Fly Products POWER JET User manual

POWER JET
OWNER'S MANUAL
Released on March 2002 (rev. 1.0)
©Copyright by FLY Products s.r.l.
Via C. Battisti, 13
63013 GROTTAMMARE (AP) - ITALY
tel./fax [phone]
www.flyproducts.com - [email protected]

OWNER'S MANUAL POWER JET Rev. 1.0
©Copyright by FLY Products s.r.l. Page 2
INDEX
1.0 - FLY PRODUCTS WORLD..................................................................................................................................................3
1.1 Safety First!....................................................................................................................................................................3
1.2 Notation Used.................................................................................................................................................................3
1.3 Congratulations on Your New POWER JET!..................................................................................................................4
1.4 POWER JET Features ...................................................................................................................................................4
2.0 - UNPACKING AND ASSEMBLING YOUR POWER JET.....................................................................................................6
2.1 Package Contents..........................................................................................................................................................6
2.2 Frame Assembly.............................................................................................................................................................6
For correct assembly proceed in the following order: ........................................................................................................7
2.3 Harness Mounting ..........................................................................................................................................................9
2.4 Prop Mounting..............................................................................................................................................................11
2.5 Spark Plug...................................................................................................................................................................12
2.6 Assembly Inspection.....................................................................................................................................................12
3.0 - PREPARING FOR YOUR FIRST FLIGHT........................................................................................................................12
3.1 Fuel and Oil..................................................................................................................................................................12
3.2 Before Starting the Engine ...........................................................................................................................................13
3.3 Starting and Stopping Engine.......................................................................................................................................13
3.3.1 Stopping the Engine .............................................................................................................................................13
3.3.2 Starting the Engine...............................................................................................................................................14
3.3.3 Choking the engine...............................................................................................................................................15
3.4 Carburetor Adjusting.....................................................................................................................................................16
3.5 Engine Break-In............................................................................................................................................................17
3.6 Harness Adjustment.....................................................................................................................................................17
3.6.1 Ground Handling Straps.......................................................................................................................................18
3.6.2 Flight Straps..........................................................................................................................................................19
3.6.3 Hang-test in a Simulator.......................................................................................................................................20
4.0 - FLYING YOUR POWER JET............................................................................................................................................21
4.1 Preflight Inspection..................................................................................................................................................21
4.2 In-flight Starting ............................................................................................................................................................21
5.0 - OPTIONAL ACCESSORIES.............................................................................................................................................22
5.1 Tool Kit.........................................................................................................................................................................22
5.2 Reserve Parachute.......................................................................................................................................................22
5.3 Speed Bar ....................................................................................................................................................................22
5.4 Fuel Viewing Mirror........................................................................................................................................................23
6.0 - PACKING YOUR POWER JET FOR TRAVEL.................................................................................................................23
6.1 Disassembling for local travel.......................................................................................................................................23
6.1.1 Disassembling the Prop Cage ..............................................................................................................................23
6.2 Disassembling and packing for long-distance travel.....................................................................................................23
6.2.1 Fuel Tank drain.....................................................................................................................................................24
6.2.2 Draining All Fuel ...................................................................................................................................................24
6.2.3 Removing The Harness........................................................................................................................................24
6.2.4 Cage Disassembly................................................................................................................................................24
7.0 - MAINTENANCE................................................................................................................................................................25
7.1 Cleaning.......................................................................................................................................................................25
7.2 Prop Care.....................................................................................................................................................................26
7.4 Repairs.........................................................................................................................................................................26
7.5 Carburetor Maintenance...............................................................................................................................................27
7.6 Long Term Storage.......................................................................................................................................................27
8.0 - TROUBLESHOOTING......................................................................................................................................................28
8.1 Diagnosing and starting a flooded engine ....................................................................................................................28
8.2 Troubleshooting Chart..................................................................................................................................................29
9.0 - SPECIFICATIONS AND PERFORMANCE.......................................................................................................................30
9.1 Specification and Performance Summary Chart...........................................................................................................30
10.0 - MISCELLANEOUS..........................................................................................................................................................32
10.1 Obtaining Repair Parts...............................................................................................................................................32
10.4 Pre-Flight Checklist Examples....................................................................................................................................32
10.5 Pre-Flight Checklist Example 1 ..................................................................................................................................33
10.6 Pre-Flight Checklist Example 2 ..................................................................................................................................34

OWNER'S MANUAL POWER JET Rev. 1.0
©Copyright by FLY Products s.r.l. Page 3
1.0 - FLY PRODUCTS WORLD
Welcome to the FLY PRODUCTS world! We are one of the oldest builders of Powered Paragliders
(PPG’s) in the world. We at FLY PRODUCTS put all of our experience to give you the state-of-the-art
quality in all of our products.
1.1 Safety First!
Powered ParaGliding (PPG) is the most exciting, least expensive, safest, most accessible form of
aviation available! However, it is still aviation, and it brings with it all the inherent potential dangers 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 qualified 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.
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.
Enjoy PPGing to the fullest, and welcome to the sport!
Please read and be sure you thoroughly understand this Operator’s Manual before starting or flying your
POWER JET. It contains information critical to the safe operation of the Powered Paraglider.
1.2 Notation Used
Certain special terms (NOTE,CAUTION,WARNING) will be used throughout this manual. Their
usage is defined below.
ANOTE 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.

OWNER'S MANUAL POWER JET Rev. 1.0
©Copyright by FLY Products s.r.l. Page 4
ACAUTION 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.
AWARNING 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 PRODUCTS’s 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 comfortable flying 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:
xVery High Thrust/Weight Ratio – PJ125 weighs only 46 lbs., and produces 110 lbs static thrust
xEasy disassembly and assembly in minutes
xClutch-driven prop doesn’t spin during critical inflation, launch, and landing
xGear-driven reduction drive
xForce-air cooling
xTuned Pipe
xExtremely quiet
xIn-flight Restarting
xVery 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).

OWNER'S MANUAL POWER JET Rev. 1.0
©Copyright by FLY Products s.r.l. Page 5
1.5 Diagram of Components
The following figures illustrate the basic components of the POWER JET PJ125.
Fig. 1 Rear View of Power Jet Fig. 2 Side View, with Prop and
Prop Cage Removed for Clarity

OWNER'S MANUAL POWER JET Rev. 1.0
©Copyright by FLY Products s.r.l. Page 6
2.0 - UNPACKING AND ASSEMBLING YOUR POWER
JET
2.1 Package Contents
Fig. 3 The packing contents of the PJ125.
The figure below illustrates the components that will be packed with your POWER JET.
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
six support rods.

OWNER'S MANUAL POWER JET Rev. 1.0
©Copyright by FLY Products s.r.l. Page 7
For correct assembly proceed in the following order:
Step 1
Place the PJ125’s central frame (the engine unit) on a flat surface.
Step 2 - 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. 5 - Support rods
Step 3 - Assembling upper
frames
Make sure that the cage netting
is in front of the cage support
rods as shows in the pics.
Place the upper frame quarters
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. 6 - Upper mount Fig. 7 - Velcro strap lock
Step 4 & 5 - 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. 8 - Mount side frames.

OWNER'S MANUAL POWER JET Rev. 1.0
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Step 6 & 7 - 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.
Fig. 9 - Mate lower frames.
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 8 - 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.

OWNER'S MANUAL POWER JET Rev. 1.0
©Copyright by FLY Products s.r.l. Page 9
2.3 Harness Mounting
The PJ125’s 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:
The 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 SYSTEM
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
Top 80 engine the tendency is to turn left.
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, we’ll adjust them
later.

OWNER'S MANUAL POWER JET Rev. 1.0
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Fig. 13 Mounting the bottom
straps
Fig. 14 Close-up of mounting
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.
Fig.15 Mounting the top harness straps
This completes the harness mounting. Inspect your work to ensure that all is OK.