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BLACKHAWK! LITE 125 2.0, Engine Manual And Maintenance Manual

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BLACKHAWK! LITE 125 2.0 Engine Manual And Maintenance Manual Download Page 59

 

Engine Manual Talon 190 and Lite 125 Ver .99b 

 

4/08/2019 

pg. 59 
 

Exhaust Port Couplings Section 

 

 

 

The Exhaust port couplings hold the exhaust assembly together. They are designed to flex with the 
vibration of the engine as regular bolts would just sheer off after a couple of flights. There are 2 
Exhaust couplings: 
 

 

Exhaust Port Coupling

 holds the J-Pipe to the exhaust port coming of the head of the engine. 

 

J-Pipe Coupling

 holds the J-Pipe to the Expansion Chamber part of the exhaust 

The couplings use a spring tightened bolt to hold the 2 parts of the coupling together. The bolts on the 
coupling only need to be tightened to the point where if you grab the coupling with your hand it should 
not rotate around the exhaust pipe. Each bolt should be evenly tightened to assure the coupling applies 
even pressure while holding the exhaust pipes together. 
 

 

Only tighten the bolt / spring assembly enough to the point where you cannot rotate the 
coupling assembly by hand 

 

Do not try to re-use high temp steel locking nuts. Once they are removed they should be 
replaced 

 

If you want to be extra safe you can use 2 locking nuts on each bolt assembly to assure they do 
not loosen or fall off 

Replace the nuts, bolts, and the springs if they look rusted, or if the bolt threads are excessively 
wearing against the coupling flange. In some instances the spring will break and the bolt will begin to 
rattle when the engine is run giving you a clear sign these need to be replaced. Make sure to check the 
exhaust port coupling bolts and springs with each flight check as the vibration of the engine will cause 
the bolts and springs to wear over time. 
 
 
 
 
 

Summary of Contents for LITE 125 2.0

Page 1: ...de and Maintenance Manual BlackHawk Paramotors USA Inc Phone 209 418 5990 Email Team BlackHawkParamotor Com Address 8591 Hogan Dam Road Valley Springs CA 95252 Engine Manual Version 1 00 Last Updated Apr 12 2019 ...

Page 2: ...ks inherent with this type of activity including possible serious injury or death Using this equipment in any other way than what it was originally designed for and or intended use greatly increases these risks BlackHawk Paramotor USA Inc it s employees representatives or dealers shall not be held liable for personal third party or property damages or injuries in any way Note BlackHawk is not acco...

Page 3: ...e Sensor 14 Tachometer Sensor 14 Tips and Tricks to keep your 2 stroke motor fine tuned 15 Torque Settings for each Engine 15 Propeller Bolts 15 Cylinder Head Bolts 16 Cylinder Head Temperature 17 125 Lite Engine Temp Specs 17 Talon 190 Engine Temp Specs 17 What to Adjust if your Engine is running to HOT 18 Spark Plug 18 Elevation Change 18 Inlet Carb Filter could be clogged 19 Vacuum Leak around ...

Page 4: ...ke troubleshooting 28 Step 1 Check the Air 28 Step 2 Check the Spark Plug 28 Step 3 Check the Fuel Carburetor 29 Engine Maintenance 31 Maintenance Window for Active Pilots 31 Maintenance Window for Seasonal Pilots 33 Break In a New Paramotor Engine 34 Carburetor Check 34 Startup 36 Mid Range to Idle RPM Test 36 Engine RUN IN Test 37 Full Power RPM Test 37 Post Break In Check List 37 Initial Break ...

Page 5: ...Diaphragm Replacement 46 Remove the Carburetor from the Lite 125 48 Re Install the Carburetor on the Engine 50 Lite 125 Carburetor Rebuild Kit and the diaphragms used 51 Lite 125 Carburetor Diaphragm Replacement 52 Carburetor Complete Rebuild Video 53 Fuel Line Section 54 Fuel Line Replacement Instructions 54 Exhaust Port Couplings Section 59 Warranty 60 Duration of Warranty 60 The Following Situa...

Page 6: ...explain this information to you of course there is but it s not necessary One thing to keep in mind as you become familiar with your Paramotor you will begin to understand the characteristics of your engine what it sounds like and how it feels as you rev your engine through the different RPM ranges Understanding the feel and sound of your engine as it operates normally is important this is quickes...

Page 7: ...utch and Lower Pulley Array 5 Upper Pulley 6 Propeller Mount 7 Carburetor 8 J Pipe 9 Expansion Chamber 10 Stinger Exhaust Silencer Talon 190 Engine Component List 1 Spark Plug 2 Cylinder Head 3 Cylinder chamber 4 Clutch and Lower Pulley Array 5 Upper Pulley 6 Propeller Mount 7 Carburetor 8 J Pipe 9 Expansion Chamber 10 Stinger Exhaust Silencer ...

Page 8: ...son who does not understand a 2 stroke engine enough information to use this manual competently If you want to understand more about 2 Stroke engines then visit the Wiki page at https en wikipedia org wiki Two stroke_engine Above is a diagram of a 2 stroke engine You can see there are no belts gears or other moving parts except for the piston and the crankcase area The reed valves only allow the a...

Page 9: ...until it begins to uncover the exhaust port The majority of the pressure in the cylinder is released after the port begins to open and the burnt air fuel mixture begins to flow out of the engine During the down stroke the falling piston creates a positive pressure in the crankcase area which causes the reed valve to close The air fuel mixture in the crankcase is compressed until the piston travels...

Page 10: ...rt last The piston is now compressing the air fuel mixture in the cylinder chamber During the up stroke the piston creates a vacuum in the crankcase area and this causes the reed valve to open and pulls the new air fuel mixture into the engine crankcase area The 2 Stroke engine is now back at the beginning of its engine cycle where the piston is at TDC The spark plug has just fired and the engine ...

Page 11: ...ures the force by Inch Pounds How to set the Torque Wrench When you get the Torque Wrench it should be set to zero inch pounds as shown in the picture When you go to set the torque on the wrench you will turn the handle to the right clockwise to add torque There are 2 measure points on the torque wrench The major torque settings are located on the bar of the wrench and are divided by 10 or 15 inch...

Page 12: ...e bolt a little more before it reaches the torque setting then that is OK and this is why you try again to make sure it s done right b Try to avoid over tightening the bolt This can be done when you keep moving the torque wrench after it makes a tink sound Just because the torque wrench will flex you can move it past this point and apply more torque to the bolt then what is specified by the torque...

Page 13: ...s regular Super Unleaded gas for your car the higher the octane the better You will then mix in the oil so that it will work correctly for your Paramotor 2 stroke engine The orange bar across the top of the mixture jar has different fuel to oil mixture ratios columns and the one you want to use says 2 5 40 1 There are 2 sets of numbers in that column The numbers on the left are used for Liter meas...

Page 14: ...nds at 400 to keep the maximum engine lifespan Installation The temperature sensor is an O ring that will fit around Spark Plug and will fit between the Cylinder head and where the Spark Plug screw together Make sure the temperature sensor wire does not touch the cooling fins on the Cylinder head as it could cause the sensor to not work correctly due to the high heat Zip tie the sensor wire to the...

Page 15: ...g a normal flight and can become loss due to that stress Propeller Bolts The Propeller Bolts use a torque settings of 100 In lbs on a 6mm hex bolt and there are 6 bolts that hold the propeller to the pulley You want to make sure you use the mounting plate that is basically a giant washer to spread the pressure of the 6 bolts across the propeller In some cases the propeller will use a spacer plate ...

Page 16: ... Engine Head Nuts is in the morning before you do any flights and the engine has been off for at least 8hrs This will assure your engine is at room temperature Do not attempt to adjust or tighten the cylinder head nuts after a flight this will cause you to over tighten the nuts due to the elevated temperature of the engine Depending on the engine you are working on they use different torque settin...

Page 17: ...ave a temperature sensor on your engine you can use this and when the engine reaches 410 210 you will need to back off the throttle o Just reducing the throttle by a little 300 rpm will greatly reduce the cylinder head temperature on your engine If you are flying on a hot day hotter than your normally fly this is when you want to pay attention to engine temperature as it will climb up to 15 8 hott...

Page 18: ...this manual Elevation Change If you normally fly at the beach and then you travelled to the mountains you want to make sure you adjust the Fuel to Air mixture on the carburetor This is a common mistake with new pilots to not adjusting the Fuel to Air mixture based on the starting elevation This is something each pilot will learn about their engine and were to adjust the Fuel to Air mixture based o...

Page 19: ...clogged This is just a little screen inside the carburetor that keeps particles from entering your engine through the fuel As you run your Paramotor this will filter out particles and begin to restrict the fuel that can enter the carburetor As a part of the maintenance you perform on your Paramotor you want to periodically check on and clean this filter to assure your carburetor is working correct...

Page 20: ... keep in mind is to be safe Please fly in safe conditions and make sure your Paramotor and Paraglider equipment is ready for a flight 2 Begin by climbing to safe altitude There is no need to use extra throttle to get up quickly just fly like you normally would a You do not want to fly to high up or too far away from your Landing Zone You want to fly in that area so you can land quickly and check t...

Page 21: ...assures you that the Fuel to Air mixture on your carb is set correctly This will also help assure you get the most power and longest lifespan out of your engine Use the chart below as a guide to determine the correct Fuel to Air mixture that your engine is burning Spark Plug Lean Major The Spark Plug head will look greyish white in color There will be very little to no carbon buildup This can caus...

Page 22: ...piston rings causing the engine to loose compression The engine will run rough due to the dab mixture of Fuel to Air Uncontrolled Detonation of fuel in the cylinder that can cause the engine to overheat and burn up If you find that you need to adjust the fuel mixture on your Paramotor then you need to understand how to adjust the fuel mixture on the carburetor Use the picture above to locate the f...

Page 23: ...ast thing you want to do is to pull on the starter over and over again trying to get the fuel into the engine so it will run The first thing we suggest is to use a Zip Tie mounted to the Airbox so that you can easily setup the carburetor to be primed with fuel Carburetor Primer with a Zip Tie You can use the tip of a zip tie and slide that under the hose clamp so it is held tightly with the Airbox...

Page 24: ...el is flowing into the carburetor when you are squeezing the primer bulb If you are in a quiet place you can put your ear next to the carburetor and you can hear when the fuel squirt into the carb jets and into the engine The goal is to not over prime or flood the engine during this step At this point you should have enough fuel in the carburetor to give it a start Set the fuel metering diaphragm ...

Page 25: ...gine instead it might sputter a little bit but it will continue to run When you are turning the engine off there is no need to run the engine at a high rpm and then hit the kill switch This only floods the motor the next time you want to start it Starting Your Paramotor Electric Starter If you have an electric starter on your Paramotor then make sure the battery is plugged in and you can press the...

Page 26: ...ead center on the stroke and when it goes just pass this point you will hear a k thunk from the engine compression as it passes top dead center The compression stroke is what winds up the spring on the Flash Start Now you can let the pull start retract and on the second pull pull on the starter until you hear a click This is the point where the Flash Start is ready to engage Now give a normal pull...

Page 27: ... in a cool even temperature room between 60 and 85 degrees Fahrenheit Remember high heat humidity and direct sun light kill the rubber parts on your Paramotor engine If you put your Paramotor engine in a shed that sits out in the sun and the temperature in the shed reaches a 120 then you are not really helping your Paramotor engine Long Term Storage More than 30 days If you are not going to use yo...

Page 28: ... mixture is correctly being done by the carburetor and getting into the piston chamber so the spark plug can ignite it As a preliminary step you should pull the start cord on the engine not trying to start it and feel as you pull the cord that the engine has a resistance from the compression build up as the engine turns over and then a release of this pressure as it completes its engine cycle and ...

Page 29: ...is is a sign that you have flooded the engine The best way to fix this with the spark plug out is to start the engine and let the piston push out the excess fuel through the spark plug port that is open without a spark plug in it You should do this until you stop seeing fuel mist come out of the spark plug port If you are not in a rush you can remove the Airbox and spark plug and let the engine si...

Page 30: ...ugh The next part to check is the carburetor jets You will need to remove the air filter from the carburetor so you can see into the carb itself Then open the fuel metering diaphragm on the carb and then use the primer bulb to pump fuel into the carburetor If the carburetor jets are working correctly then you should see fuel drip from the jets in the carburetor You will need to hold the throttle v...

Page 31: ...used in the engine and this degrades gaskets diaphragms fuel lines filters etc Keep these tips in mind when you think about the maintenance of your Paramotor engine Please be aware that the climate you live in can greatly affect the rubber parts on your Paramotor direct sunlight and or high temperatures and or high humidity are the worst conditions and degrade these components faster than normal K...

Page 32: ... belt Verify the belt is not showing any signs of cracking on the edges Verify the belt is not fraying apart on the edges o Check the Fuel lines and Primer Bulb If fuel lines are not pliable or feel stiff when squeezed replace them If the Primer Bulb feels stiff its best to replace this o Drain and clean the fuel tank Remove the fuel tank from the Paramotor and disconnect the fuel line Then use re...

Page 33: ... age quickly and become brittle and are the most likely parts to fail if your Paramotor has been idle for a long period of time especially once they have been used with gas 4months Inspect the Fuel Filter as it may block fuel from passing though if it s to old Inspect the Fuel lines as they may become stiff and brittle and may leak fuel during flight if not checked Inspect the Primer Bulb as it ma...

Page 34: ... on your new engine to measure these points correctly If you do not have a Tachometer and Temperature gauge then we recommend that you work with a Paramotor expert to help you out with these steps When you begin to break in the Paramotor engine it will be off your back on the ground for these first few step Please make sure the Paramotor is secured to a rack and fence post a tree or something secu...

Page 35: ... a turn more Blackhawk Talon 190 Walbro WB37 Carburetor These settings are defined to be rich on purpose in order to avoid any damage to your engine Low End Screw o This requires a small flat tip screw driver o The mixture screw should be set to 1 1 8 turns o Turn the mixture screw clockwise just until it stops do not try to tighten the screw Then turn the screw counter clockwise 1 full turns plus...

Page 36: ...ld notice the engine will begin to run smoother When you let off the throttle the idle RPM should also be smoother then when you first started the engine Once your engine reaches a running temperature of 200 250 this stage is complete During this initial startup phase do not run the engine at a high RPM you want to keep the engine around 3000RPM to properly warm up the engine parts and to prevent ...

Page 37: ...the exhaust as these parts will be very hot from the engine test You may need to use gloves to protect your hands 5 Start the engine again and bring it back up to 4000 RPM in steps a Start at 2500RPM for 5min b Then go to 3000 3500RPM for 5min c Then up to 4000RPM for 5min 6 Then bring up the RPM on the engine to 4500RPM for 15min 7 Turn the engine off and again perform another visual inspection a...

Page 38: ... the engine This can be done with excessive loads by doing tandem rides or using full throttle on the engine for excessive periods of time You should always vary the RPM of the engine while you are flying this helps correctly set the piston rings You should also monitor the temperature of the engine during this period and avoid reaching or going over 400 204 Your First Flights After you have perfo...

Page 39: ...ight checks help assure you have a safe flight each and every time Post Flight checks are the most important as it helps assure your next flight is safe and if you find an issue it s not just before you want to fly Post Flight Checks A Post Flight check should be performed after each and every flight This is the best way to get familiar with your Paramotor because you will easily identify when som...

Page 40: ...o Warm up the engine Paramotor on the ground You can start engine on the ground secured to a rack fence post tree or something that will hold the Paramotor frame securely while the engine is running for this part only Do not rev engine past 2500 RPM to prevent the prop from spinning Only run the engine on the ground until it reaches a temp of 200f or until the idle RPM starts to level and smooth o...

Page 41: ...set to rich the fuel metering needle may not be seating properly allowing excess fuel to enter the carburetor and making it run rich Check the spark plug as it may be fouled Ignition Coil is Faulty Check the magnets on the flywheel are not rusted change the coil as a last step Low Compression Check for engine vacuum leaks check the cylinder head bolts torque check the reed valves as a broken reed ...

Page 42: ...recoil spring is broken in the pull start and would need to be replaced Excessive Smoke from Exhaust Air Fuel Mixture is Incorrect Carburetor mixture settings could be running to rich Incorrect Fuel to Oil Ratio The amount of oil in the fuel could be over the 40 1 ratio causing the engine to burn an excessive amount of oil Worn or stuck Piston Rings The piston rings are stuck in and not expanding ...

Page 43: ...lease contact us or a qualified BlackHawk Dealer for assistance Carburetor Section Zip Tie Primer Setup You can use the tip of a zip tie and slide that under the hose clamp so it is held tightly with the Airbox The zip tie is used to open the fuel metering diaphragm so you can easily prime the carburetor with the fuel primer bulb from the gas tank Once the fuel has reached the carburetor you need ...

Page 44: ...the fuel line firmly and slide and wiggle the pliers back and forth to remove the fuel line 4 Disconnect the vacuum line Again use a pair of pliers to grab the vacuum line firmly and slide and wiggle them back and forth to remove the vacuum line 5 Un screw the 2x 4 mm hex bolts that hold the carburetor assembly to the carburetor mounting plate Now you can remove the bolts with the Airbox adapter t...

Page 45: ...n top of the throttle cable plate and put that on top of the carburetor Then mount the assembly to the engine using the mounting points as shown above Tighten the bolts when you have the carb mounted correctly 3 Now you can connect the fuel line and the vacuum line from the engine crankcase to the carburetor 4 Re assemble the throttle Make sure you do not pull on the throttle cable to much as this...

Page 46: ...reen filter shown in the picture above Make sure you use the same size fuel inlet screen filter as there are 2 different sizes in the carburetor rebuild kit You can keep the rest of the parts as they may be helpful later on Talon 190 Carburetor Diaphragm Replacement 1 Working with the carburetor on a work bench remove the 4x screws holding the fuel pump cover on the fuel pump side of the carbureto...

Page 47: ...on top of the diaphragm Make sure the alignment holes are correctly lined up as shown by the arrows in the picture above 6 Install the fuel pump cover back on the fuel pump side of the carburetor and tighten the 4x screws that hold it in place 7 Flip the carburetor over to the other side so we can replace the fuel metering diaphragm and gasket 8 Remove the 4 screws holding the fuel metering cover ...

Page 48: ...u through how to remove the carburetor from the BlackHawk Lite 125 1 Remove the air box from the carburetor by loosening the hose clamp that holds the Airbox to the carburetor 2 Disconnect the throttle cable from the throttle arm on the carburetor Loosen the Barrel nut so it can slide off the cable Then you can slide the throttle cable out of the throttle arm in the direction of the arrow so it be...

Page 49: ...and wiggle the pliers back and forth to remove the fuel line 4 Disconnect the vacuum line Again use a pair of pliers to grab the vacuum line firmly and slide and wiggle them back and forth to remove the vacuum line 5 Un screw the 2x 4 mm hex bolts that hold the carburetor assembly to the carburetor mounting plate Now you can remove the bolts with the Airbox adapter that sits on top of the carburet...

Page 50: ...embly to the engine using the mounting points as shown above Tighten the bolts when have the carburetor mounted correctly 3 Now you can connect the fuel line and the vacuum line from the engine crankcase to the carburetor Make sure to re install the hose clamp on the fuel line and on the fuel inlet port on the carburetor The fuel line will come off or leak fuel if the hose clamp is not installed c...

Page 51: ...m so you can easily prime the carburetor with the fuel primer bulb Once the fuel has reached the carburetor you need to remove the zip tie from the fuel metering hole on the side of the carburetor so it will run normally Lite 125 Carburetor Rebuild Kit and the diaphragms used The carburetor kit will come with more parts then are used with these instructions You only need to replace the diaphragms ...

Page 52: ...nlet screen filter If you press down on one side of the screen with a small screw driver it will rotate out and you can grab it easily 5 The Carburetor kit may come with both a rubber and a membrane diaphragm Use the membrane diaphragm as it is more durable and longer lasting The rubber diaphragm will be colored black while the membrane diaphragm is a tan color 6 Install the fuel pump gasket on to...

Page 53: ...diaphragm and that assembly goes on top of the cover plate Make sure the alignment holes in both the gasket and the diaphragm are lined up correctly as shown above 12 Install the fuel metering cover plate back on the carburetor using the 4x screws from step 16 Carburetor Complete Rebuild Video If you are looking for more information about how to rebuild the carburetors used for the BlackHawk Lite ...

Page 54: ...s these parts need to be replaced Talon 190 Titan 210 Airmax 220 Fuel Line Parts Fuel line 1 1 4 inch internal diameter Fuel line 2 3 16 inch internal diameter Fuel Filter Fuel Primer Bulb 4x Fuel Clamp 4x Zip ties Lite 80 90 125 Fuel Line Parts Fuel line 1 1 4 inch internal diameter Fuel Filter Fuel Primer Bulb 4x Fuel Clamp 4x Zip ties Fuel Line Replacement Instructions 1 Begin by removing the f...

Page 55: ... tubing that is being used as a spacer with the zip ties to hold the fuel line in place These will be used again later to hold the new fuel line to the Paramotor frame 3 Un strap the Fuel Tank from the Paramotor frame and remove the fuel tank and fuel line assemble from the Paramotor frame 4 Remove the fuel line from the fuel tank by loosening the hose clamp at the bottom of the fuel tank ...

Page 56: ...e to look like your old one Use the same length fuel line between the fuel tank and the primer bulb and then from the primer bulb to the fuel filter Leave the 3 16 fuel line extra long from the fuel filter up to the carburetor We will trim this down when we attach the fuel line to the Paramotor frame a Lite 80 90 125 Motors i Use the 1 4 inch fuel line from the fuel tank all the way up to the carb...

Page 57: ...the fuel should be pointed towards the carburetor d The fuel filter has an arrow indicating in which direction fuel should flow through it Make sure the arrow is pointed towards the carburetor The small end of the cone points towards the gas tank 7 Use the fuel clamps from step 5 and re install these around the primer bulb and fuel filter 8 Connect the new fuel line to the fuel tank and then insta...

Page 58: ...of the fuel filter c Use 1 zip tie on the upper motor mount to hold the fuel line in place before it reaches the carburetor 10 Now you can hold the fuel line up to the fuel inlet port on the carburetor and determine where to cut the fuel line so it connects to the carburetor in a straight line The fuel line should not have any kinks or bends between the zip tie mount and the carburetor inlet port ...

Page 59: ...xhaust pipe Each bolt should be evenly tightened to assure the coupling applies even pressure while holding the exhaust pipes together Only tighten the bolt spring assembly enough to the point where you cannot rotate the coupling assembly by hand Do not try to re use high temp steel locking nuts Once they are removed they should be replaced If you want to be extra safe you can use 2 locking nuts o...

Page 60: ...idental falls crashes or dropping of the engine or its components Overheating and seizure of the engine due to prolonged high speed running of the engine running with excessive loads running with inadequate loads running with insufficient 2 stroke engine oil mixed with the fuel or running with no 2 stroke engine oil mixed with the fuel or with a carburetor that is not tuned correctly The presence ...

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