Manual Zenoah G45
Manual Zenoah G45
3 5
7
1
6
G26 Air 1
G26/231Marine 2
G26/G231 Heli 3
G38 4
G62 5
GT80 Twin 6
G45 7
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Propeller Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exploded Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
G26/G231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
G38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
G45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
GT80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Non-Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Introduction
Congratulations on purchasing a Zenoah® engine. Cared This instruction manual has been developed to ensure
for properly, these high-quality, finely crafted engines will optimum performance from the Zenoah engine you have
offer many years of reliability. 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 func- 7. Use a thickly padded glove when hand starting
tions. For specific information on mounting, see the the engine.
instruction manual included with the model airplane, heli-
8. Make all carburetor adjustments from behind
copter or boat in which you intend to install the engine.
the propeller.
This model engine will give you considerable pleasure,
9. To stop the engine, the black lead wire from the
satisfaction and performance if you strictly follow these
coil should be grounded to the engine body, or use the
safety instructions and take heed of the warnings as to
throttle linkage to shut off the air by closing the throttle
the engine’s safe and proper use. This engine has more
valve completely.
than enough power to cause harm if misused or if the
safety precautions are not observed. 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!
Always 10. Ensure that all spectators, especially children, are at
1. Use genuine parts for replacement. least 20 feet away when you start running the engine.
2. Check the propeller, rotor (helicopter) or screw 11. Make sure your fuel is kept in a safe place well away
propeller (boat) prior to each time the engine is used. from sparks, heat or anything that could ignite the fuel.
If nicked, scratched, cracked or damaged in any way,
Recommendations
replace it with a new one.
1. Use safety glasses or goggles when starting and
3. Use the correct size and pitch of propeller for your
running your engine.
engine; refer to the propeller chart in this manual.
2. Do not run the engine in the vicinity of loose gravel
4. It is extremely important to balance the propeller
or sand. The propeller may throw such materials into
prior to installation of the engine. Failure to do so may
your eyes. The engine could also ingest these harmful
cause damage to the Zenoah engine and/or the airframe.
materials.
Securely tighten the propeller nut against the washer
and propeller. 3. Avoid loose clothing when operating your model
engine, as it could become entangled in the propeller,
5. Inspect the tightness of the propeller nut prior to
creating the possibility of bodily harm. All loose objects
each flight.
(screwdrivers, pencils, nickel cadmium glow drivers,
6. Keep your face and body away from the path of the etc.) should be removed from your pockets so that they
propeller blades when starting or running your engine. do not fall into the propeller.
attempt to handle them until they have cooled. bled without any specific difficulties. Refer to the Engine
Maintenance Section for specific instructions on these
2. Always run your model engines in a well-ventilated
procedures. If you need service to your Zenoah engine,
area. Similar to automotive engines, model engines pro-
please send it to the authorized service center at the
duce harmful carbon monoxide fumes.
following address:
3. Never modify the flywheel.
Horizon Hobby, Inc.
4. Check the flywheel. If it’s damaged, replace it with a Attention: Zenoah Service
new one. 4105 Fieldstone Road
Champaign, IL 61822
5. When mixing the fuel or operating the engine, do so
Phone: (217) 355-9511
in a well-ventilated area
6. Remember that model engines produce a substantial Engine Parts Identification
amount of power, more than enough to seriously injure It’s important to be able to identify the parts of your
people and/or do considerable damage to property. Zenoah engines. Attached you will find an exploded view
Always use common sense, skill and constant obser- of Zenoah engines, as well as a chart including part
vance of safety precautions. numbers and descriptions. This will assist you in easily
and rapidly identifying the respective parts of your
Zenoah engine.
Support Equipment
The following items are not included with your Zenoah
engine but are necessary for operation.
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 be Zenoah Oil Zenoah Start Kit
ZEN20001 ZEN20002
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.
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.
Boat
1. Fill the tank with fuel.
2. Push the priming bulb located on the carburetor until
fuel appears in the priming bulb (for helicopter).
Idle Screw
3. Choke the engine and open the throttle valve approxi-
mately 1/3–1/2 of the full open position.
1. Start the engine without making any adjustments.
4. Quickly pull the starter cord until the initial firing of
the engine is heard. 2. Make adjustments only when the engine shows signs
of inefficient operation.
5. When the initial firing is heard, open the choke, set
the throttle valve at the idle position or at the position 3. Standard settings of each needle is as follows:
slightly open from the idle position and quickly pull the
a. Low-Speed Needle: 11/8 plus/minus 1/4
starter cord a few more times until the engine starts.
b. High-Speed Needle: 13/8 plus/minus 1/4
6. For helicopter operation, you should adjust the rotor-
pitch to obtain a 9,000 to 10,000 rpm of the engine at Idle Screw: Turning this screw clockwise increases the
full throttle operation. idling rpm. Turning it counterclockwise decreases the
idling rpm.
Stopping the Engine Low-Speed Needle: This is the fuel adjust screw (not
The ability to shut down the engine in an emergency is the air screw). Turning this needle clockwise makes the
extremely important. For stopping the engine, the black gas mixture leaner, and turning it counterclockwise
lead wire from the coil should be grounded to the engine makes it richer.
To extend the life of your Zenoah® engine, the following • Washing gasoline
is recommended: • Brush
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 pro- The engine can be disassembled or reassembled without
peller prior to use. 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
5. For long-term storage, make sure there is no fuel left list are required (stopper, puller assembly), in addition
in the tank or the engine. Remove the spark plug(s) and to general tools. Be sure to use a new gasket when the
apply several drops of high-quality oil (e.g., Marvel Air crankcase and cylinder have been disassembled.
Tool Oil) to the top of the engine and into the spark plug Note: Because the crankshaft is of the assembly type,
hole. Rotate the crankshaft several times. Store the do not disassemble, hit or twist its end.
engine in the box it came in or on the airplane with the
nose down in order to keep oil in the bearings.
Disassembly
Servicing the Engine 1. Dismount the engine from the model.
Required Tools 2. Remove the carburetor and insulator carefully without
• Regular screwdriver damaging the gasket.
• Hexagonal wrench (4mm/5/32") 4. Remove the spark plug and ignition module.
Piston Piston Ring Hole (mm) ø8.01 ø8.05 ø8.01 ø8.05 Cylinder Gauge
When inserted in a
Piston End Gap (mm) 0.05–0.25 0.5 0.05–0.25 0.5 Thickness Gauge new cylinder
Ring
Width (mm) 0.98 0.93 0.98 0.93 Micro Meter
Piston Pin Diameter (mm) ø8 ø7.98 ø8 ø7.98 Micro Meter
Connecting Rod small end (mm) ø11 ø11.05 ø11 ø11.05 Cylinder Gauge
Crankshaft Dia. at Main Bearing (mm) ø12 ø11.98 ø12 ø11.98 Micro Meter
Eccentricity (mm) –– 0.07 –– 0.07 Dial Gauge
Axial Play (mm) –– 0.5 –– 0.5 Thickness Gauge
10
The spark plug does not spark The spark plug does spark
11
Propeller Chart
This chart enables you to select the best propeller for Note: All recommendations are based on engines using
initial setup of your Zenoah® engine. APC brand props.
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
G26 Heli 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
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SPECIFICATIONS
Displacement Bore Stroke Weight K HP Carb
(cu in) (in) (in) (oz) (ISO) (H/M) (Walbro)
G26A/M/H 1.55 1.41 1.1 54/57 M8x1.25/6x1 2.4 WT645/WT644/WT677
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
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Q’ty/
G80A Index
No. Part No. Description unit
01 ZEN8001 CYLINDER 2
02 ZEN8002 INTAKE MANIFOLD (BLACK) 1
20 ZEN8020 PISTON 2
21 ZEN8021 PISTON RING 2
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