Vittorazi Motors Moster 185 Factory R User manual

MOSTER 185 FACTORY R
Maintenance manual
release V1/2022
valid for MY20-MY22 versions

Moster 185 Factory R - Maintenance manual - V1 2

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Contents
1Introduction 6
2Be careful! Read it completely 8
3Maintenance 10
3.1 Maintenance schedule 11
3.2 Spark plug 15
3.2.1 Spark plug disassembly 15
3.2.2 Spark plug maintenance 15
3.2.3 Spark plug assembly 16
3.3 Airbox 17
3.3.1 Airbox disassembly 17
3.3.2 Airbox check 19
3.3.3 Airbox assembly 21
3.4 Carburettor 23
3.4.1 Carburettor disassembly 23
3.4.2 Carburettor check 26
3.4.3 Carburettor assembly 27
3.5 Reed valve 30
3.5.1 Reed valve disassembly 30
3.5.2 Reed valve check 32
3.5.3 Reed valve assembly 33
3.6 Gaskets 35
3.7 Exhaust system 36
3.7.1 Manifold, exhaust bushing disassembly 36
3.7.2 Manifold, exhaust bushing check 38
3.7.3 Manifold, exhaust bushing assembly 39
3.7.4 Silencer disassembly 42
3.7.5 Silencer check 45
3.7.6 Silencer assembly 46
3.8 Rubber mountings 49

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3.8.1 Rubber mountings disassembly 49
3.8.2 Rubber mountings check 54
3.8.3 Rubber mountings assembly 54
3.9 Pull starter system 59
3.9.1 Pull starter system disassembly 59
3.9.2 Pull starter system maintenance 62
3.9.3 Pull starter system assembly 64
3.10 Flywheel, coil 68
3.10.1 Flywheel, coil disassembly 68
3.13.2 Flywheel, coil maintenance 71
3.13.3 Flywheel, coil assembly 71
3.11 Transmission 74
3.11.1 Belt removal 75
3.11.2 Belt disassembly 76
3.11.3 Bell, clutch disassembly 78
3.11.4 Transmission maintenance 82
3.11.5 Bell, clutch assembly 86
3.11.6 Pulley assembly 90
3.11.7 Belt insertion 93
3.11.8 Belt tensioning 95
3.12 Piston, cylinder, head 96
3.13.1 Piston, cylinder, head disassembly 96
3.12.1 Piston, cylinder, head disassembly 97
3.12.2 Piston, cylinder, head maintenance 99
3.12.3 Piston, cylinder, head assembly 101
3.13 Crankcase 106
3.13.1 Crankcase disassembly 106
3.13.2 Crankcase maintenance 111
3.13.3 Crankcase assembly 114
3.14 Tightening values 122

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1Introduction
Congratulations and thanks for being a Vittorazi qualified professional.
This manual is intended as a point of reference for aircraft manufactures, dealers, professional
people dealing with Vittorazi Motors. Please study this professional manual carefully before
starting the maintenance activity. The purpose of this manual is to provide all the necessary
information to the professional in order to allow a proper maintenance of the engine, carried out
autonomously and in total security. The professional manual includes: technical descriptions of
the maintenance phase and reference values.
All the components of Vittorazi Motors are checked and tested in a process of industrial quality
control before the assembling. Then by sampling the complete motors are checked to assure the
functionality of all the parts through a complete test of twenty minutes on the bench. Note that
the reliability, performance and durability of the engine also strongly depend on the correct
maintenance of which you are in charge.
In case you need further explanations, you can contact directly the headquarters of Vittorazi
Motors. Please include in the request, the six-digit serial number that identifies the motor and a
photo of the item in question.
Also take into account the availability of Illustrated Parts Catalogue (IPC), manual updates, service
bulletins, FAQs, other documents in our official website. The video tutorials are available on the
Vittorazi Motors official YouTube channel. Below the links.
IPC, manuals, bulletins, newsletter, warranties, FAQ
https://www.vittorazi.com/en/services/
Vittorazi Official YouTube channel: video and free tutorials available
https://www.youtube.com/user/VITTORAZIMOTORS

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Reading tips:
Attention, danger, risk
Any situation or condition which may result in a serious danger
Recommendation, warning, important advice

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2Be careful! Read it completely
To fly in total safety, you must read the following recommendations:
•This engine is not certified. This engine does not fulfil airworthiness regulations. The
products are dedicated to non-certified aircraft and flying as a recreational or sporting
activity.
•Final-user must be aware that the engine can stop, break or shut down at any time.
Such an event may require an immediate and forced landing in inadequate,
congested or impervious areas, with the possibility in the end of causing the death of
the pilot or other persons involved.
•The aircraft equipped with this engine must be conducted in full compliance with
rules and regulations in force relating to the activity of leisure and sport aviation, with
regard to the country in which the operations are carried out.
•Vittorazi Motors and its distributors decline any direct or indirect responsibility related
to this kind of activity. By using a new engine, the owner agrees that these terms and
conditions have been accepted at the time of purchase of the product.
•The engine is not covered by any liability insurance. The use of the engine
automatically determines the assumption of all risks and personal liability for personal
injury or damage to third parties resulting from the activity.
•Improper use of the products or improper technical service (in relation to the
specifications contained in the user, installation and maintenance manual) will held
harmless the company from any liability for any damage due to the malfunctioning
and immediately void the warranty of the product. So, do not use the motor if it has
not been properly maintained or if it has not been used correctly over time.
•Vittorazi does not assume any responsibility for those engines that are used with parts
that are not original, not approved, modified or that have suffered an improper use.
Use of spare parts not original and not recognized by Vittorazi, can make the engine
dangerous and will void the warranty.
•Unauthorized modifications to the motor, to the reduction, to the propeller can
invalidate the warranty of the motor and can compromise the reliability of the aircraft
and its safety. In case it is necessary to intervene, we invite you to contact an authorized
dealer Vittorazi.
•Some geographical areas, due to particular weather conditions such as pressure,
temperature and humidity can affect the performance of the engine. Before taking
off, test the engine on the ground and make sure it does not behave abnormally.

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•Always start the engine on a flat and clean surface, without stones or sand. During all
phases in which the engine is kept running near the ground (such as heating, take off,
landing) it is necessary to maintain a safe distance from the engine. A good safety
distance is 100 meters in every direction.
The following engine speed limits must be respected to avoid engine failures, to keep the
warranty valid and to have a correct maintenance scheduling according to the Vittorazi
program:
•Do not keep the engine at full revs for more than 60 seconds.
•Do not keep revs higher than 7.000 RPM during long cruising flights or long climbs.
The average power delivered by the engine during a flight should remain below the
indicated threshold. Contact the aircraft manufacturer for further clarification.
The temperature limit of CHT is 220° Celsius. Do not persist above this temperature
threshold, engine overheating and irreversible damage could occur.
The use of an EGT instrument is mandatory. Install the sensor in the prearranged position of
the manifold (thread the hole according to the size of the sensor). The temperature limit of
EGT is 650° Celsius. Do not persist above this temperature threshold, engine overheating
and irreversible damage could occur.
The use of the head cooling shroud in combination with Vittorazi approved propellers is
mandatory in this model to ensure performance and correct engine temperatures.

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3Maintenance
To ensure a safe, long-lasting product and to keep the warranty valid, the user must follow a
maintenance schedule as outlined in the manuals and record the service work in the service
booklet (available in the Warranty chapter of the user manual). An hour meter integrated in the
aircraft is required, always working and well installed to the engine.
Any procedure of installation, maintenance and/or repair of the products must be carried out
exclusively with the original Vittorazi Motors parts and tools specified by Vittorazi, in compliance
with the specifications contained in the user, installation and/or maintenance manual of the
products; to ensure maximum safety and performance of the products, the above-mentioned
procedures will be carried out by mechanics with proven experience in the ultralight aviation or
general aviation or with experience gained by Vittorazi Motors professional training courses.
Failure to do so, will held harmless the company from any liability for any damage due to the
malfunctioning and immediately void the warranty of the product.
Maintenance work must be carried out when the engine is cold.

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3.1 Maintenance schedule
Refer to the following maintenance indicated time schedule to fly in total safety. Work on the
engine is only allowed to be carried out by experienced mechanic and authorized dealers. These
are prescribed checks at certain interval times to avoid engine problems through preventative
maintenance.
Note:
1) or after a year
2) rope, spring, hooks or a new pull starter system
3) springs
4) each time the component is disassembled
5) head, exhaust port, decompressor hole
6) tensioning
Caption:
Cleaning
Check
Measuring
Replacement
Lubricate with WD-40

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Flight hours
Before each flight
Every 10 h
Every 25 h
Every 50 h
Every 100 h
Every 150 h
Every 200 h
Pre-flight checklist
Screws and nuts
(tightening)
Carburation from
spark plug colour
Spark plug
Spark plug connector
Carburettor
Carburettor
membranes
1)
Airbox Snaplock
Airbox
Airbox sponge and
sleeve
1)
Reed valve petals
Pull starter system
2)
The table follows in the next page

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Flight hours
Before each flight
Every 10 h
Every 25 h
Every 50 h
Every 100 h
Every 150 h
Every 200 h
Kit exhaust bushing
(1𝑠𝑡joint)
Exhaust bushing
(2𝑛𝑑joint)
3)
Exhaust manifold with
springs
Soundproofing
material silencer
Silencer rubber
1)
Gaskets (cylinder,
carburettor, reed
valve, exhaust,
silencer)
4)
Piston
Piston roller bearing
Head and cylinder
5)
The table follows in the next page

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Flight hours
Before each flight
Every 10 h
Every 25 h
Every 50 h
Every 100 h
Every 150 h
Every 200 h
O-ring head
4)
Rubber mountings
(engine, exhaust)
1)
Oil seal carter case
Crankshaft bearings
Crankshaft
Belt
6)
Reduction
bearings
Centrifugal clutch
Clutch bell

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3.2 Spark plug
Components to replace
Spark plug (ACC090).
Special tools
Not required.
Values
Distance between the spark plug electrodes:
0,7 mm (new spark plug)
0,9 mm (worn spark plug limit).
Spark plug: 25 Nm.
3.2.1 Spark plug disassembly
Disconnect the connector and unscrew the spark plug.
3.2.2 Spark plug maintenance
Check the colour of the spark plug: see user manual.
Use a feeler gauge to measure the distance between the spark plug electrodes.
Worn spark plug limit
(mm)
0,9
If the distance between the electrodes is equal to or greater than the indicated limit or if
scheduled maintenance is required, replace the spark plug.

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The new spark plug for the engine must be of the same type and rating as the one to be
replaced (NGK BR9EIX).
Check the connector: if it is damaged or the connection to the spark plug is not stable, replace it.
Check the ignition cable: there must be no cuts or cracks, otherwise replace the ignition coil
(including ignition cable).
3.2.3 Spark plug assembly
The distance between the electrodes of the new spark plug must be 0,7 mm, otherwise
adjust.
Screw the spark plug into the head and tighten with the torque shown in the figure.
25 Nm

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3.3 Airbox
Components to replace
Time limit
Sleeve with filter (AT093a).
100h or 1 year
Snaplock (MP093d).
25 h
Special tools
Not required.
Values
Clamp screw: 2,5 Nm.
3.3.1 Airbox disassembly
Unhooking the safety strap.

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Loosen the screw of the clamp securing the sleeve to the carburettor and remove the airbox.
Fold the sleeve inwards and remove it from the airbox.
Remove the Snaplock.

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3.3.2 Airbox check
Clean the sponge with specific filter chemicals. Clean the airbox cavity with compressed air. To
obtain a good seal between the components, degrease the connector of the airbox (1) and the
internal part of the sleeve (2) with a product suitable for cleaning rubber (the sleeve is made up
of a mixture of NBR and PVC).
Check the integrity of the airbox.
Check the sleeve groove.

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Check the filter, in particular the bonding with the sleeve and the various parts of the sponge.
Check the Snaplock, in particular the central hole (the photo shows a comparison between a new
component on the left and a worn one on the right).
Connect the Snaplock to the pin on the motor to check that the engagement is stable.
If the above components are damaged, replace them immediately. For routine
maintenance, follow the table.
Use extreme caution when checking, as failure to replace damaged components can lead
to detachment of the airbox and impact with the propeller.