paragliding training center
by Had Robinson
Updated January 2019 – the tool part numbers are from Harbor Freight (U.S.A. only).
You have purchased a $6,000 paramotor and you are going to use $10 worth of tools (some screwdrivers and a pair of pump pliers) to work on it. I hope this does not make sense.
These are the tools that you need to properly service most paramotors including the Top 80. While Harbor Freight does not make professional quality tools, they are more than adequate for the occasional mechanic. Failure to use the proper tools is a guarantee that you will damage your engine. Suffice it to say, there are some who lack basic mechanic-type skills or would rather not work on their engines. In that case, contact us or a competent local mechanic who knows high performance 2 cycle engines. These are almost always the the chainsaw, kart racing, or dirt-bike guys and it is worth the effort to find out who they use to service their engines. If at all possible, find a kart racing engine expert. These guys are the world experts on 2 stroke engines.
I do not recommend taking these finely tuned, high performance engines to a lawnmower repair shop. Most of them are incompetent and will wreck your paramotor. Most motorcycle shops do not even know what a diaphragm carburetor is or how it works, I am sorry to say. If you do not know what a torque wrench is or how it works, you will find servicing any engine challenging. Our site can help but you may have to do a web search for the really basic instructions of engine repair and how the tools work.
The tools listed below are followed by the Harbor Freight stock number, if they carry it. A few items are only available from auto parts stores, from a specialty tool supplier, or from Amazon.com. The stock numbers, brands, etc. may change over time so pilots may have to do a little extra work to locate the tools listed here. Often enough, these tools are on sale at HF, sometimes at 50% or more off. It is easiest to go online and order by stock number. These tools are also available in auto parts stores but you will pay much more for them and they are of the same quality. The basic tool set will allow pilots to work on nearly everything except some parts of the ignition system and the crankcase assembly.
See the Fuel equipment, section A, for the equipment needed to safely fill, drain, mix, store your fuel.
Air compressor with accessories #61615, #68260, #60356
(best) or a can of compressed gas used for removing dust
Air-tool oil #68094 – this oil is lightweight and contains no detergents or additives as does automobile engine oil.
Anti-seize lubricant – available from auto parts stores
14 Oz. Brake cleaner – this is required to remove grease, oil, and grime from parts before assembling. Auto parts stores have it.
Clutch puller Tool #MANEF – available only from Miniplane-USA (for the Top 80 engine only). Other engines may require special pullers!
Compression Tester Kit 8 Pc #69885 If you have a flash starter on your engine, this tool will not work.
2-1/2 lb. Neon Orange Dead Blow Hammer #41798
Depth gauge – used with the digital caliper to measure the metering lever value (optional – see the tune up page step #12)
6 in. Digital Caliper with SAE and Metric Fractional Readings #68304 Professional calipers are more accurate but the HF ones will work.
7 Function Digital Multimeter #90899 It is an amazing value at $10 for its accuracy. The more expensive ones are easier to use and tougher.
Permatex part #81950 Ultra Slick Engine Assembly Lube, 4 oz. – put on all sleeve bearings when assembling them. Available from auto parts stores.
3/8" x 6" extension – available from auto parts store but not from Harbor Freight
16 oz. ball peen Hammer #61304
2.5 lb. dead-blow Hammer #69003
10 Pc Metric Hex Key Set # 94597
6 Pc 3/8 in. Drive Metric Hex Socket Set #69546
7 Pc 3/8" drive metric extra long hex bit socket set (to remove the cooling box from the engine)
Fine Hook & Pick Set #93514
Mini Hook and Pick Set #66836 – very handy for picking out seals and small parts that fall down holes in the engine
Hoses – 1/4" and 1/8" hoses are handy to have. Miniplane USA and auto parts stores sell them by the foot.
White lithium grease, small tube – available from auto parts stores. I don't recommend the spray-can type.
18 in. Telescoping Magnet tool #37187 Ever drop a nut down some hole? Can't get your fingers in somewhere? This tool can be very useful.
Technical Measuring Set 6 Pc #94447
Needle File Set 12 Pc #00468
7 Pc Pliers Set #69357
Puller set, bolt type #62620 – used to aid in the removal of propeller hubs
Puller set, three-Jaw 3 Pc #69105 – used to disassemble a redrive on engines that have them
Pin Punch Set 8 Pc #93424
3 Oz. Clear RTV Silicone #96041 – DO NOT USE ORDINDARY HOUSEHOLD SILICONE GLUE!
8 Pc Screwdriver Set #94607
Chapman screwdriver kit model #8900 – optional and available from Amazon or eBay, it is expensive precision set of tools.
Siphon for fuel transfer – see the "Fuel equipment" section. A "jiggle-type" siphon is the best way to move fuel around.
21 Pc 1/4 in. Drive Metric High Visibility Socket Set #67998
20 Pc 3/8 in. Drive Metric High Visibility Socket Set #67999
Lead-Free Rosin Core Solder #69378 – used to measure cylinder head/piston spacing (a.k.a. "squish")
K-D 165 Spark Plug Gauge & Gap tool – this is the only gauge with the right sizes for paramotor spark plugs. Available from Amazon.com
Lisle #20200 Spark Plug Hole Thread Chaser – available on Amazon for around $5. This is a critical tool per recommendation of NGK.
3/8 in. Drive 13/16 in. Sparkplug Socket #67793
18 In. Low Voltage Test Leads #66717 (these are needed to connect the multimeter to various part of the engine)
0.20 oz. Semi-Permanent blue Threadlock #96059
0.20 oz. Permanent red Threadlock #96055
3/8 in. Drive Click Type Torque Wrench #807 DO NOT USE TORQUE WRENCHES WITH ADAPTERS!
1/4 in. Drive Beam-type Torque Wrench – It is better to get this beam type torque wrench rather than the HF cheapie which is not as precise.
Stainless Steel Toolbox – 20 in. #93168 – the plastic ones tend to fall apart with ordinary use. The bag types do not protect your tools well.
6 in. swivel vise with Anvil #67040 (highly recommended but optional)
12 Oz. WD-40® Smart Straw Lubricant #93189 – don't even think of working on an engine without this stuff
9 Pc Metric Combination Wrench Set #42305
If you plan to do any ignition work you will need these tools:
Feeler Gauge 32 Pc #32214 quantity (2)
Hand Riveter Set #38353
Aluminum Blind Rivet Assortment (500 Piece) #67668
3/8 in. Variable Speed Reversible Drill #60614
High Speed Steel Drill Bit Set 13 Pc #61723
1500 Watt Dual Temperature Heat Gun 572°/1112° #96289
42 Pc Marine Heat Shrink Tubing Assortment With Case #67598
Here are the special tools needed that are not included above:
If you are planning to check or adjust the timing of your engine, go to the check timing page or the timing page on this site, respectively, for the tools needed. You should not have to check/adjust the timing unless there has been some catastrophe....