Zenoah G230RC Owner's Service Manual
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Zenoah G230RC Owner's Service Manual

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OWNER'S SERVICE MANUAL
G230RC
T2070-93110 (205)
WARNING
• 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.

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  • Page 1 T2070-93110 (205) OWNER’S SERVICE MANUAL G230RC WARNING • 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...

  • Page 3: Specifications

    1. Specifications Overall Size (L x W x H) 167 x 204 x 195mm Weight 2.07kg Engine Type G230RC Displacement 22.5cm Clutch Engagement 6000rpm (STD Spring) Carburetor Type WT-603 Spark Plug NGK CMR7H Spark Plug Gap 0.65mm Rotating Direction Counter-Clockwise (View From PTO) 2.

  • Page 4: Engine Starting

    3. Engine Starting • Push the primer pump several times until Fig.1 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) •...

  • Page 5: Maintenance Chart

    5. Maintenance 1) MAINTENANCE CHART Before Every Every Items Action 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 ↑...

  • Page 6: Maintenance Specifications

    5. Maintenance 3) MAINTENANCE SPECIFICATIONS Items Standard Limit Measuring Device Remarks Compression (kg/cm Compression Gage Bore (mm) ø32 Plating damaged Eye Checking At the skirt end and the right angle to Diameter (mm) ø31.97 ø31.87 Micro Meter the piston pin. Piston Ring 1.01 1.11...

  • Page 7: Ignition System

    5. Maintenance 5) IGNITION SYSTEM Items Standard Limit Measuring Device Remarks Spark Plug Air Gap (mm) 0.6~0.7 Thickness Gauge Ignition Coil/Flywheel Air Gap (mm) Thickness Gauge Reading between Primary — Volt Meter primary terminal and Coil iron core. Resistance Reading between (Ω) sparking cord end and Secondary...

  • Page 8: Special Tools

    6. Special Tools 7) SPECIAL TOOLS Part Name Part No. External Appearance Usage Puller Assy 2890-96100 To remove rotor. To hold crankshaft when Piston Stopper 4810-96220 disassembling/assembling clutch and rotor. Rod Assy 1101-96220 To remove/install piston pin. Air Gap Gauge 3330-97310 To set ignition coil.
  • Page 9 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. Clutch Bolt 3. Remove clutch bolts(14mm Hex.). (14mm Hex.) Rotor Nut 2) REMOVING ROTOR (FAN) 4.

  • Page 10: Removing Piston Pin

    7. Service Guide 4) REMOVING PISTON PIN Rod Assy 1. Remove snap rings from both sides of the Piston piston pin. 2. Engage the rod assy(1101-96220) to the Plastic Hammer piston pin and gently tap with a plastic hammer to push out the pin while holding piston firmly. NOTE Hard hammering may damage the big end of the connecting rod.

  • Page 11: Troubleshooting

    9. Trouble Shooting 1) ENGINE DOES NOT START Description Cause Countermeasure No spark in the spark plug Spark Plug 1. Wet spark plug electrodes Make them dry 2. Carbon deposited on the electrodes Cleaning 3. Insulation failure by insulator damage Exchange 4.

  • Page 12: Parts List

    10. Parts list...
  • Page 13 10. Parts list Model Name & Cord Key# Part Number Description Q'ty GR23101 GR23102 GR23103 GR23104 Remarks G230RC G230RC1 G230RC2 G230RC3 T2070-12110 CYLINDER T2070-12210 GASKET 01252-30522 BOLT M5x22L 1148-13161 INSULATOR 1140-13151 GASKET, INSU 3330-14121 GASKET, CARB 0263-90520 SCREW M5x20L T2070-15110 MUFFLER –...
  • Page 14 10. Parts list Model Name & Cord Key# Part Number Description Q'ty GR23101 GR23102 GR23103 GR23104 Remarks G230RC G230RC1 G230RC2 G230RC3 3310-81260 • DIAPHRAGM T2070-81210 • BODY-A 1751-81520 • COVER 1751-81510 • PUMP 2867-81270 • SPRING 3356-81310 • VALVE inlet 1480-81420 •...

  • Page 15: Warranty

    11. Warranty 1) SCOPE OF APPLICATION This engine manufactured by Komatsu Zenoah Co. (hereinafter referred as KZ) and sold to the user directly or through distributor/manufacturer, shall entitle to be covered by this warranty. 2) LIMIT OF WARRANTY KZ warrants that ; 1.
  • Page 16 Head Office : 1-9 Minamidai, Kawagoe-city, Saitama, 350-1192 Japan Phone: (+81)492-43-1117 Fax: (+81)492-43-7197...

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