Zenoah G320PUM, Owner'S Manual

Page 1: ...only parts which have been certified by Zenoah Zenoah assumes that no responsibility for this engine that is modified or used for any other applications Purchaser has all responsibilities against any...

Page 2: ...2...

Page 3: ...ng 6 Screw Propeller and Exhaust System 7 Fueling System 8 Starting 9 How to Stop The Engine 9 Carburetor Adjustment 10 Engine Break In 12 Operation 12 Maintenance 13 Special Tools 18 Service Guide 19...

Page 4: ...e and check it Start the engine on a flat surface without pebble stones Never modify the rotor Check the rotor If it is damaged replace it with a new one When mixing the fuel or operating the engine c...

Page 5: ...g to the Fig 1 Make sure that gasket and carburetor are mounted as described in fig 1 The engine does not start if carburetor is mounted upside down position CAUTION Engine Assembling 1 Engine 2 Gaske...

Page 6: ...sure that the engine should be mounted at least by 4 points both at engine s PTO side and recoil starter side Note 1 Be sure to set flat washers or metal plates on the reverse side of the mount to pre...

Page 7: ...when the maximum output is generated by using the exhaust system you are going to select And then decide the appropriate screw propeller that would meet such engine speed rpm that the exhaust system r...

Page 8: ...line is very flammable Avoid smoking and any fires near fuel 3 To prevent all possible problems on fueling system make sure to use the fuel filter which has more than 300 mesh or equivalent and gasoli...

Page 9: ...arter cord until the initial combustion noise is heard e When the initial combustion noise is heard open the choke set the throttle valve at the idle position or at the position slightly open from the...

Page 10: ...e atmospheric pressure altitude and an exhaust system etc of the area where the engine is used Start the engine without making any adjustments Make readjustments only when the engine shows any mal run...

Page 11: ...t a position which is 1 4 open from best mixture maximum R P M position High Speed needle Turning this needle clockwise makes the mixture gas leaner and turning it counterclockwise richer Set this nee...

Page 12: ...boat it may be better to operate the engine at slow RPM for 1 3 tank and mid high RPM for 2 3 tank The engine is already tuned up to get high performance and needs correct maintenance to keep such hi...

Page 13: ...rs Note Leakage Check Damage Crack Idling Speed Check Adjust Spark Plug gap Check Adjust Replace if necessary Cylinder barrel Check Cleaning Piston Ring Check Cleaning Muffler Bolt Check Cleaning Bear...

Page 14: ...io 9 7 Type Walbro WT Carburetor Venture mm 13 5 Starting Recoil Starter Type CDI Ignition Timing BTDC 30 7000rpm Standard CMR7H NGK Option Hot Type CMR6H No load max Speed rpm 20000 Idling Speed rpm...

Page 15: ...Groove and 0 02 0 04 0 1 Thickness Gauge Piston Ring mm End Gap mm 0 1 0 3 0 5 Thickness Gauge Width mm 0 98 0 93 Micro Meter Piston Pin Diameter mm 9 8 98 Micro Meter Connecting Rod Small end mm 12 1...

Page 16: ...Leak Tester Inlet Valve 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 Fly...

Page 17: ...7 Cylinder M5 P 0 8 7 9 6 9 8 8 Crankcase M5 P 0 8 5 8 4 7 6 9 Spark Plug M10 P 1 0 10 8 8 8 12 8 Muffler M5 P 0 8 8 8 6 9 9 8 Ignition Module M5 P 0 8 6 4 4 9 7 8 SO Coil M4 P 0 7 1 8 1 5 2 0 Recoil...

Page 18: ...o remove rotor 2 Piston Stopper 4810 96220 3 Hex Wrench 3304 97611 4 Snap Ring Pliers 5500 96110 To remove snap ring 5 Puller 581965501 To remove pulley assy To hold crankshaft when disassembling asse...

Page 19: ...OR 1 Remove the spark plug fit the piston stopper P N 4810 96220 into the cylinder 2 Remove the pulley assy by puller P N 581965501 and ratchet Fig 2 Fig 3 3 Remove the rotor using puller assy P N 577...

Page 20: ...olts M5x2 while pressing the ignition module toward rotor 3 Remove the 0 5mm plate and confirm that the air gap is 0 5 0 6mm by thickness gage 3 REMOVING PISTON PIN Fig 6 1 Remove snap rings from both...

Page 21: ...may come off during engine operation and damage the engine 5 APPLY LIQUID GASKET Fig 8 Apply the liquid gasket Three Bond TB1217F when taking the Cover TR on or off Apply a thin layer Do not let the...

Page 22: ...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 23: ...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 with dust Cleaning 3 Poor fuel qualit...

Page 24: ...24 Parts List G320PUM 967289101...

Page 25: ...WRENCH 1 97 577 40 97 01 PULLER A 1 OP 98 4810 96220 STOPPER 1 OP 99 3699 91975 SPARK PLUG NGK CMR6H 1 OP 1 585 87 83 01 CYLINDER A 1 2 585 72 72 01 COVER TR FLYWHEEL SIDE 1 3 585 72 71 01 COVER TR CL...

Page 26: ...10 81230 LEVER 1 68 3310 81240 SCREW 1 69 3310 81250 PIN 1 70 2630 81330 SCREW 1 71 3350 81380 SPRING 1 72 T2070 81370 SHAFT 1 73 2670 81410 SPRING throttle 1 74 2880 81470 SCREW 3 75 3310 81340 VALVE...

Page 27: ...ng through distributor manufacture 2 Zenoah shall not compensate any other accompanied or benefit losses caused to user and distributor manufacture by such faults and through repairing or replacing 4...

Page 28: ...Head Office 1 9 Minamidai Kawagoe city Saitama 350 1165 Japan Phone 81 49 243 1115 Fax 81 49 243 7197...