Zenoah Komatsu G260RC Guida all'applicazione
G230RC/G260RC
OWNER’S SERVICE MANUAL
T2070-93111 (307)
•This engine is designed
for the radio controlled
car use. Komatsu Zenoah
assumes that no
responsibility for this
engine that is modified or
used for any other
applications.
Purchaser has all
responsibility against any
laws and regulations
existing in the country,
Komatsu Zenoah is
exempt from such law
and regulations.
•Read this OWNER’S
SERVICE MANUAL before
operating this engine.
WARNING
1. Specifications
2. Fuel
•Mix high-octane (over 95) gasoline and high
grade 2 cycle oil (JASO FC Grade oil or ISO
EGC grade) in the ratio of 25 : 1.
1) Never use any alcohol fuel or alcohol added
fuel, or the rubber parts in the carburetor
and engine will be damaged.
2) Gasoline is very flammable. Avoid smoking,
bringing any fires near fuel.
3) To prevent all possible problem on fueling
system, make sure to use the fuel filter and
fuel pipe packed as accessories.
WARNING
Engine Type G230RC G260RC
Overall Size (L x W x H) 167 x 204 x 195mm
Weight 2.07kg
Displacement 22.5cm325.4cm3
Clutch Engagement 6000rpm (STD Spring)
Carburetor Type WT-603A
Spark Plug CHAMPION RZ7C
Spark Plug Gap 0.65mm
Rotating Direction Counter-Clockwise (View From PTO)
3
3. Engine Starting
4. Operation
•Push the primer pump several times until
overflown fuel flows out. (Fig.1)
•Close the choke lever(Fig.2), and move the
throttle lever 1/4~1/3 open position.
•Pull the starter(knob) quickly until first firing
noise. (Fig.3)
•Open the choke(Fig.2), throttle idle~1/4 open
•Pull the starter quickly
•Operate engine for a few minutes for the
warming up.
•In case of engine warm condition, choking may
not be necessary.
•Over choking may cause starting difficulty due
to wet spark plug.
In this case change spark plug or dry it, and
remove fuel rest in the cylinder by pulling
starter.
IMPORTANT
•This engine is already tuned up to get high
power and high speed, and needs correct
maintenance to keep such high performance.
•The details for operation may be described in
the separate owners manual to be issued by car
manufacturer.
•Be sure to have the engine cool down for 30
seconds at idle speed after full throttle running.
Fig.1
Choke
Lever
Open
Close
Throttle Lever
Fig.2
Fig.3
4
5. Maintenance
1) MAINTENANCE CHART
Before Every Every
Items Action Use 25 hours 100 hours Note
Leakage, Check ✔
Damage/Crack
Idling Speed Check/Adjust ✔✔✔
Air-cleaner Check/Cleaning ✔✔ Replace if necessary
Spark Plug(gap) Check/Adjust ✔✔ ↑
Cylinder(barrel) Check/Cleaning ✔✔ ↑
Piston, Ring Check/Cleaning ✔✔ ↑
Muffler & Bolt Check/Cleaning ✔✔✔ ↑
Bearings Check/Cleaning ✔✔ ↑
Crank Shaft Check/Alignment ✔↑
2) SPECIFICATIONS AND TECHNICAL DATA
Items Unit G230RC G260RC Remarks
Bore x Stroke mm 32 x 28 34 x 28
Displacement cm322.5 25.4
Effective Compression Ratio 9.2 8.8
Type Walbro WT ←
Carburetor
Venture(mm) ø12.7 ←
Starting Recoil Starter ←
Type TCI ←
Ignition
Timing BTC 30°/8000rpm ←
Standard RZ7C ←CHAMPION
CR8HVX
with Terminal Nut
Option(Hot Type) CMR6H ←↑
Clutch Engagement Speed rpm 6000 ←
No load max Speed rpm 19500 ←
Idling Speed rpm 4000 ←
Without Air Cleaner
Max. Power kW/rpm 2.15/14000 2.20/14000
and Muffler
Max. Torque N.m/rpm 1.79/10000 1.87/10000 ↑
Fuel Consumption g/kW·h 750 (550) 765 (565) ↑
Carburetor H 1 3/4 ± 1/4 ←
Standard setting L 1 1/2 ± 1/4 ←
5
NGK
Option(For Race)
Spark Plug ←
5. Maintenance
4) CARBURETOR
Items Standard Limit Measuring Device Remarks
Metering Lever set (mm) 1.65 ± 0.16 Vanier
Inlet Valve Opening Pressure (kg/cm2)1.3~2.3 Leak Tester
Inlet Valve Closing Pressure (kg/cm2)0.7~1.7 Leak Tester
6
3) MAINTENANCE SPECIFICATIONS
G230RC G260RC
Items Standard Limit Standard Limit
Measuring Device
Remarks
Bore (mm) ø32
Plating damaged
ø34
Plating damaged
Eye Checking
Diameter (mm) ø31.97 ø31.87 ø33.97 ø33.87 Micro Meter
Piston Ring
0.81 0.91 1.01 1.11 Thickness Gauge
Groove width (mm)
Piston Pin Hole (mm) ø8.01 ø8.05 ø8.01 ø8.05 Cylinder Gauge
Clearance between
Piston and 0.03~0.06 0.15 0.03~0.06 0.15
Cylinder (mm)
Clearance between
Groove and 0.02~0.04 0.1 0.02~0.04 0.1 Thickness Gauge
Piston Ring (mm)
End Gap (mm) 0.05~0.25 0.5 0.05~0.25 0.5 Thickness Gauge
Width (mm) 0.78 0.73 0.98 0.93 Micro Meter
Piston Pin Diameter (mm) ø8 ø7.98 ø8 ø7.98 Micro Meter
Connecting Rod Small end (mm)
ø11 ø11.05 ø11 ø11.05 Cylinder Gauge
Crankshaft Dia. at Main Bearing (mm)
ø12 ø11.98 ø12 ø11.98 Micro Meter
Eccentricity (mm) — 0.07 — 0.07 Dial Gauge
Axial Play (mm) — 0.5 — 0.5 Thickness Gauge
Gritty or Gritty or
Main Bearing — — —
Feels Flat Spot Feels Flat Spot
At the skirt end
and the right angle
to the piston pin.
When inserted in
a new cylinder.
Piston
Cylinder
Piston
Ring
Micro Meter
Cylinder Gauge
5. Maintenance
5) IGNITION SYSTEM
Items Standard Limit Measuring Device Remarks
Spark Plug Air Gap (mm) 0.6~0.7 0.7 Thickness Gauge
Ignition Coil/Flywheel Air Gap (mm) 0.3 0.4 Thickness Gauge
Primary 0.7 — Volt Meter
Secondary 6100 — Volt Meter
Reading between
primary terminal and
iron core.
Reading between
sparking cord end and
iron core.
6) TIGHTENING TORQUE
Items Screw Size Standard (kg·cm) Limit (kg·cm) Remarks
Carburetor M5 (P=0.8) 35 30~40
Insulator M5 (P=0.8) 35 30~40 with Locktight glue
Clutch M6 (P=1.0) 65 50~80
Rotor M8 (P=1.0) 130 100~150
Cylinder M5 (P=0.8) 70 60~80
Crankcase M5 (P=0.8) 65 50~80
Spark Plug M10 (P=1.0) 110 100~120
Muffler M5 (P=0.8) 90 70~100
Fan Cover M5 (P=0.8) 35 30~40
Ignition Coil M4 (P=0.7) 33 25~40
Starter Case M4 (P=0.7) 13 10~15
Tapping Screw TP 4.3 25 20~30
Coil
Resistance
(Ω)
7
6. Special Tools
7) SPECIAL TOOLS
Part Name Part No. External Appearance Usage
1Puller Assy 2890-96100 To remove rotor.
2Piston Stopper 4810-96220
3Rod Assy 1101-96220 To remove/install piston pin.
4Air Gap Gauge 3330-97310 To set ignition coil.
5Hex Wrench 3304-97611
6Snap Ring Pliers 5500-96110 To remove snap ring.
To hold crankshaft when
disassembling/assembling
clutch and rotor.
For socket screw of Hex.
3mm, 4mm and 5mm.
8
7. Service Guide
1) REMOVING CLUTCH SHOE
1. Remove the housing and plug cap.
2. Remove the spark plug and fit the
stopper(4810-96220) into the plug hole.
3. Remove clutch bolts(14mm Hex.).
2) REMOVING ROTOR (FAN)
4. Remove the rotor nut(12mm Hex.).
5. Remove the rotor using the puller assy (2890-
96100). Apply 8mm puller bolts.
3) ASSEMBLING ROTOR
Insert the gauge(3330-97310) in between the
rotor magnet metal and the coil.Tighten screws
while pressing the coil against the rotor.
Air Gap 0.3 ~ 0.4mm
Clutch Bolt
(14mm Hex.)
Rotor Nut
17mm Hex.
Puller Bolts
Puller
Rotor
Wrench
Air Gap Gauge
Ignition Coil
9
7. Service Guide
4) REMOVING PISTON PIN
1. Remove snap rings from both sides of the
piston pin.
2. Engage the rod assy(1101-96220) to the
piston pin and gently tap with a plastic hammer
to push out the pin while holding piston firmly.
Hard hammering may damage the big end of
the connecting rod.
5) INSTALLING PISTON
1. Make sure to point the arrow mark on the
piston to the exhaust side.
2. Fit the circlip in the groove so as to face the
end gap below.
Deformed circlip may come off during engine
operation and damage the engine.
6) CARBURETOR ADJUSTMENT
The carburetor comes with a standard setting, it
is for optimum performance under the barometric
pressure and climatic conditions at factory, so it
may be re-adjusted according to load applied.
Idle rpm : 4000 ± 300 rpm (STD Spring)
H needle : 1 3/8 ± 1/4
L needle : 1 1/4 ± 1/4
NOTE
NOTE
Plastic
Hammer
Rod Assy
Piston
Arrow Mark
Circlip
End Gap
Piston
H needle L needle
Idle Screw
10
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