Zenoah G240RC, Owner'S Manual

Page 1: ...e use of radio control car Please use this engine in conjunction with the manual for radio control car or radio control equipment you are going to use Any modification of the engine or any use of othe...

Page 2: ...2...

Page 3: ...S 4 SAFETY PRECAUTIONS 5 FUEL 7 ENGINE STARTING 8 OPERATION 9 MAINTENANCE 10 SPECIAL TOOLS 15 SERVICE GUIDE 16 TROUBLE SHOOTING 19 PARTS LIST G240RC 22 PARTS LIST G270RC 26 PARTS LIST G290RC 30 WARRAN...

Page 4: ...C Overall Size L x W x H 166 x 205 x 196mm Weight 2 07kg Displacement 22 5cm3 25 4cm3 28 5cm3 Clutch Engagement 6000rpm STD Spring Carburetor Type WT 990 Spark Plug NGK CMR7H Spark Plug Gap 0 65mm Rot...

Page 5: ...ent as you enjoy your hobbies The fuel is toxic Do not let it get into your eyes or mouth Store it in a cool place out of the reach of infants and children Use of open flames around the fuel is strict...

Page 6: ...ng sleeves neckties and the like Failure to do so could result in injury When mounting the engine to a model make sure to follow the model s operating manual If necessary reinforce the engine mounting...

Page 7: ...added fuel or the rubber parts in the carburetor and engine will be damaged 2 Gasoline is very flammable Avoid smoking and any fires near fuel 3 To prevent all possible problems on fueling system make...

Page 8: ...Fig 3 Open the choke Fig 2 throttle idle 1 4 open Pull the starter quickly Operate engine for a few minutes for the warming up In case of engine warm condition choking may not be necessary Over chokin...

Page 9: ...gh speed and needs correct maintenance to keep such high performance The details for operation may be described in the separate owners manual to be issued by car manufacturer Be sure to have the engin...

Page 10: ...00 hours Note Leakage Check Damage Crack Idling Speed Check Adjust Air cleaner Check Cleaning Replace if necessary Spark Plug gap Check Adjust Cylinder barrel Check Cleaning Piston Ring Check Cleaning...

Page 11: ...Starting Recoil Starter Type TCI Ignition Timing BTC 30 8000rpm Standard CMR7H NGK CR8HIX with Terminal Nut Option Hot Type CMR6H Clutch Engagement Speed rpm 6000 STD Spring No load max Speed rpm 195...

Page 12: ...Groove and 0 02 0 04 0 1 0 02 0 04 0 1 0 02 0 04 0 1 Thickness Gauge Piston Ring mm End Gap mm 0 05 0 25 0 5 0 05 0 25 0 5 0 05 0 25 0 5 Thickness Gauge Width mm 0 78 0 73 0 98 0 93 0 98 0 93 Micro M...

Page 13: ...ve Closing Pressure kg cm2 0 7 1 7 Leak Tester 5 IGNITION SYSTEM Items Standard Limit Measuring Device Remarks Spark Plug Air Gap mm 0 6 0 7 0 7 Thickness Gauge Ignition Coil Flywheel Air Gap mm 0 3 0...

Page 14: ...9 4 9 with Locktight glue Clutch M6 P 1 0 6 4 4 9 7 8 Rotor M8 P 1 0 12 7 9 8 14 7 Cylinder M5 P 0 8 6 8 4 7 8 8 Crankcase M5 P 0 8 6 4 4 9 7 8 Spark Plug M10 P 1 0 10 8 8 8 12 8 Muffler M5 P 0 8 8 8...

Page 15: ...Piston Stopper 4810 96220 3 Rod Assy 1101 96220 To remove install piston pin 4 Air Gap Gauge 3330 97310 To set ignition coil 5 Hex Wrench 3304 97611 6 Snap Ring Pliers 5500 96110 To remove snap ring T...

Page 16: ...spark plug and fit the stopper 4810 96220 into the plug hole 3 Remove clutch bolts 14mm Hex 2 REMOVING ROTOR FAN 4 Remove the rotor nut 12mm Hex 5 Remove the rotor using the puller assy 2890 96100 Ap...

Page 17: ...tor Air Gap 0 3 0 4mm 4 REMOVING PISTON PIN 1 Remove snap rings from both sides of the piston pin 2 Engage the rod assy 1101 96220 to the piston pin and gently tap with a plastic hammer to push out th...

Page 18: ...during engine operation and damage the engine 6 CARBURETOR ADJUSTMENT The carburetor comes with a standard setting it is for optimum performance under the barometric pressure and climatic conditions...

Page 19: ...Switch is OFF ON the switch 2 Switch failure Exchange 3 Primary wiring earthed Repair Sparks appear in the spark plug Compression 1 Over sucking of fuel Drain excess fuel fueling is normal 2 Too rich...

Page 20: ...Water in fuel Change with good fuel 4 Piston start to seizure Replace piston and cylinder 5 Muffler choked with carbon Cleaning Overheating 1 Fuel too lean Adjust carburetor 2 Clogging of cylinder fin...

Page 21: ...21 PARTS LIST...

Page 22: ...22 PARTS LIST G240RC X374323111...

Page 23: ...23 G240RC X374323111...

Page 24: ...81150 DIAPHRAGM 1 65 1751 81470 GASKET 1 66 3310 81260 DIAPHRAGM 1 67 T2070 81210 BODY A 1 68 1751 81520 COVER 1 1 848ER812A0 CYLINDER 1 2 T2075 13120 GASKET 1 3 3310 12281 BOLT 4 M5x20L 4 1148 13162...

Page 25: ...129 1764 51220 SPRING 5000rpm IN 1 OP 130 3699 91975 SPARKPLUG NGK CMR6H 1 OP 131 3699 91809 SPARKPLUG Champion RZ7C 1 OP 69 1751 81510 PUMP 1 70 2867 81270 SPRING 1 71 3356 81310 VALVE inlet 1 72 14...

Page 26: ...26 PARTS LIST G270RC X374326111...

Page 27: ...27 G270RC X374326111...

Page 28: ...81150 DIAPHRAGM 1 65 1751 81470 GASKET 1 66 3310 81260 DIAPHRAGM 1 67 T2070 81210 BODY A 1 68 1751 81520 COVER 1 1 848ET812A0 CYLINDER 1 2 T2075 13120 GASKET 1 3 3310 12281 BOLT 4 M5x20L 4 1148 13162...

Page 29: ...129 1764 51220 SPRING 5000rpm IN 1 OP 130 3699 91975 SPARKPLUGNGK CMR6H 1 OP 131 3699 91809 SPARKPLUG Champion RZ7C 1 OP 69 1751 81510 PUMP 1 70 2867 81270 SPRING 1 71 3356 81310 VALVE inlet 1 72 148...

Page 30: ...30 PARTS LIST G290RC 966669901...

Page 31: ...31 PARTS LIST G290RC 966669901...

Page 32: ...1150 DIAPHRAGM 1 65 1751 81470 GASKET 1 66 3310 81260 DIAPHRAGM 1 67 T2070 81210 BODY A 1 68 1751 81520 COVER 1 1 574 79 09 01 CYLINDER 1 2 T2075 13120 GASKET 1 3 3310 12281 BOLT 4 M5x20L 4 1148 13162...

Page 33: ...1764 51220 SPRING 5000rpm IN 1 OP 130 3699 91975 SPARKPLUGNGK CMR6H 1 OP 131 3699 91809 SPARKPLUG Champion RZ7C 1 OP 69 1751 81510 PUMP 1 70 2867 81270 SPRING 1 71 3356 81310 VALVE inlet 1 72 1480 81...

Page 34: ...ants that 1 The quality disclosed in the specifications 2 The engine which shall be considered defective by Zenoah caused by material or production fault 3 Limits of Compensation 1 Zenoah compensates...

Page 35: ...e even if the fault has been caused during the period of terms of Warranty in case that 1 Any faults failures caused from neglect of proper operation and maintenance described in OWNER S MANUAL 2 Any...

Page 36: ...1 9 Minamidai Kawagoe city Saitama 350 1165 Japan Phone 81 49 243 6917 Fax 81 49 243 7197...