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Zenoah G240RC - page 1
OWNER'S MANUAL 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 desig ...
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Zenoah G240RC - page 2
2 ...
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Zenoah G240RC - page 3
3 SPECIFICATIONS.....................................................4 SAFETY PRECAUTIONS..........................................5 FUEL .........................................................................7 ENGINE STARTING..................................................8 OPERATION ............................................................ ...
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Zenoah G240RC - page 4
4 SPECIFICA TIONS 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) ...
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Zenoah G240RC - page 5
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 care to act with good judgment as you enjoy you ...
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Zenoah G240RC - page 6
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. ...
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Zenoah G240RC - page 7
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 carburetor and engine will be damaged. 2) Gasoline is ...
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Zenoah G240RC - page 8
8 ENGINE ST ARTING • 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 • Pull the starter quickly • Operate ...
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Zenoah G240RC - page 9
9 OPERA TION • 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 runni ...
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Zenoah G240RC - page 10
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 Check/Cleaning ✔✔ ↑ Muffler & ...
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Zenoah G240RC - page 11
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 ← Standard CMR7H ← NGK CR8HIX with Te ...
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Zenoah G240RC - page 12
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 (mm) Piston Pin Hole (mm) ø8.01 ø8.05 ø8.01 ...
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Zenoah G240RC - page 13
13 MAINTENANCE 4) CARBURETOR Items Standard Limit Measuring Device Remarks Metering Lever set (mm) 1.65 ± 0.16 Vanier Inlet Valve Opening Pressure (kg/cm 2 ) 1.3~2.3 Leak Tester Inlet Valve Closing Pressure (kg/cm 2 ) 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 ...
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Zenoah G240RC - page 14
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 Spark Plug M10 (P=1.0) 10.8 8.8~12.8 Muffler M5 ...
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Zenoah G240RC - page 15
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 snap ring. To hold crankshaft when disassembling/asse ...
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Zenoah G240RC - page 16
16 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. 3. Remove clutch bolts(14mm Hex.). 2) REMOVING ROTOR (FAN) 4. Remove the rotor nut(12mm Hex.). 5. Remove the rotor using the puller assy (2890-96100). Apply 8mm puller bolts. Clutch Bolt (14mm He ...
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Zenoah G240RC - page 17
17 SERVICE GUIDE 3) ASSEMBLING ROTOR Insert the gauge(3330-97310) in between the rotor 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 pin. 2. Engage the rod assy(1101-96220) to the piston pin and gently tap with a plast ...
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Zenoah G240RC - page 18
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. 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 performa ...
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Zenoah G240RC - page 19
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. Burn out of electrodes Exchange Magneto 1. Ignit ...
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Zenoah G240RC - page 20
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 fuel Change with good fuel 4. Piston start to seiz ...
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Zenoah G240RC - page 21
21 PA R TS LIST ...
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Zenoah G240RC - page 22
22 P ARTS LIST G240RC (X374323111) ...
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Zenoah G240RC - page 23
23 G240RC (X374323111) ...
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Zenoah G240RC - page 24
24 KEY# PART NUMBER DESCRIPTION REMARKS Q'TY/ UNIT KEY# PART NUMBER DESCRIPTION REMARKS Q'TY/ UNIT 35 1140-21162 CASE, CLUTCH 1 36 3350-15250 BOLT 4 M5x16L 37 1140-55310 PLATE 1 38 0224-30614 BOLT 1 M6x14L 39 T2070-71110 ROTOR 1 40 T2070-71200 COIL-A 1 42 T2075-72210 CAP 1 43 1400-72121 SPRING 1 44 5500-72130 GROMMET 1 45 1260-71261 SPACE ...
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Zenoah G240RC - page 25
25 KEY# PART NUMBER DESCRIPTION REMARKS Q'TY/ UNIT KEY# PART NUMBER DESCRIPTION REMARKS Q'TY/ UNIT 104 848ER883C0 • VALVE 1 105 1918-82160 • WASHER 1 107 T2070-31111 COVER, FAN 1 108 3310-12281 BOLT 4 M5x20L 109 848ER83111 COVER-A 1 110 1850-32160 SCREW 1 M4x12L 111 1900-31410 SCREW 2 TP4.5x18L 112 3699-91867 SPARKPLUG NGK CMR7H 1 113 ...
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Zenoah G240RC - page 26
26 P ARTS LIST G270RC (X374326111) ...
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Zenoah G240RC - page 27
27 G270RC (X374326111) ...
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Zenoah G240RC - page 28
28 KEY# PART NUMBER DESCRIPTION REMARKS Q'TY/ UNIT KEY# PART NUMBER DESCRIPTION REMARKS Q'TY/ UNIT 35 1140-21162 CASE, CLUTCH 1 36 3350-15250 BOLT 4 M5x16L 37 1140-55310 PLATE 1 38 0224-30614 BOLT 1 M6x14L 39 T2070-71110 ROTOR 1 40 T2070-71200 COIL-A 1 42 T2075-72210 CAP 1 43 1400-72121 SPRING 1 44 5500-72130 GROMMET 1 45 1260-71261 SPACE ...
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Zenoah G240RC - page 29
29 KEY# PART NUMBER DESCRIPTION REMARKS Q'TY/ UNIT KEY# PART NUMBER DESCRIPTION REMARKS Q'TY/ UNIT 104 848ER883C0 • VALVE 1 105 1918-82160 • WASHER 1 107 T2070-31111 COVER, FAN 1 108 3310-12281 BOLT 4 M5x20L 109 T2070-32100 COVER-A 1 110 1850-32160 SCREW 1 M4x12L 111 1900-31410 SCREW 2 TP4.5x18L 112 3699-91867 SPARKPLUG NGK CMR7H 1 11 ...
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Zenoah G240RC - page 30
30 W ARRANTY 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 quality disclosed in the specifications. 2. The en ...
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Zenoah G240RC - page 31
31 W ARRANTY 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 from neglect of proper operation and maintenance ...
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Zenoah G240RC - page 32
Head Office : 1-9 Minamidai, Kawagoe-city, Saitama, 350-1165 Japan Phone: (+81)49-243-1115 Fax: (+81)49-243-7197 ...
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