Assembly - Zenoah AIR G26 Instruction Manual

Engine Care and Maintenance
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 con-
necting 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 crank-
shaft. (Apply lithium grease to the lip area of the oil seal
and fit it, paying attention to its direction.)
8
(continued)
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 muf-
fler bolts and mount the muffler.
14. Apply threadlock (Blue Threadlock Z-42) to the igni-
tion module set screws and fix the coil temporarily.
15. Set the rotor (flywheel) so that the magnet is located
on the opposite side of the module (G-38). Place a thick-
ness 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 set screws 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.