Engine Care and Maintenance (continued)

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 con 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.)

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.

Troubleshooting Guide for Gasoline Engines

Generally speaking, there are very few things that will keep today’s modern engines from starting. Use good quality “fresh” fuel and make sure that good plugs are

installed. Should the engine fail to start after these items are verified, refer to the charts on the following page.

8

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APC Zenoah instruction manual Troubleshooting Guide for Gasoline Engines, Assembly G38
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Zenoah specifications

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