Zenoah 966669901 User manual

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 designed for the use of radio control car.
Please use this engine in conjunction with the manual for radio control car or
radio control equipment you are going to use.
●Any modification of the engine or any use of other applications is prohibited.
●The purchaser (user) shall bear all obligations and responsibilities stipulated
by law, local ordinance and the likes.
Husqvarna Zenoah Co., Ltd. shall bear no responsibility whatsoever.
Model: G240RC/G270RC/G290RC
Model code: X374323111 (G240RC)
Model code: X374326111 (G270RC)
Model code: 966669901 (G290RC)
 -26

2

3
SPECIFICATIONS.....................................................4
SAFETY PRECAUTIONS..........................................5
FUEL .........................................................................7
ENGINE STARTING..................................................8
OPERATION .............................................................9
MAINTENANCE ......................................................10
SPECIAL TOOLS ....................................................15
SERVICE GUIDE ....................................................16
TROUBLE SHOOTING ...........................................19
PARTS LIST (G240RC)...........................................22
PARTS LIST (G270RC)...........................................26
PARTS LIST (G290RC)...........................................30
WARRANTY............................................................34
CONTENTS

4
SPECIFICATIONS
Engine Type G240RC G270RC G290RC
Overall Size (L x W x H) 166 x 205 x 196mm
Weight 2.07kg
Displacement 22.5cm325.4cm328.5cm3
Clutch Engagement 6000rpm (STD Spring)
Carburetor Type WT-990
Spark Plug NGK CMR7H
Spark Plug Gap 0.65mm
Rotating Direction Counter-Clockwise (View From PTO)

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 your
hobbies.
•The fuel is toxic. Do not let it get into your eyes or mouth. Store it in a
cool place, out of the reach of infants and children.
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.
WARNING AVERTISSEMENT ADVERTENCIA
Los gases de escape del motor de
este producto contienen
sustancias químicas conocidas
por el Estado de California como
causantes de cáncer,
malformaciones en recién nacidos
y otros problemas de
reproducción.
Les échappements du moteur de
ce produit contiennent des
produits chimiques connus par
l’Etat de Californie comme étant
responsables de cancers,
d’anomalies congénitales et
d’autres atteintes à l’appareil
reproducteur.
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.
WARNING AVERTISSEMENT ADVERTENCIA
Los gases de escape del motor de
este producto contienen
sustancias químicas conocidas
por el Estado de California como
causantes de cáncer,
malformaciones en recién nacidos
y otros problemas de
reproducción.
Les échappements du moteur de
ce produit contiennent des
produits chimiques connus par
l’Etat de Californie comme étant
responsables de cancers,
d’anomalies congénitales et
d’autres atteintes à l’appareil
reproducteur.

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.
•Please wear clothing that facilitates your safety. Remove all scarves,
•To prevent burns, make sure not to touch the engine while it is
operating or immediately after it has stopped.
•Do not run the motor in poorly ventilated places. Do not breathe the
exhaust, as it is a health hazard.
•Use of open flames around the fuel is strictly prohibited, because of
danger of fire.

7
FUEL
•Mix gasoline (octane over 95) and high grade 2 cycle engine oil (mixing use type;
JASO FC grade or ISO-L-EGC grade) at mixing ratio 25~40:1.
•The mixing ratio is according to the oil recommendation.
[ NOTE ]
1) Gasoline may contain maximum of 10% Ethanol (grain alcohol) or up to 15% MTBE
(Methyl tertiary-butyl ether).
Gasoline containing Methanol (Wood Alcohol) is NOT approved.
2) Gasoline is very flammable. Avoid smoking and any fires near fuel.
3) To prevent all possible problems on fueling system, make sure to use the fuel filter
which has more than 300 mesh or equivalent and gasoline proof rubber pipe or
equivalent.
Incorrect fuel filter may cause engine trouble like fuel passage stuffing in carburetor,
or piston surface scratching etc.

8
ENGINE STARTING
•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 engine for a few minutes for the warming up.
•In case of engine warm condition, choking may not be
necessary.
•Over choking may cause starting difficulty due to wet
spark plug.
In this case change spark plug or dry it, and remove
fuel rest in the cylinder by pulling starter.
IMPORTANT
Choke Lever
Open
Close
Primer Pump
Fig.1
Throttle Lever
Fig.2
Fig.3

9
OPERATION
•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
running.

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 & Bolt Check/Cleaning ✔✔✔ ↑
Bearings Check/Cleaning ✔✔ ↑
Crank Shaft Check/Alignment ✔↑

11
MAINTENANCE
2) SPECIFICATIONS AND TECHNICAL DATA
Items Unit G240RC G270RC G290RC Remarks
Bore x Stroke mm 32 x 28 34 x 28 36 x 28
Displacement cm322.5 25.4 28.5
Effective Compression Ratio 8.9 8.9 9.9
Type Walbro WT ←←
Carburetor
Venture(mm) ø12.7 ←←
Starting Recoil Starter ←←
Type TCI ←←
Ignition
Timing BTC 30°/8000rpm ←←
Standard CMR7H ←←NGK
CR8HIX
with Terminal Nut
Option(Hot Type) CMR6H ←←↑
Clutch Engagement Speed rpm 6000 ←←STD Spring
No load max Speed rpm 19500 ←←
Idling Speed rpm 4000 ←←
Max. Net Power kW/rpm 1.81/12000 1.86/12000 2.0/13000
Max. Net Torque N.m/rpm 1.58/9000 1.63/9000 1.69/9000
Fuel Consumption g/kW·h 616 653 600
Carburetor H 1 1/8 ± 1/4 ←←
Standard setting L 1 1/4 ± 1/4 ←←
↑
Option(For Race)
Spark Plug ←←

12
MAINTENANCE
3) MAINTENANCE SPECIFICATIONS
G240RC G270RC G290RC
Items Standard Limit Standard Limit Standard Limit Measuring Device Remarks
Bore (mm) ø32 Plating damaged ø34 Plating damaged ø36 Plating damaged Eye Checking
Diameter (mm) ø31.97 ø31.87 ø33.97 ø33.87 ø35.97 ø35.87 Micro Meter
Piston Ring 0.81 0.91 1.01 1.11 1.01 1.11 Thickness Gauge
Groove width (mm)
Piston Pin Hole (mm) ø8.01 ø8.05 ø8.01 ø8.05 ø8.01 ø8.05 Cylinder Gauge
Clearance between
Piston and 0.03~0.06 0.15 0.03~0.06 0.15 0.03~0.06 0.15
Cylinder (mm)
Clearance between
Groove and 0.02~0.04 0.1 0.02~0.04 0.1 0.02~0.04 0.1 Thickness Gauge
Piston Ring (mm)
End Gap (mm) 0.05~0.25 0.5 0.05~0.25 0.5 0.05~0.25 0.5 Thickness Gauge
Width (mm) 0.78 0.73 0.98 0.93 0.98 0.93 Micro Meter
Piston Pin Diameter (mm) ø8 ø7.98 ø8 ø7.98 ø8 ø7.98 Micro Meter
Connecting Rod Small end (mm) ø11 ø11.05 ø11 ø11.05 ø11 ø11.05 Cylinder Gauge
Crankshaft Dia. at Main Bearing (mm) ø12 ø11.98 ø12 ø11.98 ø12 ø11.98 Micro Meter
Eccentricity (mm) — 0.07 — 0.07 — 0.07 Dial Gauge
Axial Play (mm) — 0.5 — 0.5 — 0.5 Thickness Gauge
Gritty or Gritty or Gritty or
Main Bearing — — — —
Feels Flat Spot Feels Flat Spot Feels Flat Spot
At the skirt end and
the right angle to
the piston pin.
When inserted in
a new cylinder.
Piston
Cylinder
Piston
Ring
Micro Meter
Cylinder Gauge

13
MAINTENANCE
4) CARBURETOR
Items Standard Limit Measuring Device Remarks
Metering Lever set (mm) 1.65 ± 0.16 Vanier
Inlet Valve Opening Pressure (kg/cm2)1.3~2.3 Leak Tester
Inlet Valve Closing Pressure (kg/cm2)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 Gauge
Ignition Coil/Flywheel Air Gap (mm) 0.3 0.4 Thickness Gauge
Primary 0.7 — Volt Meter
Secondary 6100 — Volt Meter
Reading between
primary terminal and
iron core.
Reading between
sparking cord end and
iron core.
Coil
Resistance
(Ω)

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 (P=0.8) 8.8 6.9~9.8
Fan Cover M5 (P=0.8) 3.4 2.9~3.9
Ignition Coil M4 (P=0.7) 3.2 2.5~3.9
Starter Case M4 (P=0.7) 1.3 1.0~1.5
Tapping Screw TP 4.3 2.4 1.9~2.9

15
SPECIAL TOOLS
Part Name Part No. External Appearance Usage
1Puller Assy 2890-96100 To remove rotor.
2Piston Stopper 4810-96220
3 Rod Assy 1101-96220 To remove/install piston pin.
4Air Gap Gauge 3330-97310 To set ignition coil.
5Hex Wrench 3304-97611
6Snap Ring Pliers 5500-96110 To remove snap ring.
To hold crankshaft when
disassembling/assembling
clutch and rotor.
For socket screw of Hex.
3mm, 4mm and 5mm.

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 Hex.)
Rotor Nut
17mm Hex.
Puller Bolts
Puller
Rotor

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 plastic hammer to push out the
pin while holding piston firmly.
Hard hammering may damage the big end of the
connecting rod.
NOTE
Wrench
Air Gap Gauge
Ignition Coil
Plastic
Hammer
Rod Assy
Piston

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 performance under the barometric pressure and
climatic conditions at factory, so it may be re-adjusted
according to load applied.
Idle rpm : 4000 ± 300 rpm (STD Spring)
H needle : 1 1/8 ± 1/4
L needle : 1 1/4 ± 1/4
NOTE
Arrow Mark
Circlip
End Gap
Piston
H needle L needle
Idle Screw

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. Ignition coil inside failure Exchange
2. Damaged cable sheath or disconnected cable Exchange or repair
Switch 1. Switch is OFF ON the switch
2. Switch failure Exchange
3.Primary wiring earthed Repair
Sparks appear in the spark plug
Compression & 1. Over sucking of fuel Drain excess fuel
fueling is normal 2. Too rich fuel Adjust carburetor
3. Overflow Carburetor adjust or exchange
4. Clogging of air cleaner Wash with mixed gasoline
5. Faulty fuel Change with proper fuel
Fueling normal but 1. Worn out cylinder, piston, or piston ring Exchange
poor compression 2. Gas leakage from cylinder and crank case gasket Apply liquid gasket and reassemble.
No fuel supply 1. Choked breather air hole Cleaning
2. Clogged carburetor Cleaning
3. Clogged fuel filter Exchange fuel filter

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 seizure Replace piston(and cylinder)
5. Muffler choked with carbon Cleaning
Overheating 1. Fuel too lean Adjust carburetor
2. Clogging of cylinder fin with dust Cleaning
3. Poor fuel quality Exchange with proper fuel
4. Carbon deposited in the combustion chamber Cleaning
5. Spark plug electrode red hot Thoroughly clean, adjust spark gap
[ 0.6~0.7(0.023~0.028in) ]
Others 1. Dirty air cleaner Wash with mixed gasoline
2. Over loading Reduce load