The Power Jet II Manual
Table of Contents

1.0 FLY PRODUCTS WORLD

1.1 Safety First!

1.2 Notation Used

1.3 Congratulations on Your New POWER JET!

1.4 POWER JET Features

1.5 Diagram of Components
2.1 Package Contents

2.2 Frame Assembly

2.3 Harness Mounting
2.4 Prop Mounting
2.5 Spark Plug

2.6 Assembly Inspection

3.1 Fuel and Oil
3.2 Before Starting the Engine
3.3 Starting and Stopping Engine
3.3.1 Stopping the Engine

3.3.2 Starting the Engine

3.3.3 Choking the Engine
3.4 Carburetor Adjusting
3.5 Engine Break-In
3.6 Harness Adjustment
3.6.1 Ground Handling Straps
3.6.2 Flight Straps
3.6.3 Hang-test in a Simulator

4.1 Preflight Inspection

4.2 In-flight Starting
5.1 Tool Kit

5.2 Reserve Parachute

5.3 Speed Bar
5.4 Fuel Viewing Mirror
6.1 Disassembling for local travel
6.1.1 Dissassembling the Prop Cage
6.2 Disassembling and packing for long-distance travel
6.2.1 Fuel Tank Drain
6.2.2 Draining All Fuel
6.2.3 Removing The Harness
6.2.4 Cage Disassembly

7.0 MAINTENANCE

7.1 Cleaning
7.2 Prop Care
7.3 Spark Plug
7.4 Repairs
7.5 Carburetor Maintenance
7.6 Long Term Storage

8.1 Diagnosing and starting a flooded engine

8.2 Troubleshooting Chart
9.1 Specification and Performance Summary Chart
9.2 Torque Specification Chart
10.1 Obtaining Repair Parts
10.2 Owner Registration

10.3 Warranty

10.4 Pre-Flight Checklist Examples
10.5 Pre-Flight Checklist Example 1

10.6 Pre-Flight Checklist Example 2

1.0 Fly Products World
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Welcome to the FLY PRODUCTS world!  We are one of the oldest builder of Powered Paragliders (PPGÍs) in the world.  We at FLY PRODUCTS put all of our long experience into our products for to give you the state-of-the-art in all of our products. 

1.1   Safety First!
Powered ParaGliding (PPG) is the newest form of aviation.  ItÍs also the most exciting, least expensive, safest, most accessible form of aviation EVER!  However, it is still aviation, and it brings with it all the inherent potential dangers of any form of aviation.  People can, and do, get hurt and even killed in any form of aviation, including PPG.  For that reason it is imperative that all PPG pilots receive proper training from certified instructors, offer PPG the respect all aviation deserves, respect weather and conditions, and realize that in the end, it is the pilot himself that is responsible for his own safety and the safety of fellow pilots and bystanders.  Enjoy PPGing to the fullest, and welcome to the sport!   

Please read and be sure you thoroughly understand this OperatorÍs Manual before starting or flying your POWER JET.  It contains information critical to the safe operation of the Powered Paraglider.    

Powered Paragliding is an extremely demanding sport that requires exceptional levels of attention, judgement, maturity, self-discipline, and attention to detail.  It is unlikely that you will be able to participate in it safely unless you make a conscious and continual commitment to your own safety.

Due to the inherent risks in flying this or any PPG, no warranty of any kind can be made against accidents, bodily injury, equipment failure, and/or death.

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.

1.2   Notation Used
Certain special terms (NOTE, CAUTION, WARNING) will be used throughout this manual.  Their usage is defined below.

A NOTE provides supplemental information to help clarify a point being made in the text.  Generally, a NOTE is provided to help assembly, use, or maintenance of the product.  Disregarding a NOTE could cause inconvenience, but would not cause damage or personal injury.

A CAUTION provides supplemental information to help clarify an area where equipment damage could occur.  Disregarding a CAUTION could result in permanent and significant mechanical damage, however personal injury is unlikely.

A WARNING provides supplemental information to help clarify an area where personal injury or even death could occur from negligence.  Disregarding a WARNING could result in serious injury or even death.

1.3   Congratulations on Your New POWER JET!
FLY PRODUCTSÍs POWER JET Model PJ125 is truly a remarkable, state-of-the-art Powered Paraglider that represents a huge leap forward in PPG technology. The PJ125 will provide you with outstanding performance and superb, quiet flying comfort for hundreds of hours of safe and enjoyable flight. 

1.4   POWER JET Features
The following is a brief list of some of the many features that are found on the POWER JET PJ125:

  • Very  High Thrust/Weight Ratio ¿ PJ125 weighs only 46 lbs., and produces 110 lbs static thrust
  • Easy disassembly and assembly
  • Clutch-driven prop doesnÍt spin during critical inflation, launch, and landing
  • Gear-driven reduction drive
  • Force-air cooling
  • Tuned Pipe
  • Extremely quiet
  • In-flight Restarting
  • Very good fuel economy and duration ¿ PJ125 flies 6 hours on only 15 liters (4 US gal) of fuel (with 150 lb pilot and modern wing)

 

1.5   Diagram of Components
The following figures illustrate the basic components of the POWER JET PJ125.

Fig. 1 Rear View of Power series
Fig. 2 Side View, with Prop and Prop Cage Removed for Clarity


2.0 - UNPACKING AND ASSEMBLING YOUR POWER JET
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2.1ææ Package Contents
The figure below illustrates the components that will be packed with your POWER JET.

Fig. 3  The packing contents of the PJ125. 

2.2   Frame Assembly


Fig. 4  The frame assembly of the PJ125.

Frame assembly and disassembly on the PJ125 is very fast and easy. 

The frame consists of four parts, and they are held together by the support rods.

To init the assembling, Place the PJ125Ís central frame (the engine unit) on a flat surface.

For an easy and correct assembly proceed in the following order:


Fig. 5 - Support rods

Step n. 1. - Support rods.

Plug all six cage support rods into their bushings
on the central frame (engine),
take attention to put longest on the top.



Fig. 6 - Upper mount

Step n. 2 - Assembling upper frames

Make sure that the cage netting is in front of the cage support rods as shows in the picts.
Place the upper frame quartes onto the upper support rods and rotate the frames until plug in the inserts in the related holes.

Lock the velcro strap as shown.


Fig. 7 - Velcro strap lock


Fig. 8 - Mount side frames.

Step n. 3 and 4 - Assembling sides frames

Place the side frames onto the side support rods and plug in the inserts in the related holes.

Lock the side velcro straps.



Fig. 9 - Mate lower frames.

Step n. 5 and 6 - Assembling lower frames

Place the lower frames onto the central engine unit frame plugging the inserts in the related holes.

Lock the lower velcro straps.

NOTE!  The cage support rods must be completely seated into their bushings in the frame, and into their bushings in the cage,
if they are not seated completely into their bushings, you will be unable to fasten the netting into place in the next step.

Step n. 7 - Fasten the net.
Attach the netting tension strings as shown in the figures, simply passing the string-hook into the string loop, pull it tight, and then hook it back onto the string loop.

Fig. 10 - The string loop
 

Fig. 11 - String lock

This completes the assembly of the prop cage.

2.3   Harness Mounting
The PJ125Ís harness mounts to the central frame with six attachment points. 
They are: the top harness mounting straps (or triangular carabiners), the ground handling straps, and the distance bars.

DISTANCE BARS: These distance bars are extremely easy to mount and dismount since they slide easily into the central frame. The end of the distance bars are made of a square aluminum profile that does not allow them to rotate. Due to the compression of the harness, the distance bars can not slide out of their fittings during flight.

Fig. 12  Distance bar sistem. 

ANTITORQUE SISTEM

The distance bars are designed to favor the sliding of front harness webbing in a way that the pilot finds the proper angle with the paraglider. With this system the discharge of the propeller torque onto the risers is avoided, which usually gives the the tendency to turn one direction that in the case of the rotation of the Solo 210 engine the tendency is to turn right.

LATERAL WIDENING OF DISTANCE BARS.
The distance bars allow a lateral movement which is useful for the pilot to enter easily into the harness.

Next, attach the bottom of the harness, then work toward the top.  
Attach the bottom ground handling straps as shown in Fig. 13.
Do this for the left and right sides.  Leave these straps at their loosest setting for now, weÍll adjust them later.

Fig. 13  Mounting the bottom straps

Fig. 14 Close-up of mounting straps


Fig. 15 Mounting the top harness straps

Finally, fasten two top mounting straps around the top tube of the frame (Fig. 15).  Fasten these belts securely as in Fig. 14,
or, in case of the model with the eyelet bolts, hook the two triangular carabiners to the eyelets.

This completes the harness mounting.  Inspect your work to ensure that all is OK.

2.4   Prop Mounting
NOTE:  Here is some terminology weÍll use in this section.

The ñfrontî is the direction the pilot faces while flying, the ñrearî is the opposite direction. 
The ñfrontî of the prop can be identified by the thick side of the prop blades. 
The ñrearî side of the prop can be identified by the thin side of the prop blades as the upper blade section shown in fig. 9. 
The ñrear prop flangeî is the one that is most rearward when the prop is mounted.
The ñfront prop flangeî is the one that is mounted on the reduction drive. 
 

Fig. 16 Upper view of a propeller section.

Mounting the prop is quick and easy. 
Place the rear prop flange on the rear side of the prop.
Insert the four (4) prop bolts through the rear prop flange and prop. 
Place the black rubber friction washer over the prop bolts on the front side of the prop as shown in Fig. 16. 


Now mate the prop/rear flange/bolt assembly to the front prop flange that is on the reduction drive.

 
Place nylon-insert lock nuts on the bolts, and tighten them evenly. 
The correct torque to use is 50-inch lbs. MAX.  


A more practical ñfield methodî of torquing is to tighten the bolts snuggly
and evenly, but not enough to begin to crush the wood of the prop.

The red arrow in picture, indicate the sense of propeller rotation.

2.5    Spark Plug
Set the spark plug gap to 0.025î  (0.635mm).  Install the spark plug and torque to specifications (120-inch lbs. or 10 ft-lbs.). 

2.6   Assembly Inspection
It is critical to fully inspect the assembly of the POWER JET and find and remedy any 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 at least 2.5 inches (4 fingers) at all points
  • Check the fuel tank and fuel delivery system
  • Check for correct mounting of prop, and correct torque of prop bolts

3.0 PREPARING FOR YOUR FIRST FLIGHT

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3.1ææ Fuel and Oil
FLY PRODUCTS recommends the use of a premium unleaded automotive gasoline of 92 octane or higher, and the use of premium synthetic 2-cycle oil.  Mix fresh gas 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 72 hours. 

The recommended fuel/oil ratio is 50:1.  Be sure to thoroughly agitate the mixture to completely dissolve the oil.  Use only fresh fuel and oil, and use clean containers, funnels, hoses, etc. 

To fill the fuel tank, remove the fuel tank by unscrewing the fuel tank cap .  Take care not to get dirt, dust, etc. onto the fuel pickup.

It is recommended that the fuel be poured into the tank using a straining-type of funnel.  Fill the tank with the desired amount of fuel..  Tighten the fuel cap securely.

NOTE:  Wipe up any spilled fuel immediately, as the fuel/oil mixture is highly flammable, and an in-flight fire would be catastrophic.  Also, the oil will leave a residue, which will attract and retain dust and dirt.

WARNING!  Use common sense when refueling.  Do not refuel a hot or running engine, do not smoke or allow on-lookers to smoke while refueling.  Do not refuel near heat or open flame.

3.2   Before Starting the Engine
Before starting the engine on the ground, ensure that the unit is in an area free from dirt, rocks, dust, etc. that could be sucked up and thrown around by the propeller. 

Check assembly of the unit, and especially check any and all nuts, bolts, and screws, that could be loose.  Also check all parts of the prop cage for looseness.  The prop produces a significant amount of thrust, and can suck things into it from a surprising distance. 

WARNING!  Ensure that no bystanders or onlookers are close by when starting the motor.  The most dangerous place to stand is in the plane of the propeller.  This is where dust, dirt, rocks, nuts, bolts, etc. will be thrown if they are picked up by the prop.  

At full RPM, the prop tips are moving in excess of 370mph, and pushing the air rearward at over 62mph.  This amount of force can pick up anything loose in the area and throw it around like a bullet.  Not only can it severely injure you or bystanders, even small items like dirt can inflict significant damage to the prop.

3.3   Starting and Stopping Engine

 

3.3.1   Stopping the Engine
Since itÍs important to know how to stop the engine once itÍs started, letÍs cover ñStopping the Engineî first.  To stop the engine, simply depress the ñSTOPî button (fig. 10 - "A" ) and hold it until the engine comes to a complete stop. 

A - STOP button

B - START button

C - Throttle lever

D - Throttle lever hold to half power

E - Velcro strap

Fig. 17 - The handgrip  

It is important to be aware of some other engine stopping techniques, should the stop switch not function correctly. 
The stop switch may not function correctly due to

  1. faulty switch,
  2. broken or frayed wires,
  3. bad connections to any part of the stop switch circuitry. 
For this reason, the following emergency stop procedures are available:
To stop the engine if the stop switch doesnÍt function correctly, you can
  • Place your hand over the airbox intake hole
  • Place the carburetor choke in  the ñONî position
  • Squeeze the fuel line (requires an aggressive squeeze, and takes about two minutes to stop the motor)

3.3.2   Starting the Engine

Now that weÍve covered stopping the motor, letÍs get to the fun part! 
There are three different positions that can be used to start the engine.  These positions are:
  • Standing in front of the unit, holding the unit on the ground
  • Strapped into the unit, standing on the ground
  • In Flight
WeÍll cover each of these starting options in turn.

If the engine is cold it's very important to fill the fuel pipes squeezing the apposite fuel pump placed near the fuel tank.

  • Standing in front of the unit, holding the unit on the ground
    WARNING!  The method of holding the throttle handle is important in this position.  Hold the throttle handle such that you can easily reach the stop button, but not so that you can inadvertently squeeze the throttle.  A common accident can happen where you hold the throttle in the same hand that you hold the motor unit, and if you squeeze the throttle a little, the thrust of the machine will push the throttle onto your hand, causing you to squeeze the throttle even more.  Make sure that you CANNOT inadvertently squeeze the throttle handle when starting in this position.
    • Stand in front of the unit, and place your left hand on the top of the central frame tube.  Hold the throttle in your left hand also, noting the warning above.  Grasp the pull-starter cord with your right hand.
    • Gently pull the pull-starter cord until you feel the engineÍs compression.  Allow the pull-starter cord to rewind into the motor. Rapidly and sharply pull the starter cord.  The engine should start after one or two pulls.
    • Gently pull the pull-starter cord until you feel the engineÍs compression.  Allow the pull-starter cord to rewind into the motor. Rapidly and sharply pull the cord.  The engine should start after one or two pulls.
  • Strapped into the unit, standing on the ground
    In this position is possible to leave the throttle hanging to the right side of the harness, grasp the pull-starter cord with both hands and proceed like to the position above.
  • In-Flight
    For information on this starting position, refer to the ñIn-Flight Startingî section under ñFlying Your POWER JETî.

CAUTION!  Do not allow the starter-rope to snap back into place after youÍve started the motor.  Gently place it back into place.

3.3.3   Choking the engine

If the engine hasnÍt been run in a few hours and is no longer warm to the touch, use of the choke will be needed.  The choking procedure is as follows:
  • Move the choke lever to the ñONî position.
  • Pull the starter rope until the engine starts.
  • Move the choke lever to the ñOFFî position.
  • Allow the engine to stabilize a few seconds before applying throttle.
The choke lever and itÍs ñONî and ñOFFî position can be seen in Fig. 11.

3.4   Carburetor Adjusting

Our carburetor is provided with a starter for the very first starting (cold starting) Flip up switcher A in position 2 for starting, in position 1 for functioning.
You can set the carburetion at the desired revs. by the long black downward screw C. By turning it anticlockwise you rich the mixture, while the opposite you lean it.
The basic setting is between 1 and 2.5 turns from the shut position.
The C screw must be turned very gently, always verifying the cleanliness of the "passage" (the point where the nozzle of the idle enters the nozzle of the full, at about half revs.) in revving up. If the engine pops, you tighten it, if it abates you loosen it.
The D screw sets the revs. at idle, by opening the butterfly valve.


Fig. 18  POWER JET  PJ125  carburetor

Components shown:

A ¿ Choke Lever,

Position ñ1î is Choke OFF
Position ñ2î is Choke ON

B ¿ Carburetor Diaphragm

C ¿ Idle Mixture Screw

D ¿ Idle Speed Screw


The POWER JET carburetor has two adjustments, detailed in Fig. 11.

Carburetor adjusting proceeds as follows: Warm the engine by allowing it to idle for at least 5 minutes.  Adjust the idle mixture C for the fastest idle possible.  Once attained, adjust D for the slowest smooth and stable idle possible.

Often, after making a few adjustments to the carburetor, it is necessary to ñstart overî, and go back to the original factory settings.   The original factory settings for the carburetor are:

  • Idle Mixture Screw (C in Fig. 18): 1.5 turns out from stop
  • Idle Speed Screw (D in Fig. 18): 1.5 turns out from stop

To restore the adjustments to the factory settings, GENTLY turn the screws CW until they hit their stops, and then back them out (CCW) the number of turns described above.

3.5   Engine Break-In
Break-in of the POWER JETÍs Top 80 Engine is required before the first flight.  Proper break-in will provide you with a better running engine, it will also provide for considerably longer engine life. During the break-in, gently change RPM from idle to full-throttle and back.  Do not rapidly change RPM, as this causes unnecessary wear and tear on the clutch.  The procedure is as follows:

  • Run the engine, varying the RPM, for 2 minutes.
  • Stop the engine and let it cool for 2 minutes.  Check for loose bolts, etc. during this time.
  • Run the engine, varying the RPM, for 5 minutes.
  • Stop the engine and let it cool for 5 minutes.  Check for loose bolts, etc. during this time.
  • Run the engine, varying the RPM, for 10 minutes.
  • Stop the engine and let it cool for 5 minutes.  Check for loose bolts, etc. during this time.
  • Continue 10 minutes of running, 5 minutes of cooling until 30 minutes of run time is achieved.

At this point, you can fly the POWER JET, however avoid long durations of full power, and vary the throttle setting often. 
For heavier pilots that require more power to fly, it is recommended that 1 hour of non-flying break-in be completed before flying. 
Break-in is complete after 10 liters of fuel have been run through the engine.

CAUTION!  Be wary of overheating during the break-in process.  It will show itself as a loss of power. 
Should this occur, reduce power and land as soon, as is practicable.   Allow the engine to cool. 
Check to ensure the carburetor mixture is correct (a lean condition can also produce overheating) before flying again.

3.6   Harness Adjustment

The PJ125Ís harness consists of two separate strapping systems, one used to comfortably support the paramotor assembly unit on the pilotÍs back while on the ground, and the other is used to support the paramotor and pilot while flying.  This system also correctly aligns the thrust angle of the prop.  The two systems have separate purposes, and are adjusted separately.

 

3.6.1   Ground Handling Straps

In the Fig. 19, the ground handling straps are in green, the flight straps are in red.

Fig. 19  Side and Front Views of Ground Handling Straps and the flight straps

The ground handling straps as shown above are best adjusted standing on the ground, with the POWER JET on the pilotÍs back. 
The purpose of the shoulder straps and shoulder pads is to carry the weight of the POWER JET while on the ground. 
The purpose of the ground handling chest strap is to keep the ground handling shoulder straps from falling off the pilotÍs shoulders.

  • The adjustment procedure for the ground handling straps is as follows:
  • Strap into the paramotor and stand up.
  • Adjust the Shoulder Straps until the shoulder pads are carrying the weight of the paramotor.
  • Snug the ground handling chest strap .
  • Adjust the thigh straps, the tightness of the thigh straps will determine how easily you can slide into the seat after takeoff. 
    Adjust these with the use of a simulator.

The ground handling straps are adjusted correctly if:

  • The weight of the paramotor is on the shoulder pads
  • The shoulder pads/straps wonÍt fall off the shoulders
  • The seat can be moved out from under  the buttocks easily
  • You can easily slide into the seat after takeoff
  • You can run easily and the seat and thigh straps donÍt interfere with your ability to run.

3.6.2   Flight Straps

Fig. 20  Side and Front View of Flight Straps

In Fig. 20, the flight straps are red. 

The purpose of each flight strap is as follows:

  • Length ñBî determines the carabiner height.  Higher accommodates larger pilots.  Lower accommodates smaller pilots and provides more weight shift capability.  This length has a variable adjustment locations. 
  • Length ñCî is adjusted by buckle ñ5î, and it sets the thrust angle.  Adjust it so the thrust angle is zero to five degrees below horizontal.  This must be done in a simulator.   See ñHang Test in a Simulatorî below.
  • Lenght "D", is used to adjust the back of pilot's distance from the PPG.
  • Proceed to final adjusting of the harness in the simulator.

3.6.3   Hang-test in a Simulator

It is HIGHLY recommended that you perform a hang-test in a simulator before the initial flight of the POWER JET, and every time you make a harness adjustment thereafter.  A simulator can consist of two ropes tied to a horizontal (and strong) tree limb, two ropes tied to rafters in your garage or basement, etc.

Fig. 21 Carabiner Positioning

Once you have made your initial adjustments, strap into the POWER JET and clip the carabiners into the simulator.  Gently lift your feet and get seated in the harness.

Continue to adjust the harness until the following criteria are met:

  • The ground-handling straps should be loose and comfortable
  • The ground handling chest strap should be loose (still buckled, but loose)
  • No part of the harness should hamper free movement of your arms and the throttle cable.  Make sure you can reach your arms up very high with no strain or interference from the harness
  • The propeller shaft must be approximately 5, and no more than 10, degrees below horizontal


WARNING!  The carabiner hook-in loop must be located beneath the flight strap, as shown below in Fig. 15.  This orientation places the pilotÍs weight on the strap itself, rather than on the stitching of the loop.

4.0 FLYING YOUR POWER JET™
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4.1ææ Preflight Inspection
Before your first flight, and before every flight, it is absolutely essential to perform a pre-flight inspection on your aircraft.

WARNING!  Failure to perform a sufficient preflight has been a contributing factor to accidents in all kinds of aircraft.  Equipment damage, bodily injury, even death can occur due to equipment problems not caught in a preflight inspection.  As the saying goes, ñPreflight as if your life depends on it, because it does!î
NOTE!  Example Pre-Flight Checklists can be found at the end of this manual.  It is highly recommended that you use one of the examples, or create your own, print it out, laminate it, and use it whenever you fly. 

Also note that these Checklists are examples only, FLY PRODUCTS is not responsible for their use or for their completeness.

4.2   In-flight Starting
One very valuable feature of the PJ125 is its ability to be started while in flight.  This feature allows the pilot the freedom to turn-off the engine and glide silently, to enjoy the exhilaration of thermal soaring, and then when he gets low, to start the engine and climb back up to do it again.  The process of in-flight starting is very simple.
First, release the paragliderÍs brake toggles.

WARNING!  Failure to release the brake toggles before attempting in-flight restarting could result in excessive braking of the paraglider.  This could result in loss of control, a stall, spin, and possible crash.

Next, reach up over your shoulder and grasp the start handle.  Give the start handle an aggressive, quick pull.  The engine will start. Grasp the gliderÍs brake toggles, and gently add power.

5.0 OPTIONAL ACCESSORIES
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5.1ææ Tool Kit

It is highly recommended that a tool kit be assembled and carried in one of the harness pouches. 
The following tools, at a minimum, are suggested for the tool kit:

  • Spark plug wrench (13/16î)
  • Metric Allen wrenches
  • Vice Grips
  • Combination wrenches (10mm, 13mm)
  • Screwdrivers (both Phillips and Straight)

5.2   Reserve Parachute
A reserve parachute can be fitted to the POWER JET, and is a highly recommended safety item.  Many different mounting locations and methods are possible and acceptable, and the one you choose depends on many things such as which hand you want to deploy with, what type of reserve you have, where you prefer to mount it (front, left or right side), etc.  For this reason, FLY PRODUCTS cannot make a generalized statement of what the best mounting configuration is for you.  It is highly recommend that you seek assistance from your PPG instructor on the mounting of your reserve parachute.  It is also highly recommended that you receive training (a reserve parachute clinic) covering topics reserve deployment topics such as reserve re-packing and parachute care, performing a PLF (Parachute Landing Fall), and when to make the decision to deploy your reserve.

WARNING!  A reserve parachute is a life-saving backup system, to be used in life-threatening emergencies only.  A reserve parachute should never be deployed ñfor funî or to ñsee what itÍs likeî.  A reserve parachute deployment is an extremely dangerous event.  You surrender control over your aircraft, you have no choice as to your landing location and could land on rocks, roads, power lines, etc.  Even with a correctly deployed parachute, your impact speed with the ground is significant.  Also, reserve parachutes are not guaranteed to deploy correctly.  Remember the expression, ñA reserve parachute isnÍt your second chance, itÍs your last chance.î  Carry a reserve parachute, and deploy it only if it is absolutely necessary. 

5.3   Speed Bar
A speed bar can be mounted to the POWER JET harness.  Optional pulleys can be added to the harness to facilitate the application and routing of the speed-bar. 
These pulleys can be obtained from your POWER JET dealer.

5.4  Fuel Viewing Mirror
A fuel viewing mirror is an excellent optional accessory.  A variety of mirrors are available at local department stores, or a bicycle specialty store.  Look for a lightweight mirror that will mount on the frame.  Hang in a simulator and adjust the mirror for easy viewing of the contents of the fuel tank.

6.0 PACKING YOUR POWER JET™ FOR TRAVEL
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6.1ææ Disassembling for local travel
For local travel in a car, only partial disassembly is necessary.  This disassembly includes removing the prop cage and prop. 
Since there are four (4) prop bolts and only two (2) bolts on the reduction drive assembly (commonly called ñre-driveî),
it is faster to remove the entire reduction drive assembly than it is to remove the prop.

6.1.1   Disassembling the Prop Cage
Unclip the hook on the cage net tension string, (Fig. 7)  and follow the reverse procedure as described before in cap. 2.2.
The complete cage is now disassembled and ready for transport.
Now remove the prop and reduction drive assembly.  This is done by removing the two nuts that hold the reduction drive to the engine.
Your POWER JET is now ready for local transport.

6.2   Disassembling and packing for long-distance travel
Disassembly and packing for long-distance or airline travel requires complete disassembly of the POWER JET, and then packing into a suitably padded and protected box for travel.  The first steps of the process are the same as for local travel, except you should remove the prop from the reduction drive and leave the reduction drive on the machine.  The rest of the process is below:

6.2.1   Fuel Tank drain
For airline travel, make sure you completely drain the tank, and wipe the inside dry by inserting a paper towel and thoroughly drying tank.
NOTE!  Make sure you check, and comply with, FAA regulations as well as regulations of the specific airline that you are traveling before taking the machine aboard an airliner.

6.2.2   Draining All Fuel
With the fuel tank completely drained, start the engine and allow it to idle until it stops running.  At this point, all of the fuel will have been removed from the carburetor and fuel lines.

6.2.3   Removing The Harness
Remove the top two harness straps that go around the top tube of the central (engine) frame (or, in case, unhook the two triangular carabines ).
Remove the distance bars from their seating .
Remove the ground handling straps by threading the lower straps up through the buckles.
This completes the harness removal.

6.2.4   Cage Disassembly
Remove the cage in the inverse order as described before.

7.0 MAINTENANCE
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Periodic maintenance is required in order to keep your POWER JET in top operating condition. The following chart provides the suggested maintenance schedule.

Table 1

Interval Inspect Replace
During and after Break-In All screws, nuts, bolts, prop cage, netting, harness webbing, etc.  
Every 5 hours All screws, nuts, bolts, prop cage, netting, harness webbing, etc. Spark Plug, check color is light brown. Check spark plug cap.  
Every 25 hours All screws, nuts, bolts, prop cage, netting, harness webbing, etc. Clean, re-gap spark plug  
Every 50 hours Clutch Diameter and clearance, Clutch Bell (min thickness 1.2mm), De-carbonize Cylinder head. Inspect piston ring for sticking and condition Spark Plug and fuel filter
Every 75 hours Re-drive gears, bearings and clutch basket
Replace bearings and repack with No. #2 grease
Every 100 hours Crankshaft seal Piston ring, piston pin, piston pin bearing and pin keepers
Every 200 hours Crankshaft bearings Piston and cylinder assembly, all bearings and crankshaft seals
Yearly
(regardless of hours)
Fuel pump and carburetor diaphragms. Crankshaft seals and condition of all plastic parts Fuel hose, fuel filter, Spark Plug

7.1 Cleaning
Clean your POWER JET with clean water and a mild soap. Dust and dirt can be brushed off, or removed with water and mild soap. Grease and oil can be removed with a good water-based degreaser such as “Simple Green”.

7.2 Prop Care
Avoiding Prop Damage
It is very easy to damage the propeller by sucking up dirt or rocks when running the motor on the ground. To avoid this, either place the unit on a sheet of plywood or something similar, or use a nice clean area such as a nicely mowed yard. An alternative is to strap the motor on and start it in the standing position.

Prop Balancing
Balancing of the propeller is very critical. The prop blades are subjected to accelerations as high as 2000 G’s! Therefore, a weight difference of only 1 gram can cause forces as high as 2kg. This force will cause a vibration at the speed of the propeller RPM, and can cause enough vibration to break welds or tubes of the frame. Therefore, correct prop balance is of the utmost importance.

There are several good articles available on the Web at www.poweredparaglider.com, that explain correct prop balancing. It is highly recommended to perform the balancing procedure on your prop.

Keeping the Prop Clean
Wipe all dirt and oil from the prop when finished flying. Oil, if left on the prop for long periods of time, can seep into the wood and cause an imbalance.

Store the Prop Horizontally
When storing the paramotor, rotate the prop to a horizontal position. This is because if the prop is stored vertically, moisture and oils in and on the prop can migrate downward and cause prop imbalance. This phenomenon can only happen on wood props.

Prop Repair
Small dents and dings in the propeller can be repaired with a mixture of baking soda and super glue. The exact procedure is beyond the scope of this manual, but several very good articles on prop repair are available on the web at www.poweredparaglider.com. After minor repairs are performed, make sure that you balance the prop thoroughly.

7.3 Spark Plug
The recommended sparkplug for the Top 80 motor on the SCT80 is the B9ES. The “resistor” version of this plug, the BR9ES is also recommended, and is particularly helpful at reducing interference on radios or music devices.

Spark plug gap is 0.025” (0.635mm). Recommended cleaning and gapping interval is every 25 hours. Recommended replacement interval is every 50 hours.

7.4 Repairs
Minor repairs can be performed on the prop, cage, cage guard, and harness. Major repairs should be performed by a trained service technician, or by Para-Lite™.

Para-Lite™ provides full repair services including frame, prop, harness, and engine repairs. Para-Lite™ also carries all parts and supplies to keep your POWER JET in top operating condition.

Caution! Repairs to the harness or any stress-carrying areas of the POWER JET should only be performed by a certified parachute rigger. If in doubt, contact Para-Lite™.

7.5 Carburetor Maintenance


Fig. 27 Cleaning the carburetor’s internal filter

The diaphragm carburetor is provided with an internal filter that may get clogged and cause loss of power. To clean this filter, remove the four screws on the side that the fuel line enters the carburetor. Remove the aluminum lid. Do not remove the filter, clean it while it is still in its seat. Clean it with a gentle blast of compressed air, or a brush wet in fuel. Cover a portion of the filter with your finger to prevent it from slipping out of its seat. Reassemble by reversing the above steps. See Fig. 27.

7.6 Long Term Storage
Long Term Storage is defined as anything longer than 3 months. The long-term storage procedure is as follows:

  • Remove fuel tank and drain completely.
  • Start and run engine at idle until it stops from fuel starvation. This is to remove all fuel from the carburetor and lines.
  • Remove spark plug. Inject 4 teaspoons of 2-cycle oil into the spark plug hole. Gently pull the starter rope a few times to distribute the oil, then reinstall the plug.
  • Clean the prop of any dirt and/or oil.
  • Clean the cage, harness, etc. so that it is free from dirt and/or oil.
  • Cover the machine with a sheet or light cloth.
  • Store in a clean, dry place.

8.0 TROUBLESHOOTING
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8.1 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 pull the starter cord 5 to 10 times while holding the throttle in the full-open position and with the choke in the OFF position. This will remove excess fuel from the engine.
  • Install the dry spark plug, and start using the normal procedure, however do not choke the engine.

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 were to start, the prop would rapidly spin to full RPM and damage or injury would most likely occur!

 
 

8.2 Troubleshooting Chart

Symptom Possible Causes Solutions
Engine does not start

No fuel in tank

Fill tank per fueling instructions

Fuel pickup does not reach all the way to bottom of tank

Inspect fuel pickup and ensure that it reaches the bottom

Spark Plug cap not in place

Ensure spark plug cap is installed

Incorrect Choke Procedure

Follow procedure outlined in section entitled ñChoking the engine î

Insufficient pull on starter rope

Give a strong, sharp pull on the rope

Fouled Spark Plug

Inspect plug, clean and re-gap, or replace with a new plug

Incorrect Spark Plug Gap

Gap the plug to 0.025î  (0.635mm)

Engine starts,
but does not continue to run

Incorrect Choke Procedure

Follow procedure outlined in section entitled  ñChoking the engine î

Engine is flooded

Follow procedure outlined in section entitled ñDiagnosing and starting a flooded engine î

Incorrect Idle Speed adjustment

See section entitled ñCarburetor Adjusting î

Incorrect Idle Mixture adjustment

See section entitled ñCarburetor Adjusting î

Excessive Vibration

Prop out of balance

See section entitled ñProp Care î

Loose fasteners

Check and tighten engine mounting bolts, muffler bolts, prop bolts, etc.

9.0 SPECIFICATIONS AND PERFORMANCE
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9.1 Specification and Performance Summary Chart

Item

Specification

Engine Make and Model

Top 80

Engine Type

Single cylinder, air cooled

Displacement

80 cc

Bore x Stroke

47.6mm X 44mm

Power Output

15.4HP (11.5 kW)

Ignition System

CDI

Carburetor

Walbro WG Series

Rotation Direction

Clockwise, as viewed from rear

Air Cleaner

None, Input Silencer

Spark Plug

B9ES or BR9ES

Fuel

Premium auto gas, 92 Octane or higher

Fuel/Oil Ratio

50:1

Starting System

Recoil pull starter

Prop

2 blade, 49 inch diameter

Thrust (lbs., kg)

105lbs, 48kg

Climb rate

2.5m/s with a DHV ½ wing

Frame

Aluminum, aircraft tubing