Fuel; Engine Starting; Running In; Ordinary Servicing - Polini Thor 250 Use And Maintenance Manual

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- Damages to the engine caused by foreign bodies;
- Servicing operated by persons outside Polini or by not authorized
people;
- Use of the engine for competition purposes
- Final user obligations
Claims shall be done by delivering the engine to a Polini authorized
dealer. The user shall provide the original document that proves the
purchasing or the warranty ticket authenticated by Polini or by its
distributor. To keep the validity of the warranty the user shall carry
out recurrent servicing according to the use and maintenance manual.
- Limited liability
Pursuant to this warranty, Polini's obligations are limited to the
defective parts reparation or, at its discretion, to change one or more
parts, necessary to remedy every malfunctioning caused by defective
materials or labor covered by the warranty. Polini or the distributor
can't be held responsible for problems or damages to persons/things/
animals during the engine life. We remind you that this product is
not certificated and it is only dedicated to experimental
aircraft and that it can break or suddenly stop working. No warranty
or compensation is foreseen for damages caused to:
- persons/animals/things during the engine use
- persons/animals/things caused by a collide with the propeller or
with parts detached from the engine
- frame, parts and/or propeller caused by the collide with parts
coming out from the engine
- costs for rescue, shipping, phone or rent after the collide, problems
or loss of time, or other indirect damages.
Danger! This not-certified engine can suddenly stop working. The
engine stop can require emergency landings causing injuries or death.
The aircraft thrusts by this engine should fly in open spaces only or
during the daylight. The buyer assumes all the risks for the use and
he knows that by using it the engine can suddenly stop working. This
product is not covered by products and public liability. Who flies with
this engine or only switches it on assumes all the risks inherent to
engine flying sport and all the responsibilities for damages to things
or persons or death caused by the use of this product.
On accounts of this, the guarantee does not cover damages caused by
the installation of the engines on machines that requires certified
engines, on machines that are not adequate, on machines that
requires different type of engine. The vendor won't be responsible for
damages caused by the users or third parties.

2 - FUEL

Thor is a 2-stroke engine that needs oil/petrol mixture. Only use good
lead-free petrol purchased by a petrol station with 98 octanes. Add
good 2% synthetic oil to the petrol. It is possible to use a 1,5% oil
mixture with the following oils:
MOTUL 800-VALVOLINE RACING 2T FULL SYNTHETIC SAE 50 - BARDAL
KXT - ELF 976 – ELF 909
Never keep the petrol into containers for a long time because its
quality will be damaged. Only use certified metallic containers for
petrol carriage. Mix up the petrol with the oil ONLY when you are
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using it.
WARNING: The nature of the carbon deposits on the cylinder
head, spark plug and exhaust port give important information about
the fuel mixture burning in your engine. Remember that mixes that
contain too much oil do not extend the engine's life.
ATTENTION: petrol is extremely inflammable and explosive.
Carry out these operations in a well ventilate place and with the
engine switched off. Refrain from smoking and avoid all naked
flames or sparks where petrol is being drained or where re-fuelling is
being performed.
ATTENTION! For American customers only. The European range of
octane is different from the American one:
e.g. EU 95 OCTANE = US 91 OCTANE / EU 98 OCTANE = US 93
OCTANE
For THOR engines you have to use a high-octane gasoline (not less
than US 91)

3- ENGINE STARTING

Start the engine only when all is in good conditions and perfectly
working and check that there aren't persons, things or animals
around. Furthermore check that all the nuts are well tightened.
3.1- MANUAL STARTER
Fill in the fuel system till the petrol reaches the carburetor hole and
then pump up three times (using the Polini manual bulb- Code
316.0016) to fill in the bowl. To start the engine pull upwards the
black level placed in the upper side of the carburettor. Operate the
starter without accelerating till the engine starts. Once it runs switch it
off, disconnect the starter and start the engine again slightly
accelerating. For your safety only start the engine after your harness
has been COMPLETELY fixed!
3.2- ELECTRIC STARTER
Fill the fuel system in as shown in the previous paragraph.
If your engine is equipped with a Polini throttle control press the two
black buttons together and slightly accelerate till the engine runs. If
necessary operate the starter to make the engine starter easier when
it is cold. If the engine is not equipped with a Polini throttle control
please refer to the instructions of the vehicle's manufacturer to find
out the switch on/off buttons.
3.3- THOR 250 DUAL SPARK ELECTRIC STARTER AND
IGNITIONS TESTS
Fill the fuel system as indicated in paragraph 3.1.
Thor 250 DUAL SPARK engine has a control console with a cut-out
switch (photo 1) that must be fixed in a comfortable position and easy
to be reached by the pilot.
The engine has two separated ignitions and the console let you check
the correct working of both the ignitions.
When the ignition is on OFF position the engine is switched off and the
electric starter does not work. By moving the switch to ON position the
led will light.
Use the central black key (START) to start the engine. After having
started the engine keep KEY 1 pressed to disable ignition 1 and it is
possible to check the correct working of ignition 2. The engine must
keep on working. Now release KEY 1.
Repeat the test keeping KEY 2 pressed. It disables ignition 2 and it is
possible to check the correct working of ignition 1. The engine must
keep on working. Now release KEY 2.
Now to end the test press KEY1 and KEY2 simultaneously, so disabling
both the ignitions. The engine now has to stop.
Now start the engine again and it is ready to fly.
NOTE 1: to switch the engine off in standard conditions use the switch
moving the level in OFF position.
NOTE 2: The secondary electronic ignition works using the battery.
This ignition, if fed, (switch in ON position) has an electric input even
with the engine switched off. This input can discharge the battery in a
few days. It is important to re-position the cut-out switch in OFF
position. (LED switched off)
NOTE 3: If the battery should be completely discharged it is possible to
use the engine by starting it manually. Keep into consideration that till
the battery does not reach a minimum charge level the engine will
work with one ignition only.
ATTENTION: keep the switch in your hand during all the stages
and be ready to operate it in case of any technical fault. If necessary
keep it pressed till the engine has completely stopped.
Once the engine starts we suggest testing the right functioning of the
kill switch button. After having checked it, start the engine again
without accelerating and without using the starter. Now start the
engine and leave it idling until it warms up to normal operating
temperature.

4- RUNNING IN

Run your engine in as instructed below to ensure that the engine and
transmission bed in correctly and to ensure continuous reliability in
future. Once the engine starts, leave it idling until it warms up to
normal temperature. We suggest running the engine 15 minutes at
medium-low engine power output gently accelerating and with
different intensity. Now we suggest checking the correct idling
calibration. During the first flights or for the first 20 litres of petrol
we suggest not keeping the engine at the maximum rpm for too much
time, considering that the 2-stroke engine doesn't stand to the
constant rpm even if of medium power. We suggest varying the
engine rpm. Check the carburetion after the first landing. Repeat the
running in every time you change one of the following parts: piston,
piston rings, cylinder, crankshaft or main bearings.
5- ENGINE SWITCHING OFF
Switch the engine off by pressing the button till the complete stop.
If the engine is equipped with the Polini throttle control the switch off
button is of red colour and you find it in the upper side; otherwise
refer to the frame/throttle's manufacturer to find out the switch off
button. For the Thor 250 Dual Spark move the lever of the control
board in OFF position to disconnect simultaneously both the ignitions
and switch the engine off
6- CARBURETION
The carburetion setting must be executed by professional people only.
It is possible to make a fast analysis of the carburetion by checking
the spark plug colour. To do it, switch the engine off after having run
it for some second under charge. Remove the spark plug unscrewing it
with the proper tool and verify the colour of the porcelain that must
be of light-brown colour with tendency to dark. A light colour of the
spark plug electrode means a lean carburetion; if you use the engine
in this conditions may cause the engine failure. Do not use the engine
in these conditions and apply to an authorized retailer to set it up.
7- CLEANING
Clean the engine when it is switched off and cold to avoid burns. Clean
the engine with a soft cloth soaked with neutral cleansing and
non-aggressive.
WARNING: Do not use acids that may damage the engine.
8- CARRIAGE
ATTENTION: Carry the engine only when it is cold.
Follow the frame manufacturer's instructions for its carriage and how
to use the fuel tank during its carriage. Be careful of the petrol during
the carriage: its leaking may cause a fire.
ATTENTION: During the carriage of the engine it is strictly
recommended to maintain the propeller locked together with its nut in
order to avoid that the flange thread that sticks out may be damaged
or in case of fall it might break the crankshaft.
8.1- CARRIAGE OF THE ENGINE WITH BOWL CARBURETOR
The bowl carburetor has a breather pipe studied to carry the engine
when lying. To empty the carburettor unscrew half turn the breather
brass nut (highlighted in photo 2 with an arrow) and wait till all the
fuel enters the tank. Tighten the brass connection again. Now the
carburettor is empty and you can lay the engine ready to be carried.
ATTENTION: never unscrew more than half a turn the breather
nut to avoid damaging the OR seal. Never tight too hard.

9- ORDINARY SERVICING

ATTENTION: THE SERVICING OPERATIONS MUST BE DONE BY
QUALIFIED PEOPLE ONLY. IF THE INSTRUCTIONS MENTIONED BELOW
WILL RESULT NOT CLEAR, WE SUGGEST ASKING FOR SPECIALISTS BY
POLINI MOTORI RETAILERS OR WHOLESALERS. FOLLOW CAREFULLY
WHAT DESCRIBED BELOW.
Maintenances and servicing necessary for the best set up of your
engine should be done regularly, or on all occasions before you start
your engine. All the tasks and adjustments described below can be
done easily by following the instructions given in this manual. Refer
to your POLINI MOTORI dealer for scheduled services and repairs, and
insist that only original spare parts are used to replace worn or
broken components. Refer to the servicing tables in sections 12 below
for the frequency with which the various servicing operations must be
performed.
9.1- REMOVE AND CLEAN THE AIR FILTER
Dirty air filter is one of the most common causes of poor engine
performance. Clean the filter periodically or change it. Remove the
filter loosening the clamps, unscrew the 4 screws using a cross
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