Zenoah G800bpu 1 User Manual

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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