Corsair BLACK BULL User manual

CORS
-
AIR
ENGINES
[
USER’S MANUAL BLACK
BULL
ENGINE]
Distributed by: CORS
-
AIR SRL Via G.
Falcone, 4 arco di ibbiano ( RE) ITALY tel. [phone] MAIL:
[e-mail] web page: www.corsairmotors.com

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INDEX
IDENTIFICATION OF THE OWNER AND
INTRODUCTION
2
TECHNICAL AND STRUCTURAL
FEATURES
3
MAIN TORQUES 5
ASSEMBLEY 6
ADJUSTMENT CARBURETOR /
RUNNING IN
7-8
MAINTENANCE
TENSION OF REDUCTION BELT 11
WARRANTY 13
TROUBLE SHOOTING 14
IMPORTANT ADVICE 15
NOTES 1

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IDENTIFICATION OF THE OWNER
Owner
Address
Serial number
Reseller
Address
Owner’s signature
Reseller’s signature and stamp
Date of sale
Introduction:
Thank you for choosing our engine BLACK BULL CORS-AIR ENGINE.
We tried to do everything possible to give accurate and update technical
information in this manual.
The Company riserve the right to make technical and aesthetic changes without notice in
order to improve quality of product.
The information written here is the exclusive property of CORS-AIR.
So they are not allowed reproduction or replication in whole or part without the express
permission of the CORS-AIR.
This manual has been prepared to provide technical information necessary for the

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installation and repair of motors.
We invite you to spend some time reading this to avoid risks to the health and safety of
people and economic damage.
Furthermore, we invite you to deliver this manual together with the engine 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 every problem, because YOUR AND THE OTHER PEOPLE’S
SAFETY IS THE MOST IMPORTANT THING FOR US.
CYCLE
TWO STROKE
TOTAL DISPLACEMENT
235 C.C.
BORE
70mm
STROKE
61mm
COMPRESSION RATIO
10.5:1
COOLING
BY AIR
PEAK RPM max.
8000 /8300 RPM
PISTON
WITH TWO PISTON RINGS
EAD
IN ALLOY WITH HIGH PERCENTAGE OF SILICONAN
HEMISPHERIC COMBUSTION CHAMBER, WITH SQUISH
CRANKCASE
MOLTEN IN G-AL SI UNI 3051 ALLOY
SUBSEQUENTLY TREATED AND ANODIZED AGAINST
SEA SALT
CONNECTING ROD
IN COPPER PLATED STELL 18 NI CR MO5 JOINED TO
THE DRIVE SHAFT THROUGH VERY PRECISE HIGH
SPEED SILVER-PLATED ROLLER BEARINGS
CARBURATOR
DIAPHRAGM
FEEDING
SIX BLADE REED-VALVE SYSTEM CONNECTED TO THE
CRANKCASE
SPARK PLUG
NGK BR8ES OR SIMILAR
SYSTEM
SIX PORT DISTRIBUATION AND EXHAUST WITH
BOOSTER

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CYLINDER
IN ALLOY WITH NIKASIL COATING
REDUCTION
WITH POLY V BELT AVAIBLE IN 1:3.0
CYLINDER EAD
TEMPERATURE
MAX TEMPERATURE 230°C MEASURED UNDER SPARK
PLUG
EXHAUST GAS TEMPERATURE NOT EXCEEDING 5 0 C°
ENGINE MOUNTING
BY 4 SHOCK ABSORBING RUBBER MOUNTS
ROTATION
COUNTERCLOCKWISE
DRIVE S AFT
IN 18 NI CR MO5 WITH 5 THERMIC TREATMENTS ON
EVERY COMPONENT
SEAL RING
IN VITON WITH VERY HIGH RESI STANCE AND LONG
DURATION
FUEL
MIXTURE 2,2% / 2.5% WITH SYNTHETIC OIL,
SUGGESTED BRANDS: MALOSSI 7.1—WLADOIL
K2T—ELF 2T MOTO
OIL
2.2% - 2,5%
ENGINE WEIG T
HAND START KG 16,7 COMPLETE WITH 2018 VERS.
EXHAUST AND INCLUDING RUBBER MOUNTS AND
AIRBOX IN CARBON
ELECTRIC START KG. 17,4 COMPLETE WITH 2018
VERSION EXHAUST, INCLUDING RUBBER MOUNTS AND
AIRBOX IN CARBON

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MAIN TORQUES
IMPORTANT:
MAIN TORQUES
Kg. m
(Nm)
NUTS TO FIX THE HEAD 2,5 25
NUTS TO FIX HALF-CRANKCASE 1,2 12
NUTS TO FIX THE PINION (SMALL PULLEY) 3,5 35
NUTS TO FIX IGNITION HANDWHEEL (manual
version)
4,5 45
NUTS TO FIX IGNITION HANDWHEEL (electric
version)
2,5 25
GAP BETWEEN COIL AND HANDWHEEL MIN. 0,3 mm
MAX. 0,4 mm
TIGHTENING OF REED VALVES PLATE 1,2 12
PISTON RINGS GAP TOLLERANCE 0,25 mm

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Remember that the battery of the electric start should be recharged
before starting the engine.
ASSEMBLY:
You can install the engine on the frame by using 4 rubber mounts of 40 x 30
mm between the back flange and the engine mount.
To attach the propeller use only bolts of class 10.8 (100 Kg) and make sure
that their length is enough to exit from the reductor-pulley. Tighten the 6 bolts
M8 in a cross, at 1.5 Kg.m.(15Nm). Re-check the torque of the bolts after the
first hour of engine’s working.
We suggest not touse a variable pitch carbon prop, because the big hub
pushes the prop too forward, with possible damages to pulley and bearings.
For the connection between the carburetor and the fuel tank use a proper
hose of the right diameter.
The length of the fuel line should not be longer than 80 cm.
It is advisable to install a manual primer bulb to get the fuel to the carburetor
before for starting. This device will allow the fuel to arrive to the carburettor,
protecting in this way the battery.
IMPORTANT NOTES
DO NOT try to start the engine without the propeller.
DO NOT start the engine with loose bolts or parts, since this can cause the
detaching of the propeller, the ovalization of the propeller holes, the damage
of the electric start and the breakage of the rubber mounts.
BATTERY must be loaded and use a 6 Ah battery.

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IMPORTANT! BEFORE FLYING C ECK ALWAYS EVERY PART OF
YOUR CRAFT, FROM ENGINE TO FRAME.
Verify that there are no damaged electric wires, that there are no leaks from
hoses, tank, carburettor or engine’s crankcase, that the propeller is not
damaged or loose, that the exhaust-pipe has no cracks, that the frame is not
bent or broken because of falls, that rubber mounts are not cracked, that the
reduction belt is not loose and every bolt is tight.
Finally you can start the engine, leaving it to warm up at a speed of 3000 to
4000 rpm with head temperature at least 120 °C, before start taking off so to
avoid piston seizing.
FUEL
Use for the mixture only premium gas for cars 8 octane, together with good-
quality, synthetic oil for mixtures at a quantity of 2.2% /2,5%.
DO NOT USE MIXTURE ALREADY DONE AT PETROL PUMPS.
When you prepare the mixture, make sure that the can has not dirt or water in
it, filter the fuel with cotton white textile into a clean can and then add the oil.
Never run the engine without the air-filter, because dirt and dust raised by the
propeller can damage it.
RUNNING-IN
All CORS-AIR engines, before being delivered, are subject to a severe
quality-check, in order to verify if all the components respect the fixed
parameters, but a further running-in is anyway necessary.
A GOOD RUNNING-IN WILL PROLONG THE LIFE OF YOUR ENGINE.
Go to a quiet place, put a thick rubber carpet under your unit to avoid that
stones or other things damage the propeller by putting it on earth and let
the engine work at a speed of 2500 rpm for 5 minutes, then regulate speed at
3000/3500 rpm for 15 minutes, then at 4000 rpm for other 15 minutes.
Switch off the engine and check that there are no loose nuts or bolts and that
every component is ok.

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BE CAREFUL NOT TO TOUCH HOT PARTS (POWER UNIT AND
EXHAUST PIPE).
Start the engine again and take it step by step to 4000 rpm for 5 minutes,
then accelerate to 4500 rpm for 15 minutes. During the first 10 hours, do not
subject the engine to extreme efforts and speed.
Also during normal use excessive loads (ex. tandems with passenger) can
force the engine with possible damages to the engine itself.
ALWAYS C ECK at sight your unit before and after every flight, for loose
parts or damage.
During the run-in period vary the power often for a proper piston ring setting.
CARBURETOR
Your Black Bull is equipped with a Tryton carburettor, specially adapted for
the Cors-Air engines;
it’s a top quality membrane carburettor, 100% made in Italy, that grants an
optimal performance, with decreased consumption and a better
atomization of the mixture fuel/air.
It’s a little more sensitive to settings and is suggested for a competition use or
for pilots skilled in mechanics who want the best results.
CARBURETOR
SETTINGS
BLACK BULL engine
( all configurations)
L screw 30/35 minutes
H screw 1 hour + 40 minutes

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MAINTENANCE
 AFTER THE FIRST HOUR OF RUNNING, CHECK THE BELT
TENSIONING AND IN CASE RE-TENSIONING IT.
 AFTER THE FIRST 2 HOURS, TIGHTEN HEAD NUTS (IN CROSS
ORDER) WITH A TORQUE WRENCH AT 2.5 Kg.m (25Nm).
 AFTER THE FIRST 3 HOURS OF ENGINE RUNNING MAKE A NEW
BELT CHECK UP AND IN CASE RETENSIONING IT.
Please note that if you find black dust inside pinion and/or rubber inside
pinion’s groove, it means that belt is not well tensioned and need to be
tightened.
Every 20 hours check:
 The condition and gap (0,7 mm) of the spark plug electrode
 Clean the air-filter, in case you have a fuel filter before carburetor, clean
it also.
 The torque of every bolt
 The tension and condition of the reduction belt
 Fuel lines and wiring
 That the cord of the starter has no abrasions
Every 50 hours check:
 Same controls of the 20 hours and furthermore
 The torque of the engine’s crankcase nuts
 Change spark plug
 Change the petals of the reed valve
 The reduction belt and the play of the pulley and change them in case
of need

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 The condition of the starter gears (version with electric start)
 Once a year (independently from flight hours) change the diaphragm of
the carburettor
N.B.: It is advisable to keep records of all maintenance in a log book for the
engine.
It is also advisable to install an instrument (CHT) to control the head
temperature at sight, it is important because you can understand when your
engine is running at the proper temperature before taking off.
If you install also an EGT probe you will be able to check the temperature of
exhaust gas and avoid the engine seizure. The max. temperature of exhaust
gas is 5 0 C°
DO NOT EXCEED T IS TEMPERATURE
Tutorials on our web page at:
http://www.corsairmotors.com/en/download/

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TENSION OF T E REDUCTION BELT DRIVE
USE CAUTION
Attention: a belt which is “over tensioned” can do permanent damage to the
bearings inside of the pulley hubs and drive shaft.
Therefore we strongly suggest for you to follow carefully these instructions.
Before adjusting the belt take a felt pen or marker and make a small sign on
the cam shaft and on the front of the reduction plate.
This is your Zero or start point and from here you will be able to clearly see
how much you move the eccentric tensioning cam in relation to the reduction
plate.
Remember “these are Fine adjustments” and we suggest not to rotate the
cam any more than 1 mm per adjustment.
After each adjustment you can try to start the engine and check the result.
If the engine does not start well then it usually means the belt is still too loose
and is slipping - in this case repeat the operation by tensioning the belt
another 1 mm.
Consider that if the belt slips a little, but the engine still starts fine, then the
tension is correct.
Belt tension always increases automatically when the engine is running
because of thermal expansion in the pulleys.
Once you have found the correct tension , do not adjust it any more.
In case of doubts please contact your paramotor dealer – or CORS-AIR.

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To adjust the belt do the following:
 Loosen the safety bolt located high up behind the reduction mounting
plate and the side bolt.
 Once these are loosened then you can turn the cam with a n.27 mm
size wrench - careful to observe the 1 mm increments.
 Once you have finished turning the cam remember to re-tighten the
safety bolts, first the exagonal bolt, by keeping firm the cam with the
wrench, and then the side bolt.
 Should you notice any black rubber dust inside small pulley ( pinion),
your belt needs to be re-tensioned because it is loosing.
IGNITION (ONLY FOR ENGINE WIT AND START)
In case the coil and/or the handwheel must be changed, it is compulsory to
turn to your dealer or to trained personnel, even if this operation can appear
simple at the first sight, since the timing of the engine, if wrong, can change
the performance and cause damage to the engine.
To check the timing: the distance between the coil and the flywheel magnet is
0,40 mm.
CORS-AIR AND ITS RESELLERS REMAIN AT YOUR DISPOSAL FOR
EVERY INFORMATION AND ADVICE ABOUT THE USE OF THE ENGINE.

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WARRANTY
CORS-AIR engines are manufactured with top-quality material, therefore
warranty is valid also for their accessories.
DURATION OF WARRANTY
 1 YEAR beginning from the date of sell or exit from CORS-AIR
 Warranty includes spare parts and labour, transport excluded.
WARRANTY IS VOID IN T E FOLLOWING SITUATIONS:
Alterations to the engine not approved by CORS-AIR.
Wear&tear of components of the engine due to the instructions within
the product manual not being adhered to.
Accidental falls, crash or dropping of the engine or its components.
Overheating and seizure of the engine due to prolonged high speed
running of the engine, running with excessive loads, running with
inadequate loads, running with insufficient oil in the petrol (for a wrong
tuning of the carburettor) or running with petrol only (oil mixture
omitted).
The presence of dirt, sand or foreign bodies in the carburettor of the
engine.
Corrosion through bad storage of the engine or inadequate preparation
for storage of the engine.
Running the engine without an air-filter fitted to the carburettor.
Miss-assembly of engine parts or components not assembled by
CORS-AIR but by the manufacturer of the paramotor or by the end
user, supplied disassembled for packing and transport purposes,
included all electrical or electronic components including electric starter.
Corrosion of the engine or components emanating from stone chips or
any other impact or abnormal stress damage.

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Work other than the maintenance set out in the product manual having
been carried out on the engine by anyone other than CORS-AIR or
official dealers.
Incidental or consequential loss or damage.
Service bulletins from CORS-AIR not having been adhered to.
Engine used for racing use.
TROUBLE S OOTING

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SOME FINAL IMPORTANT ADVICE
DON’T HOLD IDLE
SPEED OR HAS
CANNOT
REACH
IRREGULAR MAXIMUM
SPEED
SPEED
SWITCH ON/OFF
CONNECTION OF CABLE OF THE
SPARK PLUG
CORRECT SPARK PLUG GAP
CONNECTIONS OF THE ELECTRIC
PLANT
THE FUEL ARRIVES CORRECTLY
FROM THE TANK TO THE
CARBURETTOR
DISMANTLE THE SPARK
PLUG AND DRY IT
BEFORE REASSEMBLING
SPARK PLUG, TAKE OFF
THE FUEL LINE FROM
CARBURETOR AND START
THE ENGINE 2/3 TIMES
THE REED VALVE PETALS ARE
OPENED OR BROKEN
CLEAN AND ADJUST THE
CARBURETTOR
CABLE PULLING THROTTLE IS
NOT FULLY OPEN
CLEAN THE CARBURETOR NETS
inside
THERE IS NO TANK-FILTER
RESTRICTION IN THE FUEL PIPE
SPARK PLUG
CHANGE HEAD GASKET
AND THE CYLINDER GASKET
CHECK
PROBLEMS
SOLUTION
DON’T
START FLOODED HEAD IS DECARBONED

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NEVER
switch on the engine with people near propeller, or to sides.
The BREAKAGE of a propeller can cause very severe hurts even several
metres away.
DO NOT keep engine at peak rpm after the take off, except for the absolutely
necessary time and for emergencies (obstacles or sudden wind).
REMEMBER that the longer the propeller is and more thrust you get but less
cooling system is granted to the engine which it will operate under stress.
So keep under control the temperature of the engine with proper instruments
(CHT under spark plug and we reccomend also EGT of the exhaust gas
check page. 5 for the correct engine temperature)
In addition, dismantle the propeller at regular intervals and check that it is
perfectly balanced, since an unbalanced propeller, even slightly, creates
micro-vibrations which are not felt by the pilot, but can damage seriously
parts of the engine with consequent breakages.
Please do NOT forget that the propeller has mass and a considerable inertial
moment, so it’s advisable not to vary suddenly the RPM of the engine, both in
flight and on the ground.
These violent stresses could cause damages to the reduction, to the engine,
to the belt and also possible deformations to the fixing holes of the propeller.
Once you have found the perfect carburation, DO NOT modify it unless you
change flying place going to much higher or lower altitudes or unless climate
and temperature are very different from the ones where you fly usually.
DO NOT FLY in bad weather conditions, you’ll fly the day after.
REMEMBER: FLIG T IS FOR FUN, NOT FOR RISKING YOUR LIFE!
AVE A GOOD FLIG T AND ENJOY YOURSELF.

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STORAGE OF T E ENGINE FOR A LONG TIME
In case the engine is not used for a long time, act like this:
 Empty the fuel tank, included the fuel lines and the carburetor.
 Disassemble the battery (version with electric start).
 Unscrew the spark plug and pour into the hole a teaspoon of oil for
engines, then re-install the spark plug letting the propeller turn slowly by
hand for 2 or 3 times completely.
 Disassemble the propeller.
 Loosen the reduction belt.
 Plug the hole of the exhaust pipe.
 Cover everything with a cloth and put it in a dry place.
 Once a month charge the battery and let the pinion of the drive shaft
turn by hand 2 or 3 times completely.
COMPLETE KIT FOR E-PROPS PROPELLERS
COMPLETE KIT FOR HELIX PROPELLERS
K2 PINS LENGHT 57 MM
K3 PROPELLER DISC FOR HELIX
K4 CENTRAL BOLT M12X40
K5
SAFETY CLIP

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NOTES:
________________________________________________________________
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