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848ER893A0 (804)
OWNER'S MANUAL
Model: G240RC/G270RC
Model code: X374323111 (G240RC)
Model code: X374326111 (G270RC)
Thank you for using ZENOAH ENGINE.
● Please read this Owner’s Manual thoroughly before operating and use the
engine correctly according to this Owner’s Manual.
(For safety reasons, please contact your sales dealer before operating this
engine if there is something that you do not understand.)
● This engine has been designed for the use of radio control car.
Please use this engin
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CONTENTS SPECIFICATIONS.....................................................4 SAFETY PRECAUTIONS..........................................5 FUEL .........................................................................7 ENGINE STARTING..................................................8 OPERATION .............................................................9 MAINTENANCE ......................................................10 SPECIAL TOOLS ....................................................15 SE
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SPECIFICATIONS Engine Type G240RC G270RC Overall Size (L x W x H) 166 x 205 x 196mm Weight 2.07kg 3 3 Displacement 22.5cm 25.4cm 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) 4
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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 care to act with good judgment 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 op
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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. 6
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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 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 sure to use the fuel filter which has mor
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ENGINE STARTING • Push the primer pump several times until overflown fuel Primer Pump Fig.1 flows out. (Fig.1) • Close the choke lever, and move the throttle lever Choke Lever 1/4~1/3 open position. (Fig.1)(Fig.2) Close • Pull the starter(knob) quickly until first firing noise. (Fig.3) Open • Open the choke(Fig.2), throttle idle~1/4 open • Pull the starter quickly Fig.2 • Operate engine for a few minutes for the warming up. IMPORTANT Throttle Lever • In case of engine warm condition, choking may
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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 seconds at idle speed after full throttle running. 9
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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 Check/Cleaning ✔✔ ↑ Muffler & Bolt Check/Cleaning ✔✔✔ ↑ Bearings Check/Cleaning ✔✔ ↑ Crank Shaft Check/Alignment ✔ ↑ 10
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MAINTENANCE 2) SPECIFICATIONS AND TECHNICAL DATA Items Unit G240RC G270RC Remarks Bore x Stroke mm 32 x 28 34 x 28 3 Displacement cm 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 ← Standard CMR7H ← NGK CR8HIX ↑ Option(For Race) ← Spark Plug with Terminal Nut Option(Hot Type) CMR6H ←↑ Clutch Engagement Speed rpm 6000 ← No load max Speed rpm 19500 ← Idling Speed rpm 4000 ← Max. Pow
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MAINTENANCE 3) MAINTENANCE SPECIFICATIONS G240RC G270RC Items Standard Limit Standard Limit Measuring Device Remarks Bore (mm) ø32 Plating damaged ø34 Plating damaged Eye Checking Cylinder At the skirt end and Diameter (mm) ø31.97 ø31.87 ø33.97 ø33.87 Micro Meter the right angle to the piston pin. Piston Ring 0.81 0.91 1.01 1.11 Thickness Gauge Groove width (mm) Piston Pin Hole (mm) ø8.01 ø8.05 ø8.01 ø8.05 Cylinder Gauge Piston Clearance between Micro Meter Piston and 0.03~0.06 0.15 0.03~0.06 0
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Ω MAINTENANCE 4) CARBURETOR Items Standard Limit Measuring Device Remarks Metering Lever set (mm) 1.65 ± 0.16 Vanier 2 Inlet Valve Opening Pressure (kg/cm ) 1.3~2.3 Leak Tester 2 Inlet Valve Closing Pressure (kg/cm ) 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 0.4 Thickness Gauge Reading between Primary 0.7 — Volt Meter primary terminal and Coil iron core. Resis
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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 Spark Plug M10 (P=1.0) 10.8 8.8~12.8 Muffler M5 (P=0.8) 8.8 6.9~9.8 Fan Cover M5 (P=0.8) 3.4 2.9~3.9 Ignition Coil M4 (P=0.7) 3.2 2.5~3.9 Starter Case M4 (P=0.7) 1.3 1.0~1.5 Tapping Screw TP 4.3 2.4 1.
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SPECIAL TOOLS Part Name Part No. External Appearance Usage 1 Puller Assy 2890-96100 To remove rotor. To hold crankshaft when 2 Piston Stopper 4810-96220 disassembling/assembling clutch and rotor. 3 Rod Assy 1101-96220 To remove/install piston pin. 4 Air Gap Gauge 3330-97310 To set ignition coil. For socket screw of Hex. 5 Hex Wrench 3304-97611 3mm, 4mm and 5mm. 6 Snap Ring Pliers 5500-96110 To remove snap ring. 15
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SERVICE GUIDE 1) REMOVING CLUTCH SHOE 1. Remove the housing and plug cap. 2. Remove the spark plug and fit the stopper(4810- 96220) into the plug hole. Clutch Bolt (14mm Hex.) 3. Remove clutch bolts(14mm Hex.). 2) REMOVING ROTOR (FAN) Rotor Nut 4. Remove the rotor nut(12mm Hex.). 5. Remove the rotor using the puller assy (2890-96100). Apply 8mm puller bolts. 17mm Hex. Puller Bolts Puller Rotor 16
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SERVICE GUIDE 3) ASSEMBLING ROTOR Ignition Coil Insert the gauge(3330-97310) in between the rotor Wrench magnet metal and the coil.Tighten screws while pressing the coil against the rotor. Air Gap 0.3 ~ 0.4mm Air Gap Gauge 4) REMOVING PISTON PIN 1. Remove snap rings from both sides of the piston pin. Rod Assy 2. Engage the rod assy(1101-96220) to the piston pin Piston and gently tap with a plastic hammer to push out the Plastic pin while holding piston firmly. Hammer NOTE Hard hammering may
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SERVICE GUIDE 5) INSTALLING PISTON End Gap 1. Make sure to point the arrow mark on the piston to the Arrow Mark exhaust side. Piston 2. Fit the circlip in the groove so as to face the end gap Circlip below. NOTE Deformed circlip may come off 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 H needle L needle climatic conditions at factory, so it may be re-adjuste
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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. Burn out of electrodes Exchange Magneto 1. Ignition coil inside failure Exchange 2. Damaged cable sheath or disconnected cable Exchange or repair Switch 1. Switch is OFF ON the switch 2. Switch failur
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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 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 with
