Corsair BLACK DEVIL PRO User manual

U S E R ’ S M A N U A L E N G I N E
B L A C K D E V IL P R O
H A N D S TA R T, E L EC T R I C
A N D C L U T C H V E R SI O N

INDEX
IDENTIFICATION
OF THE OWNER AND
INTRODUCTION
3
TECHNICAL
AND STRUCTURAL FEATURES
4
M
AIN TORQUES
5
A
SSEMBLY / ADJUSTMENT CARBURETOR
6
RUNNING
IN
7
M
AINTENANCE / CENTRIFUGAL CLUTCH
8
T
ENSION OF REDUCTION BELT / IGNITION /
STORAGE
9
W
ARRANTY
10
T
ROUBLE SHOOTING / IMPORTANT ADVICE
11
PARTS
12-
14
SCHEME FOR ELECTRIC SYSTEM
14
N
OTES
15
W W W . C O R SA I R MO T O RS .C O M
IN FO @C O RSAIR MO T OR S. C OM 2

W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 3
INTRODUCTION
Thank you for choosing our engine the BLACK DEVIL PRO. We invite you to spend some time
reading this manual, which will let you discover all the features of your engine. Advices on
maintenance and operation will help you to have a reliable engine and to preserve your
investment. 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.
IDENTIFICATION OF THE OWNER
Owner
Address
Serial number
Reseller
Address
Owner’s signature
Reseller’s signature and stamp
Date of sale

BLACK DEVIL
W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 4
CYCLE
T
WO STROKE
TOTAL DISPLACEMENT
172,5
C.C.
BORE
65
mm.
STROKE
52
mm.
COMPRESSION RATIO
11:1
COOLING
B
Y AIR
PEAK RPM max.
8.000 / 8200
RPM
PISTON
W
ITH TWO PISTON RINGS
HEAD
IN
ALLOY WITH HIGH PERCENTAGE OF SILICONAN HEMISPHERIC
COMBUSTION
CHAMBER, WITH SQUISH
CRANKCASE
M
OLTEN IN G-ALSI9 UNI 3051 ALLOY SUBSEQUENTLY TREATED
AND
ANODIZED AGAINST SEA SALT
CONNECTING ROD
IN
COPPER PLATED STELL 18 NICRMO5 JOINED TO THE DRIVE
SHAFT
THROUGH VERY PRECISE HIGH SPEED SILVER-PLATED ROLLER
BEARINGS
CARBURATOR
DIAPHRAGM
FEEDING
F
OUR BLADE REED-VALVE SYSTEM CONNECTED TO THE
CRANKCASE
SPARK PLUG
N
GK BR9ES OR SIMILAR
SYSTEM
S
IX PORT DISTRIBUTION
CYLINDER
IN
ALLOY WITH NIKASIL COATING
REDUCTION
W
ITH POLY V BELT AVAIBLE IN 1:2.2–1:2.3—1:2.5—1:2.6—
1:2,88
CYLINDER HEAD
TEMPERATURE
MAX
TEMPERATURE 200°C MEASURED UNDER SPARK PLUG
E
XHAUST GAS TEMPERATURE NOT EXCEEDING 590 C°

BLACK DEVIL PRO
W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 5
ENGINE MOUNTING
B
Y4 SHOCK ABSORBING RUBBER MOUNTS
ROTATION
C
OUNTERCLOCKWISE
DRIVE SHAFT
I
N18 NICRMO5 WITH 5 THERMIC TREATMENTS ON EVERY
COMPONENT
ROLLER BEARINGS
F
IT FOR HIGH SPEED CLASS C3
SEAL
RING
RECHARGING
SYSTEM
I
NVITON WITH VERY HIGH RESI STANCE AND LONG DURATION
SECOND COIL WITH CHARGE
REGULATOR available for
LIFE PO battery or LEAD battery
FUEL
M
IXTURE 2,2% - 2.5% WITH SYNTHETIC OIL, SUGGESTED BRANDS
:
M
ALOSSI 7.1—WLADOIL K2T—ELF 2T MOTO
OIL
2,2%
- 2.5% TOP QUALITY OIL 100/100 SYNTHETIC
ENGINE WEIGHT
H
AND START KG 13,95
•
COMPLETE WITH AIRBOX, NEW EXHAUST, AND FOUR RUBBER
MOUNTS
E
LECTRIC START KG 14,45
•
COMPLETE WITH AIRBOX, NEW EXHAUST, AND FOUR RUBBER
MOUNTS
H
AND START WITH CLUTCH KG 14,90
•
COMPLETE WITH AIRBOX, NEW EXHAUST, AND FOUR RUBBER
MOUNTS

MAIN TORQUES
W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 6
MAIN TORQUES Kg. m (Nm)
N
UTS TO FIX THE HEAD 2,5 25
N
UTS TO FIX HALF-CRANKCASE 2,5 25
B
OLTS TO FIX THE BACK FLANGE TO THE
CRANKCASE
2,0 20
N
UTS TO FIX THE PINION TO THE FRONT
PART
OF THE DRIVE SHAFT 4,5 45
N
UTS TO FIX BACK PART OF DRIVE SHAFT
TO
IGNITION
HANDWHEEL 3,5 35
G
AP BETWEEN COIL AND HANDWHEEL 0,4 mm
IMPORTANT: remember that the battery of the electric start should be recharged before
starting the engine.
In case LiPo batteries are used, detach the recharge wire (yellow) and follow all safety
precautions for LiPo batteries use.

W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 7
ASSEMBLY:
You can install the engine on the frame by using 4 rubber mounts of 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 to use 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 (1,2 times the max. expenditure per hour, that means sending 11 liters/hour). The
length of the fuel line must not be more 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.
IMPORTANT!
BEFORE FLYING CHECK 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 2.200 to 3.000 rpm with
head temperature at least 120 °C.

W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 8
FUEL
Use for the mixture only premium gas for cars 98 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, put always the oil
first and mix thoroughly.
Never run the engine without the air-filter, because dirt and dust raised by the propeller can
damage it.
ADJUSTMENT OF THE CARBURETTOR
The carburettor has two mixture adjustment screws, 1 marked L adjusting low speed and 1 marked H
for high speed.
In order to make the adjustment, gently tighten clockwise then unscrew:
These adjustments can be different on the basis of weather conditions and flight altitudes.
Ideal mixture is reached when the insulator of the spark plug is coffee brown; if the colour is
black, the mixture is too rich, therefore turn screw H clockwise 1/8 round per time. If the spark plug is
grey/white, the mixture is lean, therefore turn screw H and L counterclockwise always 1/8 round per
time. If you can’t calculate 1/8 round, you can use as an example a watch and turn 5 minutes per
time. Remember that if the mixture is too lean, THE PISTON CAN SEIZE. You can see better the colour
of the spark plug by keeping the engine for 20 seconds at maximum speed and switching it off
suddenly without letting it slow down. Once you have found the perfect mixture do not change it
unless you change flight place or climate conditions, since register screws can be damaged by
continuous adjustments.
CARBURETOR
SETTINGS
BLACK DEVIL LIGHT
engine
( all configurations)
L screw 30 / 35 minutes
H screw 1 hour + 30/40 minutes

RUNNING-IN
W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 9
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 craft 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.
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 CHECK at sight your craft 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.

MAINTENANCE
10
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 AT 380/400 Hz.
-Every 20 hours:
Check the condition and gap (0.7 mm) of the spark plug
Clean the air-filter, the carburettor filter placed at the end of the fuel pipe and the filter of the
fuel tank
Check the torque of every bolt
Check the tension and condition of the reduction belt
Check fuel lines and wiring
Check that the cord of the starter has no abrasions
-Every 50 hours
Same controls of the 20 hours and furthermore:
Check the torque of the engine’s crankcase nuts
Change spark plugs
Change the petals of the reed valve
Check the reduction belt and the play of the pulley and change them in case of need
Check the conditions 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.

W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 11
TENSION OF THE 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.
Correct belt tensionin is from 380 to 400 Hz.
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.
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 the you can turn the cam with a n.27 mm size wrench - careful to
observe the 1mm increments.
•Once you have finished turning the cam remember to re-tighten the safety bolts, first the back
bolt, by keeping firm the cam with the wrench, and then the side bolt.
IGNITION (ONLY FOR ENGINE WITH HAND 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 0,3/0,5 mm.

WARRANTY
W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 12
CORS-AIR engines are manufactured with top-quality material, therefore warranty is valid
also for their accessories.
Warranty includes spare parts and labour, transport excluded.
For any defective part, please contact your reference authorized dealer or Cors-Air
directly, so that you can get proper indications about how to handle it.
DURATION OF WARRANTY
1 YEAR beginning from the date of sell or exit from CORS-AIR
WARRANTY IS VOID IN THE 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 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.
Corrosion of the engine or components emanating from stone chips or any other impact
or abnormal stress damage.
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.
CORS-AIR AND ITS RESELLERS REMAIN AT YOUR DISPOSAL FOR EVERY INFORMATION AND
ADVICE ABOUT THE USE OF THE ENGINE.

TROUBLE SHOOTING
W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 13
THE ENGINE DOES NOT START
Please check:
switch on-off
cable of the spark plug
correct spark plug gap
all the connections of the electric plant
that fuel arrives correctly from the tank to the carburettor
FLOODED ENGINE
Dismantle the spark plug
dry it well
before re-assembling it, let the propeller turn slowly 2/3 times.
THE ENGINE DOES NOT HOLD IDLE SPEED OR HAS AN IRREGULAR SPEED
Clean and adjust the carburettor.
Check the reed valve petals are closing completely.
Hold the reed up to a light and you should not see any light past the petal seating area.
THE ENGINE CANNOT REACH MAXIMUM SPEED
Check cable pulling throttle fully open.
Check that there is no dirt in the carburettor or tank-filter nor restrictions in the fuel pipe, due
to too tight curves, or air bubbles.
Check the spark plug; is it’s worn, change it with one of the same brand and same heat range.
In case the head is dismantled to be decarboned, change both the head gasket and the
cylinder gasket.

W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 14
SOME FINAL IMPORTANT ADVICE
NEVER switch on the engine with people near propeller, or to sides.
The BREAKAGE of a propeller can cause very severe hurts even several meters 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).
If you use big propellers, REMEMBER that cooling is not perfect flying at high speed,
so keep under control the temperature of the engine with proper instruments
(CHT).
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 sharp and 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: FLIGHT IS FOR FUN, NOT FOR RISKING YOUR LIFE! HAVE A
GOOD FLIGHT AND ENJOY YOURSELF.

W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 15
ELECTRIC SYSTEM WITH RECHARGING KIT

16
Instructions for assembly:
-Put some light or medium Loctite on the 4/6 pins and tighten
them completely
-Always use the aluminum disk
-Insert the propeller
-Insert the propeller disk
-Insert the central bolt and tighten it at about 1,5 Kg (15Nm),
checking that the clip can be inserted
-Insert the safety clip
Propeller quick release system
HELIX model EPROP model

W W W . C O R SA I R MO T O RS .C O M
IN F O@C ORS AI RMO TORS. CO M 17
Notes:
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________