848H6393A3 (009)
OWNER’S MANUAL
MODEL:
G800BPU
G800BPU-1
警 告
WARNING
• Do not modify any parts of the engine.
• This engine is designed to be used to Radio
controlled products.
• In case any modification by customer,
ZENOAH shall not bear any responsibility from
the damage caused by such modification.
• Keep ignition system well maintained.
● この製品はラジオコントロール
飛行機用に設計されています。
● 改造、組み替えされて使用され
た場合当社は一切の責任を負い
ません。
● 特に電装品は常に点検、整備し
てご使用ください。
September 2010
[ NOTE ]
1. Be sure to use a gasoline-resistant fuel piping. (Do not use any silicon rubber tube).
2. Never use any alcohol fuel or alcohol added fuel, or the rubber part in the carburetor will
be damaged.
5. Operation
1. Avoid starting engine by hand flipping propeller as it may cause injury. Make sure to start
by using built-in spring starter or large size electric starter with reduction gear (available
on the market) .
2. Make sure to put on thick glove when starting engine.
How to Start the Engine
1. Fill the fuel tank with the fuel.
2. Close the choke valve and open the throttle valve approximately 1/3 ~ 1/2 of the full open
position.
3. Rotate the propeller counterclockwise until the piston passes over its top dead point.
Then rotate it clockwise for 1/2 ~ 3/4 revolution to wind up the spring, and release the
propeller. Repeat this several times until the initial firing sound is heard.
4. Upon hearing the initial firing open the choke valve and set the throttle to the idle or
slightly open position. Take the same procedure as mentioned above step 3, and the
engine will start.
[ NOTE ]
• Be sure to keep holding propeller firmly by other hand while winding up the spring for
starter.
• Be sure to open the choke when the engine first fires.
• When the choke is opened, be sure to close the throttle valve to a position near the idle
position before starting the engine (If the engine is started while the throttle wide open it will
develop a high level of power and thrust which can be very dangerous).
How to Stop the Engine
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.
BLACK LEAD
RED LEAD
KILL
SWITCH
ENGINE BODY
EARTH
6. Carburetor Adjustment
The carburetor is provided with 3 adjust screws which are set to the best (approximately)
positions by our company, but they may need a little adjustment depending on the
temperature, atmospheric pressure (altitude), etc. of the area where the engine is used. Start
the engine without making any adjustments. Make readjustments only when the engine
shows any mal-functioning.
[ NOTE ]
Be sure to stop the engine before starting the adjustment, thus ensuring safety.
Idle Screw: Turning this screw clockwise increases the idling R.P.M. Turning it
3
counterclockwise decreases the idling R.P.M
Low Speed Needle: This is the fuel adjust screw (not the air screw). Turning this needle
clockwise makes the mixture gas leaner and turning it counterclockwise
makes it richer.
High Speed Needle: Turning this needle clockwise makes the mixture gas leaner and
turning it counterclockwise richer. Set this needle at a position which is 1/8 ~
1/4 open from the maximum R.P.M. position while the airplane is on ground.
High Speed
Needle
Low Speed
Needle
Standard setting
H : 11/4 1/4
L : 11/8 1/4
Idle Screw
[ NOTE ]
1. Do not tighten the High and Low Speed needles too firmly.
2. Ensure the engine is fully warmed up before use. When the engine has just started and is
not fully warmed up there may be insufficient acceleration from low speed operation and
the engine may stop.
7. Engine Break-in
No specific break-in is required. The engine is gradually breaking in as it is used and the
output will increase also increased gradually.
8. Maintenance
This engine is used for power source for radio controlled airplane so you are strictly
requested to check engine and relative parts of airplane.
1) Daily check (before starting)
• Leakage, damage, crack
• Muffler fixing bolts (torque, crack)
• Propeller hub (transformation, fixing bolts/nut)
(P/N:2629-51410 or 2629-91510, 3544-11510 and 1100-43231)
• Rotor (transformation, play, airgap)
2) Every 25 hours check
• Spark plug (gap, cleaning)
• Cylinder (abrasion)
• Piston/Ring (abrasion)
• Bearing (Gritty)
According to the checks, replace any part if necessary.
9. Servicing
The engine can be disassembled or reassembled without any specific difficulties, but be
careful of the following matters;
a. For disassembling, the special tools shown in the parts list are required in addition to the
general tools. Be sure to use a new gasket when the crankcase and cylinder have been
disassembled and reassembled.
b. Disassembling rotor
1. Disassemble the spring starter.
4
2. Put the stopper (P/N.2670-96220) into a sparkplug hole (Fig.1) of the cylinder(✽) which
is located closer to the rotor than other cylinder when viewed from intake manifold side
(Fig.2).
(✽)
Stopper
Fig. 2
Fig. 1
3. Turn the rotor counterclockwise until piston touches the stopper.
4. Unscrew the rotor nut.
5. Remove the rotor by using the puller (P/N. 1490-96101).
Do not hit the crankshaft end by metal hammer, that may cause the crankshaft to be
bent out of alignment.
c. Assembling crankcase
1. Apply grease on the oil seal lips and oil on the bearing.
2. Assemble the crankshaft with a new gasket.
3. When both front and rear crankcases are tightened, the portion of gasket protruding on
the cylinder mount surface should be cut off with a knife until the gasket becomes flush
with the cylinder mounted surface.
d. Assembling piston
Before assembling the piston, apply the oil on the small end bearing and piston, and set
the piston ensuring that the arrow mark on the top of piston is directed toward the
direction of exhaust port.
e. Re-assembling cylinder and intake manifold
1. Coat the oil on the inner surface of cylinder.
2. The piston is provided with a knock pin which stops the piston ring from turning. Set the
split section of piston ring at the knock pin and assemble the cylinder ensuring not to
break the piston ring.
3. Keep cylinder bolts unfastened before installing the intake manifold to the cylinder.
4. Fixing the intake manifold to the intake port of each cylinder.
5. Then, tighten cylinder bolts.
f. Assembling rotor
Make sure to put lock tight (Medium strength type: TreeBond 1322N, LOCTITE 242,243,
PACER ZAP Z-42) on the rotor fixing nut (P/N:1100-43231).
g. Recommended tightening torque for bolts/nuts
Be sure to follow the recommended tightening torque for bolts/nuts in assembling at each
part.
1. Rotor nut (M10)
2. Crankcase bolt (M5)
3. Cylinder bolt (M5)
4. Engine mount bolt (M6)
5. Propeller hub bolt (M6)
6. Source coil bolt (M4)
h. Adjusting air gap of coil.
:
:
:
:
:
:
250 ~ 300 kg-cm
50 ~ 90 kg-cm
50 ~ 90 kg-cm
80 ~ 120 kg-cm
80 ~ 120 kg-cm
15 ~ 20 kg-cm
The air gap of coil should be adjusted to 0.3 mm (0.01").
i. Adjusting ignition time.
This engine with the point-less C.D.I. type requires no adjustments of ignition time.
5
10. Specifications
Model ..............................................G800BPU · G800BPU-1
Type ................................................Air cooled two stroke cycle opposed cylinder type gasoline engine
Displacement ..................................79.9cc (4.88cu. in)
Bore x Stroke x Number of cylinder.......40.5mm x 31mm x 2 (1.60 in x 1.22 in x 2 )
Compression ratio ...........................8.1 : 1
Maximum output ..............................5.52kW/10000rpm [4.41kW/10000rpm with Muffler]
Operating engine speed ..................1800 ~ 10000rpm
Weight .............................................3.5kg (7.9Ibs) with mufflers & spring starter
Ignition system ................................CDI type flywheel magneto
Carburetor .......................................WALBRO WJ-64
Fuel .................................................Gasoline oil mixture 25 ~ 40 : 1
Spark plug .......................................CHAMPION RCJ-7Y
Recommended propeller sizes (inch) ....26 x 8 ~ 10, 24 x 10 ~ 12, 22 x 12 ~ 14
Specifications are subject to change without notice.
11. Parts List
G800BPU, G800BPU-1
6
G800BPU, G800BPU-1
Q' ty
/unit
Q' ty
Index
No.
Index
No.
Parts No.
Description
Parts No.
Description
/unit
1
2
T2080-12110 Cylinder
T2080-14110 Manifold
2850-14123 Gasket, inlet
3310-72150 Bolt
2
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
4
1
1
2
1
1
1
1
1
1
1
2
1
1
2
2
8
1
4
2
2
1
1
50
51
52
2670-21250 • Elbow
1065-81100 • Pipe
2898-21310 Gasket, crankcase
1
1
1
4
2
4
2
4
2
4
1
0~2
1
1
1
1
1
1
2
1
2
2
2
4
2
2
2
4
4
1
3
4
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
3
4
53 01252-30520 Bolt
54 T2002-41110 Piston
55 8488C41200 Ring, piston
5
2898-81000 Carburetor assy, WJ-64
3304-81441 • Ring
1148-81390 • Ring
6
7
56
57
58
59
60
61
62
63
2850-41310 Pin, piston
1300-41320 Snap ring
2850-41410 Bearing
2850-41510 Thrust washer
2898-42000 Crankshaft comp
1300-42410 Shim
8
2898-81120 • Cover
2898-81130 • Cover
2898-81150 • Shaft
2898-81340 • Valve
2898-81170 • Shaft
2898-81440 • Lever
2898-81180 • Valve
3310-81311 • Valve
2898-81450 • Plug
9
10
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
36
37
38
39
40
1000-43240 Key
1100-43231 Nut
64 01641-21016 Washer
65
66
67
68
69
70
71
72
73
74
75
0290-21025 Washer
1490-71110 Rotor
3360-81440 • Plug
2898-81220 • Ball
2629-71210 Source coil
2629-71311 Ignition coil
2898-71510 Cord
2898-81240 • Gasket
2898-81230 • Gasket
2898-81260 • Diaphragm
2898-81270 • Diaphragm
3310-81240 • Screw
2898-81330 • Screw
2898-81140 • Screw
1492-81560 • Screw
3310-81351 • Screw
2898-81370 • Spring
2898-81350 • Spring
1491-81160 • Spring
2898-81390 • Spring
2898-81420 • Needle
2898-81410 • Needle
1282-81560 • Screen
3306-81380 • Screen
7620-81610 • Pin
2850-72110 Cap, plug
1400-72121 Spring
1630-73110 Spark plug
0263-30414 Screw
0260-30422 Screw
2898-15110 Muffler
76 T2100-15210 Gasket, muffler
77
78
79
3356-15220 Bolt
2850-15230 Nut
2898-74110 Mount
80 01252-30614 Bolt
81
3310-71150 Washer
2699-75110 Boss
❈82
❈83
❈84
❈85
2699-75200 Clutch comp
2699-75310 Spring
2699-75320 Collar
2898-81250 • Lever
2880-81470 • Screw
3356-81430 • Plug
❈86 01252-30625 Bolt
❈87
88
2699-75410 Pad
2628-51101 Hub. propeller comp
2898-14131 Gasket, carburetor
❈89 04025-00312 • Pin, spring
41 01252-30550 Bolt
90
91
92
93
94
95
96
3544-11510 Bolt
42
43 01252-30520 Bolt
2898-14210 Gasket, cylinder
2629-51310 Hub, washer
2629-51410 Bolt
2629-91510 Bolt
44
45
2898-21001 Crankcase assy (No.45~51)
2629-21130 • Pin
1110-91320 Socket
1490-96101 Puller assy (Optional)
2670-96220 Stopper (Optional)
46 06030-06202 • Bearing
47 04065-03515 • Snap ring
48 06034-06202 • Bearing
49
1400-21220 • Oil seal
❈ : Without for G800BPU-1.
7
12. Warranty
WARRANTY TERMS
1) Scope of Application
This engine manufactured by Husqvarna Zenoah Co., Ltd. (herein after “Zenoah”).
And sold to the user directly or through distributor/manufacturer, shall entitle to be
covered by this warranty.
2) Limits of Warranty
Zenoah warrants that;
1. The quality disclosed in the specifications.
2. The engine which shall be considered defective by Zenoah, caused by material or
production fault.
3) Limits of Compensation
1. Zenoah compensates such quality, material and production faults by repairing or
replacing through distributor/manufacture.
2. Zenoah shall not compensate any other accompanied or benefit losses caused to
user and distributor/manufacture by such faults and through repairing or
replacing.
4) Term of Warranty
Three (3) months after purchased by end- user subject to 12 months from produced
month.
5) Exempt from Warranty
Zenoah shall not warrant this engine even if the fault has been caused during the
period of terms of Warranty, in case that.
1. Any faults, failures caused from neglect of proper operation and maintenance
described in OWNER’S MANUAL.
2. Any modification not approved by Zenoah.
3. Normal abrasion and deterioration.
4. Consuming parts.
5. Using any parts which have not been certified by Zenoah.
6. Add-on or modified use.
1-9 Minamidai, Kawagoe-city, Saitama, 350-1165 Japan
Phone: (+81)49-243-6917 Fax: (+81)49-243-7197
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