Polini Thor 100, Thor 200 Use And Maintenance Manual

THOR 100 - 200

USE AND MAINTENANCE MANUAL

PI 470

INTRODUCTION

Congratulation for purchasing a Polini engine. By purchasing it
you have become one of a large family of satisfied Polini pro­ducts owners. Thor product has been designed to perform as com­petitively as possible. Read this use and maintenance manual
carefully throughout before flying with your new engine. This
manual contains important information that will help you to
achieve the best satisfactions with the use of the Thor 100 engi­ne. To ensure care-free and satisfying usage you must get to
know your new engine thoroughly and set it up correctly before
you start using it.

INDEX

1- GENERAL ADVICES
2- FUEL
3- ENGINE STARTING
4- RUNNING IN
5- ENGINE SWITCING OFF
6- CARBURETION CHECK
7- CLEANING
8- CARRIAGE
9- ORDINARY SERVICING
10- HOW TO BEHAVE IN FLIGHT
11- ENGINE FITTING ON THE FRAME
12- SERVICING TABLE

1- GENERAL ADVICES

Polini Motori and the distributor decline any and all responsibility
whatsoever - either direct or indirect - for the use of the engine,
above all in the case the engine is modified or manumitted by
third parties. Polini Motori doesn’t assume responsibility for
damages caused by little servicing or wrong assembly, excluding
the pieces from the warranty. Any technical modification may be
introduced by the buyer, who assumes all the responsibilities for
possible damages; spare parts for any modification are not under
warranty. We advice you that any engine modification made by
the buyer or the removal of original parts may make the engine
dangerous to be used!
The user is invited to respect and follow what written in the use
and maintenance manual for his own and third parties safety.
When you use this engine you are making a very dangerous
action, so you may have the maximum care before, during and
after flying, in order to avoid serious accidents. We invite you to
be careful to prevent accidents or damages and to keep always in
mind that:

- the engine can’t solve all the flight problems, so it is important
to avoid dangerous maneuverings. One of the most common
errors is to fly over zones where it is not allowed to land; you
have always to take into consideration the possibility of engine
failure or the need to make an emergency landing. It is forbid-

den to fly over built-up areas, urban centers, to drop things or
liquids when flying.

- the lack of engine power can disturb the flight stability: the
engine could stop suddenly and you may be obliged to make an
emergency landing on a safety area.
Before using it, for your own and third parties safety, it is neces­sary to be sure that the weather conditions are good, or anyway
adequate for a safety flight, in order not to compromise the good
engine work. Rain or unfavorable weather conditions, besides
being dangerous, could also damage the engine, prejudicing its
normal working. It is not allowed to use the paramotor when
raining or with strong wind. Only fly if the wind speed, its direc­tion and the conditions grant a safety flight. It is important to
check the weather forecasting for the hours close to the flight
and to know the taking off and landing areas. Because of the

risks inherent to the paramotor use, and the flight,
Polini doesn’t give any warranty against accidents,
breakings, injuries or death. To fly with a paramotor
always needs great attention. Be aware that you fly at
your risk. Before every use check the good condition of
your paramotor. This engine is not covered by any
responsibility insurance. By using it you automatically
assume all the risks inherent the paramotor sport or
the personal responsibility towards damages to
yourself or to third parties, accidents, injuries or death.
We invite you to carefully read the instructions contai­ned in this manual since they are helpful for a better
knowledge of the products and the use itself and useful
to prevent and contain the risks.

WARRANTY

All the Polini engines are manufactured with high quality mate­rials which grant a product without defects, under the conditions
that the buyer purchase the products from a Polini authorized
dealer.

VALIDITY OF THE WARRANTY

The warranty is valid for a period of 12 months from the date of
purchase. It is necessary to activate the warranty by filling the
form out and keeping the payment slip or the invoice.

COVERAGE

The present warranty covers the engine damages caused by
defective parts, in shape or materials, for projects not in confor­mity with the use indicated, wrong assembly by the manufactu­rer. The warranty includes spare parts only. Delivery costs
are charged to the user.
The warranty doesn’t cover damaged caused by:

- Engine modifications not approved by Polini;

- Wear and tear of the parts;

- Carelessness, lack of servicing, accidents, installations or wrong
maintenance;

- Accidental falls or engine fall or of its components;

ENGLISH

TECHNICAL LIST THOR 100

Polini Engine 2 stroke monocylinder
Cooling Forced air
Bore for stroke 52 x 52
Displacement 110 cm

3

Power 20,5 HP at 8900 R.P.M.
Cylinder Aluminum with Gilnisil coating
Compression ratio 12,5:1
Piston Two chromium plated rings mm 1
Intake Reed valve in the crankcase
Carburetor Walbro / Polini PWK
Air filter Air box
Ignition Electronic and with battery charger possible
Battery charger prearrangement Output power 80 W at 5500 RPM
Spark plug hood 5k Ω resistance
Fuel type Lead free petrol with 2% synthetic oil
Gear reduction unit Helical teeth in oil bath with 3,43 reduction ratio
Starting Pull start with self winding cable
Clutch Centrifugal in oil bath
Muffler Expansion with oval silencer
Engine weight 13,8 Kg
Propeller rotation Clockwise

TECHNICAL LIST THOR 200

Polini Engine 2 stroke monocylinder
Cooling Forced air
Bore for stroke 64 x 60
Displacement 193 cm

3

Power 29 HP at 7400 R.P.M.
Cylinder Aluminum with Gilnisil coating
Compression ratio 11,4:1
Piston Two chromium plated rings mm 1
Intake Reed valve in the crankcase
Carburetor Polini PWK Ø 28 / Walbro
Air filter Air box
Ignition Electronic and with battery charger possible
Battery charger prearrangement Output power 80 W at 5500 RPM
Spark plug hood 5k Ω resistance
Fuel type Lead free petrol with 2% synthetic oil
Gear reduction unit Helical teeth in oil bath with 2,8 reduction ratio
Clutch Centrifugal in oil bath
Muffler Expansion with oval silencer
Engine weight 17,5 Kg (18,5 with electric starter)
Propeller rotation Clockwise

- Engine improper use or misusage;

- Assembly of parts or components not specified for the engine
use;

- Engine overheating or stop after long usage, beyond the term
indicated by Polini;

- Missing or irregular engine servicing as suggested by Polini, use
of improper petrol or oils, presence of dirty parts or foreign
bodies in the engine, even sucked;

- Engine overwork because overloaded;

- Engine or parts deterioration because of improperly storage;

- Faulty engine assembly, including the use of not original Polini
parts or coming from third parties;

- Damages to the engine caused by foreign bodies;

- Servicing operated by person outside Polini or by not authori
zed people;

- Competition use of the engine.

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 are 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 a paramotor or only

switches it on assumes all the risks inherent to the

paragliding sport and all the responsibilities for dama­ges to things or persons or death caused by the use of
this product.

2- FUEL
Thor 100/200 is a 2-stroke engine that needs oil/petrol mixture.
Only use good lead-free petrol purchased by a petrol station with
98 octane. Add good 2% synthetic oil to the petrol. It is possible
to use a 1,5% oil mixture with the following oils:
MOTUL 800 - CASTROL 242 - BARDAL KXT - ELF 976 - ELF 909.
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.

3- ENGINE STARTING

Start the engine only when all is in good conditions and perfectly
working. Furthermore check that all the nuts are well tightened.

3.1 WALBRO CARBURATOR (THOR 100-200)

First cold starting: fill in the fuel system using the pump provided
(carefully follow the instructions provided by the frame’s manu­facturer to find out it and use it in the correct way). To make this
operation easier push softly with a finger the diaphragm through
the hole indicated by the arrow in photo 1. Fill it in till the petrol
reaches the carburettor. At that moment immediately stop; if you
go on acting on the pump the petrol will leak causing the engine
flooding.

01

WALBRO WG8 CARBURETOR (THOR 100 engine only):
Move the starter level to the off position (photo 1); now hand the
starter and start pulling the rope till it grows hard. Pull with
strength without accelerating till the engine seems to start wor­king (do not repeat this operation more than 3 times otherwise
the engine may flood). Now move the starter lever to the on

position (photo 2) and act on the starting rope without accelera­ting. If the engine doesn’t work with the first two attempts, try
again accelerating gently.

02

3.2 24/28 PWK CARBURETOR

Fill in the fuel system till the petrol reaches the carburetor hole
and then pump up three times (using the pump provided- Code

316.0016) to fill out the bowl. To start the engine pull upwards
the black level placed in the upper side of the carburettor.
Work the starter without accelerating till the engine start. Once it
works 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!

3.3 THOR 200 ENGINE STARTING WITH ELECTRIC
STARTER

According to the carburettor model (Pwk or Walbro WB37) refer
to section 3.1 and 3.2 to fill in the fuel system. For the model
with electric starter the Polini throttle system has 3 buttons on the
bottom part of the throttle device. To start both the engines push
the black buttons together and slightly accelerate. For your safety
only proceed with this operation after your harness has been
COMPLETELY fixed!

ATTENTION: keep the switch in your hand during all the stages
and be ready to work it in case of any anomaly. 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 idle until it warms up to normal
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 idle 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 (section

6). Repeat the running in every time you change one of the fol­lowing parts: piston, rings, cylinder, crankshaft or main bearings.

5- ENGINE SWITCING OFF

Switch the engine off by pressing the button till the complete stop
(see the frame manufacturer’s instructions to find the button
position)

6- CARBURETION CHECK

For a complete carburetion check switch the engine off after
having worked it for some minutes under load. Remove the
spark plug; unscrew it by using the proper key and verify that
the porcelain colour is light-brown. On the contrary, ask to an
authorized dealer for the calibration.

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 cold. Follow the

frame manufacturer’s instructions for its carriage. Be careful of
the petrol during the carriage; its leaking may cause a fire.

8.1 CARRIAGE OF THE ENGINE WITH PWK
CARBURETOR

PWK 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 3 with an arrow) and wait till
the fuel enters the tank. Close the brass connection again. Now
the carburettor is empty and you can lay the engine ready to be
carry.

ATTENTION: never unscrew more than half a turn the bre-

ather nut to avoid damaging the OR seal. Never close too hard.