G230RC/G260RC - davesmotors.com

1 g230rc /G260 RCOWNER S SERVICE MANUALT2070-93112 (704) This engine is designedfor the radio controlledcar use. Zenoah assumesthat no responsibility forthis engine that ismodified or used for anyother has allresponsibility against anylaws and regulationsexisting in the country,Zenoah is exempt fromsuch law and regulations. Read this OWNER SSERVICE MANUAL beforeoperating this engine. WARNING1. Specifications2. Fuel Mix high-octane (over 95) gasoline and highgrade 2 cycle oil (JASO FC Grade oil or ISOEGC grade) in the ratio of 25 : ) Never use any alcohol fuel or alcohol addedfuel, or the rubber parts in the carburetorand engine will be ) Gasoline is very flammable.

2 Avoid smoking,bringing any fires near )To prevent all possible problem on fuelingsystem, make sure to use the fuel filter andfuel pipe packed as TypeG230 RCG260 RCOverall Size (L x W x H)167 x 204 x Engagement6000rpm (STD Spring)Carburetor TypeWT-603 BSpark PlugNGK CMR7 HSpark Plug DirectionCounter-Clockwise (View From PTO)33. Engine Starting4. Operation Push the primer pump several times untiloverflown fuel flows out. ( ) Close the choke lever( ), and move thethrottle lever 1/4~1/3 open position. Pull the starter(knob) quickly until first firingnoise. ( ) Open the choke( ), throttle idle~1/4 open Pull the starter quickly Operate engine for a few minutes for thewarming up.

3 In case of engine warm condition, choking maynot be necessary. Over choking may cause starting difficulty dueto wet spark plug. In this case change spark plug or dry it, andremove fuel rest in the cylinder by This engine is already tuned up to get highpower and high speed, and needs correctmaintenance to keep such high performance. The details for operation may be described inthe separate owners manual to be issued by carmanufacturer. Be sure to have the engine cool down for 30seconds at idle speed after full throttle LeverOpenCloseThrottle Maintenance1) MAINTENANCE CHARTB efore Every Every ItemsActionUse25 hours100 hoursNoteLeakage, Check Damage/CrackIdling SpeedCheck/Adjust Air-cleanerCheck/Cleaning Replace if necessarySpark Plug(gap)Check/Adjust Cylinder(barrel)Check/Cleaning Piston, RingCheck/Cleaning Muffler & BoltCheck/Cleaning BearingsCheck/Cleaning Crank ShaftCheck/Alignment 2)

4 SPECIFICATIONS AND TECHNICAL DATAI temsUnitG230 RCG260 RCRemarksBore x Strokemm32 x 2834 x Compression WT CarburetorVenture(mm) StartingRecoil Starter TypeTCI IgnitionTimingBTC 30 /8000rpm StandardCMR7H NGKCR8 HVXwith Terminal NutOption(Hot Type)CMR6H Clutch Engagement Speedrpm6000 No load max Speedrpm19500 Idling Speedrpm4000 Without Air CleanerMax. MufflerMax. Fuel Consumptiong/kW h750 (550)765 (565) CarburetorH1 3/4 1/4 Standard settingL1 1/2 1/4 5 Option(For Race)Spark Plug 5. Maintenance4) CARBURETORI temsStandardLimitMeasuring DeviceRemarksMetering Lever set (mm) Valve Opening Pressure (kg/cm2) ~ TesterInlet Valve Closing Pressure (kg/cm2) ~ Tester63) MAINTENANCE SPECIFICATIONS G230 RCG260 RCItemsStandardLimitStandardLimitMeasuri ng DeviceRemarksBore (mm) 32 Plating damaged 34 Plating damagedEye CheckingDiameter (mm) MeterPiston GaugeGroove width (mm)Piston Pin Hole (mm) GaugeClearance betweenPiston and ~ ~ (mm)Clearance betweenGroove and ~ ~ GaugePiston Ring (mm)End Gap (mm) ~ ~ GaugeWidth (mm) MeterPiston Pin Diameter (mm) 8 8 MeterConnecting Rod Small end (mm)

5 11 11 GaugeCrankshaft Dia. at Main Bearing (mm) 12 12 MeterEccentricity (mm) GaugeAxial Play (mm) GaugeGritty orGritty orMain Bearing Feels Flat SpotFeels Flat SpotAt the skirt endand the right angleto the piston inserted ina new RingMicro MeterCylinder Gauge5. Maintenance5) IGNITION SYSTEMI temsStandardLimitMeasuring DeviceRemarksSpark Plug Air Gap (mm) ~ GaugeIgnition Coil/Flywheel Air Gap (mm) Volt MeterSecondary6100 Volt MeterReading betweenprimary terminal andiron betweensparking cord end andiron ) TIGHTENING TORQUEI temsScrew SizeStandard (kg cm)Limit (kg cm)RemarksCarburetorM5 (P= )3530~40 InsulatorM5 (P= )3530~40with Locktight glueClutchM6 (P= )6550~80 RotorM8 (P= )130100~150 CylinderM5 (P= )7060~80 CrankcaseM5 (P= )6550~80 Spark PlugM10 (P= )110100~120 MufflerM5 (P= )9070~100 Fan CoverM5 (P= )3530~40 Ignition CoilM4 (P= )3325~40 Starter CaseM4 (P= )

6 1310~15 Tapping ScrewTP ~30 Coil Resistance( )76. Special Tools7) SPECIAL TOOLSPart NamePart AppearanceUsage1 Puller Assy2890-96100To remove Stopper4810-962203 Rod Assy1101-96220To remove/install piston Gap Gauge3330-97310To set ignition Wrench3304-976116 Snap Ring Pliers5500-96110To remove snap hold crankshaft whendisassembling/assemblingclutch and socket screw of , 4mm and Service Guide1) REMOVING CLUTCH SHOE1. Remove the housing and plug the spark plug and fit thestopper(4810-96220) into the plug 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).

7 Apply 8mm puller ) ASSEMBLING ROTORI nsert the gauge(3330-97310) in between therotor magnet metal and the screwswhile pressing the coil against the Gap ~ Bolt(14mm Hex.)Rotor Nut17mm BoltsPullerRotorWrench Air Gap GaugeIgnition Coil97. Service Guide4) REMOVING PISTON snap rings from both sides of thepiston the rod assy(1101-96220) to thepiston pin and gently tap with a plastic hammerto push out the pin while holding piston firmly. Hard hammering may damage the big end ofthe connecting ) INSTALLING sure to point the arrow mark on thepiston to the exhaust the circlip in the groove so as to face theend gap below.

8 Deformed circlip may come off during engineoperation and damage the ) CARBURETOR ADJUSTMENTThe carburetor comes with a standard setting, itis for optimum performance under the barometricpressure and climatic conditions at factory, so itmay be re-adjusted according to load rpm : 4000 300 rpm (STD Spring)H needle : 1 3/8 1/4L needle : 1 1/4 1/4 NOTENOTEP lastic HammerRod AssyPistonArrow MarkCirclipEnd GapPistonH needleL needleIdle Screw109. Trouble Shooting1) ENGINE DOES NOT STARTD escriptionCauseCountermeasureNo spark in the spark plugSpark Plug1. Wet spark plug electrodesMake them dry2. Carbon deposited on the electrodesCleaning3.

9 Insulation failure by insulator damageExchange4. Inproper spark gapAdjust to ~ Burn out of electrodesExchangeMagneto1. Ignition coil inside failureExchange2. Damaged cable sheath or disconnected cableExchange or repairSwitch1. Switch is OFFON the switch2. Switch wiring earthedRepairSparks appear in the spark plugCompression & 1. Over sucking of fuelDrain excess fuelfueling is normal2. Too rich fuel Adjust carburetor3. OverflowCarburetor adjust or exchange4. Clogging of air cleanerWash with mixed gasoline5. Faulty fuelChange with proper fuelFueling normal but1. Worn out cylinder, piston, or piston ringExchangepoor compression2.

10 Gas leakage from cylinder and crank case gasketApply liquid gasket and fuel supply1. Choked breather air holeCleaning2. Clogged carburetorCleaning3. Clogged fuel filterExchange fuel filter112) LACK OF POWER OR UNSTABLE RUNNINGD escriptionCauseCountermeasureCompression is normal 1. Air penetration from fuel pipe joints, etcSecure connectionand no misfire2. Air penetration from intake tube joint or Change gasket or tightening screwscarburetor joint3. Water in fuelChange with good fuel4. Piston start to seizureReplace piston(and cylinder)5. Muffler choked with carbon CleaningOverheating1. Fuel too leanAdjust carburetor2. Clogging of cylinder fin with dustCleaning3.