Minari 180 & 200 specifications, torque, & maintenance

Many of the specifications including maintenance intervals for the Minari are the same as for the Top 80 or the Thor engines e.g. coil clearance and the like..

Before putting any paramotor in service, new or used, CHECK THE TORQUE of the head nuts!

General

Clutch, bearings, manual start – inner bearing 17x35x10 SKF 6003 2RSH C3; outer bearing 15x32x9 SKF 16002-2Z (these bearings are better than OEM)

Clutch diagram manual start

Clutch diagram electric start

Cylinder gasket squish – 1.3mm -1.5mm (0.051"-0.59")

Cylinder head maximum temperature – see "Engine cylinder head maximum temperature" below

Engine compression – 90 psi at sea level; 4,000' MSL 80 psi.  These values are approximate.  Pressures are low because of the decompression port.

Engine cylinder head maximum temperature – 200ºC - 220ºC (390ºF - 428ºF)  The engine will be destroyed if it is run at temperatures higher than this for more than a few minutes!  Note: when the cylinder wall temperature exceeds 180ºC, the lubricating properties of the oil quickly deteriorate.  Minari allows 220ºC-260ºC but I do not recommend operating at these temperatures.

Engine dimensions

Engine 180, general information (from Minari)

Engine 200, general information (from Minari)

Engine, main bearings

Engine, main seals, dual lip – pulley side NAK TF 25x47x7; flywheel side NAK TF 20x47x7  – SEALS MUST BE IDENTICAL TO THE NAK TF!!

Engine, pulley – Use Top 80 clutch puller w 6mm bolts and 8mm flange nuts under the bolt heads to remove.  Heat not necessary.

Engine 180, parts diagram (non-clutched engine)

Engine 200, parts diagram (clutched engine)

Engine, piston-cylinder clearance – 0.04mm - 0.10mm (.002" - .004")  Example of how to measure piston-cylinder clearance

Engine, ring gap – 0.45mm - 0.55mm (.018" - .022")

Engine RPM, maximum – 8,000-8,300

Engine temperature – see "Engine cylinder head maximum temperature" above

Exhaust nuts – these nuts are prone to loosening.  Use RED threadlock on them and torque to the correct value (see "Torque values" below)

Fuel/oil specifications

Head temperature maximum – see "Engine cylinder head maximum temperature" above

Ignition, coil – many models IDM #150 (same as Top 80), coil must be installed with wiring facing out.  Some models use the more advanced IDM coil powered by a magneto.

Ignition coil primary resistance – 1.1 Ohms (but not zero)

Ignition coil resistance + OEM secondary wire resistance – 17.5K Ohms ±10%.  With our secondary kit installed, the value will be 8.8K Ohms ±10%.  Note: Minari, like Miniplane as of 2018, now uses the better ignition coil supplied by IDM.  The new secondary wire resistance is <15 Ohms which is the same as the secondary wire we supply in our replacement kits.  RATHER THAN MEASURE RESISTANCE WHICH CAN VARY FROM MODEL TO MODEL, TEST THE SPARK.

Ignition coil secondary resistance – 8K Ohms ±10% (depends on model)  Measure with a needle stuck into the secondary wire right where it comes out of the coil.  See the paragraph above for a better way to test the ignition system.

Ignition coil to flywheel gap – 0.38mm (0.015")

Ignition timing – clutched engines 15-16º BTDC; non-clutched engines 18-19º BTDC.

Parts diagram – see "Engine, Parts diagram" above

Piston ring gap – see "Engine, ring gap" above

Propeller bolts – qty (6)  55mm x M8  70mm x M8  90mm x M8 depending on the propeller construction.

RPM maximum – see "Engine RPM, maximum" above

Spark plug – NGK BR8ES (cold weather); BR9ES (hot weather) This spark plug is a resistor type in order to help suppress ignition noise.  The B8ES or B9ES can also be used without any problems but you may notice more radio interference.

Spark plug gap – 0.7mm-0.9mm (0.027" - 0.035") Always set the gap to the minimum.  Electric start engines do not spin the flywheel fast enough to generate the typical 20KV spark but only a 5KV spark which needs the lesser gap.  The greater value is the maximum value, not the range.  You cannot gap the plug correctly without a wire-type gauge!

Speed system pulley – Harken H404 (superior to any of the OEM brands, especially Viadana)

Starter cord pulleys – Harken 082 (superior to the OEM Viadana)

Temperature maximum – see "Engine cylinder head maximum temperature" above

Threadlock – read this important page on threadlock and how to use it and when NOT to use it.

Timing – see "Ignition timing" above

Weight, dry – 24 kg (53 lb) manual start, no fuel, includes the complete Miniplane frame.  Add 1.1 kg (2.4 lb.) for electric start

Torque values

Torque values for the Minari – This handy page was created by Frank Hoffmann and was gathered from experience and the values given on page EN17 of the Minari User Guide.  The Minari guide is not very useful because it has too many values missing and some errors e.g. "carter screws" should be "starter screws".  NOTE: The exhaust nuts (#18) are prone to loosening.  Use RED threadlock on them and safety wire.  The safety wire will ensure that the nuts holding the exhaust manifold assembly will not fall off.

Go to the Top 80 specification page to read the torque section if you cannot find the value you need in Frank's page or in the Minari User Guide.  The Top 80 page has a discussion on torque and why different value must be used sometimes.

The Italian paramotor manufacturers continue to use button-head screws on their engines, regardless whether they are needed or not.  Button-head screws have soft heads which make them very easy to strip with a hex bit when attempting to remove them.  Replace them with hex-head or socket-head screws, as necessary.

If you do not see the torque for a particular screw, bolt, or nut in Frank's table, use the general values below:

Maintenance

This maintenance schedule here is for average use.  If you run at full power most of the time, fly near the ocean, or launch from sandy areas, you may have to check and replace things more often.

Use a Sharpie to write reminders on the top of the redrive (or other semi-flat area).  They are easily removed/changed with mineral spirits.  This way, you won't forget.  You have an hour meter/tachometer installed right?

writing reminders on the Top 80 redrive

ALWAYS check the torque of the cylinder head nuts after a few hours on new engines or engines that have had cylinder head maintenance!

First 1 hour

Belt tension – new belts loosen up very quickly and must be re-tensioned after an hour or two use.

NEW engines

Every year (minimum)

Every 15 hours

Every 25 hours

Every 50 hours*

Every 100 hours

Every 200 hours

Every 400 hours

*Every 50 hours if AVGAS is used

Reed petal note:  You do not want the petals breaking off and going through the engine as here.  Photo courtesy of Tom Bird

broken reed valve petal

Turkey Vulture