®
ENGINE INSTRUCTION MANUAL
4
3
5
2
7
1
6
1
G26 Air
G26/231Marine
G26/G231 Heli
2
3
4
G38
G62
GT80 Twin
5
6
7
G45
Very Important
FAILURE TO READ AND FOLLOW THESE INSTRUCTIONS BEFORE YOU PROCEED MAY RESULT IN ENGINE
DAMAGE AND THE VOIDING OF YOUR WARRANTY!
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-
tions. For specific information on mounting, see the
instruction manual included with the model airplane, heli-
copter or boat in which you intend to install the engine.
7. Use a thickly padded glove when hand starting
the engine.
8. Make all carburetor adjustments from behind
the propeller.
This model engine will give you considerable pleasure,
satisfaction and performance if you strictly follow these
safety instructions and take heed of the warnings as to
the engine’s safe and proper use. This engine has more
than enough power to cause harm if misused or if the
safety precautions are not observed.
9. To stop the engine, the black lead wire from the
coil should be grounded to the engine body, or use the
throttle linkage to shut off the air by closing the throttle
valve completely.
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
least 20 feet away when you start running the engine.
1. Use genuine parts for replacement.
11. Make sure your fuel is kept in a safe place well away
from sparks, heat or anything that could ignite the fuel.
2. Check the propeller, rotor (helicopter) or screw
propeller (boat) prior to each time the engine is used.
If nicked, scratched, cracked or damaged in any way,
replace it with a new one.
Recommendations
1. Use safety glasses or goggles when starting and
running your engine.
3. Use the correct size and pitch of propeller for your
engine; refer to the propeller chart in this manual.
2. Do not run the engine in the vicinity of loose gravel
or sand. The propeller may throw such materials into
your eyes. The engine could also ingest these harmful
materials.
4. It is extremely important to balance the propeller
prior to installation of the engine. Failure to do so may
cause damage to the Zenoah engine and/or the airframe.
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,
creating the possibility of bodily harm. All loose objects
(screwdrivers, pencils, nickel cadmium glow drivers,
etc.) should be removed from your pockets so that they
do not fall into the propeller.
5. Inspect the tightness of the propeller nut prior to
each flight.
6. Keep your face and body away from the path of the
propeller blades when starting or running your engine.
3
Safety Instructions (continued)
Caution
Disassembly
®
1. Model engines get very hot while running. Do not
attempt to handle them until they have cooled.
The Zenoah engine can be disassembled or reassem-
bled without any specific difficulties. Refer to the Engine
Maintenance Section for specific instructions on these
procedures. If you need service to your Zenoah engine,
please send it to the authorized service center at the
following address:
2. Always run your model engines in a well-ventilated
area. Similar to automotive engines, model engines pro-
duce harmful carbon monoxide fumes.
3. Never modify the flywheel.
Horizon Hobby, Inc.
4. Check the flywheel. If it’s damaged, replace it with a
new one.
Attention: Zenoah Service
4105 Fieldstone Road
Champaign, IL 61822
Phone: (217) 355-9511
5. When mixing the fuel or operating the engine, do so
in a well-ventilated area
Engine Parts Identification
6. Remember that model engines produce a substantial
amount of power, more than enough to seriously injure
people and/or do considerable damage to property.
Always use common sense, skill and constant obser-
vance of safety precautions.
It’s important to be able to identify the parts of your
Zenoah engines. Attached you will find an exploded view
of Zenoah engines, as well as a chart including part
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
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.
Zenoah Oil
ZEN20001
Zenoah Start Kit
ZEN20002
4
Mounting the Engine
Make sure the engine is mounted on the aircraft using
aircraft grade plywood that’s at least 6mm in thickness
for the G26 engine, and 10mm in thickness for the G38
through GT80 twin, or a mount of equivalent strength.
Make sure it’s firmly mounted with 4 bolts.
1. Be sure to set flat washers or a metal plate on the
reverse side of the mount to prevent the bolts from sink-
ing into the mount. Periodically check the engine mount
for loose bolts.
2. Since the engine is equipped with a floatless carbure-
tor with a diaphragm pump, the direction of the cylinder
and position of the fuel tank can be freely selected.
3. If the engine is mounted on a shock (rubber) mount
placed between the engine and the firewall for anti-vibra-
tion, check the hardness of the rubber, making sure it’s
not too soft, in order to avoid excessive vibration during
engine operating rpms. Note carefully if the engine is
vibrating at idle, as excessive vibration can result in
erratic engine operation due to overflow at the carburetor.
4. It is suggested that the bolts for the muffler be coated
with threadlock when mounting the muffler to the engine.
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.
Starting the Engine—Aircraft
Magnet
Before attempting to start the engine, be sure to read
through all the steps for starting the engine as outlined
below:
Fig 1-A
Fig 1-B
1. Make sure the spark (glow) plug(s) are installed and
tightened. Check the condition of the plug cap for cracks
or breaks.
Zenoah engines are equipped with the ultra compact
C.D.I. type flywheel magneto ignition system and should
be started according to the following procedure:
2. Be sure the propeller is properly secured.
Note: The magneto system is timed in such a
way that when the compression stroke starts
(refer to Figure 1-A) sparks are never produced
on the spark plug, no matter how fast the pro-
peller is flipped. The correct starting procedure
is to quickly flip the propeller when the edge of
the magnet on the rotor is approaching the coil
(Figure 1-B). This means that the propeller
should be quickly flipped at about 90 degrees
in crank angle before the compression stroke is
about to start.
3. Make sure the fuel tank line(s) are properly connected.
The main line should be connected to the carburetor
spray bar.
4. Be certain the mufflers are installed properly.
5. Fill the fuel tank.
6. Choke the engine and turn the propeller through a
few times until the fuel appears at the carburetor.
7. Set the throttle valve at the idle position or at the
position slightly open from idle.
5
Operation (continued)
8. Quickly flip the propeller in a counterclockwise
direction according to the procedure described in
the note above.
body, or the throttle valve should be closed completely.
Installation of a “stop” or “kill” switch is recommended.
Red Lead
9. The engine should start after a few flips of the
propeller.
Black Lead
10. Be sure to open the choke when the initial firing
of the engine is heard.
11. When the choke is opened, be sure to close the
throttle valve to a position near the idle position before
the next flipping of the propeller is attempted.
CAUTION: If the engine is started when the throt-
tle is wide open, a great thrusting force will be
generated, which can be very dangerous.
Engine
Body
Kill Switch
Ground
12. If you do not use a chicken stick to start the engine,
be sure to wear a thick glove when flipping the propeller
and use all fingers, except the thumb, for the flipping
operation.
Refer to the example shown in the following diagram.
Carburetor Adjustment
The carburetor is provided with three adjustment screws,
which are factory set to the best (approximate) posi-
tions. They may need minor adjustment, depending upon
the temperature, humidity, atmospheric pressure (alti-
tude), etc., of the area where the engine is being used.
13. Do not over-rev the engine. These engines are
designed to develop maximum output with the standard
muffler and the recommended propeller size. Please
refer to the propeller chart on page 10 to confirm the
®
proper propeller for the applicable Zenoah engine.
Low-Speed Needle
High-Speed Needle
Starting the Engine— Helicopter and
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
slightly open from the idle position and quickly pull the
starter cord a few more times until the engine starts.
3. Standard settings of each needle is as follows:
a. Low-Speed Needle: 11/8 plus/minus 1/4
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
full throttle operation.
Idle Screw: Turning this screw clockwise increases the
idling rpm. Turning it counterclockwise decreases the
idling rpm.
Stopping the Engine
The ability to shut down the engine in an emergency is
extremely important. For stopping the engine, the black
lead wire from the coil should be grounded to the engine
Low-Speed Needle: This is the fuel adjust screw (not
the air screw). Turning this needle clockwise makes the
gas mixture leaner, and turning it counterclockwise
makes it richer.
6
Operation (continued)
High-Speed Needle: Turning this needle clockwise
makes the gas mixture leaner, and turning it counter-
clockwise makes it richer. Set this needle at a position
which is 1/4 open from the maximum rpm position while
the aircraft is on the ground.
When the engine has just started and is not warm
enough, there may be insufficient acceleration
and the engine may die. Be sure to allow the
engine to warm up at idle for a few minutes
before conducting normal operation.
Note: Do not tighten the high and low speed
needles too tightly.
Engine Care and Maintenance
• Engine oil
Recommendations
To extend the life of your Zenoah® engine, the following
is recommended:
• Washing gasoline
• Brush
1. Use a Zenoah quality 2-stroke oil mixed at 32 to 1.
2. Use the recommended spark plugs.
• Scraper
• Cloth
3. Use the proper propeller size and balance the pro-
peller prior to use.
The engine can be disassembled or reassembled without
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
list are required (stopper, puller assembly), in addition
to general tools. Be sure to use a new gasket when the
crankcase and cylinder have been disassembled.
5. For long-term storage, make sure there is no fuel left
in the tank or the engine. Remove the spark plug(s) and
apply several drops of high-quality oil (e.g., Marvel Air
Tool Oil) to the top of the engine and into the spark plug
hole. Rotate the crankshaft several times. Store the
engine in the box it came in or on the airplane with the
nose down in order to keep oil in the bearings.
Note: Because the crankshaft is of the assembly type,
do not disassemble, hit or twist its end.
Disassembly
1. Dismount the engine from the model.
Servicing the Engine
Required Tools
2. Remove the carburetor and insulator carefully without
damaging the gasket.
• Regular screwdriver
3. Remove the muffler.
• Phillips screwdriver
4. Remove the spark plug and ignition module.
5. Remove the propeller hub.
• Hexagonal wrench (4mm/5/32")
• Open wrench (19mm/3/4")
• Plastic hammer
6. Remove the rotor (flywheel). If it cannot be detached,
use a plastic hammer and tap the part lightly.
• Thickness gauge
a. Screw the stopper in place of the spark plug, then
turn the rotor counterclockwise until the piston
touches the stopper. Take care, as it can cause dam-
age to the piston or connecting rod if the stopper is
not screwed in to the bottom.
• Tapered round rod
• Liquid gasket (Permatex or equivalent)
• Threadlock (Blue Threadlock Z-42 or equivalent)
• Lithium grease
b. Loosen and remove the rotor securing nut.
7
Engine Care and Maintenance (continued)
c. Remove the rotor by using the puller. Do not hit
the crankshaft with the plastic hammer, as this can
increase the runout of the shaft.
7. Wipe the contact surfaces of the cylinder block
and crankcase, and apply liquid gasket (Permatex
or equivalent).
7. Remove the mounting plate.
8. Put the piston in the cylinder, with the piston’s arrow
facing in the exhaust port direction. Set the crankshaft
to the cylinder block. Then, fit the oil seal to the cylinder
block. The snap ring joint should be set vertically to
the cylinder.
8. Remove the four bolts from the crankcase.
9. Tap around the case fitting side gently with the plastic
hammer and slowly separate the crankcase from the
cylinder block.
9. Fit the crankcase to the cylinder block and tighten
10. Pull out the crankshaft with the piston, bearings, and the bolts.
other parts attached.
10. Check that the crankshaft can be smoothly turned
by hand.
11. Remove the Woodruff key from the crankshaft.
12. Remove the oil seal, snap ring and bearings.
13. Remove the circlip and pull out the piston pin.
11. Put back the Woodruff key.
12. Replace the rotor (flywheel), fitting it to the Woodruff
key. Tighten the hub nut after having applied threadlock
(Blue Threadlock Z-42 or equivalent) to the threads.
14. Remove the thrust washers and needle bearing from
the smaller end of the connecting rod (G38).
13. Apply threadlock (Blue Threadlock Z-42) to the muf-
fler bolts and mount the muffler.
15. Remove the piston ring.
16. Wash each part. Check for abrasion and damage, and
replace any part that is defective.
14. Apply threadlock (Blue Threadlock Z-42) to the igni-
tion module set screws and fix the coil temporarily.
15. Set the rotor (flywheel) so that the magnet is located
on the opposite side of the module (G-38). Place a thick-
ness gauge between the core of the module and rotor
(flywheel) and adjust the clearance to 0.25 ^ 0.35 mm
(0.01 ^ 0.014 in). Then tighten the set screws after
having applied threadlock (Blue Threadlock Z-42)
to them.
Assembly (G38)
1. Apply engine oil (SAE #30) to the inside of the
cylinder and to the needle bearings on the larger end
of the connecting rod.
2. Fit the piston ring to the piston.
3. Mount the needle bearing and thrust washer (with
its oil slot facing inside) to the smaller end of the con-
necting rod and apply engine oil (SAE #30).
16. Using a new gasket, fix the insulator with screws
to which threadlock (Blue Threadlock Z-42) has been
applied.
4. With the arrow on the top of the piston facing the
straight side (opposite side to the propeller) of the
crankshaft, fit the piston to the top of the connecting
rod and insert the piston pin with its blank end to the
exhaust port side.
17. Using a new gasket, mount the carburetor with
screws, paying attention to its mounting direction.
18. Tighten the mounting plate, using screws with
threadlock (Blue Threadlock Z-42) applied.
19. Install the spark plug.
5. Fit the circlip.
6. Fit the bearings, snap ring and oil seal to the crank-
shaft. (Apply lithium grease to the lip area of the oil seal
and fit it, paying attention to its direction.)
Note: Disassembly and assembly steps were
written using a G38 engine as an example, but
they apply to all engines.
8
Engine Care and Maintenance (continued)
Maintenance Chart
Items
Every 100 hours
Note
Every 25 hours
Action
Before Use
Leakage,
Damage/Crack
;
;
;
Check
Losing Speed
Air-cleaner (PUH)
Spark Plug (gap)
Cylinder (barrel)
Piston, Ring
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
Check/Adjust
Check/Cleaning
Check/Adjust
;
;
Replace if necessary
G
G
G
G
G
G
G
G
G
Check/Cleaning
Check/Cleaning
Check/Cleaning
Check/Cleaning
Check/Alignment
Check
Muffler & Bolt
Bearings
;
;
Crankshaft
Rotor
;
;
;
Propeller Hub (PU)
Water Jacket (PUM)
Check/Alignment
Check/Leakage
Specifications & Technical Data
Items
Type
Unit
––
G260PUM
G260PUH
G231PUM
G260PU
Air Cooled
34 x 28
25.4
G231PUH
Air Cooled
A
Water Cooled
A
Air Cooled
A
Water Cooled
32 x 28
Bore x Stroke
Displacement
mm
cm3
A
A
22.5
A
Effective
Compression Ratio
––
A
A
A
8.4
A
Type (Walbro)
Venturi (mm)
WT-644
A
WT-677
A
WT-644
A
WT-645
12.7
WT-677
A
Carburetor
Air Cleaner
Starting
––
Dry Type
––
––
Dry Type
Hand Flipping or
Electric Motor
––
Recoil Starter
A
A
A
CDI
28/7000
RZ7C
––
Type
BTDC/rpm
STD
A
30/7000
A
A
A
A
––
A
A
A
A
A
––
Ignition
A
Spark Plug
Option
CMR8H/7H
CMR6H/7H
1800
APC 18 x 8
rpm
3500
Idle Speed
3000
3500
3000
Max. Power
Min. Torque
Fuel Consumption
Weight
rpm
rpm
cc
2.16/12000
1.94/9500
710
1.71/13000
1.42/9500
760
2.09/12000
1.79/10000
720
1.62/12000
1.48/9000
790
1.58/13000
1.34/9000
700
kg
1.54
1.77 (*1.57)
1.55
1.69 (* 1.52)
1.78 (*1.58)
9
Engine Care and Maintenance (continued)
Maintenance Specifications
Standard
Limit
Standard
Limit
Items
Remarks
Measuring Device
Cylinder
Piston
ø34
Plating damaged
ø32
Plating damaged
Bore (mm)
Eye Checking
At the skirt end and
the right angle to the
piston pin
ø31.87
Micro Meter
ø33.97
ø33.87
ø31.97
Diameter (mm)
Piston Ring
Groove Width (mm)
1.01
1.11
1.01
1.11
Thickness Gauge
Cylinder Gauge
ø8.01
ø8.05
ø8.01
ø8.05
Piston Ring Hole (mm)
Micro Meter
Cylinder Gauge
Clearance between Piston
and Cylinder (mm)
0.03–0.05
0.15
0.03–0.05
0.15
Clearance between Groove
and Piston Ring (mm)
0.02–0.04
0.05–0.25
0.1
0.5
0.02–0.04
0.05–0.25
0.1
0.5
Thickness Gauge
Thickness Gauge
When inserted in a
new cylinder
End Gap (mm)
Width (mm)
Piston
Ring
0.98
ø8
0.93
0.98
ø8
0.93
Micro Meter
Micro Meter
Piston Pin Diameter (mm)
Connecting Rod small end (mm)
Crankshaft Dia. at Main Bearing (mm)
ø7.98
ø7.98
ø11.05
ø11.98
0.07
Cylinder Gauge
ø11
ø12
––
ø11.05
ø11.98
0.07
ø11
ø12
––
Micro Meter
Dial Gauge
Eccentricity (mm)
Axial Play (mm)
––
0.5
––
0.5
Thickness Gauge
Gritty or
Has Flat Spot
Gritty or
Has Flat Spot
––
––
––
Main Bearing
10
Troubleshooting Guide for Gasoline Engines
Generally speaking, there are very few things that will
keep today’s modern engines from starting. Use good
quality “fresh” fuel and make sure that good plugs are
installed. Should the engine fail to start after these items
are verified, refer to the charts on the following page.
a) The engine does not start.
Seizure, intrusion of a foreign substance
The crankshaft
does not rotate
Disassemble and repair
Clogging inside the
Disassemble and clean
carburetor
The fuel has not been fed to
the carburetor
The crankshaft
rotates
Clogging of the fuel
Clean
piping
Loosened
spark plug
Abrasion or damage of
the cylinder, piston, or
piston ring
The fuel has been fed to the
carburetor
Tighten further
No compression
(normally 7 kg/cm2
99.5 psi or more)
Replace
Compression adequate
The spark plug does not spark
The spark plug does spark
Wet plug
Remove the spark
plug and dry it
The Stop switch has
been turned off
Wiring is disconnected
The spark plug is defective
The ignition module is defective Replace
The air gap is too large
The spark plug gap is too large
Turn on
The carburetor has
not been properly
adjusted
The fuel is not
suitable
Repair
Replace
Readjust
Replace
Adjust
Adjust
b) The engine stops by itself
The crankshaft does not rotate
or is abnormally heavy
It suddenly stops
See a)
The crankshaft
rotates
Put back
Repair
The plug cap has come off
Wiring disconnection
Spark plug bridge
Use a standard plug
Use clean fuel
The Stop switch has
been turned off
Turn on
It slows down and stops
Out of fuel
Refuel
Not out of fuel
The fuel is not fed to the carburetor
Water is mixed in the fuel
See a)
Replace
c) Lower power output
Readjust
Repair
Replace
Replace
Clean
The carburetor has not beeen properly adjusted
Air suction from a carburetor joint or oil seal
Abrasion of the piston ring
The fuel is not suitable
Clogging of the muffler or exhaust port due to carbon
Overheating
Replace
The spark plug heat range is not proper
d) The engine does not stop
Overheating
The Stop switch is defective
Switch wiring is disconnected
See c)
Repair
Repair
11
Troubleshooting Guide for Gasoline Engines
(continued)
In the event that none of the above procedures result
in the engine running properly, contact our service
department for suggestions at:
Horizon Hobby, Inc.
4105 Fieldstone Road
Champaign, IL 61822
Phone: 217-355-9511 (M–F 8:00–5:00 CST)
Propeller Chart
This chart enables you to select the best propeller for
initial setup of your Zenoah® engine.
Note: All recommendations are based on engines using
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
G26A
PROPELLER
16x8 @ 8,700
G231 Heli
G26 Heli
Adjust pitch of rotor to obtain
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
G45 Gas
G62 Gas
GT80 Gas
18x10 @ 7,300
20x10 @ 7,200
22x10 @ 7,200
22x12 @ 7,200
24x10 @ 7,200
12
Engine Specifications
OUTSIDE DIMENSIONS (MM)
Optional
Mufflers
Operating
RPM
Items
Length
Width
Height
G26A
G26M
G26H
139mm
139mm
139mm
105mm
105mm
105mm
181mm
181mm
181mm
2,000–10,000
2,000–10,000
2,000–10,000
BIS07123
—
—
G231 HELI
G231 MARINE
G38
142mm
142mm
105mm
105mm
130mm
130mm
140mm
257mm
181mm
181mm
215mm
185mm
185mm
190mm
3,000–11,000
3,500–15,000
2,000–9,000
2,000–10,000
2,000–10,000
1800–10,000
—
—
170mm
BIS07138
BIS07145
BIS07163
BIS07445/6
G45
152mm
G62
162.5mm
191.5mm
GT80
SPECIFICATIONS
Carb
(Walbro)
K
(ISO)
HP
(H/M)
Displacement
Bore
(in)
Stroke
(in)
Weight
(oz)
(cu in)
1.55
1.4
M8x1.25/6x1
2.4
2.2
2.2
3.3
4.75
6
WT645/WT644/WT677
WT644/WT643
WT338/WTA-6A
HDA-48D
G26A/M/H
G231M/H
G38
1.41
1.3
1.1
54/57
54
M8x1.25
M10x1.25
8x1
1.1
2.3
1.5
1.3
67
G45
2.74
3.8
1.69
1.9
1.22
1.4
74
10x1
HDA-48D
G62
73
—
WJ-64
GT80
4.8
1.59x2
1.22x2
126
* w/spring starter
13
Exploded Illustration
G26/G231
14
Quantity per unit
Key # Zen Part #
HH Part #
Description
G260 G260 G260 G231 G231
PU PUM PUH PUM PUH
1-1
1- 2
2-1
2-2
3
4
5
6
7
8
9
T2075-12110
T2077-12110
T2076-12110
T2078-12110
T2076-12210
07851-00515
07000-13040
T2076-12320
1160-12330
T2075-13120
3310-12281
T2075-13150
1148-13162
T2075-14120
T2075-2111
ZEN2601
CYLINDER
CYLINDER
CYLINDER
CYLINDER
JACKET
JOINT
1
–
–
–
–
–
–
–
–
1
6
1
1
1
1
1
1
3
1
1
2
1
1
–
–
–
1
–
1
2
1
1
2
1
6
1
1
1
1
1
1
3
1
1
2
1
–
1
1
–
–
–
–
–
–
–
–
1
6
1
1
2
1
1
1
3
1
1
2
1
1
–
–
–
–
1
1
2
1
1
2
1
6
1
1
1
1
1
1
3
1
1
2
1
–
1
–
1
–
–
–
–
–
–
–
1
6
1
1
2
1
1
1
3
1
1
2
1
1
–
ZEN2301RC
ZEN2601M
ZEN23102M
ZEN23103M
ZEN2304M
ZEN32105M
ZEN23106M
ZEN23107M
ZEN23108
ZEN2309
ZEN23110
ZEN23111
ZEN23112
ZEN23114
0-RING 3 x 40
O-RING 1.5 x 15.5
BOLT M3 x 8
GASKET, CYLINDER
BOLT M5X20
GASKET, INSULATOR
INSULATOR
GASKET, CARBURETOR
CRANKCASE, COMPLETE
CRANKCASE, REAR
CRANKCASE, FRONT
PIN
GASKET
SEAL, 12 x 22 x 7
BEARING
SNAPRING
BEARING
10
11
12
13
14
15
16
17
18
19
20
21
2629-21130
T2075-21140
2169-21210
1155-21240
04065-02812
06034-06001
1850-21220
ZEN6213
ZEN23116
ZEN2317
ZEN2318
ZEN2319
ZEN2320
ZEN2321M
SEAL, 12 x 28 x 7
14
Exploded Illustration
G26/G231 continued
Quantity per unit
Key # Zen Part #
HH Part #
Description
G260 G260 G260 G231 G231
PU PUM PUH PUM PUH
22
01252-30530
T2088-41110
T2070-41110
T2088-41210
T2070-41210
1600-41310
1101-41310
1260-41320
5500-41410
1101-41340
T2075-42000
1155-74110
0262-10516
1650-43230
1160-75210
1861-75101
0263-30414
1000-43240
1140-43250
2629-71210
1160-71211
1155-71110
0260-30422
0263-30414
T2075-72210
1400-72121
2629-71311
3699-91809
3699-91975
0263-30565
1142-83110
848ES08300
848EP18300
1000-03030
T2075-81000
T2076-81000
ZEN2322
ZEN2623
ZEN2320RC
ZEN26224
ZEN2321RC
ZEN2625
ZEN2325
ZEN2326
ZEN2327
ZEN2328
ZEN23129
ZEN2330
ZEN2331
ZEN2332
ZEN2333M
ZEN2634
ZEN2341
ZEN6227
ZEN2337
ZEN6236
ZEN2339M
ZEN2354
ZEN6241
ZEN2341
ZEN2638
ZEN6239
ZEN6237
ZEN26451
ZEN2667M
ZEN2648
ZEN2647
ZEN2649
ZEN23150H
ZEN2650
ZEN2651
ZEN23151
ZEN23152
ZEN2359
ZEN2360
ZEN2361
ZEN2362
ZEN23156
ZEN2357
ZEN2357H
ZEN2358
BOLT, M5 x 30
PISTON
PISTON
RING
RING
PISTON PIN
PISTON PIN
SNAP RING
BEARING
4
1
–
1
–
1
–
2
1
2
1
1
3
1
–
–
–
1
1
1
–
1
2
2
1
1
1
1
–
2
2
1
–
1
1
–
–
1
1
1
1
1
2
–
1
–
1
–
–
–
1
4
1
–
1
–
1
–
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
1
1
2
2
1
–
1
–
1
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1
4
1
–
1
–
1
–
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
1
–
2
–
–
1
–
–
–
1
–
–
–
–
2
–
2
–
1
–
1
1
1
1
4
–
1
–
1
–
1
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
1
1
2
2
1
–
1
–
1
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1
4
–
1
–
1
–
1
2
1
2
1
1
3
–
1
1
4
1
1
–
1
1
2
2
1
1
1
1
–
2
–
–
1
–
–
–
1
–
–
–
–
2
–
2
–
1
–
1
1
1
1
23-1
23-2
24-1
24-2
25-1
25-2
26
27
28
29
30
31
32
33
34
35
36
37
38-1
38-2
39
40
41
42
43
44
45
WASHER
CRANKSHAFT, COMPLETE
MOUNT, PLATE
SCREW, M5 x 16
NUT, M8
PULLEY
RECOIL ASSEMBLY
SCREW, M4 x 14
KEY
SHIM
COIL, (GREY)
COIL, (RED)
ROTOR
SCREW M4 x 22
SCREW M4 x 14
PLUG CAP
SPRING
COIL
SPARK PLUG RZ7C
SPARK PLUG MARINE ONLY
SCREW, M5 x 55
SPACER, 5 x 10 x 1.6
AIR TUNNEL (VENTURI)
CLEANER ASSEMBLY
TUBE
CARBURETOR ASSY WT-645
CARBURETOR ASSY WT-644
CARBURETOR ASSY WT-643
HUB
STUD
WASHER
NUT, M8
GASKET, MUFFLER
BOLT, M5 x 50
BOLT, M5 x 60
SCREW, M4 x 8
46
47
48
49
50
51-1
51-2
51- 3 T2077-81000
52
53
54
55
56
57-1
57-2
58-1
58-2
59-1
59-2
60
1152-43260
1152-43281
1152-43290
3350-53410
1140-13141
01252-30550
01252-30560
0263-30408
0263-90416
T2075-15110
1148-08010
1145-15412
1158-15420
T3039-91310
T2075-98110
ZEN2358H/RC SCREW, M4 x 16
ZEN2655
ZEN2355
ZEN2366
ZEN2367
MUFFLER
MUFFLER
SPACER
SPACER
61
62
ZEN23124RC SOCKET
ZEN23144 OPTION FOR G260PUM/
G231PUM ONLY
–
1
–
1
15
Exploded Illustration
G38
(Standard Accessory for
G380PU)
Q’ty/
Q’ty/
unit
Q’ty/
unit
Index
No.
Index
Index
No.
unit
Part No.
Part No.
Description
Description
MODULE
ROTOR (NEW)
SPACER (MODULE)
PLUG CAP (BLACK)
CAP SPRING
Part No.
ZEN3801 CYLINDER
ZEN3802 INSULATOR
ZEN3803 CARB GASKET
ZEN3804 INSULATOR SCREW
ZEN3805 INSULATOR GASKET
ZEN3806 MUFFLER ASSEMBLY
No.
Description
1
1
3
1
1
1
3
1
1
2
1
4
1
1
21 ZEN3821 PIN RETAINER
22 ZEN3822 CONROD SPACER
23 ZEN3823 CONROD BEARING
24 ZEN3824 CRANKSHAFT
25 ZEN3825 CRANKSHAFT BEARING
26 ZEN3826 FRONT OIL SEAL
27 ZEN3827 SNAP RING
28 ZEN3828 REAR OIL SEAL
29 ZEN3829 KEY
30 ZEN3830 ROTOR NUT
31 ZEN3831 LOCK WASHER
32 ZEN3832 ROTOR WASHER
33 ZEN3833 PROP HUB (NEW)
34 ZEN3834 HUB BOLT
35 ZEN3835 PROP WASHER (NEW)
36 ZEN3836 PROP BOLT (NEW)
2
2
1
1
2
1
1
1
1
1
1
1
1
2
1
2
37 ZEN3837
38 ZEN3838
39 ZEN3839
40 ZEN6238
41 ZEN6239
42 ZEN6242
43 ZEN3843
44-1 ZEN3844
44-2 ZEN3850
45 ZEN3845
46 ZEN3846
47 ZEN3847
ZEN3870
1
2
3
4
5
6
1
1
1
2
1
1
1
2
1
4
4
1
1
1
1
1
SPARK PLUG, C859
MODULE BOLT
11 ZEN3811 MUFFLER GASKET
12 ZEN3812 MUFFLER BOLT
13 ZEN3813 CRANKCASE
14 ZEN3814 CASE BOLT
15 ZEN3815 CASE WASHER
16 ZEN3816 CASE PLUG
17 ZEN3817 PLUG GASKET
18 ZEN3818 PISTON
CARB ASS’Y (HT-338) W/CHOKE
CARB ASS’Y (WTA-6) W/O CHOKE
CARB SCREW
MOUNT
G380PU
for
}
MOUNTING BOLT
GASKET SET
SCREW/NUT SET
ZEN3871
19 ZEN3819 PISTON RING
20 ZEN3820 PISTON PIN
16
Exploded Illustration
G45
Index
Q’ty/
unit
Q’ty/
unit
Q’ty/
unit
Index
No.
Index
No.
Part No.
Description
No. Part No. Description
Part No.
Description
1
2
3
4
5
6
7
8
9
ZEN4501 CYLINDER
1
1
1
2
1
1
4
1
1
2
2
1
3
1
2
1
1
1
1
21 ZEN4504 BOLT
22 ZEN4522 PIPE
23 ZEN4523 PISTON
24 ZEN4524 PISTON RING
25 ZEN4525 PISTON PIN
26 ZEN6223 PIN RETAINER
27 ZEN6224 CONROD BEARING
28 ZEN4528 WASHER
29 ZEN4529 CRANKSHAFT COMP.
30 ZEN6228 SHIM
4
1
1
2
1
2
1
2
1
0-2
1
1
1
2
1
1
1
1
40 ZEN6237 IGNITION COIL
41 ZEN6238 PLUG CAP (BLACK)
42 ZEN6239 CAP SPRING
43 ZEN4543 SOURCE COIL SCREW
44 ZEN6241 COIL SCREW
45 ZEN6242 SPARK PLUG
46 ZEN6243 CARBURETOR ASSEMBLY
47 ZEN4547 BOLT
1
1
1
2
2
1
1
2
2
2
1
1
4
4
1
1
1
1
ZEN4502 INSULATOR
ZEN4503 INSULATOR GASKET
ZEN4504 BOLT
ZEN6204 CARBURETOR GASKET
ZEN4506 CYLINDER GASKET
ZEN4504 BOLT
ZEN6207 MUFFLER
ZEN6208 MUFFLER GASKET
48 ZEN6245 WASHER
49 ZEN6246 WASHER
50 ZEN6247 BOLT
10 ZEN6209 MUFFLER BOLT
11 ZEN6210 MUFFLER NUT
13 ZEN4513 CRANKCASE COMP.
14 ZEN6213 CASE PIN
15 ZEN6214 SNAP RING
16 ZEN6215 BEARING
17 ZEN6216 REAR OIL SEAL
18 ZEN6217 FRONT OIL SEAL
19 ZEN6276 ELBOW FUEL NIPPLE
20 ZEN4520 CASE GASKET
31 ZEN6227 KEY
32 ZEN6229 FLYWHEEL NUT
33 ZEN6230 PROP HUB
34 ZEN6232 HUB BOLT
35 ZEN6233 WASHER
36 ZEN6234 PROP BOLT
37 ZEN6257 MAGNETO ASSEMBLY
38 ZEN6235 ROTOR
51 ZEN6248 MOUNT
52 ZEN6249 BOLT
53 ZEN6250 WASHER
54 ZEN6251 PULLER ASSEMBLY
55 ZEN6252 STOPPER (OPTIONAL)
56 ZEN6253 GUIDE (OPTIONAL)
57 ZEN4557 WRENCH (OPTIONAL)
*
for G450PU
}
39 ZEN6236 SOURCE COIL
1
17
Exploded Illustration
G62
(Accessory for G620PU-1)
*
Index
Index
No.
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Q’ty/
unit
4
1
1
2
1
2
1
2
1
0-2
1
1
2
1
Q’ty/
unit
Index
Q’ty/
unit
1
1
1
1
1
4
1
1
2
2
1
3
1
2
1
1
1
4
1
Part No.
ZEN6221
ZEN6222
ZEN6223
ZEN6224
ZEN6225
ZEN6226
ZEN6227
ZEN6228
ZEN6229
ZEN6230
Part No.
ZEN6239
ZEN6240
ZEN6241
ZEN6242
ZEN6243
ZEN6244
ZEN6245
ZEN6246
ZEN6247
ZEN6248
ZEN6249
ZEN6250
ZEN6251
ZEN6252
ZEN6253
ZEN6200
ZEN6255
ZEN6256
ZEN6257
No.
21
22
23
24
25
26
27
28
29
30
Description
PISTON RING
PISTON PIN
Description
No. Part No. Description
1
2
3
4
5
6
7
8
PLUG CAP SPRING
IGNITION COIL SCREW
SOURCE COIL SCREW
SPARK PLUG, C859
CARBURETOR ASSEMBLY
CARB MOUNT SCREW
CARB WASHER
ZEN6201
ZEN6202
ZEN6203
ZEN6204
ZEN6205
ZEN2309
ZEN6207
ZEN6208
ZEN6209
ZEN6210
ZEN6211
ZEN6213
ZEN6214
ZEN6215
ZEN6216
ZEN6217
ZEN6218
ZEN6219
ZEN6220
CYLINDER
2
2
1
1
2
2
2
1
1
4
4
1
1
1
1
1
1
1
INSULATOR GASKET
INSULATOR
PIN RETAINER
NEEDLE BEARING
CONNECTING ROD SPACER
CRANKSHAFT COMP.
KEY
CARBURETOR GASKET
CYLINDER BASE GASKET
CYLINDER BOLT
MUFFLER
SHIM
WASHER
MUFFLER GASKET
MUFFLER BOLT
MUFFLER NUT
CRANKCASE COMP.
CASE PIN
FLYWHEEL NUT
TAP PROP BOLT
9
HUB,PROPELLER COMP
.
MOUNT
10
11,12
13
14
15
16
17
18
19
20
*
for G62PU
FOR G620PU-1
PIN FOR G620PU-1
HUB BOLT
BOLT
}
WASHER
ZEN6231
ZEN6232
ZEN6233
ZEN6234
ZEN6235
ZEN6236
ZEN6237
ZEN6238
31
32
33
34
35
36
37
38
PULLER ASSEMBLY
STOPPER (OPTIONAL)
PISTON PIN GUIDE (OPTIONAL)
SPRING STARTER
SNAP RING
PROP WASHER
PROP BOLT
BEARING
1
1
1
1
REAR OIL SEAL
FRONT OIL SEAL
CRANKCASE GASKET
CASE ASSEMBLY BOLT
PISTON
ROTOR
SOURCE COIL
IGNITION COIL
PLUG CAP (BLACK)
HIGH-SPEED NEEDLE
LOW-SPEED NEEDLE
MAGNETO ASSEMBLY
1
18
Exploded Illustration
GT80
Index
No.
Q’ty/
unit
Index
No. Part No.
Index
No. Part No.
Q’ty/
unit
Q’ty/
unit
Description
Description
Part No. Description
1
2
3
4
5
6
7
8
9
ZEN44501 CYLINDER
ZEN44502 MANIFOLD
ZEN44503 MANIFOLD GASKET
ZEN44504 MANIFOLD BOLT
ZEN44505 CARBURETOR ASS’Y
ZEN44506 CARBURETOR GASKET
2
1
2
4
1
1
2
2
8
1
4
2
2
1
1
1
1
1
4
2
4
22 ZEN44522 PISTON PIN
23 ZEN44523 PIN RETAINER
24 ZEN44524 BEARING
25 ZEN44525 THRUST WASHER
26 ZEN44526 CRANKSHAFT COMP
2
4
2
4
1
0-2
1
1
1
1
2
1
2
2
2
4
2
2
43 ZEN44543 MOUNT
44 ZEN44544 BOLT
45 ZEN44545 BOSS
46 ZEN44546 CLUTCH COMP
47 ZEN44547 SPRING
48 ZEN44548 COLLAR
49 ZEN44549 WASHER
50 ZEN44550 BOLT
51 ZEN44551 PAD
52 ZEN44552 HUB. PROPELLER COMP
53 ZEN44553 PIN
54 ZEN6232 HUB BOLT
55 ZEN6233 HUB WASHER
56 ZEN6234 PROP BOLT
57 ZEN6247 TAP PROP BOLT
58 ZEN44555 SOCKET
59 ZEN6251 PULLER ASS’Y (OPTIONAL)
60 ZEN44554 STOPPER (OPTIONAL)
ZEN44556 HIGH-SPEED NEEDLE
ZEN44557 LOW-SPEED NEEDLE
1
3
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
27 ZEN6228
28 ZEN6227
29 ZEN6229
30 ZEN6235
31 ZEN6236
32 ZEN6238
SHIM
ZEN4547
CARB BOLT
KEY
ZEN44508 CYLINDER GASKET
ZEN44509 BOLT
NUT
ROTOR
10 ZEN44510 CRANKCASE ASS’Y
SOURCE COIL
IGNITION COIL
11 ZEN6213
12 ZEN6215
13 ZEN6214
14 ZEN44514 BEARING
15 ZEN6217
16 ZEN6276
17 ZEN44517 PIPE
18 ZEN44518 CRANKCASE GASKET
19 ZEN44509 BOLT
20 ZEN44520 PISTON
21 ZEN44521 PISTON RING
PIN
BEARING
SNAP RING
33 ZEN44533 CORD
34 ZEN6238
35 ZEN6239
36 ZEN6242
PLUG CAP (BLACK)
CAP SPRING
FRONT OIL SEAL
SPARK PLUG, C859
FUEL NIPPLE ELBOW
37 ZEN44537 SCREW
38 ZEN44538 SCREW
39 ZEN44539 MUFFLER
40 ZEN44540 MUFFLER GASLET
2
4
41 ZEN6209
MUFFLER BOLT
42 ZEN44542 NUT
Q’ty/
unit
Index
No. Part No.
G80A
Description
01 ZEN8001 CYLINDER
02 ZEN8002 INTAKE MANIFOLD (BLACK)
20 ZEN8020 PISTON
2
1
2
2
21 ZEN8021 PISTON RING
19
Warranty Information
Zenoah® engines are guaranteed against workmanship
and manufacturing defects for a period of 3 years from
the original date of purchase. This warranty is limited to
the original purchaser and is not transferable.
1. Include complete name and address information
inside the carton, as well as clearly writing it on the
outer label/return address area.
2. Include a note containing a brief summary of the
difficulty and include the following information:
Warranty repairs will not cover:
• Normal engine wear
• Propeller size and brand used
• Type of spark plug used
• Type of engine mount
• Damage due to insufficient maintenance
• Damage related to over-revving of the engine due
to small prop size or unreasonable use
• Approximately how much running time the engine had
before difficulty
• Rusted bearings
3. Date your correspondence and be sure your name and
address appear on this enclosure.
• Crash damage
• Damage due to use of improper fuel and/or spark plug
4. Include a phone number where you can be reached
during the business day.
• Damage due to lean runs, such as rusted bearings,
seized connecting rod or piston, etc.
Warranty Repairs
• Damage caused by foreign objects
To receive warranty service you must include your origi-
nal dated sales receipt to verify your proof-of-purchase
date. Providing that warranty conditions have been met,
your engine will be repaired without charge.
• Damage caused by unreasonable mounting or running
conditions (dust, insufficient cooling, improper mount-
ing, improper propeller size of lack of balancing, etc.)
• Damage due to improper disassembly
• Modifications of any kind
Non-Warranty Repairs
Should your repair cost exceed 50% of the retail
purchase cost, you will be provided with an estimate
advising you of your options. Any return freight for
non-warranty repairs will be billed to the consumer.
If your engine needs repair, ship it in its original box,
freight prepaid to:
Horizon Service Center
Attn: Zenoah Service
4105 Fieldstone Road
Champaign, IL 61822
Phone: (217) 355-9511
We accept both Visa and MasterCard for payment.
Please include your card number and expiration date.
The Consumer Warranty Registration below must be
completely filled out and mailed to:
Note: Do not use the engine’s original box as the
shipping box. Rather, package this box inside a
sturdy shipping box.
Horizon Service Center
Attn: Zenoah Warranty
4105 Fieldstone Road
Champaign, IL 61822
20
Warranty Information (continued)
Registration Form
Fill in and mail this form along with your dated sales
receipt (send a copy, keep the original for your files)
within 10 days of purchase to:
Horizon Service Center
Attn: Zenoah Warranty Dept.
4105 Fieldstone Road
Champaign, IL 61822
Engine Type: ________________________________________________________________________________
Date of Purchase: ______________________________________________________________________________
Owner’s Name:
______________________________________________________________________________
Street Address: ______________________________________________________________________________
City/State/Zip: ________________________________________________________________________________
Daytime Phone Number: ________________________________________________________________________
Purchased From: ______________________________________________________________________________
Dealer’s Name: ________________________________________________________________________________
Street Address: ______________________________________________________________________________
City/State/Zip: ________________________________________________________________________________
Please cut on dotted line.
21
22
23
|