Before using this engine, please read these instructions carefully.
Introduction
Congratulations on your purchase of the newest and one of the most technically advanced 2-stroke gas model airplane engines in
the world. Whether you are new to the sport of model aviation or an experienced flier, you will enjoy the features of the new Evolution
GX engine. Evolution engines are designed to be the most powerful in their class, extremely easy to start and operate, and provide years of enjoyable service.
These engines incorporate many unique design features that ensure success with your new engine. This user’s guide is intended to provide the basic information
required to operate and maintain your Evolution GX engine.
Important: While the Evolution engine is extremely easy to operate, if this is your first experience flying a model airplane, it is highly recommended that you have
the help of an experienced modeler during the first few flights. Your local hobby shop or flying club can put you in touch with an experienced pilot in your area.
Warranty Period
Exclusive Warranty- Horizon Hobby, Inc., (Horizon) warranties that
the Products purchased (the “Product”) will be free from defects in
materials and workmanship for a period of 2 years from the date of
purchase by the Purchaser.
Limited Warranty
(a) This warranty is limited to the original Purchaser (“Purchaser”)
and is not transferable. REPAIR OR REPLACEMENT AS PROVIDED
UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE
PURCHASER. This warranty covers only those Products purchased
from an authorized Horizon dealer. Third party transactions are not
covered by this warranty. Proof of purchase is required for warranty
claims. Further, Horizon reserves the right to change or modify this
warranty without notice and disclaims all other warranties, express
or implied.
(b) Limitations- HORIZON MAKES NO WARRANTY OR
REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NONINFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE OF THE PRODUCT. THE PURCHASER ACKNOWLEDGES THAT
THEY ALONE HAVE DETERMINED THAT THE PRODUCT WILL SUITABLY
MEET THE REQUIREMENTS OF THE PURCHASER’S INTENDED USE.
(c) Purchaser Remedy- Horizon’s sole obligation hereunder shall be
that Horizon will, at its option, (i) repair or (ii) replace, any Product
determined by Horizon to be defective. In the event of a defect, these
are the Purchaser’s exclusive remedies. Horizon reserves the right to
inspect any and all equipment involved in a warranty claim. Repair
or replacement decisions are at the sole discretion of Horizon. This
warranty does not cover cosmetic damage or damage due to acts
of God, accident, misuse, abuse, negligence, commercial use, or
modification of or to any part of the Product. This warranty does not
cover damage due to improper installation, operation, maintenance,
or attempted repair by anyone other than Horizon. Return of any
goods by Purchaser must be approved in writing by Horizon before
shipment.
Damage Limits
HORIZON SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT OR
CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR
COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCT,
WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY,
NEGLIGENCE, OR STRICT LIABILITY. Further, in no event shall the
liability of Horizon exceed the individual price of the Product on which
liability is asserted. As Horizon has no control over use, setup, final
2
assembly, modification or misuse, no liability shall be assumed nor
accepted for any resulting damage or injury. By the act of use, setup
or assembly, the user accepts all resulting liability.
If you as the Purchaser or user are not prepared to accept the liability
associated with the use of this Product, you are advised to return
this Product immediately in new and unused condition to the place
of purchase.
LAW: These Terms are governed by Illinois law (without regard to
conflict of law principals).
Safety Precautions
This is a sophisticated hobby Product and not a toy. It must be
operated with caution and common sense and requires some basic
mechanical ability. Failure to operate this Product in a safe and
responsible manner could result in injury or damage to the Product
or other property. This Product is not intended for use by children
without direct adult supervision. The Product manual contains
instructions for safety, operation and maintenance. It is essential
to read and follow all the instructions and warnings in the manual,
prior to assembly, setup or use, in order to operate correctly and avoid
damage or injury.
Questions, Assistance, and Repairs
Your local hobby store and/or place of purchase cannot provide warranty support or repair. Once assembly, setup or use of the Product
has been started, you must contact Horizon directly. This will enable
Horizon to better answer your questions and service you in the event
that you may need any assistance. For questions or assistance,
please direct your email to productsupport@horizonhobby.com, or
call 877.504.0233 toll free to speak to a service technician.
Inspection or Repairs
If this Product needs to be inspected or repaired, please call for a
Return Merchandise Authorization (RMA). Pack the Product securely
using a shipping carton. Please note that original boxes may be
included, but are not designed to withstand the rigors of shipping
without additional protection. Ship via a carrier that provides tracking
and insurance for lost or damaged parcels, as Horizon is not responsible for merchandise until it arrives and is accepted at our facility.
A Service Repair Request is available at www.horizonhobby.com on
the “Support” tab. If you do not have internet access, please include
a letter with your complete name, street address, email address and
phone number where you can be reached during business days,
your RMA number, a list of the included items, method of payment
for any non-warranty expenses and a brief summary of the problem.
Your original sales receipt must also be included for warranty con-
sideration. Be sure your name, address, and RMA number are clearly
written on the outside of the shipping carton.
Warranty Inspection and Repairs
TO RECEIVE WARRANTY SERVICE, YOU MUST INCLUDE YOUR ORIGINAL SALES RECEIPT verifying the proof-of-purchase date. Provided
warranty conditions have been met, your Product will be repaired or
replaced free of charge. Repair or replacement decisions are at the
sole discretion of Horizon Hobby.
Non-Warranty Repairs
Should your repair not be covered by warranty, the repair will
be completed and payment will be required without notification
or estimate of the expense unless the expense exceeds 50%
of the retail purchase cost. By submitting the item for repair you
are agreeing to payment of the repair without notification. Repair
estimates are available upon request. You must include this request
with your repair. Non-warranty repair estimates will be billed a
minimum of ½ hour of labor. In addition you will be billed for return
freight. Please advise us of your preferred method of payment.
Horizon accepts money orders and cashiers checks, as well as Visa,
Master Card, American Express, and Discover cards. If you choose
to pay by credit card, please include your credit card number and
expiration date. Any repair left unpaid or unclaimed after 90 days
will be considered abandoned and will be disposed of accordingly.
Please note: non-warranty repair is only available on electronics
and model engines.
Electronics and engines requiring inspection or repair should be
shipped to the following address:
Horizon Service Center
4105 Fieldstone Road
Champaign, Illinois 61822
All other Products requiring warranty inspection or
repair should be shipped to the following address:
Horizon Product Support
4105 Fieldstone Road
Champaign, Illinois 61822
Please call 877-504-0233 with any questions or
concerns regarding this product or warranty.
Mounting the Engine
Most model airplane designs make provision for an engine
mount. It is extremely important that the engine mount be
securely attached to the airplane’s firewall and that the engine
is securely fastened to the engine mount. Follow the instructions
included with the airplane for mounting the engine.
The engine should be fastened in place with 4 screws through
a conventional beam mount. Use 10x32 screws for the 40GX. If
you decided to fasten the engine using a flexible motor mount,
always choose parts with enough integrity and strength. Make
sure all screws are tightened and regularly check that they are
tight and in good condition.
Important: Air is necessary to cool the engine during operation.
Make sure that sufficient air circulation through the cowling is
provided. As a basic reference, the outlet area should be 3–5 times
the area of the inlet area to provide adequate cooling.
Throttle Linkage
Carefully attach the throttle linkage to the engine using a ball
link on the carburetor. Make sure that the linkage is free to
operate from low throttle to high throttle and confirm that the low
throttle setting on the transmitter closes the carburetor butterfly
to the low idle position. Adjust the length of the pushrod until full
throttle opens the carburetor butterfly fully, while low throttle, low
trim completely closes the butterfly.
Attaching the Fuel Lines
Use large gasoline-compatible fuel line in the fuel tank as well
as the supply line to the engine. Use 5/32 brass/copper fuel
tubing to plumb the fuel tank. Be sure that the clunk inlet hole is
of sufficient size to work with this size of large fuel tubing.
Selecting a Suitable Propeller
The Evolution 40GX has been designed to generate maximum
power at 8000 rpm, according to the type of exhaust used. If you
wish to utilize the maximum power output, choose a propeller,
which will allow the engine to reach these revolutions, or slightly
lower revolutions. (The engine will unload in the air depending on
the aircraft speed and propeller selected.) We do not recommend
using propellers that allow the engine to reach more than 8500
rpm on the ground.
Fuel for the Evolution Gas Engine
The Evolution gas engine has been designed to run on a mixture
of high-quality 91 octane unleaded gasoline and synthetic oil
intended for racing 2-stroke gasoline engines. For the break-in
period of the new engine, mix the fuel in a ratio of 30 parts
gasoline to 1 part ashless oil lubricant. The engine will require
approximately 2 gallons of fuel for sufficient break in. Included
with the engine is the ashless break-in oil. After break in, use a
ratio of 40 parts gasoline to 1 part lubricant.
Suggested Propeller Dimensions
18x6 20x8 21x8
40GX
Evolution 40GX Ignition System
The 40GX uses an ignition system that can have the "battery test"
function disabled or enabled. The engine comes with the ignition system
battery test disabled. You can activate the ignition system "battery
test" function by inserting the small red jumper provided in the ignition
package. PLEASE READ THE INSTRUCTIONS ON ENABLING THE BATTERY
TEST FUNCTION IF YOU WISH TO DO SO WITH YOUR IGNITION SYSTEM.
Refer to page 8.
We recommend the use of a system power switch, or "kill switch," so
that the ignition can safely be turned on and off. When you prepare to
install the ignition in the aircraft, please check to make sure the ignition
system battery test is "DISABLED" (the red jumper is not installed in the
ignition).
CAUTION: IF YOU ENABLE THE BATTERY TEST FUNCTION, PLEASE READ THE
FOLLOWING FOR YOUR OWN PROTECTION:
During the battery test, a series of flashes are generated and voltage is
measured. This will cause a spark plug to be fired for up to 2 seconds
to check the condition of the battery prior to starting the engine. If the
engine is in the compressed position (i.e. the piston is above the exhaust
port in either the up or down part of the stroke), any compressed fumes
may ignite, causing the propeller to turn, and possibly the engine to
start, unintentionally.
To prevent this with the Evolution Gasoline GX Ignition System, check
to be sure the ignition system is turned off and that the piston is in the
bottom dead center (BDC) position. Bottom Dead Center can be found
by rotating the propeller through the compression stroke. As you rotate
the propeller you will feel it tighten, then suddenly loosen. Once the turn
becomes very easy, you have completed the compression stroke and are
at BDC. Once you are sure the piston is in this position, you may turn on
the ignition power switch and operate the system safely.
As always, it is important to use extreme care when near or with
engines, fuel and propellers. Please use caution when working with
these components. If you have any questions or concerns, please contact
the Horizon Support team at 1-877-504-0233 or productsupport@
horizonhobby.com.
18x8 20x10 21x10
19x8 20x12 21x12
3
Starting the Engine
Evolution Gas Engines come with a carburetor adjusted to a
basic setting. This setting should be maintained during the
initial break-in runs.
Choke Lever
Before you first start the engine, make sure that the spark
plug is screwed in and tightened and that the spark plug
socket is fitted in place properly. Fix the ignition sensor in the
proper position above the magnet with the screws enclosed.
*Follow the instructions in the ignition system section to mount
the ignition module in your model.
Important: Never turn the engine over with the ignition
Pressure Inlet
Fuel Intake
Adjusting Needle H
Adjusting Needle L
(directly below Needle H)
Throttle Lever
Idle Stop Screw
turned on unless the spark plug is inserted in the spark plug
socket. This could lead to ignition damage.
Basic setting: (minutes refer to the hands of a clock)
Carburetor Adjustments 40GX
Adjust needle (L) for low rpm range 1 turn and 30 minutes
Adjust needle (H) for high rpm 1 turn and 45 minutes
Note: One of the features of the 40GX is the way the spring-loaded choke is activated and released open. With the throttle closed, rotate the
choke closed and the choke linkage will engage the throttle lever and lock into the closed position. The choke will stay locked in place until
the throttle lever is slightly opened, and then the choke will automatically disengage from the throttle lever.
1) Be sure that the propeller nut is tight and that the spinner (if used) is secure and not touching the propeller blades. Check to be sure that the
carburetor throttle is operating properly by turning on the radio and moving the throttle stick of the transmitter to low; the carb throttle butterfly blade
should be closed completely. Now move the transmitter throttle to high and be sure the carb throttle butterfly blade opens up completely.
2) Have someone assist in holding the airplane. Close the choke completely so that the choke engages the throttle lever and remains closed. This also
automatically sets a slightly high engine idle for starting the engine.
3) When you are ready to start the engine, switch the ignition on and, using an electric starter, begin to crank the engine over counterclockwise. The motor
should fire or “pop” within a few seconds of applying the starter. At this point you have two choices of when to deactivate the choke.
a) As the engine “pops” and begins to run, you can blip the throttle slightly and this will disengage the choke lever and allow the choke to open
completely; the engine should remain running. Allow the engine to run for 30–45 seconds and then adjust for a proper idle.
b) Allow the engine to “pop” and then stop running. Open the choke now by moving the throttle just above idle to disengage the choke lever. Set the
throttle to the idle position (carb butterfly plate slightly open). Engage the electric starter to the engine again, and the engine should fire and be
running at a fast idle. Allow the engine to run for 30–45 seconds and then adjust for a proper idle.
4) If the engine does not start even after using the starter to crank the engine a second time, open the throttle to maximum, turn off the ignition and turn
the engine about 4 revolutions. Switch the ignition on again, then restart the engine with throttle at a fast idle position and the choke valve set open.
5) At this point if the engine still will not start, unscrew the spark plug and check its contacts. Clean any possible excess fuel (an indication of engine
flooding) and screw it in again. Further starting should only be done with the throttle at idle position. If the plug is dry, then probably not enough fuel
has been drawn into the carburetor. If that is the case, check the fuel feed and then return to the instructions given in paragraph 1 above.
4
After starting and warming the engine for 30–45 seconds, adjust as follows:
Step I- Move the throttle to 2/3 high throttle position quickly (fast acceleration), then repeat three times. If the engine
accelerates smoothly go to Step III; if acceleration is not smooth go on to Step II.
Step II- Faulty acceleration and a tendency to quit is usually attributable to a poor fuel mixture in the medium rpm range. Stop
the engine and recheck the fuel feed (the fuel line must not be pinched or broken). Restart the engine and test acceleration
again. If the problem persists, adjust the carburetor. Open the low speed needle by 5 minutes and retest. If acceleration is
smooth, open the needle by another 3–5 minutes—this should be done because the needle was previously set too lean; if
atmospheric conditions changed recently you may have to re-adjust the needle.
If the engine continues not to accelerate properly, open the low speed needle by 10 minutes. If the engine’s operation does not
improve, shut it off and check the basic setting, restart the engine and test the acceleration. If the engine runs correctly, proceed
to Step III.
Step III- If it continues to not accelerate properly, open the low speed needle by another 10 minutes. If acceleration is faulty, the
defect is likely to lie somewhere other than an adjustment.
Step IV- If the engine accelerates correctly, according to the above test, set it at idle speed and accelerate to full speed. Repeat
twice more. If the engine functions correctly, go to Step V. If it cuts out, open the low speed needle by 5–10 minutes more.
If the engine does not respond to acceleration fast enough, keep closing the low speed needle until it starts to cut out in
response to throttle opening. At that point, reopen the low speed needle by 5–10 minutes.
Step V- If the engine reacts correctly, set it at full speed. If revolutions do not drop, the engine has been adjusted successfully. If
revolutions seem to drop, open the high speed needle by about 5–10 minutes.
Caution! The engine must be stopped while you adjust the carburetor in order to prevent injury by the propeller.
Starting and running a new engine:
Having started the engine, leave it running for about 5 minutes at a higher idle speed. Then run it for about 20 minutes, while
changing revolutions from idle to 1/2–3/4 of the range and shortly holding each position—gradually prolong the holding periods. After
10 minutes of operation, open the throttle to maximum for a period of about one minute. At this point, stop the engine and let it cool
down. Then restart it and check the adjustment. If everything is all right, you can make your first flight. During the first few flights, do
not overload the engine and do not let it run at high revolutions for long periods of time (very important during hot weather). After break
in, fuel and oil should be mixed in the proportion 40:1.
- check for proper mechanical function by turning the engine
over.
- check that the carburetor is correctly installed.
- remove the carburetor cover from the feed side; check the
filter and blow off carburetor with compressed air (Caution:
When using compressed air, use eye protection.); when
re-assembling be careful to maintain the proper order of the
components.
- check the vacuum feed line.
Optional Items
Muffler Inverted Wraparound (EVO30983400)
Side Mounted (BISO5615)
Header (EVO30983269)
Tuned Silencer (EVO30983268)
Gas Start Kit (EVO1002)
Radial Mount (EVO30983398B)
Evolution 19x 8 Propeller (EVO4001)
Ignition Battery 2-cell LiPo (THP21002SPL)
Mechanical Faults
If the engine cannot be turned over easily
- a likely cause is the piston in the cylinder is seized:
loosen and unscrew the cylinder head bolts.
- carefully remove the cylinder liner.
- visually examine the piston and crankcase to find the
likely cause of the engine’s mechanical problem.
Note: Mechanical repairs must always be completed by our
professional service department.
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40GX Evolution Engine Dimensions
A
mm
136
F
mm
41
B
mm
118
G
mm
5.3
C
mm
60
H
mm
M10x1
D
mm
84
I
mm
10
E
mm
70
J
mm
46
40GX Evolution Engine Specifications
Evolution 40GX
Bore
Stroke
Displacement
Weight of engine
without ignition*
Weight of ignition unit
RPM range
* The value in the table above stands for the weight of a completely assembled engine, including the spark plug, carburetor,
drive washer and prop screws.
38mm
35mm
39.7cc/2.42 cu in
1451 g/3.19 lb
190 g/6.7 oz
1400–9500 rpm
Fuel
Break In
Lubrication
Unleaded (91 octane)
gasoline
Oil with gasoline
in mixture 1:30
Oil with gasoline
in mixture 1:40
7
Evolution GX Engine Simple Start Ignition System
Programming
Connector
LED
Ignition
LED
PROGRAMMING
programming connector
POWER
power connector
The spark ignition included with your Evolution gas engine is a modern generation electronic ignition. There are many useful functions
built into the microprocessor of this unit.
In addition to the basic ignition functions, the unit has a FAIL-SAFE feature: After 90 seconds of inactivity, it automatically switches to
an inactive state. In order to resume normal operation, it is necessary to turn the battery switch off and then back on. This function will
preserve battery life should the switch be left in the ON position during inactivity.
Installation of the GX Simple Start Ignition Unit
While installing the ignition unit in your model, be careful to have all parts that are connected to the unit and the engine situated
as far as practical from the radio receiver and radio antenna. The throttle servo should be mounted a distance of 8–12 inches from
the engine. The spark plug cable must not touch any part of the model structure as vibration may damage the cable. If this is not
practical, it will be necessary to provide an insulation material for the cable. All components must be protected from contact with
engine fuel.
Package Contents
-ignition
-LED
-programming connector
-manual
DESCRIPTION
The ICU-L ignition makes the selection of a pre-ignition curve
(“short” or “long” exhaust stroke) possible. You can change the
setting using the supplied programming connector.
The setting is permanently stored in the memory of the ignition
even if the supply voltage is turned off. You do not need to
change the setting when you turn the ignition on again.
BASIC FEATURES
-Two preprogrammed pre-ignition curves (“short,” which is the
default setting, and “long,” the tuned silencer)
-Sleep mode after 90 seconds of engine inactivity to save battery
power
-Ignition shuts off if engine runs counterclockwise
8
Enabling or Disabling Battery Test
This ignition makes it possible to enable or disable the battery test. The battery test is very useful when Li-Po or Li-Ion batteries are
used. During the test, a series of flashes are generated and voltage is measured. When the battery passes the test, that means it will
run for a minimum of 10 minutes in flight.
- Battery test is disabled when jumper is removed and programming
pins are open (this is the default condition of the engine as
shipped from Evolution)
- Battery test is enabled when jumper is plugged and programming
pins are closed
CAUTION: With the battery test enabled the engine can
unintentionally start during the testing process. Be sure to restrain
the aircraft prior to turning the ignition on when using the battery
BATTERY TEST ENABLED:
- close programming pins with
enclosed jumper
test feature.
- Enable or disable battery test when the ignition is off
If you want to change the type of silencer, do the first two steps and then continue to PROGRAMMING SEQUENCE. Otherwise, follow
these steps:
BATTERY TEST DISABLED:
- open programming pins
(remove jumper)
FIRST STEP
- Screw on pickup on engine
- Attach the plastic protection to the high
voltage cable
- Connect boot to plug
- Mount ground terminal on the high-voltage
cable bolt holding the engine to the motor
mount
- Mount the ignition to the airplane
SECOND STEP
- Connect enclosed LED to the ignition (red or
red/black wire to left)
START
- Keep clear of the propeller
- Connect battery with the ignition box
Starting Sequence
- Move propeller to put the piston at bottom dead center of its travel
- Keep your hands outside of the propeller radius to avoid serious injury
- Hold the airplane and switch on ignition
- If battery test is enabled, the ignition starts battery test; during this test, a series of sparks are
generated for about 2 seconds and LED is blinking
- If battery test is disabled, then LED blinks for about 2 seconds
- If LED turns off, you can fly; otherwise battery is low
9
Technical Data
* if batter y test is enabled
LiteVersion
170 gWeight
2x Li-I on/LiPo*Power supply
6x NiCd / NiM H*
5x NiCd / NiM H
6.5V*Minimal battery voltage*
Sleep mode after 90 seconds of engine inactivity
Battery level signalization *
Ignition goes off if engine runs counterclockwise
Choice of preignition curve
5ºPreignition point
240º / 120 ºLocation o f the magnet
600mAhMin. batter y capacity
Neve r use ignit ion with p lug cap rem oved from p lug! Befo re first
fligh t, do a rang e check wit h running e ngine.
Programming Sequence
Low battery
Sleep mode
Short silencer
Long silencer
0
100 ms
200 ms
300 ms
400 ms
500 ms
600 ms
700 ms
800 ms
900 ms
1 s
1.1 s
1.2 s
1.3 s
1.4 s
LED Blin king Types
light
dark
LED B linking In dication
One shor t flash
per seco nd
Sleep mode spar k is blocked
Unplug batter y and
reconne ct it again
TypeProblemSolution
Changing the Ignition Timing
If using the battery test function
- Make sure plug cap is attached to the plug
- Turn on ignition and power up
- Wait about 90 seconds until sleep mode is active; LED will
begin flashing once per second
- If battery test is enabled (jumper is plugged) remove the
jumper from programming pins
- Wait about 3 seconds; a flashing sequence changes itself
- Unplug battery
- Plug jumper back (to enable battery test)
WARNING! Use the ignition only in dry conditions
Use recommended number and type of cells for every ignition type
The product is specified for RC engines only (other use must be approved by the manufacturer)
Do not take off the plug cap if the ignition is on
Danger of electric injury (voltage over 20,000V)
Recharge ignition battery only outside the model
Because of possible interferences, ignition and battery should be placed at least 25 cm from the receiver
The manufacturer is not responsible for damages caused by not following the manual or by using the ignition for anything
other than RC engines. Guarantee is void if the high voltage (HV) cable or HV isolation is damaged, the pickup or batteries are
reversed, or the ignition box is opened.
If not using the battery test function
- If battery test is disabled (jumper is removed), plug the jumper
to programming pins
- Wait about 3 seconds until flashing sequence changes
- Unplug battery
- Unplug jumper back (to disable battery test)
To change silencer type, repeat the procedure again: