# ENGINE INSTRUCTION MANUAL

G26 Air G26/G231 Marine G26/G231 Heli G38 G62 GT80 Twin G45 ®

1

1

2

3

4

5

6

7 2 3 4

5

6 72 

# 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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 

# 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 h a n d s, fingers or a ny other p a rt of the bo d y to stop the propeller. Do not throw a ny 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

. R ecommendations
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

. Fa ilure to re ad a n d follow these instructions before you procee d m a y result in engine da m a ge a n d the voi d ing of your w a rr a nty!4 

# Safety Instructions (continued)



# Support Equipment C aution
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

E ngine P arts I dentification
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

. F uel —Mix gasoline and 2-stroke gas compatible oil at a mixing ratio of 25–40:1

. N ote: 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

. P ropeller —Refer to the Propeller Selection Chart located
on Page 8 to determine the best initial propeller for your particular application

. M anual or E lectric S tarter —For manual starts, a chicken stick is highly recommended

. N ever 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 EVOX1001Q5 

# 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

.



## B reak I n
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

. 

## S tarting the E ngine—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:
N ote: 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 com
pression 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 

# Operation6 

# 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

. C A UTION : If the engine is started when the throt

tle 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

. 

## S tarting the E ngine— H elicopter and B oat

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 approxi

mately 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

. 

## S topping the E ngine

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

.



## C arburetor Adjustment

The carburetor is provided with three adjustment screws, which are factory set to the best (approximate) posi

tions

. They may need minor adjustment, depending upon the temperature, humidity, atmospheric pressure (alti

tude), 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: 1 1 / 8 plus/minus 1 / 4 b

. High-Speed Needle: 1 3 / 8 plus/minus 1 / 4 I dle S crew: Turning this screw clockwise increases the idling rpm

. Turning it counterclockwise decreases the idling rpm

. L ow- S peed N eedle: 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 Screw7 

# Operation (continued)

H igh- S peed N eedle: 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

. N ote: 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

.



## R ecommendations

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

. 

## S ervicing the E ngine

R equired T ools

• 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

. N ote: 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 dam

age 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 Maintenance8 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 ( G 38)

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

. N ote: 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)

I tems 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 B efore U se



### P P P

P

P E very 100 hours



### P P P P P P P P P P P P N ote

Replace if necessary 

### ì ì ì ì ì ì ì ì ì 

## M aintenance C hart

I tems Type
Bore x Stroke Displacement

Effective Compression Ratio

Carburetor

Air Cleaner

Starting

Ignition

Spark Plug

Idle Speed

Max

. Power
Min

. Torque
Fuel Consumption Weight U nit

––

mm

cm 3

–– Type (Walbro)
Venturi (mm)

–– Type BTDC/rpm
STD Option

rpm

rpm
rpm

cc kg G 260 PUM
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 G 260 PUH
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) G 231 PUM
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 G 231 PUH
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) G 260 PU
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) 

## S pecifications & T echnical Data E very 25 hours



### P P P P P P P P P P P P10 

## M aintenance S pecifications

I tems
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 M easuring 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

–– R emarks

At the skirt end and

the right angle to

the piston pin

When inserted in a new cylinder S tandard
ø34

ø33

. 97

1

. 01

ø8

. 01

0

. 03–0

. 05

0

. 02–0

. 04

0

. 05–0

. 25

0

. 98 ø8
ø11
ø12

––

––

–– S tandard
ø32

ø31

. 97

1

. 01

ø8

. 01

0

. 03–0

. 05

0

. 02–0

. 04

0

. 05–0

. 25

0

. 98 ø8
ø11
ø12

––

––

–– L imit 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 L imit 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) T he 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/cm 2 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) T he 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 Clean Clogging of the muffler or exhaust port due to carbon The spark plug heat range is not proper c) L ower power output

d) T he engine does not stop Overheating

See c)

Repair Overheating Repair The Stop switch is defective 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

. N ote: All recommendations are based on engines using APC brand props

.

E ngine P ropeller
G 26A 16x8 @ 8,700 G 231 H eli Adjust pitch of rotor to obtain G 26 H eli 9,000–10,000 rpm of the engine at full throttle G 26 M arine G 231 M arine Diameter = 65–75mm
Pitch ratio 1

. 9–1

. 4mm G 38 G as 18x10 @ 7,300 G 45 G as 20x10 @ 7,200 G 62 G as 22x10 @ 7,200 GT 80 G as 22x12 @ 7,200
24x10 @ 7,20013 

# Engine Specifications

I tems
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 L ength W idth H eight O perating RPM O ptional M ufflers O utsi d e 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) B ore (in) S troke (in) W eight (oz) K ( ISO ) HP ( H / M ) C arb ( W albro) S pecific a tions14

Quantity P er U nit N ew Zen O ut of DateG 260 G 260 G 260 G 231 G 231 Key # P art # P art # 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 M5 X 20 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 S nap R ing 1	 1	 1	 1	 1 20	 ZEN0603406001 BEARING 1	 –	 1	 –	 1 21	 ZEN185021220 SEAL, 12 x 28 x 7	 –	 1	 –	 1	 – 14 

# Exploded Illustration

G 26/ G 231

ZEN2601 ZEN2301RCA ZEN2601M ZEN23102M ZEN2603M ZEN2304M ZEN23105M ZEN23106M ZEN2307M ZEN23108 ZEN2309 ZEN2305RC ZEN23111 ZEN23112 ZEN23114

ZEN6213 ZEN23116 ZEN3828 ZEN2318 ZEN2319 ZEN2320 ZEN2321MN ew Zen O ut of DateG 260 G 260 G 260 G 231 G 231 Key # P art # P art # 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	 P iston S topper 1	 1 15 

# Exploded Illustration

G 26/ G 231 continued Quantity P er U nit

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 ZEN20010I ndex N o. N ew P art N o. 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 , c 859
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 g 380 pu (Standard Accessory for G380PU) 

## G 38

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 I ndex N o. N ew Z EN P art N o. Description Qty/ unit O ut of Date P art N o. ZEN3836 ZEN3837 ZEN3838 ZEN3839 ZEN6238 ZEN6239 ZEN6242 ZEN3843 ZEN3844 ZEN3845 ZEN3846 ZEN3847 ZEN3871 ZEN20005

O ut of Date P art N o.I ndex N o. N ew P art N o. Description Qty/ unit I ndex N o. N ew P art N o. 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 

## G 45

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 g 450 pu 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 O ut of Date P art N o.

O ut of Date P art N o.I ndex N o. N ew Z EN P art N o. Description Qty/ unit O ut of Date P art N o. 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 I ndex N o. N ew Z EN P art N o. Description Qty/ unit O ut of Date P art N o.

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 g 620 pu -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 g 620 pu -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 , c 859
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 g 62 pu * (Accessory for G620PU-1) 

## G 62

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 ZEN6230I ndex N o. N ew Z EN P art N o. Description Qty/ unit O ut of Date P art N o.

I ndex N o. N ew Z EN P art N o. Description Qty/ unit O ut of Date P art N o.

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 , c 859
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 

## GT 80

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

I ndex N o. N ew Z EN P art N o. Description Qty/ unit O ut of Date P art N o. 01 02 20 21 40 ZEN286912110 ZENT208014110 ZENT200241110 ZEN266041211 ZEN20006 cylinder
intake manifold ( black ) piston piston ring carburetor insulator 2 1 2 2 1 

## G 80A

ZEN8001 ZEN8002 ZEN8020 ZEN8021 ZEN2000620 

# Warranty Information

W arranty R epairs
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

.
L imited W arranty (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 L imits
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)

.
S afety P recautions
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 R epairs
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

.
I nspection or R epairs
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

.
W arranty I nspection and R epairs
T o 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

.
N on- W arranty R epairs
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: H orizon S ervice C enter 4105 F ieldstone R oad C hampaign, I llinois 61822

All other Products requiring warranty inspection or repair should be shipped to the following address: H orizon P roduct S upport 4105 F ieldstone R oad C hampaign, I llinois 61822

P lease 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

. 

## R egistration F orm
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 618222223© Copyright 2007, Horizon Hobby, Inc

. www

. horizonhobby

. com ZZPZ200 6135

. 2