paragliding training center
Most troubleshooting, assembly, & tips are the same as with the Top 80
Carburetor – The Thor 100 and 130 use the WG-8. The Thor 190 and 200 use the WB-37.
Compression of engine – 130-150 psi, depending on altitude. Note: If the Flash starter is used, you will not be able to measure this value.
Clutch oil – Here is a list of the correct oils that may be used in the Thor redrive.
Cylinder Head Temperature Maximum 230°-250°C This may be increased to 265°C-280°C for brief periods. These values are from the Polini
User Manual which seem high. We use the TTO brand of gauges which register a lower average maximum running temperature than the
Polini values. Under full load, I have rarely seen the temperature exceed 180°C. In any case I would not run the engine above 200°C
using the TTO CHT.
Exhaust manifold springs – Use paraglider line to stretch the springs for replacement/removal. Do not use Vise-Grips or pliers to stretch
the springs because this will nick the tempered surface of the spring and weaken it. Here is a video on how to properly do it.
Fuel filter Info
Fuel pump vacuum – 5" Hg (dry) 7" Hg (wet w/ fuel)
Fuel Info – Note: The Polini manual specifies that pilots use unleaded fuel. We contacted Polini and they specifically stated in writing (available
on request) that pilots may use AVGAS in any of their engines. AVGAS is greatly preferred over any gasoline containing ethanol.
Gear oil – See "Clutch oil" above.
Spark Plug – NGK BR10EG, gap 0.9mm (0.035") This is a resistor type spark plug. Pilots may also use the B10EG/ES or B9EG/ES.
Use of a non-resistor plug will only increase the amount of noise created by the ignition that may be picked up by a two-way radio. The
official Polini user manual states that the spark plug boot to ground is 5K Ohms but a new Thor 130 measured 9.3K Ohms which means
that the secondary wire is a carbon-core ignition noise suppressing type. If your ignition measures the higher resistance, then you do
not need a resistor type plug. BE SURE TO PUT RED THREADLOCK ON THE PLUG TERMINAL OR IT WILL LOOSEN AND SELF DESTRUCT!
Special tools for the Thor engines
Torque conversion chart (Nm to inch pounds)Torque Values – This is the Top 80 specification page which has a thorough torque section. Hit "page down" twice to see it if you can't find what
Threadlock -- read this important page on threadlock and how to use it and when NOT to use it.
Carburetor screws 6mm – 8 Nm
Crankcase screws 6mm – 8 Nm
Crankshaft nut, clutch side – 60 Nm
Crankshaft nut, starter side – 40 Nm
Cylinder head nuts 7mm Thor 100,130 – 14 Nm
6mm Thor 200 – 12 Nm
8mm Thor 200 – 18 Nm
Engine to frame button head screws 8mm – 10 Nm – use BLUE threadlock
Exhaust stud nuts 6mm – 10 Nm – use RED (high strength) threadlock. If you do not use RED, the nuts will loosen!
Muffler button head screws 8mm – 10 Nm – use BLUE threadlock
Propeller central screw – 40 Nm – use BLUE threadlock
Reed valve screws 6mm – 8 Nm
Spark Plug – 20 Nm DO NOT USE THREADLOCK ON SPARKPLUGS!
Standard torque 5mm – 6 Nm
6mm – 10 Nm
8mm – 15 Nm
10mm – 45 Nm
12mm – 55 Nm
These are the (2) most important maintenance items that must be done after a certain number of hours on most paramotors. Use a Sharpie to write reminders on the top of the redrive (or
other semi-flat area). Any other method will not be as effective. They are easily removed/changed with mineral spirits. This way, you won't forget! You have an
hour meter/tachometer installed right?
A. REDRIVE SERVICING It is very important to change the redrive oil on schedule because it gets quickly contaminated with clutch material. If your clutch oil appears black when you change it, increase the change frequency. Note that the redrive will use oil because of slight leaks out the relief valve. You must check the redrive for the proper amount of oil every 25 hours or so.
B. Below are service items that are particular for the Polini. Pilots would do well to carefully study the servicing intervals for the Top 80 which I have developed to ensure long engine life for any 2 cycle aviation engine. The carburetor and fuel system are the most common items that must have regular service. Failure to regularly service the carburetor can result in permanent engine damage. It is advisable to measure the engine compression when it is new and use this value as a reference point.
C. The Polini Thor Flash starter has some major problems. See the Flash starter page for more information.
First 10 hours
Change redrive oil The exhaust assembly should be removed to get access to the drain plug. Use a cord (see "exhaust springs" in SPECS on how
to remove the exhaust springs. It is easy to remove the two buttonhead screws that hold the assembly to the frame.
Starter -- Either replace the Flash mechanism with the insert or secure the Flash spring to the Flash pulley as soon as possible.
See the Flash page for more information.
Replace spark plug and check gap.
Change redrive oil (change every year, at a minimum)
Replace muffler springs, as needed. They must be examined carefully for wear or damage.
Clean air filter (if you fly at the beach or a in a dusty environment, you may have to clean this filter more often)
Flash starter -- it may fail by this time. See the Flash starter page.
Starter pulleys – these pulleys are poor quality and will self-destruct if not regularly lubricated with spray white lithium grease.
Check/Replace rubber mounts on engine and exhaust system, as needed. Cracks in the rubber mounts may be difficult to see!
Replace air filter, as needed
Replace starter rope if there is any signs of wear.
Replace reed valve petals if they are leaking (a rare event).
Replace upper rod bearing and wrist pin if there is noticeable play or the engine makes a knocking sound.
Check piston rings for freedom of movement
Remove carbon and/or lead deposits from the top of piston and cylinder head. Use a scope to look into the cylinder and see what's going on.
Those who use AVGAS and fully-synthetic oil will have less maintenance, overall. Use a razor blade and a Dremel wire brush. Failure to
routinely remove deposits will increase compression and combustion temperatures. This will shorten engine life dramatically.
Clean out the decompression port with a #38 drill bit in the Thor 130, 190, and 200 models. Failure to clean this will result in greatly
increased effort needed to start the engine. If the Flash insert is used, most pilots will not be able to crank the engine over.
Replace piston and rings if engine power is significantly different than when the engine was new.
Replace all bearings and seals, if needed.
Replace crankshaft if play is excessive in the lower wrist/gudgeon pin bearing. Noisy engines probably need to be overhauled.