Zenoah G240RC Manual - Free PDF Download

Page 3 - CONTENTS

3 SPECIFICATIONS.....................................................4 SAFETY PRECAUTIONS..........................................5 FUEL .........................................................................7 ENGINE STARTING..................................................8 OPERATION .............

Page 4 - SPECIFICATIONS

4 SPECIFICATIONS Engine Type G240RC G270RC Overall Size (L x W x H) 166 x 205 x 196mm Weight 2.07kg Displacement 22.5cm 3 25.4cm 3 Clutch Engagement 6000rpm (STD Spring) Carburetor Type WT-813A Spark Plug NGK CMR7H Spark Plug Gap 0.65mm Rotating Direction Counter-Clockwise (View From PTO)

Page 5 - SAFETY PRECAUTIONS

5 SAFETY PRECAUTIONS ● These safety precautions are to prevent you and those people in the vicinity from incurring harm or damage. Make sure to observe these precautions and constantly strive to ensure safety. ● Safe use of the engine is your personal obligation and responsibility. Constantly take c...

Page 6 - • When mounting the engine to a model, make sure to follow the model’s

6 SAFETY PRECAUTIONS overly long 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 unit and the peripheral parts.

Page 7 - FUEL; • The mixing ratio is according to the oil recommendation.

7 FUEL • Mix gasoline (octane over 95) and high grade 2 cycle engine oil (mixing use type; F3C grade or ISO EGC grade) at mixing ratio 25~40:1. • The mixing ratio is according to the oil recommendation. [ NOTE ] 1) Never use any alcohol fuel or alcohol added fuel, or the rubber parts in the carburet...

Page 8 - ENGINE STARTING; IMPORTANT

8 ENGINE STARTING • Push the primer pump several times until overflown fuel flows out. (Fig.1) • Close the choke lever, and move the throttle lever 1/4~1/3 open position. (Fig.1)(Fig.2) • Pull the starter(knob) quickly until first firing noise. (Fig.3) • Open the choke(Fig.2), throttle idle~1/4 open...

Page 9 - OPERATION; maintenance to keep such high performance.

9 OPERATION • This engine is already tuned up to get high power and high 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 engine cool down for 30 seco...

Page 10 - MAINTENANCE; ) MAINTENANCE CHART

10 MAINTENANCE 1) MAINTENANCE CHART Before Every Every Items Action Use 25 hours 100 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 Chec...

Page 11 - ) SPECIFICATIONS AND TECHNICAL DATA

11 MAINTENANCE 2) SPECIFICATIONS AND TECHNICAL DATA Items Unit G240RC G270RC Remarks Bore x Stroke mm 32 x 28 34 x 28 Displacement cm 3 22.5 25.4 Effective Compression Ratio 8.9 8.9 Type Walbro WT ← Carburetor Venture(mm) ø12.7 ← Starting Recoil Starter ← Type TCI ← Ignition Timing BTC 30°/8000rpm ←...

Page 12 - ) MAINTENANCE SPECIFICATIONS

12 MAINTENANCE 3) MAINTENANCE SPECIFICATIONS G240RC G270RC Items Standard Limit Standard Limit Measuring Device Remarks Bore (mm) ø32 Plating damaged ø34 Plating damaged Eye Checking Diameter (mm) ø31.97 ø31.87 ø33.97 ø33.87 Micro Meter Piston Ring 0.81 0.91 1.01 1.11 Thickness Gauge Groove width (m...

Page 14 - ) TIGHTENING TORQUE

14 MAINTENANCE 6) TIGHTENING TORQUE Items Screw Size Standard (N·m) Limit (N·m) Remarks Carburetor M5 (P=0.8) 3.4 2.9~3.9 Insulator M5 (P=0.8) 4.4 3.9~4.9 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...

Page 15 - SPECIAL TOOLS

15 SPECIAL TOOLS Part Name Part No. External Appearance Usage 1 Puller Assy 2890-96100 To remove rotor. 2 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 sna...

Page 16 - SERVICE GUIDE; ) REMOVING CLUTCH SHOE; R e m o v e t h e s p a r k p l u g a n d f i t t h e s t o p p e r ( 4 8 1 0 -

16 SERVICE GUIDE 1) REMOVING CLUTCH SHOE 1. Remove the housing and plug cap. 2. R e m o v e t h e s p a r k p l u g a n d f i t t h e s t o p p e r ( 4 8 1 0 - 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 roto...

Page 17 - ) REMOVING PISTON PIN; NOTE

17 SERVICE GUIDE 3) ASSEMBLING ROTOR I n s e r t t h e g a u g e ( 3 3 3 0 - 9 7 3 1 0 ) i n b e t w e e n t h e r o t o r magnet metal and the coil.Tighten screws while pressing the coil against the rotor. Air Gap 0.3 ~ 0.4mm 4) REMOVING PISTON PIN 1. Remove snap rings from both sides of the piston...

Page 18 - ) INSTALLING PISTON

18 SERVICE GUIDE 5) INSTALLING PISTON 1. Make sure to point the arrow mark on the piston to the exhaust side. 2. Fit the circlip in the groove so as to face the end gap below. D e f o r m e d c i r c l i p m a y c o m e o f f d u r i n g e n g i n e operation and damage the engine. 6) CARBURETOR ADJ...

Page 19 - TROUBLE SHOOTING; ) ENGINE DOES NOT START

19 TROUBLE SHOOTING 1) ENGINE DOES NOT START Description Cause Countermeasure No spark in the spark plug Spark Plug 1. Wet spark plug electrodes Make them dry 2. Carbon deposited on the electrodes Cleaning 3. Insulation failure by insulator damage Exchange 4. Inproper spark gap Adjust to 0.6~0.7mm 5...

Page 20 - ) LACK OF POWER OR UNSTABLE RUNNING

20 TROUBLE SHOOTING 2) LACK OF POWER OR UNSTABLE RUNNING Description Cause Countermeasure Compression is normal 1. Air penetration from fuel pipe joints, etc Secure connection and no misfire 2. Air penetration from intake tube joint or Change gasket or tightening screws carburetor joint 3. Water in ...

Page 21 - PARTS LIST

Page 30 - WARRANTY; WARRANTY TERMS; covered by this warranty.; ) Limits of Warranty; Zenoah warrants that; ) Limits of Compensation; replacing through distributor/manufacture.

30 WARRANTY WARRANTY TERMS 1) Scope of Application This engine manufactured by Husqvarna Zenoah Co., Ltd. (herein after “Zenoah”). And sold to the user directly or through distributor/manufacturer, shall entitle to be covered by this warranty. 2) Limits of Warranty Zenoah warrants that; 1. The quali...

Page 31 - ) Exempt from Warranty; period of terms of Warranty, in case that.

31 WARRANTY 4) Term of Warranty Three (3) months after purchased by end- user subject to 12 months from produced month. 5) Exempt from Warranty Zenoah shall not warrant this engine even if the fault has been caused during the period of terms of Warranty, in case that. 1. Any faults, failures caused ...