ENGINE INSTRUCTION MANUAL Model: G-23 Air/Heli/Marine G-23 Glow G-38 G-62 G-45 G-445 Twin
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 for properly, these high-quality, finely crafted engines will offer many years of reliability. This instruction manual has been developed to ensure optimum performance from the Zenoah engine you have purchased.
SUPPORT EQUIPMENT The following items, which are not included with your Zenoah engine, are necessary in order to operate the model engine. 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. Note: An exception to this is the G-23 Glow engine, which uses a different carburetor.
7. Set the throttle valve at the idle position or at the position slightly open from idle. Red Lead 8. Quickly flip the propeller in a counterclockwise direction according to the procedure described in the note above. Black Lead 9. The engine should start after a few flips of the propeller. 10. Be sure to open the choke when the initial firing of the engine is heard. 11.
engine may die. Be sure to allow the engine to warm up at idle for a few minutes before conducting normal operation. TIPS FOR EXTENDED ENGINE LIFE To extend the life of your Zenoah engine, the following is recommended: DISASSEMBLY STEPS Note: Disassembly and assembly steps were written using a G-38 engine as an example, but they apply to all engines. 1. Dismount the engine from the model. 2. Remove the carburetor and insulator carefully without damaging the gasket. 1.
5. Fit the circlip. 6. Fit the bearings, snap ring and oil seal to the crankshaft. (Apply lithium grease to the lip area of the oil seal and fit it, paying attention to its direction.) 7. Wipe the contact surfaces of the cylinder block and crankcase, and apply liquid gasket (Permatex or equivalent). 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. When this is done, fit the oil seal to the cylinder block.
b) The engine stops by itself The crankshaft does not rotate or is abnormally heavy It suddenly stops The crankshaft rotates It slows down and stops c) Lower power output Out of fuel Not out of fuel See a) Put back The plug cap has come off Wiring disconnection Spark plug bridge Repair Use a standard plug Use clean fuel The STOP switch has been turned off Turn ON Refuel The fuel is not fed to the carburetor Water is mixed in the fuel See a) Replace The carburetor has not beeen properly adjusted
In the event that none of the above procedures results in the engine running properly, contact our service department for suggestions at: PROPELLER CHART Horizon Hobby Distributors 4105 Fieldstone Road Champaign, IL 61922 Phone: 217-355-9511 (Mon-Fri 8:00-5:00 CST) Engine Note: All recommendations are based on engines using APC brand props. G-23A G-23 Glow G-23 Heli PROPELLER SELECTION In the chart at right you’ll find a propeller selection list.
G-23 Note: The parts indicated “*” in the part number column are supplied as an assembly. No individual part available. A=Aircraft, H=Helicopter, M=Marine Index No. Parts No. Description A, H CYLINDER 1 ZEN2301 M CYLINDER 2 ZEN2302M M JACKET 3 ZEN2303M M JOINT 4 ZEN2304M M O RING 3X38 5 ZEN2305M M O RING 1.5X19.
G-38 (Standard Accessory for G380PU) Index No. 1 2 3 4 5 6 11 12 13 14 15 16 17 18 19 20 10 Parts No. Description ZEN3801 CYLINDER ZEN3802 INSULATOR ZEN3803 CARB GASKET ZEN3804 INSULATOR SCREW ZEN3805 INSULATOR GASKET ZEN3806 MUFFLER ASS’Y ZEN3811 MUFFLER GASKET ZEN3812 MUFFLER BOLT ZEN3813 CRANKCASE ZEN3814 CASE BOLT ZEN3815 CASE WASHER ZEN3816 CASE PLUG ZEN3817 PLUG GASKET ZEN3818 PISTON ZEN3819 PISTON RING ZEN3820 PISTON PIN Q’ty/ unit 1 1 1 2 1 1 1 2 1 4 4 1 1 1 1 1 Index No.
G-45 Index No. 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 Parts No. ZEN4501 ZEN4502 ZEN4503 ZEN4504 ZEN6204 ZEN4506 ZEN4504 ZEN6207 ZEN6208 ZEN6209 ZEN6210 ZEN4513 ZEN6213 ZEN6214 ZEN6215 ZEN6216 ZEN6217 ZEN6276 ZEN4520 Description CYLINDER INSULATOR INSULATOR GASKET BOLT CARBURETOR GASKET CYLINDER GASKET BOLT MUFFLER MUFFLER GASKET MUFFLER BOLT MUFFLER NUT CRANKCASE COMP.
G-62 * (Accessory for G620PU-1) Index No. 1 2 3 4 5 6 7 8 9 10 11,12 13 14 15 16 17 18 19 20 12 Parts No. Description ZEN6201 CYLINDER ZEN6202 INSULATOR GASKET ZEN6203 INSULATOR ZEN6204 CARBURETOR GASKET ZEN6205 CYLINDER BASE GASKET ZEN2309 CYLINDER BOLT ZEN6207 MUFFLER ZEN6208 MUFFLER GASKET ZEN6209 MUFFLER BOLT ZEN6210 MUFFLER NUT ZEN6211 CRANKCASE COMP.
G-445 Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Parts No.
POLICY 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 of the engine and is not transferable. Warranty repairs will NOT cover: 1. Include complete name and address information inside the carton, as well as clearly writing it on the outer label/return address area. 2.
CONSUMER WARRANTY REGISTRATION 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.
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