ENGINE INSTRUCTION MANUAL

G26 Air

G26/G231 Marine

G26/G231 Heli

G38

G62

GT80 Twin

G45

®

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2

3

4

5

6

7

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3

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Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Mounting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Break In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Starting the Engine, Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Starting the Engine, Heli & Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Servicing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting Guide for Gasoline Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Propeller Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Exploded Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

G26/G231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

G38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

G45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

GT80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Non-Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Registration Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3

Introduction

Safety Instructions

Very Important

This manual describes the engine’s features and functions. 

For specific information on mounting, see the instruction

manual included with the model airplane, helicopter or

boat in which you intend to install the engine. 

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.

Always

1. Use genuine parts for replacement.

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.

3. Use the correct size and pitch of propeller for your

engine; refer to the propeller chart in this manual.

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.

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.

7. Use a thickly padded glove when hand starting 

the engine.

8. Make all carburetor adjustments from behind 

the propeller.

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!

10. Ensure that all spectators, especially children, are at

least 20 feet away when you start running the engine.

11. Make sure your fuel is kept in a safe place well away

from sparks, heat or anything that could ignite the fuel.

Recommendations

1. Use safety glasses or goggles when starting and 

running your engine.

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.

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.

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. It’s important that the instructions are read

thoroughly prior to mounting and running the engine.

Failure to read and follow these instructions before you proceed may result in engine 

damage and the voiding of your warranty!
4

Safety Instructions (continued)

Support Equipment

Caution

1. Model engines get very hot while running. Do not

attempt to handle them until they have cooled.

2. Always run your model engines in a well-ventilated

area. Similar to automotive engines, model engines

produce harmful carbon monoxide fumes.

3. Never modify the flywheel.

4. Check the flywheel. If it’s damaged, replace it with a

new one.

5. When mixing the fuel or operating the engine, do so 

in a well-ventilated area

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

observance of safety precautions.

Disassembly

The Zenoah® engine can be disassembled or reassembled

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:

Horizon Hobby, Inc.

Attention: Zenoah Service

4105 Fieldstone Road

Champaign, IL 61822

Phone: (217) 355-9511

Engine Parts Identification

It’s important to be able to identify the parts of your

Zenoah engines. Inside this manual 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.

The following items are not included with your Zenoah

engine but are necessary for operation.

Fuel—Mix gasoline and 2-stroke gas compatible 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.

Evolution Oil

EVOX1001Q
5

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

sinking into the mount. Periodically check the engine

mount for loose bolts.

2. Since the engine is equipped with a floatless carburetor

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 antivibration, 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. 

Break In

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

Before attempting to start the engine, be sure to read through

all the steps for starting the engine as outlined below:

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:

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 propeller 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.

1. Make sure the spark (glow) plug(s) are installed and

tightened. Check the condition of the plug cap for cracks

or breaks.

2. Be sure the propeller is properly secured.

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.

Fig 1-A

Coil

Magnet

Fig 1-B

Operation
6

Operation (continued)

8. Quickly flip the propeller in a counterclockwise 

direction. (See note on previous page)

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. 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 throttle is wide open, a great thrusting force will be

generated, which can be very dangerous.

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.

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.

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).

3. Choke the engine and open the throttle valve approximately 1/3–1/2 of the full open position.

4. Quickly pull the starter cord until the initial firing of

the engine is heard.

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.

6. For helicopter operation, you should adjust the rotorpitch to obtain a 9,000 to 10,000 rpm of the engine at

full throttle operation.

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

body, or the throttle valve should be closed completely. 

Installation of a “stop” or “kill” switch is recommended. 

We recommend the Zenoah ZEN20000 Kill Switch. 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) positions. They may need minor adjustment, depending upon

the temperature, humidity, atmospheric pressure (altitude), etc., of the area where the engine is being used.

1. Start the engine without making any adjustments.

2. Make adjustments only when the engine shows signs

of inefficient operation.

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

Idle Screw: Turning this screw clockwise increases the

idling rpm. Turning it counterclockwise decreases the

idling rpm.

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.

Red Lead

Black Lead

Kill Switch

Engine

Body

Ground

High-Speed Needle Low-Speed Needle

Idle Screw
7

Operation (continued)

High-Speed Needle: Turning this needle clockwise makes

the gas mixture leaner, and turning it counterclockwise

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.

Note: Do not tighten the high and low speed

needles too tightly.

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.

Recommendations

To extend the life of your Zenoah® engine, the following

is recommended:

1. Use an Evolution quality 2-stroke oil mixed at 32 to 1.

2. Use the recommended spark plugs.

3. Use the proper propeller size and balance the

propeller prior to use.

4. Always adjust the engine to a slightly rich setting.

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.

Servicing the Engine

Required Tools

• Regular screwdriver

• Phillips screwdriver . .

• Hexagonal wrench (4mm/5/32")

• Open wrench (19mm/3/4")

• Plastic hammer

• Thickness gauge

• Tapered round rod

• Liquid gasket (Permatex or equivalent)

• Threadlock (Blue Threadlock Z-42 or equivalent)

• Lithium grease

• Engine oil

• Washing gasoline

• Brush

• Scraper

• Cloth

The engine can be disassembled or reassembled without

any specific difficulties, but note the following:

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.

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.

2. Remove the carburetor and insulator carefully without

damaging the gasket.

3. Remove the muffler.

4. Remove the spark plug and ignition module. 

5. Remove the propeller hub.

6. Remove the rotor (flywheel). If it cannot be detached,

use a plastic hammer and tap the part lightly.

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 damage to the piston or connecting rod if the stopper is

not screwed into the bottom.

b. Loosen and remove the rotor securing nut.

Engine Care and Maintenance 
8

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. Remove the mounting plate.

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.

10. Pull out the crankshaft with the piston, bearings, and

other parts attached.

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.

14. Remove the thrust washers and needle bearing from

the smaller end of the connecting rod (G38).

15. Remove the piston ring.

16. Wash each part. Check for abrasion and damage, and

replace any part that is defective.

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

connecting rod and apply engine oil (SAE #30).

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.

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. Then, fit the oil seal to the cylinder

block. The snap ring joint should be set vertically to 

the cylinder.

9. Fit the crankcase to the cylinder block and tighten 

the bolts.

10. Check that the crankshaft can be smoothly turned 

by hand.

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. 

13. Apply threadlock (Blue Threadlock Z-42) to the

muffler bolts and mount the muffler. 

14. Apply threadlock (Blue Threadlock Z-42) to the

ignition module setscrews and fix the coil temporarily.

15. Set the rotor (flywheel) so that the magnet is located

on the opposite side of the module (G38). Place a

thickness 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 setscrews after having

applied threadlock (Blue Threadlock Z-42) to them. 

16. Using a new gasket, fix the insulator with screws to

which threadlock (Blue Threadlock Z-42) has been applied.

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.

Note: Disassembly and assembly steps were 

written using a G38 engine as an example, but

they apply to all engines.

Engine Care and Maintenance (continued)
9

Engine Care and Maintenance (continued)

Items

Leakage,

Damage/Crack

Losing Speed

Air-cleaner (PUH)

Spark Plug (gap)

Cylinder (barrel)

Piston, Ring

Muffler & Bolt

Bearings

Crankshaft

Rotor

Propeller Hub (PU)

Water Jacket (PUM)

Action

Check

Check/Adjust

Check/Cleaning

Check/Adjust

Check/Cleaning

Check/Cleaning

Check/Cleaning

Check/Cleaning

Check/Alignment

Check

Check/Alignment

Check/Leakage

Before Use

P

P

P

P

P

Every 100 hours

P

P

P

P

P

P

P

P

P

P

P

P

Note

Replace if necessary

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Maintenance Chart

Items

Type

Bore x Stroke

Displacement

Effective

Compression Ratio

Carburetor

Air Cleaner

Starting

Ignition

Spark Plug

Idle Speed

Max. Power

Min. Torque

Fuel Consumption

Weight

Unit

––

mm

cm3

––

Type (Walbro)

Venturi (mm)

––

Type

BTDC/rpm

STD

Option

rpm

rpm

rpm

cc

kg

G260PUM

Water Cooled

ë

ë

ë

WT-644

ë

––

Recoil Starter

ë

30/7000

ë

CMR8H/7H

3500

2.16/12000

1.94/9500

710

1.54

G260PUH

Air Cooled

ë

ë

ë

WT-677

ë

Dry Type

ë

ë

ë

ë

––

3000

1.71/13000

1.42/9500

760

1.77 (*1.57)

G231PUM

Water Cooled

32 x 28

22.5

ë

WT-644

ë

––

ë

ë

ë

ë

CMR6H/7H

3500

2.09/12000

1.79/10000

720

1.55

G231PUH

Air Cooled

ë

ë

ë

WT-677

ë

Dry Type

ë

ë

ë

ë

––

3000

1.58/13000

1.34/9000

700

1.78 (*1.58)

G260PU

Air Cooled

34 x 28

25.4

8.4

WT-645

12.7

––

Hand Flipping or

Electric Motor

CDI

28/7000

RZ7C

––

1800

APC 18 x 8

1.62/12000

1.48/9000

790

1.69 (* 1.52)

Specifications & Technical Data

Every 25 hours

P

P

P

P

P

P

P

P

P

P

P

P
10

Maintenance Specifications

Items

Bore (mm)

Diameter (mm)

Piston Ring

Groove Width (mm)

Piston Ring Hole (mm)

Clearance Between Piston

and Cylinder (mm)

Clearance Between Groove

and Piston Ring (mm)

End Gap (mm)

Width (mm)

Eccentricity (mm)

Axial Play (mm)

Main Bearing

Measuring Device

Eye Checking

Micro Meter

Thickness Gauge

Cylinder Gauge

Micro Meter

Cylinder Gauge

Thickness Gauge

Thickness Gauge

Micro Meter

Micro Meter

Cylinder Gauge

Micro Meter

Dial Gauge

Thickness Gauge

––

Remarks

At the skirt end and

the right angle to

the piston pin

When inserted in a

new cylinder

Standard

ø34

ø33.97

1.01

ø8.01

0.03–0.05

0.02–0.04

0.05–0.25

0.98

ø8

ø11

ø12

––

––

––

Standard

ø32

ø31.97

1.01

ø8.01

0.03–0.05

0.02–0.04

0.05–0.25

0.98

ø8

ø11

ø12

––

––

––

Limit

Plating damaged

ø33.87

1.11

ø8.05

0.15

0.1

0.5

0.93

ø7.98

ø11.05

ø11.98

0.07

0.5

Gritty or

Has Flat Spot

Limit

Plating damaged

ø31.87

1.11

ø8.05

0.15

0.1

0.5

0.93

ø7.98

ø11.05

ø11.98

0.07

0.5

Gritty or

Has Flat Spot

Cylinder

Piston

Piston

Ring

Piston Pin Diameter (mm)

Connecting Rod, Small End (mm)

Crankshaft Dia. at Main Bearing (mm)

Engine Care and Maintenance (continued)
11

Troubleshooting Guide for Gasoline Engines

a) The engine does not start.

The crankshaft

does not rotate Seizure, intrusion of a foreign substance

The fuel has not been fed to

the carburetor

The fuel has been fed to the

carburetor

Disassemble and repair

Disassemble and clean

Clean

Loosened

spark plug

Abrasion or damage of

the cylinder, piston, or

piston ring

Tighten further

Replace

Clogging inside the

carburetor

Clogging of the fuel

piping

No compression

(normally 7 kg/cm2

99.5 psi or more)

The crankshaft

rotates

Compression adequate

Readjust

Replace

Wet plug Remove the spark

plug and dry it

The carburetor has

not been properly

adjusted

The fuel is not

suitable

The spark plug does spark

The Stop switch has

been turned off

Wiring is disconnected

Turn on

Repair

The spark plug does not spark

The spark plug is defective

The ignition module is defective

Replace

Replace

The air gap is too large Adjust

The spark plug gap is too large Adjust

b) The engine stops by itself

It suddenly stops The crankshaft does not rotate

or is abnormally heavy

The crankshaft

rotates

Out of fuel

Not out of fuel

The carburetor has not beeen properly adjusted

See a)

See a)

Put back

Repair

Use a standard plug

Turn on

Use clean fuel

Replace

The fuel is not fed to the carburetor

Water is mixed in the fuel Replace

Replace

Refuel

Readjust

It slows down and stops

The plug cap has come off

Wiring disconnection

Spark plug bridge

The Stop switch has

been turned off

Air suction from a carburetor joint or oil seal

Abrasion of the piston ring

Repair

Replace

The fuel is not suitable

Clogging of the muffler or exhaust port due to carbon Clean

The spark plug heat range is not proper

c) Lower power output

d) The engine does not stop

Overheating

See c)

Repair

Overheating

The Stop switch is defective Repair

Switch wiring is disconnected

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.
12

Propeller Chart

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)

This chart enables you to select the best propeller for

initial setup of your Zenoah engine.

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.

Note: All recommendations are based on engines using

APC brand props.

Engine Propeller

G26A 16x8 @ 8,700

G231 Heli Adjust pitch of rotor to obtain

G26 Heli 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 18x10 @ 7,300

G45 Gas 20x10 @ 7,200

G62 Gas 22x10 @ 7,200

GT80 Gas 22x12 @ 7,200

24x10 @ 7,200
13

Engine Specifications

Items

G26A

G26M

G231 HELI

G231 MARINE

G38

G45

G62

GT80

G26H

139mm

139mm

139mm

142mm

142mm

170mm

152mm

162.5mm

191.5mm

105mm

105mm

105mm

105mm

105mm

130mm

130mm

140mm

257mm

181mm

181mm

181mm

181mm

181mm

215mm

185mm

185mm

190mm

2,000–10,000

2,000–10,000

2,000–10,000

3,000–11,000

3,500–15,000

2,000–9,000

2,000–10,000

2,000–10,000

1,800–10,000

BIS07123

—

—

—

—

BIS07138

BIS07145

BIS07163

BIS07445/6

Length Width Height

Operating 

RPM

Optional 

Mufflers

Outside Dimensions (mm)

G26A/M/H

G231M/H

G38

G45

G62

GT80

* w/spring starter

1.55

1.4

2.3

2.74

3.8

4.8

1.41

1.3

1.5

1.69

1.9

1.60

1.1

1.1

1.3

1.22

1.4

1.22

54/57

54

67

74

73

126

M8x1.25/6x1

M8x1.25

M10x1.25

8x1

10x1

10x1.25

2.4

2.2

2.2

3.3

4.75

6

WT645/WT644/WT677

WT644/WT643

WT338/WTA-6A

HDA-48D

HDA-48D

WJ-64

Displacement

(cu in)

Bore

(in)

Stroke

(in)

Weight

(oz)

K

(ISO)

HP

(H/M)

Carb

(Walbro)

Specifications
14

Quantity Per Unit

New Zen Out of Date 260 G260 G260 G231 G231

Key # Part # Part # Description PU PUM PUH PUM PUH

1-1	 ZENT207512110 CYLINDER	 1	 –	 1	 –	 –

1- 2	 ZENT207012111	 CYLINDER	 –	 –	 –	 –	 1

2-1	 ZENT207612110	 CYLINDER	 –	 1	 –	 –	 –

2-2	 ZENT207812110	 CYLINDER	 –	 –	 –	 1	 –

3	 ZENT207612210	 JACKET	 –	 1	 –	 1	 –

4	 ZEN0785100515	 JOINT	 –	 2	 –	 2	 –

5	 ZEN0700013040	 O-RING 3 x 40	 –	 1	 –	 1	 –

6	 ZENT207612320	 O-RING 1.5 x 15.5	 –	 1	 –	 1	 –

7	 ZEN116012330		 BOLT M3 x 8	 –	 2	 –	 2	 –

8	 ZENT207513120	 GASKET, CYLINDER	 1	 1	 1	 1	 1

9	 ZEN331012281		 BOLT M5X20	 6	 6	 6	 6	 6

10	 ZENT207513150	 GASKET, INSULATOR	 1	 1	 1	 1	 1

11	 ZEN114813162		 INSULATOR	 1	 1	 1	 1	 1

12	 ZENT207514120	 GASKET, CARBURETOR	 1	 1	 2	 1	 2

	 ZENT207521100	 CRANKCASE, COMPLETE	 1	 1	 1	 1	 1

13	 	 CRANKCASE, REAR	 1	 1	 1	 1	 1

14	 	 CRANKCASE, FRONT	 1	 1	 1	 1	 1

15	 ZEN262921130		 PIN	 3	 3	 3	 3	 3

16	 ZENT207521140	 GASKET	 1	 1	 1	 1	 1

17	 ZEN216921210		 SEAL, 12 x 22 x 7	 1	 1	 1	 1	 1

18	 ZEN33301412	 	 BEARING	 2	 2	 2	 2	 2

19	 ZEN0406502812	 Snap Ring 1	 1	 1	 1	 1

20	 ZEN0603406001	 BEARING	 1	 –	 1	 –	 1

14 21	 ZEN185021220		 SEAL, 12 x 28 x 7	 –	 1	 –	 1	 –

Exploded Illustration

G26/G231

ZEN2601

ZEN2301RCA

ZEN2601M

ZEN23102M

ZEN2603M

ZEN2304M

ZEN23105M

ZEN23106M

ZEN2307M

ZEN23108

ZEN2309

ZEN2305RC

ZEN23111

ZEN23112

ZEN23114

ZEN6213

ZEN23116

ZEN3828

ZEN2318

ZEN2319

ZEN2320

ZEN2321M
 New Zen Out of Date 

260 G260 G260 G231 G231

Key # Part # Part # Description PU PUM PUH PUM PUH

22	 ZEN0125230530	 	 	 BOLT, M5 x 30	 4	 4	 4	 4	 4

23-1	 ZENT208841110	 	 	 PISTON	 	 1	 1	 1	 –	 –

23-2	 ZENT207041110	 	 	 PISTON	 	 –	 –	 –	 1	 1

24-1	 ZENT208841210	 	 	 RING	 	 1	 1	 1	 –	 –

24-2	 ZENT207041210	 	 	 RING	 	 –	 –	 –	 1	 1

25-1	 ZEN160041310	 	 	 PISTON PIN	 	 1	 1	 1	 –	 –

25-2	 ZEN110141310	 	 	 PISTON PIN	 	 –	 –	 –	 1	 1

26	 ZEN126041320	 	 	 SNAP RING	 	 2	 2	 2	 2	 2

27	 ZEN550041410	 	 	 BEARING	 	 1	 1	 1	 1	 1

28	 ZEN110141340	 	 	 WASHER	 	 2	 2	 2	 2	 2

29	 ZENT207542000	 	 	 CRANKSHAFT, COMPLETE	 1	 1	 1	 1	 1

30	 ZEN115574110	 	 	 MOUNT, PLATE	 1	 1	 1	 1	 1

31	 ZEN026210516	 	 	 SCREW, M5 x 16	 3	 3	 3	 3	 3

32	 ZEN165043230	 	 	 NUT, M8	 	 1	 –	 –	 –	 –

33	 ZEN116075210	 	 	 PULLEY	 	 –	 1	 1	 1	 1

34	 ZEN186175101	 	 	 RECOIL ASSEMBLY	 –	 1	 1	 1	 1

35	 ZEN026330414	 	 	 SCREW, M4 x 14	 –	 4	 4	 4	 4

36	 ZEN100043240	 	 	 KEY	 	 1	 1	 1	 1	 1

37	 ZEN114043250	 	 	 SHIM	 	 1	 1	 1	 1	 1

38-1	 ZEN262971210	 	 	 COIL, (GREY)	 	 1	 –	 –	 –	 –

38-2	 ZEN116071211	 	 	 COIL, (RED)	 	 –	 1	 1	 1	 1

39	 ZEN115571110	 	 	 ROTOR	 	 1	 1	 1	 1	 1

40	 ZEN026030422	 	 	 SCREW M4 x 22	 2	 2	 2	 2	 2

41	 ZEN026330414	 	 	 SCREW M4 x 14	 2	 2	 2	 2	 2

42	 ZENT207572210	 	 	 PLUG CAP	 	 1	 1	 1	 1	 1

43	 ZEN190072120	 	 	 SPRING	 	 1	 1	 1	 1	 1

44	 ZEN262971311	 	 	 COIL	 	 1	 1	 1	 1	 1

45	 ZENT207073110	 	 	 SPARK PLUG RZ7C	 1	 1	 1	 1	 1

	 ZEN369991975	 	 	 	 SPARK PLUG MARINE ONLY	 –	 1	 –	 1	 –

46	 ZEN026330555	 	 	 SCREW, M5 x 55	 2	 2	 2	 2	 2

47	 ZEN114283110	 	 	 SPACER, 5 x 10 x 1.6	 2	 2	 –	 2	 –

48	 ZEN848ES08300	 	 	 AIR TUNNEL (VENTURI)	 1	 1	 –	 1	 –

49	 ZENT207782000	 	 	 CLEANER ASSEMBLY	 –	 –	 1	 –	 1

50	 ZEN2650	 	 	 TUBE	 	 1	 1	 –	 1	 –

51-1	 ZENT207581000	 	 	 CARBURETOR ASSY WT-645	 1	 –	 –	 –	 –

51-2	 ZENT207681000	 	 	 CARBURETOR ASSY WT-644	 –	 1	 –	 1	 –

51- 3	 ZENT207781000	 	 	 CARBURETOR ASSY WT-643	 –	 –	 1	 –	 1

52	 ZEN115243260	 	 	 HUB	 	 1	 –	 –	 –	 –

53	 ZEN115243281	 	 	 STUD	 	 1	 –	 –	 –	 –

54	 ZEN115243290	 	 	 WASHER	 	 1	 –	 –	 –	 –

55	 ZEN335053410	 	 	 NUT, M8	 	 1	 –	 –	 –	 –

56	 ZEN114013141	 	 	 GASKET, MUFFLER	 1	 –	 2	 –	 2

57-1	 ZEN0125230550	 	 	 BOLT, M5 x 50	2	 –	 –	 –	 –

57-2	 ZEN0125230560	 	 	 BOLT, M5 x 60		 –	 –	 2	 –	 2

58-1	 ZEN026330408	 	 	 SCREW, M4 x 8	 1	 –	 –	 –	 –

58-2	 ZEN026390416	 	 	 SCREW, M4 x 16	 –	 –	 1	 –	 1

59-1	 ZENT207515110	 	 	 MUFFLER	 	 1	 –	 –	 –	 –

59-2	 ZEN114808010	 	 	 MUFFLER	 	 –	 –	 1	 –	 1

60	 ZEN114515412	 	 	 SPACER 	 	 –	 –	 1	 –	 1

61	 ZEN115815420	 	 	 SPACER	 	 –	 –	 1	 –	 1

62	 ZENT303991310	 	 	 SOCKET	 	 1	 1	 1	 1	 1

	 ZEN20010	 	 	 piston stopper, option for G260PUA/M/H	 1	 1	 1	 	

	 ZEN20005 ZEN20005	 Piston Stopper	 	 	 	 1	 1 15

Exploded Illustration

G26/G231 continued Quantity Per Unit

ZEN2322

ZEN2623

ZEN2320RC

ZEN2624

ZEN2321RC

ZEN2625

ZEN2322RC

ZEN2323RC

ZEN2324RC

ZEN2325RC

ZEN23129

ZEN2330

ZEN2331

ZEN2327RC

ZEN2333M

ZEN2634

ZEN2341

ZEN2328RC

ZEN2337

ZEN6236

ZEN2339M

ZEN2354

ZEN6241

ZEN2341

ZEN2638

ZEN6239

ZEN6237

ZEN26451

ZEN2667M

ZEN2648

ZEN2647

ZEN2649A

ZEN23150H

ZEN2650

ZEN2651

ZEN23151

ZEN23152

ZEN2359

ZEN2360

ZEN2361

ZEN2362

ZEN23156

ZEN2357

ZEN2357H

ZEN2358

ZEN2358H

ZEN2655

ZEN2355

ZEN2366

ZEN2367

ZEN23124RC

ZEN20010
Index 

No. New

Part No. Description

Qty/

unit

16

Exploded Illustration

1

2

3

4

5

6

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

ZEN337812111

ZEN333014111

ZEN333014121

ZEN026020520

ZEN333014132

ZEN337815000

ZEN284115210

ZEN333015220

ZEN337821110

ZEN0125230540

ZEN029220510

ZEN312013510

ZEN313013520

ZEN334041113

ZEN334041211

ZEN330441310

ZEN331041320

ZEN165041510

ZEN331041410

ZEN337842000

ZEN603006201

ZEN165021220

ZEN0406503212

ZEN216921210

ZEN126043240

ZEN165043230

ZEN029020820

ZEN0164120812

ZEN260951110

ZEN354411510

ZEN114543290

cylinder

insulator

carb gasket

insulator screw

insulator gasket

muffler assembly

muffler gasket

muffler bolt

crankcase

case bolt

case washer

case plug

plug gasket

piston

piston ring

piston pin

pin retainer

conrod spacer

conrod bearing

crankshaft

crankshaft bearing

front oil seal

snap ring

rear oil seal

key

rotor nut

lock washer

rotor washer

prop hub (new)

hub bolt

prop washer (new)

1

1

1

2

1

1

1

2

1

4

4

1

1

1

1

1

2

2

1

1

2

1

1

1

1

1

1

1

1

2

1

36

37

38

39

40

41

42

43

44-1

45

46

47

ZEN260951411

ZEN337871110

ZEN260971210

ZEN126071261

ZEN262972210

ZEN190072120

ZEN6242

ZEN3843

ZEN3844

ZEN026010540

ZEN337885111

ZEN026000512

ZEN337806040

ZEN20005

prop bolt (new)

module

rotor (new)

spacer (module)

plug cap (black)

cap spring

spark plug, c859

module bolt

carb ass’y (ht-338)w/choke

carb screw

mount

mounting bolt

screw/nut set

piston stopper

2

1

1

3

1

1

1

3

1

2

1

4

1

} 1 for g380pu

(Standard Accessory for G380PU) G38

ZEN3801

ZEN3802

ZEN3803

ZEN3804

ZEN3805

ZEN3806

ZEN3811

ZEN3812

ZEN3813

ZEN3814

ZEN3815

ZEN3816

ZEN3817

ZEN3818

ZEN3819

ZEN3820

ZEN3821

ZEN3822

ZEN3823

ZEN3824

ZEN3825

ZEN3826

ZEN3827

ZEN3828

ZEN3829

ZEN2327RC

ZEN3831

ZEN3832

ZEN3833

ZEN6232

ZEN3835

Index 

No. New ZEN

Part No. Description

Qty/

unit

Out of Date

Part No.

ZEN3836

ZEN3837

ZEN3838

ZEN3839

ZEN6238

ZEN6239

ZEN6242

ZEN3843

ZEN3844

ZEN3845

ZEN3846

ZEN3847

ZEN3871

ZEN20005

Out of Date

Part No.
Index 

No. New Part No. Description

Qty/

unit

Index 

No. New

Part No. Description

Qty/

unit

17

Exploded Illustration

1

2

3

4

5

6

7

8

9

10

11

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

ZEN281712111

ZEN281714110

ZEN281714121

ZEN48013180

ZEN848C9014C2

ZEN267014211

ZEN48013180

ZEN262951111

ZEN335615210

ZEN335615220

ZEN285015230

ZEN281721101

ZEN262921130

ZEN0406503515

ZENT401221240

ZEN152021220

ZEN140021220

ZEN267021250

ZEN281721311

ZEN48013180

ZEN281722210

ZEN267041114

ZEN267041211

ZEN335041310

ZEN335041320

ZEN140041410

ZEN267041510

ZEN281742001

ZEN130042410

ZEN100043240

ZEN140043230

cylinder

insulator

insulator gasket

bolt

carburetor gasket

cylinder gasket

bolt

muffler

muffler gasket

muffler bolt

muffler nut

crankcase comp.

case pin

snap ring

bearing

rear oil seal

front oil seal

elbow fuel nipple

case gasket

bolt

pipe

piston

piston ring

piston pin

pin retainer

conrod bearing

washer

crankshaft comp.

shim

key

flywheel nut

1

1

1

2

1

1

4

1

1

2

2

1

3

1

2

1

1

1

1

4

1

1

2

1

2

1

2

1

0-2

1

1

G45

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

ZEN262951110

ZEN354411510

ZEN262951310

ZEN262951410

ZEN6257

ZEN149071110

ZEN262971210

ZEN262971311

ZEN262972210

ZEN90072120

ZEN026330416

ZEN26030422

ZEN6242

ZEN6243

ZEN0125230550

ZEN6245

ZEN0160120513

ZEN262991510

ZEN262891110

ZEN0125230614

ZEN029020615

ZEN149096101

ZEN20005

ZEN6253

DISCONTINUED

prop hub

hub bolt

washer

prop bolt

magneto assembly

rotor

source coil

ignition coil

plug cap (black)

cap spring

source coil screw

coil screw

spark plug

carburetor assembly

bolt

washer

washer

bolt

mount

bolt

washer

puller assembly

stopper (optional)

guide (optional)

wrench (optional)

1

2

1

1

1

1

1

1

1

1

2

2

1

1

2

2

2

1

1

4

4

1

1

1

1

} *for g450pu

ZEN4501

ZEN4502

ZEN4503

ZEN4504

ZEN6204

ZEN4506

ZEN4504

ZEN6207

ZEN6208

ZEN6209A

ZEN6210

ZEN4513

ZEN6213

ZEN6214

ZEN6215

ZEN6216

ZEN6217

ZEN6276

ZEN4520

ZEN4504

ZEN4522

ZEN4523

ZEN4524

ZEN4525

ZEN6223

ZEN6224

ZEN4528

ZEN4529

ZEN6228

ZEN6227

ZEN6229

ZEN6230

ZEN6232

ZEN6233

ZEN6234

ZEN6257

ZEN6235

ZEN6236

ZEN6237

ZEN6238

ZEN6239

ZEN4543

ZEN6241

ZEN6242

ZEN6243

ZEN4547

ZEN6245

ZEN6246

ZEN6247

ZEN6248

ZEN6249

ZEN6250

ZEN6251

ZEN20005

ZEN6253

ZEN4557

Out of Date

Part No.

Out of Date

Part No.
Index 

No.

New ZEN

Part No. Description Qty/

unit

Out of Date

Part No.

ZEN6231

ZEN6232

ZEN6233

ZEN6234

ZEN6235

ZEN6236

ZEN6237

ZEN6238

ZEN6239

ZEN6240

ZEN6241

ZEN6242

ZEN6243

ZEN6244

ZEN6245

ZEN6246

ZEN6247

ZEN6248

ZEN6249

ZEN6250

ZEN6251

ZEN20005

ZEN6253

ZEN6200

ZEN6255

ZEN6256

ZEN6257

Index 

No.

New ZEN

Part No. Description Qty/

unit

Out of Date

Part No.

18

Exploded Illustration

1

2

3

4

5

6

7

8

9

10

11,12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

ZEN336612116

ZEN848C9014B3

ZEN261814120

ZEN848C9014C2

ZEN261614211

ZEN331012281

ZEN262951111

ZEN335615210

ZEN335615220

ZEN285015230

ZEN262921100

ZEN262921130

ZEN0406503515

ZENT401221240

ZEN152021220

ZEN140021220

ZEN262921311

ZEN335021320

ZEN261841112

ZEN261841210

ZEN336641310

ZEN335041320

ZEN140041410

ZEN261641510

ZEN262942002

ZEN100043240

ZEN130042410

ZEN140043230

ZEN262951110

cylinder

insulator gasket

insulator

carburetor gasket

cylinder base gasket

cylinder bolt

muffler

muffler gasket

muffler bolt

muffler nut

crankcase comp.

case pin

snap ring

bearing

rear oil seal

front oil seal

crankcase gasket

case assembly bolt

piston

piston ring

piston pin

pin retainer

needle bearing

connecting rod spacer

crankshaft comp.

key

shim

flywheel nut

hub, propeller comp.

for g620pu-1

1

1

1

1

1

4

1

1

2

2

1

3

1

2

1

1

1

4

1

4

1

1

2

1

2

1

2

1

0-2

1

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

ZEN0402500312

ZEN354411510

ZEN262951310

ZEN262951410

ZEN149071110

ZEN262971210

ZEN262971311

ZEN262972210

ZEN190072120

ZEN026330416

ZEN026030422

ZEN6242

ZEN6243

ZEN262982210

ZEN6245

ZEN016020513

ZEN262991510

ZEN262891110

ZEN0125230614

ZEN029020615

ZEN149096101

ZEN20005

ZEN6253

ZEN6200

ZEN6258

ZEN262981420

ZEN6257

pin for g620pu-1

hub bolt

prop washer

prop bolt

rotor

source coil

ignition coil

plug cap (black)

plug cap spring

ignition coil screw

source coil screw

spark plug, c859

carburetor assembly

carb mount screw

carb washer

washer

tap prop bolt

mount

bolt

washer

puller assembly

stopper (optional)

piston pin guide

spring starter

high-speed needle

low-speed needle

magneto assembly

1

2

1

1

1

1

1

1

1

2

2

1

1

2

2

2

1

1

4

4

1

1

1

1

1

1

1

} *for g62pu

*(Accessory for G620PU-1)

G62

ZEN6201

ZEN6202

ZEN6203

ZEN6204

ZEN6205

ZEN2309

ZEN6207

ZEN6208

ZEN6209

ZEN6210

ZEN6211

ZEN6213

ZEN6214

ZEN6215

ZEN6216

ZEN6217

ZEN6218

ZEN6219

ZEN6220

ZEN6221

ZEN6222

ZEN6223

ZEN6224

ZEN6225

ZEN6226

ZEN6227

ZEN6228

ZEN6229

ZEN6230
Index 

No. New ZEN

Part No. Description

Qty/

unit

Out of Date

Part No.

Index 

No. New ZEN

Part No. Description

Qty/

unit

Out of Date

Part No.

19

Exploded Illustration 

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

ZEN289812111

ZEN289814111

ZEN285014123

discontinued

ZEN289881000

ZEN289814131

ZEN0125230550

ZEN289814210

ZEN0215230520

ZEN289821001

ZEN202921130

ZENT401221240

ZEN0406503515

ZEN0603406202

ZEN140021220

ZEN267021250

ZEN106581100

ZEN289821310

ZEN0215230520

ZEN285041110

ZEN285041210

ZEN285041310

ZEN130041320

ZEN44524

ZEN44525

ZEN289842000

ZEN130042410

ZEN100043240

ZEN140043230

ZEN149071110

ZEN262971210

cylinder

manifold

manifold gasket

manifold bolt

carburetor ass’y

carburetor gasket

carb bolt

cylinder gasket

bolt

crankcase ass’y

pin

bearing

snap ring

bearing

front oil seal

fuel nipple elbow

pipe

crankcase gasket

bolt

piston

piston ring

piston pin

pin retainer

bearing

thrust washer

crankshaft comp

shim

key

nut

rotor

source coil

2

1

2

4

1

1

2

2

8

1

4

2

2

1

1

1

1

1

4

2

4

2

4

2

4

1

0-2

1

1

1

1

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

ZEN262972210

ZEN289871510

ZEN262922210

ZEN190072120

ZEN6242

ZEN026330414

ZEN026030422

ZEN289815110

ZENT210015210

ZEN335615220

ZEN285015230

ZEN289874110

ZEN0125230614

ZEN269975110

ZEN269975200

ZEN269975310

ZEN268975320

ZEN331071150

ZEN0125230625

ZEN269975410

ZEN262851101

ZEN0402500312

ZEN354411510

ZEN262951310

ZEN262951410

ZEN262991510

ZEN111091320

ZEN149096101

ZEN20005

ZEN289881410

ZEN289881420

ignition coil

cord

plug cap (black)

cap spring

spark plug, c859

screw

screw

muffler

muffler gaslet

muffler bolt

nut

mount

bolt

boss

clutch comp

spring

collar

washer

bolt

pad

hub. propeller comp

pin

hub bolt

hub washer

prop bolt

tap prop bolt

socket

puller ass’y (optional)

stopper (optional)

high-speed needle

low-speed needle

2

1

2

2

2

4

2

2

2

4

4

1

3

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

GT80

ZEN44501

ZEN44502

ZEN44503

ZEN3848

ZEN44505

ZEN44506

ZEN2357

ZEN44508

ZEN44509

ZEN44510

ZEN6213

ZEN6215

ZEN6214

ZEN44514

ZEN6217

ZEN6276

ZEN44517

ZEN44518

ZEN44509

ZEN44520

ZEN44521

ZEN44522

ZEN44523

ZEN44524

ZEN44525

ZEN44526

ZEN6228

ZEN6227

ZEN6229

ZEN6235

ZEN6236

ZEN6238

ZEN44533

ZEN6238

ZEN6239

ZEN6242

ZEN44537

ZEN44538

ZEN44539

ZEN44540

ZEN6209

ZEN44542

ZEN44543

ZEN44544

ZEN44545

ZEN44546

ZEN44547

ZEN44548

ZEN44549

ZEN44550

ZEN44551

ZEN44552

ZEN44553

ZEN6232

ZEN6233

ZEN6234

ZEN6247

ZEN44555

ZEN6251

ZEN44554

ZEN44556

ZEN44557

Index 

No. New ZEN

Part No. Description

Qty/

unit

Out of Date

Part No.

01

02

20

21

40

ZEN286912110

ZENT208014110

ZENT200241110

ZEN266041211

ZEN20006

cylinder

intake manifold (black)

piston

piston ring

carburetor insulator

2

1

2

2

1

G80A

ZEN8001

ZEN8002

ZEN8020

ZEN8021

ZEN20006
20

Warranty Information

Warranty Repairs

Exclusive Warranty- Horizon Hobby, Inc., (Horizon) warranties that the

Products purchased (the "Product") will be free from defects in materials and

workmanship for a period of 3 years from the date of purchase by the Purchaser.

Limited Warranty

(a) This warranty is limited to the original Purchaser ("Purchaser") and is

not transferable. REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS

WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER. This

warranty covers only those Products purchased from an authorized Horizon

dealer. Third party transactions are not covered by this warranty. Proof of

purchase is required for warranty claims. Further, Horizon reserves the right

to change or modify this warranty without notice and disclaims all other

warranties, express or implied. 

(b) Limitations- HORIZON MAKES NO WARRANTY OR

REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NONINFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE OF THE PRODUCT. THE PURCHASER ACKNOWLEDGES THAT

THEY ALONE HAVE DETERMINED THAT THE PRODUCT WILL SUITABLY

MEET THE REQUIREMENTS OF THE PURCHASER’S INTENDED USE. 

(c) Purchaser Remedy- Horizon's sole obligation hereunder shall be that

Horizon will, at its option, (i) repair or (ii) replace, any Product determined

by Horizon to be defective. In the event of a defect, these are the Purchaser's

exclusive remedies. Horizon reserves the right to inspect any and all equipment

involved in a warranty claim. Repair or replacement decisions are at the sole

discretion of Horizon. This warranty does not cover cosmetic damage or

damage due to acts of God, accident, misuse, abuse, negligence, commercial

use, or modification of or to any part of the Product. This warranty does

not cover damage due to improper installation, operation, maintenance, or

attempted repair by anyone other than Horizon. Return of any goods by

Purchaser must be approved in writing by Horizon before shipment.

Damage Limits

HORIZON SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT OR

CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR

COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCT,

WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE,

OR STRICT LIABILITY. Further, in no event shall the liability of Horizon exceed

the individual price of the Product on which liability is asserted. As Horizon has

no control over use, setup, final assembly, modification or misuse, no liability

shall be assumed nor accepted for any resulting damage or injury. By the act

of use, setup or assembly, the user accepts all resulting liability.

If you as the Purchaser or user are not prepared to accept the liability

associated with the use of this Product, you are advised to return this Product

immediately in new and unused condition to the place of purchase.

Law: These Terms are governed by Illinois law (without regard to conflict of

law principals). 

Safety Precautions

This is a sophisticated hobby Product and not a toy. It must be operated with

caution and common sense and requires some basic mechanical ability. Failure

to operate this Product in a safe and responsible manner could result in injury

or damage to the Product or other property. This Product is not intended for

use by children without direct adult supervision. The Product manual contains

instructions for safety, operation and maintenance. It is essential to read and

follow all the instructions and warnings in the manual, prior to assembly, setup

or use, in order to operate correctly and avoid damage or injury.

Questions, Assistance, and Repairs

Your local hobby store and/or place of purchase cannot provide warranty

support or repair. Once assembly, setup or use of the Product has been started,

you must contact Horizon directly. This will enable Horizon to better answer

your questions and service you in the event that you may need any assistance. 

For questions or assistance, please direct your email to

productsupport@horizonhobby.com, or call 877.504.0233 toll free to speak to a

service technician.

Inspection or Repairs

If this Product needs to be inspected or repaired, please call for a Return

Merchandise Authorization (RMA). Pack the Product securely using a shipping

carton. Please note that original boxes may be included, but are not designed to

withstand the rigors of shipping without additional protection. Ship via a carrier

that provides tracking and insurance for lost or damaged parcels, as Horizon is

not responsible for merchandise until it arrives and is accepted at our facility. A

Service Repair Request is available at www.horizonhobby.com on the “Support”

tab. If you do not have internet access, please include a letter with your

complete name, street address, email address and phone number where you

can be reached during business days, your RMA number, a list of the included

items, method of payment for any non-warranty expenses and a brief summary

of the problem. Your original sales receipt must also be included for warranty

consideration. Be sure your name, address, and RMA number are clearly written

on the outside of the shipping carton.

Warranty Inspection and Repairs

To receive warranty service, you must include your original sales receipt

verifying the proof-of-purchase date. Provided warranty conditions have

been met, your Product will be repaired or replaced free of charge. Repair or

replacement decisions are at the sole discretion of Horizon Hobby. 

Non-Warranty Repairs

Should your repair not be covered by warranty the repair will be completed and

payment will be required without notification or estimate of the expense unless

the expense exceeds 50% of the retail purchase cost. By submitting the item

for repair you are agreeing to payment of the repair without notification. Repair

estimates are available upon request. You must include this request with your

repair. Non-warranty repair estimates will be billed a minimum of 1⁄2 hour of

labor. In addition you will be billed for return freight. Please advise us of your

preferred method of payment. Horizon accepts money orders and cashiers

checks, as well as Visa, MasterCard, American Express, and Discover cards. 

If you choose to pay by credit card, please include your credit card number

and expiration date. Any repair left unpaid or unclaimed after 90 days will be

considered abandoned and will be disposed of accordingly. Please note: nonwarranty repair is only available on electronics and model engines.

Electronics and engines requiring inspection or repair should be shipped to the

following address:

Horizon Service Center

4105 Fieldstone Road

Champaign, Illinois 61822

All other Products requiring warranty inspection or repair should be shipped to

the following address:

Horizon Product Support

4105 Fieldstone Road

Champaign, Illinois 61822

Please call 877-504-0233 with any questions or concerns regarding 

this product or warranty.
21

Warranty Information (continued)

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.

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
22
23
© Copyright 2007, Horizon Hobby, Inc. 

www.horizonhobby.com

ZZPZ200

6135.2