Owners Manual
Contents
1. Check that needle settings are not too lean air flow for cooling is sufficient and oil gas mixture is correct e Engine starts backwards 2 stroke reed valve engines can generally run in either direction Make sure the prop is flipped forcefully through the compression stroke Without enough force the prop may bounce off compression and run backwards IF ANY PROBLEM PERSISTS PLEASE CONTACT DESERT AIRCRAFT FIRST We designed and manufactured your engine and have built serviced and analyzed thousands more We cover your engine s warranty not someone at the field or a stranger on the Internet Please give us the opportunity to help first 6 Maintenance Being a high performance 2 stroke engine certain parts can wear quickly Under normal operation pistons piston rings needle bearings spark plugs etc may need occasional non warranty replacement to insure peak performance Other factors can hasten the need for replacement parts such as ingested dirt and debris exceedingly high temperatures due to improper lubrication airflow improper needle adjustments excessive prop loads etc If the engine has been involved in a crash or severe prop strike inspect it carefully for any signs of damage before operating the engine Make sure nothing was ingested into the engine Check that the prop hub rotates freely and without any run out or wobble Look for any signs of cracks in the case especially near the motor mount area2. We highly recommend filtering the gas entering the fuel tank from your field container e Cooling is critical to motor performance and longevity Allow as much cooling air as possible in through the front inlets of the cowl Air must flow through the cylinder fins not just inside the cowl to properly cool the motor Don t let the air take the easy way out Make it go through the fins Round cowls with large frontal openings need ducting to direct the air through the cylinder fins Allow an outlet opening approximately 2 1 2 times larger than the intake at the bottom rear of the cowl for the hot air to escape Without this outlet opening air won t flow through the cowl e Air ducts can be made from thin plywood balsa fiberglass or aluminum sheet to guide and force air from the front inlets to and through the cylinder fins e Keep components like the ignition system fuel tank fuel lines receivers etc shielded from heat generated by canister and tuned pipe exhaust systems Hot fuel tanks and fuel lines can cause frustrating tuning issues and over heated electronic components can have intermittent problems or total failures Ignition System When making electrical connections to the ignition system use the same gauge wire or larger as used on the red and black power leads on the ignition module all the way to the battery pack Keep wire length to a minimum Heavy duty plugs as supplied on the ignition or as used on electric cars and pla
3. Country Single Ignition Serial Twin Ignition Serial Prop Bolts Prop washer Muffler s Muffler screws Standoffs Other Items REASON FOR RETURN Crash Yes No Other Oil used Gas type Exhaust system type Has the engine been sent in for service before DESERT AIRCRAFT 1815 S Research Loop Tucson AZ 85710 520 722 0607 info desertaircraft com www desertaircraft com Why DA85 Serial DA150 Serial Other DESERT URCR
4. If the spark plug cap shows any damage do not operate the ignition If there is a short inside the cap it can cause damage to the ignition module Screws can come loose After a few flights check that all screws are secure Periodically check that all screws are tightened to the correct torque rating It s recommended to replace rather than re use the red aluminum screws whenever they are removed If exhaust flange screws become loose the flange face and threaded holes can be damaged to the point where the header or muffler won t stay tight and the cylinder needs to be repaired or replaced Torque specifications Size Torque setting Spark plug CM 6 10mm 90 in lbs Steel prop bolts M5x 45mm 75 in lbs wood props 90 in lbs carbon props Aluminum crankcase bolts M5x16mm 70 in lbs Steel cylinder base bolts M5x16mm 95 in lbs Aluminum carb mount bolts _ M5x75mm 50 in lbs Caution Care must be taken to not over tighten the carb mounting bolts Over tightening can distort and damage the injected molded reed valve parts and rubber gaskets e Use a 4m hex wrench for all M5 cap screws e For spinner mounting the crankshaft extension is threaded for M5 screws In this application steel to steel the 10 32 SAE screws supplied with most spinners will work fine in the M5 threaded hole Do not substitute 10 32 screws for any other screws on the engine e Inspect the engine periodically for any signs of fuel seepage This can indicate
5. area is free of dirt sand gravel or other loose debris Turn on the radio system and check the throttle operation and position Have someone with eye protection firmly hold the plane from a position behind the wing Close the choke completely Open the throttle to approximately 1 4 position Turn on the ignition ALWAYS BE PREPARED FOR THE MOTOR TO START ON ANY FLIP OF THE PROP whether the ignition switch is on or off Give the prop a quick firm flip counter clockwise Follow through quickly as you flip the prop so that your hand is out of the propeller s path Repeat until the motor fires or pops Open the choke Set throttle to idle position carb butterfly plate slightly open Flip the prop again until the motor runs Let the motor warm up for 15 or 20 seconds before advancing the throttle The needle farthest from the motor is the High End needle The needle closest to motor is the Low needle Turning the needles in clockwise leans the fuel mixture Turning the needles out counter clockwise richens the fuel mixture Settings will vary with altitude temperature humidity fuel carb variances etc A general starting point for the DA60 is 1 1 8 open on the Low needle 1 open on the High needle Adjusting either needle can have a slight effect on the other Example Leaning the low needle can slightly lean the high rpm range Adjust the High End needle to peak rp
6. to be bench run e Do not remove the carb s choke or throttle butterfly shaft assemblies e The carburetor should have at least 1 2 18mm of clearance between the intake and the fire wall or any other object that can restrict airflow into the carb If necessary make an opening in the firewall to clear the carb e Since the cowl effects air flow and pressures we recommend that the carburetor needles can be adjusted with the cowl on To do this small access holes can be made in the cowl for using a long narrow screw driver to adjust the needle valves Short guide tubes can often be glued into the firewall or mount to help guide the screw driver to the needles e A 24 oz or larger fuel tank is recommended The tank must be vented The carb has a strong pump so the tank can be mounted almost anywhere in the plane Keep the fuel line away from any hot engine or exhaust components The fuel line and tank stopper must be gas compatible Do not use any silicone sealers on the fuel system Gas can break it down and carry it into the carb e The inner diameter of the fuel tubing should be the same size or slightly larger than the carburetor s fuel inlet fitting s inner diameter We use 1 8 Tygon tubing Make sure all fuel line connections secure Small nylon zip ties work well to keep the fuel line on the metal fittings Make sure the fuel line is secure and not touching the exhaust or cylinder fins An inline fuel filter can be used
7. Never use a damaged or repaired prop or a prop that has struck the ground or any other object Damage that can be hard to see could turn into disaster when turning at thousands of RPM Fuel and Mix Use Premium pump gas such as 91 to 93 octane We recommend purchasing your fuel from name brand gas stations We have seen problems with cheaper gas from some discount type outlets We recommend filtering your fuel between your fuel container and your plane s fuel tank A high flow filter or clunk filter between the tank and motor is also a good idea Make sure the plane s tank is well vented and the fuel clunk moves freely Use of any other fuel or additives such as nitro formulas aviation gas white gas etc can harm the motor and void the warranty Do not use silicone sealers on the fuel system Gas can break it down and carry it into the carb We recommend a high quality synthetic oil As for brand of oil there are many good ones on the market Some oils and their mix ratios that Desert Aircraft recommends are Red line Two Stroke Racing Oil 40 to 1 Motul 800 50 to 1 and Stihl HP Ultra 50 to 1 These oils can be found at most motorcycle or chainsaw shops An option for initial break in is to use a petroleum based oil such as Lawn Boy Ashless 2 stroke oil mixed at 32 to 1 This can speed ring seating and limit the opportunity for blow by that can cause permanent damage 2 gallons fuel oil mix is sufficient Mix 2 gall
8. an air leak which can create a lean fuel air ratio which in turn can cause erratic running and engine damage If tightening the appropriate screws does not cure the problem contact Desert Aircraft e After prolonged use carbon deposits can build up on top of the piston and on the combustion dome of the cylinder Great care must be taken when trying to remove these carbon deposits to avoid damaging the parts Once an attempt to remove carbon has been made the task must be completed as any remaining carbon may be loosened and can dislodge while the engine is running This can damage the engine and or bridge the spark plug e Ifthe engine is going to be stored for long period of time it is recommended to run a few minutes worth of non ethanol fuel through the engine This can help reduce the chance of corrosion from water associated with ethanol in gasoline Often larger gas stations offer race gas or other high octane ethanol free gas Manuals may be updated with additional tips and trouble shooting info from time to time Please check our web site www desertaircraft com for current downloadable manuals and updates or contact Desert Aircraft DA60 WARRANTY Your DA60 motor and ignition system are covered with a 3 year warranty by Desert Aircraft starting from the date of purchase e This warranty covers defects in workmanship and materials only We strongly recommend to not disassemble the motor or ignition system Improper d
9. be hard to see could turn into disaster when the prop is turning at thousands of RPM Motor Installation e Mount the motor using high grade 1 4 or 6mm dia bolts with washers and locking nuts on the rear of the firewall Make sure your firewall is structurally sound The crankshaft centerline is in the exact center of the rear mounting plate bolt pattern e The preferred method to mount the is for the engine to bolt directly to the firewall with the carb protruding through a hole in the firewall This may require removing the firewall and extending the motor box and firewall to the proper dimension that lets the prop hub protrude from the cowl far enough to ensure clearance for the spinner back plate e Standoff mounts are not recommended and can damage the engines crankcase Rigid full contact mounting can reduce vibration If the engine needs to be spaced off the firewall we recommend making a full contact spacer by laminating aircraft plywood to the required thickness e The throttle arm is pre tapped for a 2 56 linkage Do not use a clevis type connector Make sure the carburetor s idle set screw is removed or set so that the carb can be fully closed by the servo at low trim Use a high quality servo for the throttle A poor quality servo or linkage will not provide accurate and repeatable throttle settings Don t use metal to metal linkages e You can un hook but don t remove the throttle return spring if the motor is not going
10. er radio issues Recommended Props Always check and tighten prop bolts before each flight Loose prop bolts allow prop movement which will shear the bolts Always use the correct length prop bolts If a spinner back plate is not used the prop bolts may be too long and can bottom out in the hub before they fully tighten against the prop washer DA60 has a very wide power band The normal peak operating rpm is 6 300 to 7 300 rpm While special break in props are not required be careful to not overload the engine during break in Some recommended props are Wood 22x10 23x8 23x10 24x8 24x10 Mejzlik Carbon 23x8 23x10 24x10 24x10 TH Mejzlik Carbon 3 blade 21x12 22x10 A general rule of thumb for good flight performance is the larger and or heavier the plane the lighter the prop load to allow the engine to create more horse power On a lighter smaller cleaner airframe horsepower requirements are not as critical You may enjoy the benefits of a larger prop disc for better down line braking torque rolling etc Smaller diameter props with more pitch especially 3 blades can reduce tip speed and noise Always use a drill guide to drill your props We normally drill from the back side first then again from the front to insure the screws don t bind in the holes Always check the balance of your prop For safety we recommend painting the tips of your props front and back with a bright color especially on black props
11. ge e ls throttle set at idle slightly higher after motor pops and choke is opened e sure prop is flipped over with authority The ignition won t fire at low speed e lf alot of fuel drips from carb the motor might be flooded If so remove and dry or replace the spark plug Try starting again without using the choke If engine doesn t fire after several flips try choking again Other issues e RPM won t go over 3 500 to 4 000 The connector between the ignition module and ignition sensor may be plugged in backwards Check the color of the wires leading into the connectors to make sure that the polarity is correct e Broken prop bolts In order for bolts to shear some type of side loading shear movement is usually required If the bolts are tightened correctly nothing moves and prop bolts will rarely break It s a good idea to replace prop bolts routinely Check prop bolts before each flight e Excessive vibration Check that the low rom needle setting is not too rich Check prop and spinner balance Make sure ignition timing is correct Check the firewall and motor box area of the aircraft for movement poor glue joints etc This area must be rigid Some aircraft on the market are lacking in this area and may require additional glue and or structure Poor quality or contaminated fuel can cause rough running e Pink or purple colored cylinders These colors indicate engine temperature has been too high at some point
12. isassembly or assembly of the motor or ignition system will void the warranty on that item e Any modifications to the motor or the ignition system other than those authorized by Desert Aircraft will void this warranty This warranty does not cover the following Shipping expenses to and from Desert Aircraft for warranty service Damage caused by improper handling operation or maintenance Damage caused by a crash Damage caused by using improper fuel or additives Damage incurred during transit to Desert Aircraft WRAP AND PACK ENGINE CAREFULLY NOTE DESERT AIRCRAFT WILL NOT SHIP ANY WARRANTY REPLACEMENT ITEMS UNTIL THE POSSIBLY DEFECTIVE ITEMS IN QUESTION ARE RETURNTEND TO AND RECEIVED AND DEEMED DEFECTIVE BY DESERT AIRCRAFT Remember This motor can stop at any time for a variety of reasons Do not fly your plane in a way that damage or harm will result if the motor stops running Desert Aircraft will not be responsible for damage caused in engine out situations DESERT AIRCRAFT 1815 S Research Loop Tucson AZ 85710 USA Ph 520 722 0607 Fax 520 722 5622 Email info desertaircraft com Web www desertaircraft com Repair Return Form Please make copy Please fill out and enclose this form when shipping items for service Customer Name Address City State Zip Phone Cell Email ltems in Box DA50 Serial DA60 Serial DA100 Serial DA120 Serial DA170 Serial DA200 serial Date
13. ly secured when starting or operating the motor Inspect motor mount bolts and firewall integrity before operating the motor Anyone in the immediate area of the motor should use eye protection during operation of the motor Keep spectators at least 30 feet away when operating the motor Turn off the motor before making any adjustments Always use the correct length propeller bolts Do not use spacers behind the propeller Spinner cones must not touch the propeller Thinner props may require using shorter prop bolts especially if not using a spinner back plate Make sure your prop bolts do not bottom out in the propeller hub Check that the propeller bolts are tight before every flight Always install an ignition kill switch to stop the motor Adjust the carburetor linkage so that the motor will stop when the carburetor is completely closed Gasoline is extremely flammable Be careful of any sparks from electrical contacts such as fuel pumps battery chargers etc Do not allow smoking in the area of your fuel supply or motor Store fuel in approved containers and in well ventilated areas Allow the motor to cool before touching or fueling Always flip the prop a few revolutions after running the motor to discharge the ignition system The ignition system develops extremely high voltage Do not touch it during operation Never use a damaged modified or repaired prop or a prop that has struck the ground or any other object Damage that can
14. m A tachometer can help but remember that the RPM normally drops a little bit after every start due to residual heat build up Don t lean the mixture any more than necessary If the rom steadily drops at full throttle or fades on long vertical maneuvers the motor is too lean and is overheating Cont d 5 Needle Adjustments Cont d e Adjust the Low End needle until you achieve a smooth idle and a reliable transition to high throttle Generally if the motor stutters or coughs in the mid range or when the throttle is advanced the low end needle is too rich and possibly even the high end needle If the motor dies quickly the low end is probably lean e Don t set the needles overly rich to protect the engine Operating the motor overly rich not only reduces power it creates other problems such as poor transition pre mature carbon build up fouled plugs excessive exhaust residue sticking rings airframe vibration and overall rough running Trouble Shooting Motor won t start e Check battery voltage should be 5 0 volts and all ignition connections wiring and switches Wires can break from vibration near connectors Check and or swap out regulator e Does fuel move towards the carb when the prop is flipped If not check tank venting clunk position and fuel lines for leaks Is the choke plate closing completely Is the carb or carb mount loose causing an air leak Air leaks on the engine usually show as fuel seepa
15. nes are recommended We recommend mounting the ignition high density foam padding with Velcro strapping Do not use sticky back Velcro or foam tape to mount the module This can cause the case to crack in the area where the tape adheres to the module and void the warranty Use a high quality switch such as JR s heavy duty switch Standard size R C receiver switches are not recommended Isolate the charge circuit from the ignition while charging the batteries In other words don t charge the ignition module Keep ignition components and wiring separated as much as possible from your receiver receiver battery servos wiring and switches Don t use metal to metal linkages to operate the throttle Use a 4 8 or 6 volt battery pack The ignition can handle the higher peak voltage of these packs when fully charged Higher voltage packs Lithium etc can be used but require a regulator We recommend a regulator with a 5 5 or 6 volt output Excessive voltage will damage the ignition system and will void the warranty We recommend 1800 mAh or larger capacity pack This size pack should be sufficient for 5 or more flights If the voltage entering the ignition shows 5 0 volts or less don t fly re charge When connecting the red pick up sensor to the ignition module make sure that the polarity of the wires entering the connectors is correct Brown to brown orange to orange Unlike some ignitions the Desert Aircraft igniti
16. on is designed to spark only when the prop is flipped at a high speed If the prop is not turned over at starting speed the ignition will not fire This helps to prevent the motor from firing accidentally Unless you are having problems starting the motor don t bother testing the ignition with the plug removed from the cylinder When removing the spark plug caps PULL STRAIGHT out on the caps Do not pull on the shielded ignition wires and do not use pliers To prevent radio interference the spark plug caps must have the split retainer ring around the base to insure a tight fit DON T FLY WITHOUT THEM Protect the shielded plug wires from rubbing against fiberglass or sharp edges of wood or metal Rubber grommets and plastic spiral wrap insulation from automotive or electronic supply stores work well Holes in the braided shielding can emit R F noise or loose connections spark plug caps connectors and switches Timing is set at the factory and should not need adjustment Contact Desert Aircraft if you have any questions regarding timing Only use NGK CM 6 spark plugs Other plugs may not fit the plug caps firmly Plug gap is 018 to 020 38 to 50 mm Never operate the ignition without a spark plug in the plug caps This can permanently damage the ignition coil Always perform a radio range check before flying If there are glitches DON T FLY Check for holes in the braided shielding loose connections or oth
17. ons of premium gas with 8 oz of oil The rings can seat in correctly without using petroleum based oil but it will take longer Break in phase The engine should run well from the beginning and improve as flight hours accumulate We do not recommend breaking the engine in on a test stand The stationary load and lack of air ducting can lead to engine over heating Proceed with flying once the engine is tuned and running correctly Engine break in can be a slow process taking place over many hours of flight time Peak RPM will improve along with idle characteristics as run time accumulates Special break in only props are not required Preferably start with a prop that allows peak RPM over 6 300 during the break in process The High needle can be set for optimum RPM or just slightly rich during break in Too rich will cause problems with excess residue and carbon build up Adjust the needles as needed and give the engine a few test flights using a variety of throttle settings and engine loads Avoid extended high rpm or extended hovering conditions for these first few flights After a few test flights the needles may need adjustment as the engine settles in and when other things change such as different props exhaust weather and altitude Starting 5 Needle Adjustments Always wear a heavy leather glove when starting the motor Check that prop bolts are tight and spinner is secure Make sure the starting
18. pESERT Owners Manual 11 10 Safety Instructions READ THIS WARNING This motor can cause severe harm to you and or others if misused or if these safety precautions and instructions are not observed Desert Aircraft is not responsible for any loss injury or damage resulting from the miss use of its products You alone are responsible for the safe operation of your motor This motor can stop at any time for a variety of reasons Do not fly your plane in such a way that damage or harm will result if the motor stops running Do not operate this motor if you do not want to be completely responsible for any damage or injury incurred or caused during its operation Read all instructions before operating your motor If you have any questions about any aspect of operating this motor do not attempt to start or operate it Never operate the motor or fly alone When operating the motor never stand or allow anyone else to stand in front of or to the side of the propeller Always stand behind the propeller Keep away from the prop while operating the motor Do not wear loose clothing near the motor or prop Do not run the motor near loose material such as dirt gravel power cords ropes sand etc Loose material can be drawn into the turning prop causing injury or damage Always operate the motor in an open area Do not operate indoors This motor can develop tremendous thrust Make sure the aircraft is proper
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