Fly Products XENIT PLUS User manual

VERSION - 04/16
© Copyright by FLY Products s.r.l.
Via Perù n. 30
63013 GROTTAMMARE (AP) - ITALY
tel./fax [phone]
www.flyproducts.com - *[email protected]
XENIT PLUS
USER’S MANUAL

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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© Copyright FLY Products s.r.l. Page
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Index
Section
Description
1
XENIT PLUS
2
SPECIFICATIONS AND PERFORMANCE
3
DIMENSIONS
4
ASSEMBLING THE FRAME
5
SETTING UP THE TRIKE FOR MONO OR TANDEM FLIGHT
6
EMERGENCY PARACHUTE
7
A-ASSIST SYSTEM
8
STARTING AND STOPPING THE ENGINE
9
MANTENANCE
10
TROBLESHOOTING
11
MISCELLANEOUS
Section 1. XENIT PLUS
The XENIT PLUS Trike is for all those pilots who want to fly alone or with a passenger in a light but solid vehicle which is
also cost-efficient, low-maintenance and easy to transport.
The cage is made in powder-coated aluminum and the carriage bar, the harnesses attach to, in stainless steel 304.
This guarantees safety, flexibility and support for the pilot and the passenger. The choice of aluminum and steel is aimed at
reducing weight whilst maintaining solidity in the most important points.
Another important factor is the use of steel cables which keep the entire Trike structure in shape and assure optimum
performance.

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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!
Section!2.!SPECIFICATIONS!AND!PERFORMANCE!
ITEM
TYPE
Engine Make and Model
Simonini MINI-3
Engine Type
Single cylinder, air cooled
Displacement cc.
270 (Bore 72,8 mm x Stroke 65 mm)
HP
36 at 7000 RPM
Static Thrust
Over 100 Kg.
Carburettor
Bing 36
Reduction System
Poli-V Belt
Reduction Ratio
2.8:1
Rotation Direction
Anticlockwise (as viewed from rear)
Prop cm./ blades
150 / 2 blade
Spark Plug
NGK B9ES(cold places) B10ES (Warm places).
Air Cleaner
Air box
Fuel
Premium auto gas, 92 Octane or higher
Fuel/Oil Ratio
2,5%!with premium-grade gasoline
3.0% with unleaded fuel
Fuel Tank Capacity
16 litres
Fuel consumption
3.2 Litres/hour at 5400 RPM
Starting System
Electric starter
Charger
Alternator battery charge in flight
Frame
Aluminium, aircraft tubing
Harness
Rip-stop nylon
Dry Weight
62 kg
MAX Pilot weight Kg.
85 + 85
Tyre pressure
1 bar

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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Section 3. DIMENSIONS
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XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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Section!4.!ASSEMBLING!THE!FRAME
For easy and correct assembly work through the following steps:
!
!
!
!
!
!
Open the Trike!
!

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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!
!
!
!
Locking the cable back!
Attach!the!right!cable!(the!one!without!the!
tensioning!device).!
!
!
Attach!the!left!cable!and!using!the!tensioning!
device!pull!the!cable!tight.!
Insert!the!push!pin!from!the!back!into!
position!

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Using!the!Velcro!strips,!secure!the!harness!to!the!lower!bar!of!the!carriage.!
!
!
Fit!the!front!belt!of!the!pilot!harness.!
High belt pilot harness !

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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!
!
Side belt
Fit!the!front!belt!of!the!passenger!harness.!
!
Place media cage
Block with velcro!

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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!
Block with velcro
Net stretching!
!
!
Secure!the!tank!in!its!placement!using!the!tank!belt.!
Connect!the!fuel!tubes.!

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!
Combine!the!2!parts!of!the!propeller.!
!
!
Screw!in!and!tighten!the!propeller!bolts!moving!across!the!disc.!
!

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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Section!5.!SETTING!UP!THE!TRIKE!FOR!TANDEM!OR!MONO!
FLIGHT!
Tandem!setup!
!
!
The!glider!attachment!must!be!positioned!further!
back!for!flights!with!a!pilot!of!over!90!kg!and!
passenger!of!less!than!85!kg.!
The!glider!attachment!must!be!positioned!
further!forward!for!flights!with!a!pilot!of!less!
than!85!kg!and!passenger!of!over!90!kg.!
Mono!setup!
!
!
Position!the!glider!attachment!as!far!back!as!
possible!and!use!position!2!for!a!pilot!of!over!90Kg.!
Position!the!glider!attachment!as!far!back!as!
possible!and!use!position!1!for!a!pilot!of!less!
than!85Kg.!
!
!

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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!
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Section!6.EMERGENCY!PARACHUTE!
A!reserve!parachute!can!be!attached!to!the!XENIT!THOR!250!and!is!highly!recommended!for!
obvious!security!reasons.!The!reserve!parachute!is!located!under!the!harness!of!the!pilot.!
Assembly!procedure!of!the!emergency!system:!
!
!
!
Insert!the!rescue!pack!in!the!pocket,!then!using!a!
piece!of!string!pull!the!loop!through!the!hole!and!
close!the!pocket!with!the!hook!!
Attach!the!handle!
!
!

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Attach!the!third!hook.!
!
Pass!the!2!parachute!straps!through!the!strap!
holder!
!
!
Attach!the!2!parachute!straps!to!the!2!
carabiners,!protect!them!with!the!2!covers.!
Side!view!of!the!mounted!rescue!pack!and!
harness.!
!
!
!
Section!7.!A!ASSIST!SYSTEM!
!
!
Attach!the!belt!to!riser!A!of!the!glider!
!
The!belt!must!be!in!tension!when!the!riser!lifts!!
during!flight.!
!

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!
!
Section!8.!START!AND!STOPPING!ENGINE!
!
This!trike!can!be!equipped!with!a!manual!accelerator!!
!
A– STOP” button
B– “START” button
C– Throttle lever
!
Manual!accelerator!
!
!
!
On!startup!(when!the!engine!is!cold)!pull!up!the!
choke!
Pump!the!fuel!

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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!
!
The (A) screw sets the revs at idle, by opening or
closing the butterfly valve
!
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Section!9.!MANTENANCE
Remember…
…that YOU are ultimately responsible for your motor and it’s proper care, FLY PRODUCTS and it’s
dealers assume NO responsibility for any engine problem resulting from improper use!
Before leaving the factory each motor has been tested for up to 30 minutes to insure that it is in proper
running order and all FLY PRODUCTS units are guaranteed of one year after purchase. The
extraordinary maintenance or repairs will do only by authorized personal.FLY PRODUCTS will replace
any defective engine parts during one year period after purchase.Note that any electric parts that are
damaged for improper use or modified in any way which could cause an engine malfunction are not
guaranteed.
Regular checks obligation.
In Germany the PPG (only with empty mass less than 120 Kg.) must not be checked once a year, it
depends on the manufacturer. Most of them declare: must be checked once a year by a qualified person.
We too align with this behaviour and recommend you to check it once a year!
The same with the canopy, it depends on the manufacturer of the canopy, most of them must be checked
in a TWO years cycle by manufacturer.
Maintenance overview.
Each!time!you!use!the!engine,!remember!to!perform!routine!checks!pre-start-up:!!
•!Check!the!silent!block!condition!in!complete!integrity!!!
•!Make!sure!the!exhaust!does!not!present!any!cracks!!
•!Ensure!that!the!propeller!does!not!present!cracks!or!dents!!
•!Make!sure!you!have!enough!fuel,!according!to!the!duration!of!intended!use!of!the!!!!!!!!!!!!
engine.!!

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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•!Check!that!the!electrical!system!and!cables!!do!not!show!abrasions!or!disruption.!!
•!Check!that!there!are!no!screws!or!parts!loosened.!!
!
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
INTERVENTIONS!EVERY!20!HOURS!!
!
•!Clean!filter!carburetor!!
•!Clean!fuel!filter!!
•!Check!the!belt!tension!and!condition!!
•!Lubricate!the!ball!joint!of!the!muffler!!
!
!!!!!!!!
INTERVENTIONS!EVERY!60!HOURS!
!!
•!Replace!the!engine!and!exhaust!silent!blocks!!
•!Replace!the!transmission!belt!!
•!Check!the!status!of!the!intake!manifold!rubber!!
•!Replace!the!exhaust!pipe!sound-absorbent!material!!
•!Check!the!electrode!gap!spark-plug:!!if!it!is!over!0.6!mm,!change!the!spark!plug!!
•!Rubber!components!such!as!!belt!transmission,!silent!block,!intake!manifold!and!
depression!tube!may!be!damaged!by!atmospheric!agents.!Their!durability!can!therefore!
be!different!from!what!is!reported,!you!should!therefore!check!their!condition!and!
provide!a!possible!replacement!even!outside!the!agreed!time.!!
!
!
INTERVENTIONS!EVERY!200!HOURS!
!!
•!Replace!all!the!bearings!(N°64!+!N°48)!!
•!Replace!all!oil!seals!(N°63)!!
•!Check!the!internal!parts!of!the!engine!and!carry!out!their!replacement!in!case!!
the!height!limit!confirm!it!is!necessary.!!
•!Cylinder:!!
-must!not!show!signs!of!seizure!or!scratches!on!the!filling!material!(nickel!silicon);!
-check!the!wear!of!the!cylinder!in!the!four!points!(shown!in!diagram!1)!on!X!and!Y!
axles,!none!of!the!heights!obtained!must!exceed!the!height!limits:!!
!
SELECTION!A:!72.830mm!
SELECTION!B:!72.840mm!
SELECTION!C:!72.850mm!
SELECTION!D:!72.860mm!
The!selection!is!shown!with!a!letter!at!the!bottom!of!the!cylinder!!
!
•!piston:!!

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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-There!must!not!be!any!signs!of!seizure!or!deep!cracks.!!
Reduction belt
ADJUSTING REDUCTION BELT
Attention:
Only qualified people can do this procedure, otherwise consult
your dealer.
The reduction belt is regulated by the manufacturer, in case of it
stretching, which is noticeable by a whistling sound and a harsh
increase in runs when accelerating, it should be adjusted.
This happens most likely when the engine is cold and when
there is a high level of air humidity.
Proceed as shown in picture,
with an allen screw keys 6 mm and 10 mm:
- loosen the four "A" bolts just sufficiently
- regulate belt tension with the "B" bolt
- tighten "A" bolts well.
BELT!TENSION!
!
WARNING:!CARRY%OUT%THE%OPERATIONS%WITH%THE%ENGINE%SWITCHED%OFF%AND%COOLED%DOWN%
During!operation,!the!belt!is!under!strain!and!wear!and!as!result,!lengthening!occurs,!
which!could!lead!to!sliding!on!the!pulleys,!with!a!subsequent!decrease!!in!the!general!
engine!performance.!!
To!restore!the!proper!tension,!loosen!the!screw!M8!(No.!42)!on!the!foot!of!the!engine!
which!fastens!the!pulley!can,!turn!screw!M12!(n°51)!anti-clock!wise!using!force!of!1.8!
Kgm!and!then!re-tighten!screw!M8!(n°42)

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BE VERY CAREFUL TO THE BELT TENSION!
CAUTION: an over-tighted belt can cause permanent damage to the bearings and to shaft of the pulley,
then we strongly recommend that you follow these instructions.
Before you begin, make a small mark from pin to the pulley so as to have a reference point for
measuring the displacement of the eccentric "C", these settings are "fine" and must not exceed 1 mm.
time!
Start the engine at each adjustment to check the result keeping in mind that the belt tension will increase
automatically with the expansion of the metal due to increased engine temperature.
!
Section!10.!TROUBLESHOOTING!
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.
•With the spark plug removed pull the starter cord 5 to 10 times 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 were to start, the prop would rapidly spin to full RPM and damage or injury would most
likely occur!
Troubleshooting Chart
SYMPTOM
POSSIBLE CAUSES
SOLUTIONS
Engine
does not
start
No fuel in tank
Fill tank per fuelling 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
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 0.025” (0.635mm)

XENIT PLUS USER’S MANUAL ____ ___ VER. 1.1
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Engine starts,
but does not
continue
to run
Engine is flooded
Follow procedure outlined in section 8.1
Incorrect Idle Speed adjustment
See section 3.4
Incorrect Idle Mixture adjustment
See section 3.1
Excessive
Vibration
Prop out of balance
See section 2.3
Loose fasteners
Check and tighten engine mounting
bolts, muffler bolts, prop bolts, etc.
Torque Specification Chart
ELEMENTS
TORQUE (Kgm)
Cylinder head bolts ( M8 BTR )
2.8
Magnet fixing nut ( M10 x 1 )
4.2
Reduction cam locking screw ( M8 )
3,2
Primary pulley locking screw ( M12 x 1.25 )
4.5
Exhaust bolts ( BTR M8 )
2.2
Propeller bolts ( M6 )
0.5
Bolts and nuts M10
4.5 - 5.0
Bolts and nuts M8
2.5 - 3.0
Bolts and nuts M6
0.8 - 1.2