FLY CASTELLUCCIO PARAMOTOR & PARAGLIDING S.R.L.

Via Copernico 12 – 63100 – ASCOLI PICENO – ITALY – Tel. +390736344204 – Fax +390736338322 Email: info@flycastelluccio.com - sito web www.flycastelluccio.com

Manual

FLASH LINE
TOP 80
English

Flash Line: Top 80 _________________________________

INDEX 1.0 FLY CASTELLUCCIO P&P 1.1 FLASH TOP 80 Features 2.0 UNPACKING AND ASSEMBLING YOUR SKY 100 2.1 Package Contents 2.2 Frame Assembly 2.3 Prop Mounting 2.4 Harness Mounting 2.5 Spark Plug 2.6 Assembly Inspection 3.0 PREPARING FOR YOUR FIRST FLIGHT 3.1 Fuel and Oil 3.2 Before Starting the Engine 3.3 Starting and Stopping Engine 3.3.1 Stopping the Engine 3.3.2 Starting the Engine 3.4 Carburetor Adjusting 3.5 Engine Break-In 3.6 Harness Adjustment 3.6.1 Ground Handling Straps 3.6.2 Flight straps 3.6.3 Hang-test in a Simulator 4.0 IN-FLIGHT STARTING 5.0 OPTIONAL ACCESSORIES 5.1 Tool kit 5.2 Reserve Parachute 5.3 Speed Bar 6.0 MAINTENANCE 6.1 Cleaning 6.2 Prop Care 6.3 Spark Plug 6.4 Repairs 6.6 Long Term Storage 7.0 TROUBLESHOOTING 7.1 Diagnosing and starting a flooded engine 7.2 Troubleshooting Chart 8.0 SPECIFICATIONS AND PERFORMANCE 8.1 Specification and Performance Summary Chart 9.0 TORQUE SPECIFICATION CHART 10.0 MISCELLANEOUS 10.1 Obtaining Repair Parts 10.2 Pre-Flight Checklist Example 10.3 Warranty and Warranty Certificate
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_________________________________ Fly Castelluccio P&P

Flash Line: Top 80 _________________________________

1.0 - FLY CASTELLUCCIO P & P
WARNING Paragliding is an extremely dangerous activity that can ad often does result in serious injury or death. The designer, manufacturer, distributor, wholesaler and retailer cannot and will not guarantee your safety when using this paraglider. You alone must judge the flying conditions, including weather, wind, congestion, launching areas and landing area before you fly. Paragliders require careful and consistent care. Overtime, solar radiation, dirt, dust, grease, water, wind, stress and other variables will degrade the performance and safety of the glider thereby increasing the risk of injury or death. Read the owner´s manual of the paraglider before you fly. Always wear a helmet and protective clothing when flying a paraglider. To use FLY CASTELLUCCIO PARAMOTOR & PARAGLIDING Paramotors , the pilot must have taken a licence for leisure sport flight. FLY CASTELLUCCIO PARAMOTOR & PARAGLIDING Company strongly recommends reading carefully this Manual before using the equipment. FLY CASTELLUCCIO PARAMOTOR & PARAGLIDING Company will not be responsible directly or indirectly, for whatever use is made of its equipment. FLY CASTELLUCCIO PARAMOTOR & PARAGLIDING strongly recommends reading carefully the check instruction to be respected before every flight. FLY CASTELLUCCIO PARAMOTOR AND PARAGLIDING reserves the right to do technical changes on its products without any obligations regarding the forwarding to its customers

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.

_________________________________ Fly Castelluccio P&P

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1 Rear View Fig. Fig.. 2 Side View _________________________________ Fly Castelluccio P&P 4 .Flash Line: Top 80 _________________________________ 1. launch.1 FEATURES The following is a brief list of some of the many features that are found on the FLASH T 80: Very High Thrust/Weight Ratio – FLASH T 80 weighs only 46 lbs. The following figures illustrate the components of the FLASH T 80. and produces 110 lbs static thrust Easy disassembly and assembly in minutes Clutch-driven prop doesn’t spin during critical inflation. and landing Gear-driven reduction drive Force-air cooling Tuned Pipe Extremely quiet In-flight Restarting Very good fuel economy and duration – FLASH T 80 flies 6 hours on only 15 liters (4 US gal) of fuel (with 150 lb pilot and modern wing).

2.0 .1 PACKAGE CONTENTS Fig.2 FRAME ASSEMBLY Frame assembly and disassembly on the Paramotor is very fast and easy.Flash Line: Top 80 _________________________________ 2.UNPACKING AND ASSEMBLING 2. 3 For correct assembly proceed in the following order: Step 1 _________________________________ Fly Castelluccio P&P 5 . 3 Fig. and they are held together by the six support rods. Fig. 3 illustrates the packing contents of the FLASH T 80. The frame consists of four parts.

Lock the velcro strap as shown. Step 3 Assembling upper frames Make sure that the cage netting is in front of the cage support rods . Place the upper frame quarters onto the upper support rods and rotate the frames until plug in the inserts in the related holes.Flash Line: Top 80 _________________________________ Step 2 Plug all six-cage support rods into their bushings on the central frame (engine). Steps 4 & 5 Assembling sides frames _________________________________ Fly Castelluccio P&P 6 . take attention to put longest on the top.

Steps 6 & 7 Fasten the net Attach the netting tension strings as shown in the figures. Lock the side velcro straps. If they are not seated completely into their bushings. pull it tight.Flash Line: Top 80 _________________________________ Place the side frames onto the side support rods and plug in the inserts in the related holes. and then hook it back onto the string loop. simply passing the string-hook into the string loop. and into their bushings in the cage. Lock the lower velcro straps. _________________________________ Fly Castelluccio P&P 7 . NOTE! The cage support rods must be completely seated into their bushings in the frame. you will be unable to fasten the netting into place in the next step. Step 6 Assembling lower frames Place the lower frames onto the central engine unit frame plugging the inserts in the related holes.

The “front prop flange” is the one that is mounted on the reduction drive. LATERAL WIDENING OF DISTANCE BARS. the staff of Fly Castelluccio P & P srl has immediately set to work to further improve its paragliders. A new type of spacer with anti-torque system (ACS) has been designed to solve the problem of the motor torque. and then work toward the top. The red arrow in image indicates the direction of propeller rotation. the “rear” is the opposite direction. Leave these straps at their loosest setting for now. we’ll adjust them later. NEW FITTINGS After just about one month from the establishment of the new company. ACS can be fitted on the models of the Mach line without applying any change to the frame. The distance bars allow a lateral movement which is useful for the pilot to enter easily into the harness. taking into account also their limited movement. 13 Do this for the left and right sides.Flash Line: Top 80 _________________________________ Step 8 String lock This completes the assembly of the prop cage. attach the bottom of the harness. Attach the bottom ground handling straps as shown in Fig. Next. The system shifts the thrust center of the propeller by a few centimeters as compared to the point where the wing is fitted. The thin side of the prop blades as the upper blade can identify the “rear” side of the prop section The “rear prop flange” is the one that is most rearward when the prop is mounted. 2. _________________________________ Fly Castelluccio P&P 8 . Spacer with low fitting are in stainless steel while those with high fitting are in aluminum.3 PROP MOUNTING The “front” is the direction the pilot faces while flying.

2. and tighten them evenly. one used to comfortably support the paramotor assembly unit on the pilot’s back while on the ground. but not enough to begin to crush the wood of the prop. and are adjusted separately.4 HARNESS MOUNTING The paramotors’s harness consists of two separate strapping systems. 4 Upper view of a propeller section.Flash Line: Top 80 _________________________________ Fig. The two systems have separate purposes. The correct torque to use is 50-inch lbs. Step 1 _________________________________ Fly Castelluccio P&P 9 . Insert the four (4) prop bolts through the rear prop flange and prop. Place nylon-insert lock nuts on the bolts. Mounting the prop is quick and easy. Place the black rubber friction washer over the prop bolts on the front side of the prop . MAX. This system also correctly aligns the thrust angle of the prop. A more practical “field method” of torquing is to tighten the bolts snuggly and evenly. and the other is used to support the paramotor and pilot while flying. Place the rear prop flange on the rear side of the prop. Now mate the prop/rear flange/bolt assembly to the front prop flange that is on the reduction drive.

Flash Line: Top 80 _________________________________ Step 2 Step 3 Step 4 _________________________________ 10 Fly Castelluccio P&P .

Flash Line: Top 80 _________________________________ Step 5 Step 6 _________________________________ 11 Fly Castelluccio P&P .

the netting is tight and on the correct side Check that nothing can get in the prop. that there are no twists on any straps Examine prop cage for correct assembly. and correct torque of prop bolts _________________________________ 12 Fly Castelluccio P&P . at a minimum. 2.635mm). that all straps are secure.5 inches (4 fingers) at all points Check the fuel tank and fuel delivery system Check for correct mounting of prop.). the following items: Review each assembly step above Examine all nuts. and fasteners are tightened correctly Check the harness for correct mounting.Flash Line: Top 80 _________________________________ This completes the harness mounting. Inspect your work to ensure that all is OK. 2. The inspection should contain.5 SPARK PLUG Set the spark plug gap to 0.025” (0.6 ASSEMBLY INSPECTION It is critical to fully inspect the assembly of the and find and remedy any problem areas before proceeding. that it is strong.inch lbs. The prop should clear the cage by at least 2. bolts. Install the spark plug and torque to specifications (120. or 10 ft-lbs.

Check assembly of the unit. dirt. Take care not to get dirt. Ensure that no bystanders or onlookers are close by when starting the motor.PREPARING FOR YOUR FIRST FLIGHT 3. that could be sucked up and thrown around by the propeller.0 . _________________________________ 13 Fly Castelluccio P&P . dust. will be thrown if they are picked up by the prop. hoses. The recommended fuel/oil ratio is 50:1. This is where dust. Mix fresh gas and oil before each flying session. and especially check any and all nuts. This amount of force can pick up anything loose in the area and throw it around like a bullet. rocks. and use clean containers. the prop tips are moving in excess of 370mph. • Wipe up any spilled fuel immediately. and can suck things into it from a surprising distance. that could be loose. The prop produces a significant amount of thrust. Do not refuel near heat or open flame. do not smoke or allow on-lookers to smoke while re-fuel. dust. the oil will leave a residue. nuts.1 FUEL AND OIL FLY CASTELLUCCIO P & P recommends the use of a premium unleaded automotive gasoline of 92 octane or higher. Tighten the fuel cap securely. Do not refuel a hot or running engine. etc. which will attract and retain dust and dirt. The most dangerous place to stand is in the plane of the propeller. • Use common sense when re-fuel. bolts. and the use of premium synthetic 2-cycle oil. Store your fuel/oil mixture in an approved. and an in flight fire would be catastrophic. rocks. Dispose of fuel/oil mixture that is older than 72 hours.2 BEFORE STARTING THE ENGINE Before starting the engine on the ground. Use only fresh fuel and oil. even small items like dirt or a loose screw can inflict significant damage to the prop. To fill the fuel tank. Also check all parts of the prop cage for looseness. Not only can it severely injure you or bystanders. remove the fuel tank cap by unscrewing it . bolts.Flash Line: Top 80 _________________________________ 3. and screws. and pushing the air rearward at over 62mph. ensure that the unit is in an area free from dirt. 3. At full RPM. etc. etc. Fill the tank with the desired amount of fuel. funnels. Also. It is recommended that the fuel be poured into the tank using a straining-type of funnel. Be sure to thoroughly agitate the mixture to completely dissolve the oil. onto the fuel pickup or the fuel tank cap. as the fuel/oil mixture is highly flammable. sealed container. etc.

and takes about two minutes to stop the motor) _________________________________ 14 Fly Castelluccio P&P .1 Stopping the Engine Since it’s important to know how to stop the engine once it’s started. It is important to be aware of some other engine stopping techniques. 17 .3. you can: Place your hand over the air box intake hole Place the carburetor choke in the “ON” position Squeeze the fuel line (requires an aggressive squeeze. 5 . 3) bad connections to any part of the stop switch circuit. 2) broken wires.Flash Line: Top 80 _________________________________ 3.The Joystick: Start button Fuel level light START button (only on models with electric starter) Throttle lever STOP BUTTON Throttle lever hold to half power The stop switch may not function correctly due to 1) faulty switch. should the stop switch not function correctly."A”) and hold it until the engine comes to a complete stop.3 STARTING AND STOPPING ENGINE 3. the following emergency stop procedures are available: To stop the engine if the stop switch doesn’t function correctly. Fig. For this reason. simply depress the “STOP” button (fig. let’s cover “Stopping the Engine” first. To stop the engine.

-Standing in front of the unit. The choking procedure is as follows: • Move the choke lever to the “ON” position. Rapidly and sharply pull the starter cord. • Pull the starter cord until the engine starts. A common accident can happen where you hold the throttle in the same hand that you hold the motor unit. 3. Gently pull the pull-starter cord until you feel the engine’s compression. grasp the pull starter cord with both hands and proceed like to the position above. use of the choke will be needed. standing on the ground In this position is possible to leave the throttle hanging to the right side of the harness. Gently place it back into place. and place your left hand on the top of the central frame tube. Allow the pull-starter cord to rewind into the motor. but not so that you can inadvertently squeeze the throttle. .Flash Line: Top 80 _________________________________ 3. . _________________________________ 15 Fly Castelluccio P&P . Hold the throttle in your left hand also. causing you to squeeze the throttle even more. Grasp the pull-starter cord with your right hand. The engine should start after one or two pulls. . • Allow the engine to stabilize a few seconds before applying throttle. the thrust of the machine will push the throttle onto your hand.Strapped into the unit.3. These positions are: • Standing in front of the unit. • Move the choke lever to the “OFF” position. standing on the ground • In Flight If the engine is cold it's very important to fill the fuel pipes squeezing the primer bulb placed near the fuel tank.Stand in front of the unit.In-Flight Do not allow the starter cord to snap back into place after you’ve started the motor. holding the unit on the ground WARNING! The method of holding the throttle handle is important in this position.3. Make sure that you CANNOT inadvertently squeeze the throttle handle when starting in this position.2 Starting the Engine There are three different positions that can be used to start the engine. holding the unit on the ground • Strapped into the unit. and if you squeeze the throttle a little.3 Choking the engine If the engine hasn’t been run in a few hours and is no longer warm to the touch. Hold the throttle handle such that you can easily reach the stop button.

you tighten it. always verifying the cleanliness of the "passage" (the point where the nozzle of the idle enters the nozzle of the full.5 turns out from Stop Idle Speed Screw (D in Fig. At idle.Flash Line: Top 80 _________________________________ 3. GENTLY turn the screws CW until they hit their stops. It will also provide for considerably longer engine life. at about half revs. Often. Position “1” is Choke OFF Position “2” is Choke ON B – Carburettor Diaphragm C – Idle Mixture Screw D – Idle Speed Screw 3. Proper break-in will provide you with a better running engine. while the opposite you lean it. The D screw sets the revs. and then back them out (CCW) the number of turns described above. Carburetor adjusting proceeds as follows: Warm the engine by allowing it to idle for at least 5 minutes. The carburetor has two adjustments.) in revving up.5 ENGINE BREAK-IN Break-in of the ’s Top 80 Engine is required before the first flight.4 CARBURETOR ADJUSTING Our carburetor is provided with a starter for the very first starting (cold starting) Flip up switcher A in position 2 for starting.18): 1. it is necessary to “start over”. and go back to the original factory settings. in position 1 for functioning. by the long black downward screw C. Adjust the idle mixture C for the fastest idle possible. Fig. adjust D for the slowest smooth and stable idle possible. Once attained. after making a few adjustments to the carburetor. The C screw must be turned very gently. You can set the carburetion at the desired revs. By turning it Counter clockwise you rich the mixture. by opening the butterfly valve. The original factory settings for the Carburetors are: Idle Mixture Screw (C in Fig. 6 FLASH T 80 carburettor Components shown: A – Choke Lever. 18): 1. If the engine pops. _________________________________ 16 Fly Castelluccio P&P .5 turns from the shut position.5 turns out from stop To restore the adjustments to the factory settings. if it abates you loosen it. The basic setting is between 1 and 2.

during this time.Flash Line: Top 80 _________________________________ During the break-in. Run the engine. 5 minutes of cooling until 30 minutes of run time is achieved. one used to comfortably support the paramotor assembly unit on the pilot’s back while on the ground. Stop the engine and let it cool for 5 minutes. and vary the throttle setting often. The two systems have separate purposes. etc. varying the RPM. as is practicable. Do not rapidly change RPM. for 2 minutes. Check to ensure the carburetor mixture is correct (a lean condition can also produce overheating) bifore flying again. Should this occur. reduce power and land as soon. Check for loose bolts. varying the RPM. It will show itself as a loss of power. This system also correctly aligns the thrust angle of the prop. gently change RPM from idle to full-throttle and back. Check for loose bolts. Stop the engine and let it cool for 2 minutes. Allow the engine to cool. Stop the engine and let it cool for 5 minutes. Check for loose bolts. Break-in is complete after 10 liters of fuel have been run through the engine. For heavier pilots that require more power to fly. Continue 10 minutes of running. during this time. etc. during this time. however avoid long durations of full power. CAUTION! Be wary of overheating during the break-in process. At this point. Run the engine. you can fly the paramotor . varying the RPM. 3.6 HARNESS ADJUSTMENT The FLASH T 80’s harness consists of two separate strapping systems. The procedure is as follows: Run the engine. it is recommended that 1 hour of non-flying break-in be completed before flying. _________________________________ 17 Fly Castelluccio P&P . as this causes unnecessary wear and tear on the clutch. for 5 minutes. for 10 minutes. and are adjusted separately. etc. and the other is used to support the paramotor and pilot while flying.

The adjustment procedure for the ground handling straps is as follows: • • • • • Strap into the paramotor and stand up.1 Ground Handling Straps In the Fig 14 & 15. the tightness of the thigh straps will determine how easily you can slide into the seat after takeoff. the ground handling straps are in red.Flash Line: Top 80 _________________________________ 3. Snug the ground handling chest strap. Adjust the thigh straps. with the Paramotor on the pilot’s back.6. The purpose of the shoulder straps and shoulder pads is to carry the weight of the paramotor while on the ground. the flight straps are black. Side and Front Views of Ground Handling Straps and the flight straps Fig14 The ground handling straps as shown above are best adjusted standing on the ground. The purpose of the ground handling chest strap is to keep the ground handling shoulder straps from falling off the pilot’s shoulders. Adjust the Shoulder Straps until the shoulder pads are carrying the weight of the paramotor. _________________________________ 18 Fly Castelluccio P&P . Adjust these with the use of a simulator The ground handling straps are adjusted correctly if: • The weight of the paramotor is on the shoulder pads • The shoulder pads/straps won’t fall off the shoulders • The seat can be moved out from under the buttocks easily • You can easily slide into the seat after takeoff • You can run easily and the seat and thigh straps don’t interfere with your ability to run.

This length has a variable adjustment locations. two ropes tied to rafters in your garage or basement. Higher accommodates larger pilots. Proceed to final adjusting of the harness in the simulator. Lower accommodates smaller pilots and provides more weight shift capability.2 Flight Straps Fig.6.6. 7 Side and Front View of Flight Straps In Fig. the flight straps are black The purpose of each flight strap is as follows: • Length “B” determines the carabineer height. and it sets the thrust angle. but loose) No part of the harness should hamper free movement of your arms and the throttle cable.3 Hang-test in a Simulator It is HIGHLY recommended that you perform a hang-test in a simulator before the initial flight and every time you make a harness adjustment thereafter. Adjust it so the thrust angle is zero to five degrees below horizontal. 7.Flash Line: Top 80 _________________________________ 3. • Length "D". • Length “C” is adjusted by a buckle . is used to adjust the back of pilot's distance from the PPG. A simulator can consist of two ropes tied to a horizontal (and strong) tree limb. Once you have made your initial adjustments. • • • The ground-handling straps should be loose and comfortable The ground handling chest strap should be loose (still buckled. This must be done in a simulator. strap into the paramotor and clip the carabineers into the simulator. 3. _________________________________ 19 Fly Castelluccio P&P . etc . Gently lift your feet and get seated in the harness.

degrees below horizontal _________________________________ 20 Fly Castelluccio P&P .Flash Line: Top 80 _________________________________ • • Make sure you can reach your arms up very high with no strain or interference from the harness The propeller shaft must be approximately 5. and no more than 10.

and is a highly recommended safety item. spin. are suggested for the tool kit: • Spark plug wrench (13/16”) • Metric Allen wrenches • Vice Grips • Combination wrenches (10mm.OPTIONAL ACCESSORIES 5. to start the engine and climb back up to do it again.0 . where you prefer to mount it (front. release the paraglider’s brake toggles. _________________________________ 21 Fly Castelluccio P&P . and then when he gets low.0 IN-FLIGHT STARTING One very valuable feature of the paramotor is its ability to be started while in flight. For this reason. Grasp the glider’s brake toggles. 5. quick pull.1 TOOL KIT It is highly recommended that a tool kit be assembled and carried in one of the harness pouches. and the one you choose depends on many things such as which hand you want to deploy with. reach up over your shoulder and grasp the start handle.Flash Line: Top 80 _________________________________ 4. The process of in-flight starting is very simple. performing a PLF (Parachute Landing Fall). It is highly recommend that you seek assistance from your PPG instructor on the mounting of your reserve parachute. The following tools. 13mm) • Screwdrivers (both Phillips and Straight) 5. left or right side). This feature allows the pilot the freedom to turn-off the engine and glide silently. FLY CASTELLUCCIO P & PS cannot make a generalized statement of what the best mounting configuration is for you. The engine will start. etc. This could result in loss of control. Many different mounting locations and methods are possible and acceptable. and possible crash.2 RESERVE PARACHUTE A reserve parachute can be fitted to the . It is also highly recommended that you receive training (a reserve parachute clinic) covering topics reserve deployment topics such as reserve re-packing and parachute care. and when to make the decision to deploy your reserve. Give the start handle an aggressive. Next. First. to enjoy the exhilaration of thermal soaring. and gently add power. what type of reserve you have. a stall. at a minimum. Failure to release the brake toggles before attempting in-flight restarting could result in excessive braking of the paraglider.

_________________________________ 22 Fly Castelluccio P&P . Optional pulleys can be added to the harness to facilitate the application and routing of the speed-bar. Remember the expression. it’s your last chance. A reserve parachute should never be deployed “for fun” or to “see what it’s like”. to be used in lifethreatening emergencies only. your impact speed with the ground is significant. power lines. 5. etc. You surrender control over your aircraft.Flash Line: Top 80 _________________________________ WARNING! A reserve parachute is a life-saving backup system.3 SPEED BAR A speed bar can be mounted to the harness.” Carry a reserve parachute. These pulleys can be obtained from your dealer. “A reserve parachute isn’t your second chance. you have no choice as to your landing location and could land on rocks. and deploy it only if it is absolutely necessary. Also. roads. Even with a correctly deployed parachute. reserve parachutes are not guaranteed to deploy correctly. A reserve parachute deployment is an extremely dangerous event.

prop cage. bolts. netting. #2 and repack grease Piston ring. bearings and clutch basket Replace bearings with No. Crankshaft seals and condition of all plastic parts Fuel hose. prop cage. etc. netting. Spark Plug _________________________________ 23 Fly Castelluccio P&P . Every 5 hours All screws.Flash Line: Top 80 _________________________________ 6. Spark Plug.2mm) De-carbonize Cylinder head. The following chart provides the suggested maintenance schedule. harness webbing. Check spark plug cap. fuel filter. harness webbing. harness webbing. bolts. Clean. etc. nuts. nuts. All screws. pin bearing and pin keepers Piston and cylinder assembly all bearings and crankshaft seals Every 25 hours Every 50 hours Every 100 hours Crankshaft seal Every 200 hours Crankshaft bearings Yearly (regardless of hours) Fuel pump and carburetor diaphragms.MAINTENANCE Periodic maintenance is required in order to keep your in top operating condition. Inspect piston ring for sticking and condition Spark Plug and fuel filter Every 75 hours Re-drive gears. netting. bolts. piston pin. re-gap spark plug Clutch Diameter and clearance Clutch Bell (min thickness 1. prop cage. Interval During and after Break-In Inspect Replace All screws. etc.0 . nuts. check colour is light brown.

Spark plug gap is 0.Flash Line: Top 80 _________________________________ 6. a balanced propeller is of the utmost importance. contact FLY CASTELLUCCIO P & P. 6. FLY CASTELLUCCIO also carries all parts and supplies to keep your in top operating condition. cage guard. FLY CASTELLUCCIO P & PS provides full repair services including frame. moisture and oils in and on the prop can migrate downward and cause prop imbalance. prop. The “resistor” version of this plug. An alternative is to strap the motor on and start it in the standing position. and is particularly helpful at reducing interference on radios or music devices. Recommended replacement interval is every 50 hours. If in doubt. Prop Balancing. or use a nice clean area such as a nicely mowed yard. To avoid this. 6.1 CLEANING Clean your Flash T80 clean water and a mild soap. This is because if the prop is stored vertically. The prop blades are subjected to forces as high as 2000 G’s! Therefore. cage.2 PROP CARE Avoiding Prop Damage. a weight difference on the propeller tips of only 1 gram can cause forces as high as 2kg. Keeping the Prop Clean Wipe all dirt and oil from the prop when finished flying.3 SPARK PLUG The recommended sparkplug for the Top 80 motor on the FLASH T 80 is the B9ES. and can cause enough vibration to break welds or tubes of the frame. Dust and dirt can be brushed off. can seep into the wood and cause an imbalance. either place the unit on a sheet of plywood or something similar. Oil. Store the Prop Horizontally When storing the paramotor.4 REPAIRS Minor repairs can be performed on the prop. and harness. Caution! Repairs to the harness or any stress-carrying areas of the should only be performed by a certified parachute rigger. Balancing of the propeller is very critical. Major repairs should be performed by a trained service technician. and engine repairs.025” (0. 6. Recommended cleaning and gapping interval is every 25 hours. or by FLY CASTELLUCCIO P & PS. Therefore.This force will cause a vibration at the speed of the propeller RPM. This phenomenon can only happen on wood props. It is very easy to damage the propeller by sucking up dirt or rocks when running the motor on the ground. if left on the prop for long periods of time. the BR9ES is also recommended. _________________________________ 24 Fly Castelluccio P&P . or removed with water and mild soap. Grease and oil can be removed with a good water-based degreaser such as “Simple Green”. harness. rotate the prop to a horizontal position.635mm).

Remove the aluminium lid held by four screws. Gently pull the starter rope a few times to distribute the oil. Clean the cage. For settings and modifications go to carburetion 6. as shown in the picture. Cover the machine with a sheet or light cloth. Do pay attention to cover with your finger about half of the filter housing. You do clean it by a spout of air or by a fuel wet soft brush. Do not remove the filter. Remove spark plug. _________________________________ 25 Fly Castelluccio P&P . then reinstall the plug.6 LONG TERM STORAGE Long Term Storage is defined as anything longer than 3 months. clean it while leaving on its seat. 8 Cleaning the carburetor’s internal filter The diaphragm carburetor is provided with an internal filter that may get clogged and cause carburetion problems that shows with power losses. To clean it is necessary to open the carburetor from the fuel entering side. it may slip out. Inject 4 teaspoons of 2-cycle oil into the spark plug hole.5 CARBURETOR MAINTENANCE Diaphragm carburetor maintenance. The long-term storage procedure is as follows: Drain fuel tank completely. This removes all fuel from the carburetor and lines. Start and run engine at idle until it stops from fuel starvation. Store in a clean.Flash Line: Top 80 _________________________________ 6. harness. so that it is free from dirt and/or oil. etc. dry place. Fig. Clean the prop of any dirt and/or oil.

follow the procedure below: • Remove the spark plug and thoroughly dry it. and start using the normal procedure. • With the spark plug removed pull the starter cord 5 to 10 times while holding the throttle in the full-open position and with the choke in the OFF position. If the engine were to start.1 DIAGNOSING AND STARTING A FLOODED ENGINE A flooded engine can be identified by the smell of unburned gasoline coming from the exhaust pipe. 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.0 – TROUBLESHOOTING 7. If you have a flooded engine.Flash Line: Top 80 _________________________________ 7. This will remove excess fuel from the engine. or by periodic weak firing and puffs of black smoke during starting attempts. however do not choke the engine. • Install the dry spark plug. the prop would rapidly spin to full RPM and damage or injury could likely to occur. (Note another indication of a flooded engine is a spark plug that is dripping with gas). _________________________________ 26 Fly Castelluccio P&P .

Follow procedure outlined replace with a new plug Gap the plug to 0. sharp pull on Follow procedure outlined in reaches the bottom Ensure spark plug cap is Solutions Fill tank per fueling _________________________________ 27 Fly Castelluccio P&P .4 See section 3.3 Choking the engine” Insufficient pull on starter rope the rope Fouled Spark Plug gap. muffler bolts.025” Inspect plug. clean and reGive a strong.Flash Line: Top 80 _________________________________ 7.4 See section 7.3.2 Check and tighten engine mounting bolts. but does not continue to run Incorrect Choke Procedure in section entitled “3. or Incorrect Spark Plug Gap (0.635mm) Engine starts.3 Choking the engine” Engine is flooded Incorrect Idle Speed adjustment Incorrect Idle Mixture adjustment Excessive Vibration Prop out of balance Loose fasteners Follow procedure outlined in section 8.2 TROUBLESHOOTING CHART Symptom Engine does not start instructions Possible Causes No fuel in tank Fuel pickup does not reach all the way to bottom of tank Inspect fuel pickup and ensure that it Spark Plug cap not in place installed Incorrect Choke Procedure section entitled “3.3.1 See section 3. etc. prop bolts.

5 kW) CDI Walbro WG Series Clockwise.) (lbs.) Fuel Tank Capacity Estimated fuel duration pilot _________________________________ 28 Fly Castelluccio P&P . as viewed None.1 SPECIFICATION AND PERFORMANCE SUMMARY CHART Item Engine Make and Model Engine Type cooled Displacement Bore x Stroke Power Output Ignition System Carburetor Rotation Direction from rear Air Cleaner Spark Plug Fuel or higher Fuel/Oil Starting System Prop diameter Thrust Climb rate DHV 1-2 Frame tubing Harness Dry Weight Dimensions assembled 33 x 16 x 16” (85 x 40 x 40 cm.SPECIFICATIONS AND PERFORMANCE 8. with a 150lb Specification Top 80 Single cylinder. air 80 cc 47..) 500 ft/m (2. Input Silencer B9ES or BR9ES Premium auto gas.6mm X 44mm 15. aircraft Rip-stop nylon 46lbs (21 Kg.0 .5 gallons (16 liters) 6 hours.) (cm) 53 x 53 x 30’’ (135 x 135 x 75 cm.4HP (11.5 m/s) with a Aluminium.) packed for travel 4. 92 Oct. 49” (125 cm. kg) 105lbs (48kg.Flash Line: Top 80 _________________________________ 8. Ratio 50:1 Recoil pull starter 2 blade.

dry friction Tuned resonant.Flash Line: Top 80 _________________________________ Noise Level mts.) Maximum Pilot weight Clutch System Exhaust System integrated silencer Max RPM Reduction System Reduction Ratio Less than 52 dBA at (10 220lbs (100kg) Centrifugal. grease bath 3. w/ 9600 RPM Gear box.65:1 _________________________________ 29 Fly Castelluccio P&P .

– TORQUE SPECIFICATION CHART _________________________________ 30 Fly Castelluccio P&P .Flash Line: Top 80 _________________________________ 9.

clearness _________________________________ 31 Fly Castelluccio P&P . Hook Up Buckles secure Chest strap tight Harness adjusted properly Reserve parachute attachment Reserve parachute deployment pin Reserve parachute handle in sight – Deploy in 3 sec.1 OBTAINING REPAIR PARTS To obtain repairs parts for your machine..2 PRE-FLIGHT CHECKLIST Site/Conditions Current weather Long-range (next few hours) forecast Winds aloft Takeoff/landing direction Obstructions (especially power lines) Wing Lay wing out into wind Lines straight and clear Riser/Line condition Quick-links tight Correct brake length Paramotor and/or Harness Webbing and straps for stress Prop Guard for alignment/stress/wear All fasteners tight Carabineers condition Radio secured Sufficient fuel Strap In.– MISCELLANEOUS 10. 10. rehearse procedure Risers hooked up correctly Carabineers locked Nothing loose to get in prop Radio for volume.Flash Line: Top 80 _________________________________ 10. call your FLY CASTELLUCCIO P & P’s local dealer.

Shipping charges are the responsibility of the purchaser. This warranty does not apply even during the warranty period. please contact your dealer or FLY CASTELLUCCIO P & PS. The dealer. ding. trip.e. This warranty applies to the product in normal usage situations only. a crash.Flash Line: Top 80 _________________________________ Helmet on. tweak. To obtain warranty service. earthquake. fastened Tuck in hood on hooded sweatshirt Start up and Launch Brake lines/risers held correctly. i. flood. will repair the product free-ofcharge. negligence. neglect. loose parts falling off and breaking the prop. or FLY CASTELLUCCIO P & PS. i. _________________________________ 32 Fly Castelluccio P&P . no tangles Kick bar tucked out of way Engine run-up to correct RPM Kill switch working (briefly push) Look UP during run! 10. fall. or other natural calamity. and then either bring the product in or have it shipped. tight. including but not limited to fire. The malfunction is caused by incorrect pilot operation. from whom you purchased the product. etc. whack. or any other piloting eventuality.e. and the purchaser shall pay repair or replacement charges if: The cause of malfunction is due to misuse. The malfunction is caused by lack of normal maintenance.3WARRANTY FLY CASTELLUCCIO P & PS will warrant their product to be free from defects in materials and workmanship for a period of six (6) months from the date of purchase. or modification. bend. The malfunction is caused by an Act of God. This includes seize of the engine due by an improper carburetor adjustment or improper fuel /oil mix.

Please read carefully the instruction manual.flycastelluccio.Flash Line: Top 80 _________________________________ WARRANTY CERTIFICATE This warranty certificate is held by: Model Version Purchase Date Place of purchase ______________________________________ ______________________________________ ______________________________________ ______________________________________ This warranty certificate is valid for two years from the date of purchase. For any other information contact your dealer or directly Fly Castelluccio P.Italy Tel (+39) 0736344204 – fax (+39)0736338322 info@flycastelluccio. & P.com www.com _________________________________ 33 Fly Castelluccio P&P . The authorized dealer _______________________ ________________________ FLY CASTELLUCCIO PARAMOTOR & PARAGLIDING SRL Via Copernico 12 – 63100 – Ascoli Piceno .

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