A few days ago, I wanted to fly, but couldn’t due to weather. So I opted for starting the motor.
It wouldn’t crank, and starter would disengage after turning the prop 1 or 2 times.
After tinkering with it a bit, I realized it was probably the battery. My brother stopped over after work that day, as I told him what was going on.
We decided, it was probably the battery.
Took it to battery warehouse. There the lady put the motor on her amp tester. The draw went down.. and wasn’t giving the full power. It was working at 12.5 volts, but couldn’t hold the load. Probably a bad cell.
This explains why it wouldn’t start, or even cranked past the tight part of the rotation where the cylinder compresses the inside.
Got the new battery, and was charged in about an hour.
Tried it again.. and still would start.
MAINTENANCE TIME
I would have waited till the fall.. but this bugger wouldn’t start..What’s the problem?
- So far I have identified the starter, since it wouldn’t stay engaged.
- Louder than normal operation, and metallic sound coming from tuned pipe.
So knowing that what I was about to do.. it was time to make a few calls. It’s a new motor, and shouldn’t be having problems. Warrenty time?
Time to make a few calls…
First I called Javier with Aerolight.com.

I explained the problem I am having with the starter. After he understood what brand I had (Fly products Kompress) he mentioned that he knew about the problem. Which is, that when the starter button is pressed the start would engage the flywheel and try to turn over the motor 1 or 2 rotations, then the motor is still running, but disengages the flywheel. It’s like a magnet is letting loose to early.
He said to send in the starter motor, and they would send me a replacment.
When removing the starter today, I noticed that the
starter mounting bracket was busted. Completely sheared off. I don’t know if this was due to the torque of the starter, busted due to the engine vibration, or just fatigued enough to break it. Probably the later two.
Looks like I will take this with me on Monday. I will be going to a machine shop client. See if they can do a quick weld for me.
AeroCorsAir.com
I needed to get in touch with Alex to get an Invoice for a replacement Cylindar head (see my posts on UPS damage after shipping from CA)
I sent Alex and email several days ago, and heard nothing. Called on Friday around lunch time, then a second time later in the afternoon. I finally got a hold of Alex.
I proceed to tell Alex how I needed and Invoice for UPS for replacement parts for a cylinder head. He also mentioned I would need an O ring too. I am glad I called, otherwise I would have missed this.
I asked about my starter and muffler problems.
He’s a smart guy, cause he started ratttling off Ohms law about resitance, and a device can only pull so much due to resistance. He also said I could hookup the starter to a car battery. Sounds like a solenoid issue, not keep the magnet charged to keep it engaged.

The starter issue was a bit of a mute point, but I figured since I had him on the phone. People on forums like to argue alot. He said he didn’t enough time to argue will everyone to set them straight.
Then I asked about the muffler and tuned pipe. He said to first Localize the problem. If it’s the tuned pipe, there is a cone on the inside. It make have come loose, or broken. If it turned sideways it could block the airflow the motor to over heat. I wonder if it could explode??
That was a defining moment for me. I could visualize an electric switch on the “Okay to fly” position immediately switch to the “Don’t you dare Fly” position.
Then since I was on the phone he decided to product an invoice. It took him about another 5 minutes.
I said Alex, “Thanks for the invoice, but uhh.. it’s in a word perfect format. I cannot read it. Could you send it again, as an RTF document?” I know what was a format that word perfect could produce and MS Word could open. It took about another 10 mintues, as he was familer with only one way of doing things. I proceded to tell him how to use the “paper clip” within outlook. I knew it was outlook cause I heard the DeeDoo sound in the background.
I got the invoice, and motivation for wrenching my motor. (disassembly)
So in summary.. here is what I learned from Alex Varv from http://www.aerocorsair.com/
- Make sure that you lube the ball joint. You can loose air through this.
- Put silicon between the tuned pipe and muffler. The rubber gasket will cover the joint.
- The starter can be hooked up to a car battery and will not burn out due to OHMs law. The device will draw as much power as it can handle due to resistance.
- Tuned pipes are expensive $350 on his website.
Another reason for doing this maintenance is my previous post about my father mentioning how loud I was compared to 4 stroke PPC (Powered Parachutes).
Now for problem #2, loose metal sound coming from tuned pipe.
I took off the down pipe, noticed no noises. Okay, time for the tuned pipe.
Shook the motor, and heard it from the tuned pipe. Something has come loose, and needs
replaced.
Good news..I just got an email from Phil. UPS is cutting a claims check to him.
So.. now I am waiting for a starter replacement, and will need to order a tuned pipe on Monday.
Woooo Hoooo.