEN2367
ZEN23124RC
Description
CARBURETOR ASSY WT-645
CARBURETOR ASSY WT-644
CARBURETOR ASSY WT-643
HUB
STUD
WASHER
NUT M8
GASKET, MUFFLER
BOLT M5X50
BOLT M5X60
SCREW M4X8
SCREW M4X16
MUFFLER
MUFFLER
SPACER
SPACER
SOCKET
G260
G260
G231
G2301
1
–
–
1
1
1
1
1
2
–
1
–
1
–
–
–
1
–
1
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1
–
–
1
–
–
–
–
2
–
2
–
1
–
1
1
1
1
–
1
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1
PU PUM PUH PUM
Exploded Illustration
G38
Index
No.
1
2
3
4
5
6
11
12
13
14
15
16
17
18
19
20
(Standard Accessory for
G380PU)
Part No. Description
ZEN3801 CYLINDER
ZEN3802 INSULATOR
ZEN3803 CARB GASKET
ZEN3804 INSULATOR SCREW
ZEN3805 INSULATOR GASKET
ZEN3806 MUFFLER ASS’Y
ZEN3811 MUFFLER GASKET
ZEN3812 MUFFLER BOLT
ZEN3813 CRANKCASE
ZEN3814 CASE BOLT
ZEN3815 CASE WASHER
ZEN3816 CASE PLUG
ZEN3817 PLUG GASKET
ZEN3818 PISTON
ZEN3819 PISTON RING
ZEN3820 PISTON PIN
Q’ty/
unit
1
1
1
2
1
1
1
2
1
4
4
1
1
1
1
1
Index
No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Part No. Description
ZEN3821 PIN RETAINER
ZEN3822 CONROD SPACER
ZEN3823 CONROD BEARING
ZEN3824 CRANKSHAFT
ZEN3825 CRANKSHAFT BEARING
ZEN3826 FRONT OIL SEAL
ZEN3827 SNAP RING
ZEN3828 REAR OIL SEAL
ZEN3829 KEY
ZEN3830 ROTOR NUT
ZEN3831 LOCK WASHER
ZEN3832 ROTOR WASHER
ZEN3833 PROP HUB (NEW)
ZEN3834 HUB BOLT
ZEN3835 PROP WASHER (NEW)
ZEN3836 PROP BOLT (NEW)
Q’ty/
unit
2
2
1
1
2
1
1
1
1
1
1
1
1
2
1
2
Q’ty/
Index
unit
No. Part No. Description
1
37 ZEN3837 MODULE
1
38 ZEN3838 ROTOR (NEW)
3
39 ZEN3839 SPACER (MODULE)
1
40 ZEN6238 PLUG CAP (BLACK)
1
41 ZEN6239 CAP SPRING
1
42 ZEN6242 SPARK PLUG, C859
3
43 ZEN3843 MODULE BOLT
44-1 ZEN3844 CARB ASS’Y (HT-338) W/CHOKE 1
44-2 ZEN3850 CARB ASS’Y (WTA-6) W/O CHOKE 1
2
45 ZEN3845 CARB SCREW
1
46 ZEN3846 MOUNT
for G380PU 4
47 ZEN3847 MOUNTING BOLT
1
ZEN3870 GASKET SET
1
ZEN3871 SCREW/NUT SET
}
13
Exploded Illustration
G45
Index
No.
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
18
19
20
14
Part No.
ZEN4501
ZEN4502
ZEN4503
ZEN4504
ZEN6204
ZEN4506
ZEN4504
ZEN6207
ZEN6208
ZEN6209
ZEN6210
ZEN4513
ZEN6213
ZEN6214
ZEN6215
ZEN6216
ZEN6217
ZEN6276
ZEN4520
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
Q’ty/
unit
1
1
1
2
1
1
4
1
1
2
2
1
3
1
2
1
1
1
1
Index
No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Part No. Description
ZEN4504 BOLT
ZEN4522 PIPE
ZEN4523 PISTON
ZEN4524 PISTON RING
ZEN4525 PISTON PIN
ZEN6223 PIN RETAINER
ZEN6224 CONROD BEARING
ZEN4528 WASHER
ZEN4529 CRANKSHAFT COMP.
ZEN6228 SHIM
ZEN6227 KEY
ZEN6229 FLYWHEEL NUT
ZEN6230 PROP HUB
ZEN6232 HUB BOLT
ZEN6233 WASHER
ZEN6234 PROP BOLT
ZEN6257 MAGNETO ASS’Y
ZEN6235 ROTOR
ZEN6236 SOURCE COIL
Q’ty/
unit
4
1
1
2
1
2
1
2
1
0-2
1
1
1
2
1
1
1
1
1
Index
No.
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
Part No. Description
ZEN6237 IGNITION COIL
ZEN6238 PLUG CAP (BLACK)
ZEN6239 CAP SPRING
ZEN4543 SOURCE COIL SCREW
ZEN6241 COIL SCREW
ZEN6242 SPARK PLUG
ZEN6243 CARBURETOR ASS’Y
ZEN4547 BOLT
ZEN6245 WASHER
ZEN6246 WASHER
ZEN6247 BOLT
ZEN6248 MOUNT
*for G450PU
ZEN6249 BOLT
ZEN6250 WASHER
ZEN6251 PULLER ASS’Y
ZEN6252 STOPPER (OPTIONAL)
ZEN6253 GUIDE (OPTIONAL)
ZEN4557 WRENCH (OPTIONAL)
}
Q’ty/
unit
1
1
1
2
2
1
1
2
2
2
1
1
4
4
1
1
1
1
Exploded Illustration
G62
* (Accessory for G620PU-1)
Index
No. Part No. Description
1 ZEN6201 CYLINDER
2 ZEN6202 INSULATOR GASKET
3 ZEN6203 INSULATOR
4 ZEN6204 CARBURETOR GASKET
5 ZEN6205 CYLINDER BASE GASKET
6 ZEN2309 CYLINDER BOLT
7 ZEN6207 MUFFLER
8 ZEN6208 MUFFLER GASKET
9 ZEN6209 MUFFLER BOLT
10 ZEN6210 MUFFLER NUT
11,12 ZEN6211 CRANKCASE COMP.
13 ZEN6213 CASE PIN
14 ZEN6214 SNAP RING
15 ZEN6215 BEARING
16 ZEN6216 REAR OIL SEAL
17 ZEN6217 FRONT OIL SEAL
18 ZEN6218 CRANKCASE GASKET
19 ZEN6219 CASE ASS’Y BOLT
20 ZEN6220 PISTON
Q’ty/
Q’ty/ Index
unit
unit No. Part No. Description
4
1
21 ZEN6221 PISTON RING
1
1
22 ZEN6222 PISTON PIN
1
1
23 ZEN6223 PIN RETAINER
2
1
24 ZEN6224 NEEDLE BEARING
1
1
25 ZEN6225 CONROD SPACER
2
4
26 ZEN6226 CRANKSHAFT COMP.
1
1
27 ZEN6227 KEY
2
1
28 ZEN6228 SHIM
1
2
29 ZEN6229 FLYWHEEL NUT
2
30 ZEN6230 PROPELLER COMP. FOR G620PU-1 0-2
1
1
31 ZEN44553 HUB
1
3
32 ZEN6232 PIN FOR G620PU-1
2
1
33 ZEN6233 HUB BOLT
1
2
34 ZEN6234 PROP WASHER
1
1
35 ZEN6235 PROP BOLT
1
1
36 ZEN6236 ROTOR
1
1
37 ZEN6237 SOURCE COIL
1
4
38 ZEN6238 IGNITION COIL
1
1
39 ZEN6239 PLUG CAP (BLACK)
Index
No.
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Part No. Description
ZEN6240 IGNITION COIL SCREW
ZEN6241 SOURCE COIL SCREW
ZEN6242 SPARK PLUG, C859
ZEN6243 CARBURETOR ASS’Y
ZEN6244 CARB MOUNT SCREW
ZEN6245 CARB WASHER
ZEN6246 WASHER
ZEN6247 TAP PROP BOLT
ZEN6248 MOUNT
*for G62PU
ZEN6249 BOLT
ZEN6250 WASHER
ZEN6251 PULLER ASS’Y
ZEN6252 STOPPER (OPTIONAL)
ZEN6253 PISTON PIN GUIDE (OPTIONAL)
ZEN6200 SPRING STARTER
ZEN6255 HIGH-SPEED NEEDLE
ZEN6256 LOW-SPEED NEEDLE
ZEN6257 MAGNETO ASS’Y
}
Q’ty/
unit
2
2
1
1
2
2
2
1
1
4
4
1
1
1
1
1
1
1
PLUG CAP SPRING
15
Exploded Illustration
GT80
Index
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part No.
ZEN44501
ZEN44502
ZEN44503
ZEN44504
ZEN44505
ZEN44506
ZEN4547
ZEN44508
ZEN44509
ZEN44510
ZEN6213
ZEN6215
ZEN6214
ZEN44514
ZEN6217
ZEN6276
ZEN44517
ZEN44518
ZEN44509
ZEN44520
ZEN44521
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
Q’ty/
unit
2
1
2
4
1
1
2
2
8
1
4
2
2
1
1
1
1
1
4
2
4
Index
No.
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Part No.
ZEN44522
ZEN44523
ZEN44524
ZEN44525
ZEN44526
ZEN6228
ZEN6227
ZEN6229
ZEN6235
ZEN6236
ZEN6238
ZEN44533
ZEN6238
ZEN6239
ZEN6242
ZEN44537
ZEN44538
ZEN44539
ZEN44540
ZEN6209
ZEN44542
Description
PISTON PIN
PIN RETAINER
BEARING
THRUST WASHER
CRANKSHAFT COMP
SHIM
KEY
NUT
ROTOR
SOURCE COIL
IGNITION COIL
CORD
PLUG CAP (BLACK)
CAP SPRING
SPARK PLUG, C859
SCREW
SCREW
MUFFLER
MUFFLER GASLET
MUFFLER BOLT
NUT
Q’ty/
unit
2
4
2
4
1
0-2
1
1
1
1
2
1
2
2
2
4
2
2
2
4
Q’ty/
Index
unit
No. Part No. Description
43 ZEN44543 MOUNT
1
44 ZEN44544 BOLT
3
45 ZEN44545 BOSS
1
46 ZEN44546 CLUTCH COMP
1
47 ZEN44547 SPRING
1
48 ZEN44548 COLLAR
1
49 ZEN44549 WASHER
1
50 ZEN44550 BOLT
1
51 ZEN44551 PAD
1
52 ZEN44552 HUB. PROPELLER COMP
1
53 ZEN44553 PIN
2
54 ZEN6232 HUB BOLT
2
55 ZEN6233 HUB WASHER
1
56 ZEN6234 PROP BOLT
1
57 ZEN6247 TAP PROP BOLT
1
58 ZEN44555 SOCKET
1
59 ZEN6251 PULLER ASS’Y (OPTIONAL) 1
60 ZEN44554 STOPPER (OPTIONAL)
1
ZEN44556 HIGH-SPEED NEEDLE
1
ZEN44557 LOW-SPEED NEEDLE
1
G80A Index
No.
01
02
20
21
16
Part No.
ZEN8001
ZEN8002
ZEN8020
ZEN8021
Description
CYLINDER
INTAKE MANIFOLD (BLACK)
PISTON
PISTON RING
Q’ty/
unit
2
1
2
2
Warranty Information
Zenoah® engines are guaranteed against workmanship
and manufacturing defects for a period of 3 years from
the original date of purchase. This warranty is limited to
the original purchaser and is not transferable.
Warranty repairs will not cover:
• Normal engine wear
• Damage due to insufficient maintenance
• Damage related to over-revving of the engine due
to small prop size or unreasonable use
• Rusted bearings
• Crash damage
• Damage due to use of improper fuel and/or spark plug
• Damage due to lean runs, such as rusted bearings,
seized connecting rod or piston, etc.
• Damage caused by foreign objects
1. Include complete name and address information
inside the carton, as well as clearly writing it on the
outer label/return address area.
2. Include a note containing a brief summary of the
difficulty and include the following information:
• Propeller size and brand used
• Type of spark plug used
• Type of engine mount
• Approximately how much running time the engine had
before difficulty
3. Date your correspondence and be sure your name and
address appear on this enclosure.
4. Include a phone number where you can be reached
during the business day.
Warranty Repairs
• Damage caused by unreasonable mounting or running
conditions (dust, insufficient cooling, improper mounting, improper propeller size of lack of balancing, etc.)
To receive warranty service you must include your original dated sales receipt to verify your proof-of-purchase
date. Providing that warranty conditions have been met,
your engine will be repaired without charge.
• Damage due to improper disassembly
Non-Warranty Repairs
• Modifications of any kind
If your engine needs repair, ship it in its original box,
freight prepaid to:
Horizon Service Center
Attn: Zenoah Service
4105 Fieldstone Road
Champaign, IL 61822
Phone: (217) 355-9511
Note: Do not use the engine’s original box as the
shipping box. Rather, package this box inside a
sturdy shipping box.
Should your repair cost exceed 50% of the retail
purchase cost, you will be provided with an estimate
advising you of your options. Any return freight for
non-warranty repairs will be billed to the consumer.
We accept both Visa and MasterCard for payment.
Please include your card number and expiration date.
The Consumer Warranty Registration below must be
completely filled out and mailed to:
Horizon Service Center
Attn: Zenoah Warranty
4105 Fieldstone Road
Champaign, IL 61822
17
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.
18
19
© Copyright 2002, Horizon Hobby, Inc.
www.horizonhobby.com
5140