CORSAIR 180MANUAL V1.1 12/05/13

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IMPORTANT NOTICES 03

ASSEMBLING OF THE PARAMOTOR 05

HARNESS AND DISTANCE BARS 07

ASSEMBLING OF THE PROPELLER 10

ASSEMBLY INSPECTION 11

TECHNICAL DATA OF THE ENGINE 12

CARBURETOR – FUEL AND OIL 14

IGNITION AND ELECTRIC 15

JOYSTICK 17

PRE-FLIGHT CHECK 18

SPARE PARTS LIST 19

DIAGNOSING AND STARTING A FLOODED ENGINE 26

REGULAR CHECKS AND MAINTENANCE 28

TERMS OF GUARANTEE 29

WARRANTY ZERTIFICATE 30

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IMPORTANT NOTICES

* * C O N G R A T U L A T I O N S * *

Thank you for choosing an excellent paramotor. Please take the time to read this

manual carefully, with this manual we will try to give advice on the maintenance and

operation that will help you have a reliable paramotor and to preserve your

investment.

Furthermore, we invite you to give this manual with the paramotor if you sell it, so it

can be useful for the next owner as well. The manufacturer and the resellers are

ready to answer your questions and, if necessary, to solve problems, because the

safety of yourself and the others is the most important thing for us. When you will

receive the motor, it will already have overcome a test of 1 hour in the factory,

verifying the operation of all the components and the operation to every speed. All

the paramotors are tested before the delivery. We reserve the right to change

specifications, components, details of the motor, in relationship to the model in

production without incurring in some obligation. The reliability, the performances and

the duration of your paramotor will also depend on your understanding of the correct

maintenance and operation of the engine. This manual describes the paramotor, its

installation, use and control.

This PPG is not covered by product liability insurance. Do not start it or fly it

unless you are willing to assume all risks inherent in the sport of Powered

Paragliding and all responsibility for any property damage, injury or death

which may result from the use of this product.

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You must be aware that any engine can fail and breakdown at any moment,

this could lead a landing in less than ideal areas with the possibility of injury to

the pilot or other people. Any powered paramotor must only fly in permitted

areas, and never to fly low above a crowd of people. Inhabited zones, water,

and areas that are difficult to land should be avoided, always remember that

the engine could stop.

Some atmospheric conditions can cause the engine to perform differently than

normal. Before beginning every flight, you must test the paramotor on the

ground. Start the engine on a flat surface that is free from stones, sand or

small parts that could be sucked in by the propeller. Be sure any persons

nearby are well clear off the thrust from the propeller and not near the

propeller at any time the motor is running. A good safety distance is 50 meters

for all directions of projection of the propeller and 20 meters for the others

directions.

Do not use a paramotor that has not been correctly maintained or not been

used for some time, or if you know that is not in good condition. The use of

not original spare parts can make the paramotor dangerous and immediately

voids the warranty. Changes to the reduction or propellers can reduce safety

and reliability of the aircraft. Before every use or test, check the condition of

the propeller and the torque of bolts of the propeller. If the propeller is

damaged do not use it, this can lead to a breakup of the propeller in rotation

or to strong vibrations that will transmit to the motor and may cause damage

or loosen bolts or components.

Never use the motor without propeller or without reduction drive.

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FRAME The frame consists of:

- a.) central module - b.) cage - c.) 2x long supports - d.) 4x middle supports

Top position: long supports Middle position: middle supports Bottom position: middle supports Assemble the complete cage and close all velcro straps

ASSEMBLING OF THE PARAMOTOR

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Insert assembled cage first in top position after that insert middle and bottom position. Close bottom velcro straps on both sides. Close netting with carabineer on both sides.

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Harness has to be connected with the special buckles. Connect harness with both buckles to the frame.

ASSEMBLING OF THE HARNESS AND THE DISTANCE BARS

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Fix the distance bars with the nut. Distance bars are moveable vertically and horizontally. Fix the shoulder strap correctly to the harness.

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ADJUSTING OF THE HARNESS The best way to familiarize yourself with the harness and your personal flying position is to use a simulator. Sit in the harness and adjust the shoulder straps correctly. The weight should be constantly shared on the shoulders. Find your seat position and adjust the straps accordingly to sit relaxed. The shoulder straps are adjusted depending on pilot weight. The flight position is optimal when the propeller shaft line is 5 ° to a maximum of 10 ° below the horizontal line.

horizontal line propeller shaft line

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On the CORSAIR 180 paramotor is mounted a HELIX carbon propeller Mount the propeller with the six M8 screw with a torque of 10Nm. Please use only original propellers otherwise you lose your warranty.

ASSEMBLING OF THE PROPELLER

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It is very important to fully inspect the assembly of your paramotor to find and remedy any potential problem areas before proceeding. The inspection should contain, at a minimum, the following items: Review each assembly step above

Examine all nuts, bolts, and fasteners for security

Check the harness for correct mounting, that all straps are secure, that

there are no twists on any straps

Examine prop cage for correct assembly, that it is strong, the netting is

tight and on the correct side

Check that nothing can get in the prop. The prop should clear the cage

by same distance at all points.

Check the fuel tank and fuel delivery system.

Check for correct mounting of prop, and correct torque of prop bolts.

ASSEMBLY INSPECTION

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TECHNICAL DATA OF THE ENGINE Engine 1 Cylinder 2-Stroke Engine

Cooling By Air

Bore 65 mm

Swept Volume 172.5 cm³

Power 25 PS bei 7900 U/Min

Thrust 70 kg

Cylinder Aluminium with Nikasil Coating

Compression 11 : 1

Piston HQ graphite , 2 rings chromed

Carburetor Walbro

Air-Filter Air box

Ignition Induktiv IDI

Spark Plug NGK BR9ES

Spark Plug Cap 5k Ω

Reduction Poly V-Belt

Reduction Ratio 1:2.88

Propeller Helix H30F 1,25m L-M-09-2

Starter Manual Starter

Exhaust Stainless steel with silencer

Consumption 3.0-3.5 L/hour at 30 kg Thrust

Weight Engine 16 kg

Propeller Direction Counter Clockwise

Tank 12 L

Total Weight of Paramotor 28.7 kg

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TIGHTENING TOURQUE TIGHTENING TOURQUE VALUE FOR ENGINE BOLTS AND SREWS

M N.m Kgf.m Lbf.ft Locking

compound

HEAD NUTS 7 14 1,4 10,36

CRANKSHAFT NUT – CLUTCH SIDE 12 60 6 44,4

CRANKSHAFT NUT – IGNITION SIDE

10 40 4 29,6

PROPELLER CENTRAL SCREW 10 40 4 29,6 Loctite 243

SPARK PLUS 20 2 14,8

CRANKCASE SCREWS 6 8 0,8 5,92

CARBURETOR LOCKING SCREWS 6 8 0,8 5,92

INTAKE MANIFOLD LOCKING SCREWS

6 8 0,8 5,92

MUFFLER STUDS NUTS 6 10 1 7,4 Loctite 270

SILENCER LOCKING SCREWS 8 15 1,5 11,1 Loctite 243

MUFFLER LOCKING SCREWS 8 15 1,5 11,1 Loctite 243

STANDARD TIGHTENING TORQUE VALUES N.m Kgf.m Lbf.ft 5 mm Bolts and nuts 6 0,6 4,44

6 mm Bolts and nuts 10 1 7,40

8 mm Bolts and nuts 25 2,5 18,50

10 mm Bolts and nuts 45 4,5 33,30

12 mm Bolts and nuts 55 5,5 40,70

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CARBURETOR – FUEL AND OIL

IMPORTANT INFORMATION We recommend using super gasoline and full synthetic oil (Castrol TTS) at 2%. Mix fresh fuel and oil before each flying session. Store your fuel/oil mixture in an approved, sealed container. Dispose of fuel/oil mixture that is older than 1 month. During running in we recommend using 2.5% oil mixture and use only full power during starting. Mixture table:

The fuel oil mixture should not be older than 1 month!

fuel 95/98 octan

full synthetic oil

Castrol TTS

full synthetic oil

Castrol TTS

LITER

1:40 (2.5%)during running in time

ml

1:50 (2%) normal use

ml

0,5 1 2 3 4 5

10

13 ml 25 ml 50 ml 75 ml

100 ml 125 ml 250 ml

10 ml 20 ml 40 ml 60 ml 80 ml

100 ml 200 ml

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IGNITION AND ELECTRIC Spark Plug: NGK BR9ES

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JOYSTICK We supply with this paramotor a special build joystick which is a novum in the paramotor market. Since it’s important to know how to stop the engine once it’s started, let’s cover “Stopping the Engine” first. To stop the engine, simply depress the “STOP” button and hold it until the engine comes to a complete stop.

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PRE-FLIGHT CHECK THE FOLLOWING POINTS SHOULD BE CARRIED OUT BEFORE EACH START!

01 VISUAL INSPECTION OF CAGE AND FRAME FOR FRACTURES

02 PROPELLER HUB WITHOUT CLEARANCE?

03 REDUCTION GEAR LEAK-PROOF ?

04 EXAMINATION OF EXHAUST AND MOTOR RUBBER ELEMENTS!

05 PETROL FILTER UNPOLLUTED?

06 MOTOR, CARBURETOR AND TANK ARE LEAK-PROOF?

07 SUFFICIENT SUPPLY OF FUEL AND OIL IN FUEL (DON’T USE MIXTURE OLDER THAN 1 MONTH) ?

08 PILOT SUSPENSION UNDAMAGED ?

09 CANOPY UNDAMAGED ?

10 GAS LEVER POSITION – CHECK THE FREE MOVEMENT!

11 VENTILATED TANK LID ON TANK?

12 PROPELLER CLEAR – START PARMOTOR – NO PERSONS NEAR BY STARTING THE PARAMOTOR

13 CARRY OUT A TEST AT FULL THROTTLE AFTER WARMING UP!

14 TEST THE SWITCH-OFF FUNCTION!

15 PILOT PROPERLY HOOKED IN?

16 WIND DIRECTION AND WIND FORCE?

17 TAKE OFF AREA CLEAR ?

18 TEST FOR LEAKS?

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SPARE PARTS LIST

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DIAGNOSING AND STARTING A FLOODED ENGINE A flooded engine can be identified by the smell of unburned gasoline coming from the exhaust pipe, or by periodic weak firing and puffs of black smoke during starting attempts. If you have a flooded engine, follow the procedure below: Remove the spark plug and thoroughly dry it. (Note another indication of a

flooded engine is a spark plug that is dripping with gas).

With the spark plug removed push the starter button for a few seconds while

holding the throttle in the full-open position. This will remove excess fuel from

the engine.

Install the dry spark plug, and start using the normal procedure.

WARNING! Ensure you have placed the spark plug cap away from all fuel sources before pulling the starter cord or a fire could occur! WARNING! Do not use a flooded engine procedure whereby you hold the throttle wide-open and then attempt to start the engine. If the engine starts, the prop would rapidly spin to full RPM and damage or injury would most likely occur! ENGINE PROBLEMS DIAGNOSTIC

REASON REMEDY

The engine doesn’t start Out of petrol Add petrol

Petrol doesn’t reach the carburetor

Check the fuel system circuit

Old or wrong petrol Empty the tank and the fuel system circuit and replace the petrol

Flooded engine Remove the spark plug, start the engine, dry or replace the spark plug.

Defective spark plug Replace it

Blockened spark plug or wet Clean and dry the spark plug or replace it

Earthened switching off cable Check the wiring

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Spark plug hood Check it

Carburetor has problems Clean and check it, eventually replace the diaphragm

No spark Check the ignition, coil and wiring

The engine doesn’t idle Dirty carburetor Calibrate the carburetor

Out-of-adjustment screws Clean and check it, eventually replace the diaphragm

Defective spark plug Replace it

The engine doesn’t reach the maximum rpm

Wrong carburetion Calibrate the carburetor

The carburetor has problems Clean and check it, eventually replace the diaphragm

The reed valve has problems Replace the reeds or the whole reed valve

Dirty air filter Clean or replace it

Dirty exhaust system Clean or replace the deadening material

Engine revved up when idling

Out-of-adjustment screws Calibrate the carburetor

Air through the gaskets Replace the gaskets and seals

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REGULAR CHECKS AND MAINTENANCE

At every use Check the bolts and screw tightening Check the silent-block conditions

After the first 10 hours Check carburetion

Every 25 hours Replace the spark plug Clean the air filter Replace the muffler springs

Every 100 hours or every year

Replace the air filter Replace the starter rope Replace the diaphragm and clean it Replace the silent-block Replace the fuel system pipes Replace the reed valves

Every 100 hours

Check the piston and piston rings Replace the pin and rollers cage Decarbonise and clean the decompression hole Replace the silencer deadening material Replace reduction gear belt

Every 200 hours Replace the piston and piston rings Replace the reed valve

Every 400 hours Replace all the bearings and seals Replace the crankshaft

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TERMS OF GUARANTEE G-Force Paramotors will warrant their product to be free from defects in materials and workmanship for a period of twelve (12) months from the date of purchase. This warranty applies to the product in normal usage situations only. The dealer, from whom you purchased the product or G-Force Paramotors will repair the product free-of-charge. To obtain warranty service please contact your dealer or G-Force Paramotors and then either bring the product in or have it shipped. Shipping charges are the responsibility of the purchaser. This warranty does not apply even during the warranty period, and the purchaser shall pay repair or replacement charges if:

The cause of malfunction is due to misuse, neglect, negligence, etc. This includes seize of the engine due by an improper carburetor adjustment or improper fuel/oil mix

The malfunction is caused by incorrect pilot operation, i.e. a crash,

whack, dork, bang, splat, ding, prong, bend, tweak, trip, fall, bounce or any other piloting eventuality.

The malfunction is caused by lack of normal maintenance or

modification, i.e. loose parts falling off and breaking the propeller.

The malfunction is caused by an Act of God, including but not limited to fire, earthquake, hurricane, flood or other natural calamity.

Purchaser has no warranty-certificate

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WARRANTY ZERTIFICATE Name of buyer: Model: ______________________________________ Date of purchase: ______________________________________ Address: ______________________________________ This warranty certificate is valid 1 year after purchase. Please read this manual carefully. For further question please ask your dealer or direct G-Force Paramotors. DEALER G-Force Paramotors ________________ ________________________

G-Force Paramotors Paurach 55, A-8332 Edelsbach

Tel.: +43 (0) 664 91 55 160 sales@gforce-paramotor.at