Operators Manual

For all Versions of

Victor 2 / Victor 2 Plus / Victor 2 Super

2009

SIMONINI FLYING SRL

Via Per Marano 4303 - 41010 San Dalmazio di Serramazzoni (Mo)

P.I and C.F. 01557360367

Tel: 0536/953005 Fax: 0536/953006.

www.Simonini-flying.com

[email protected]
THIS MANUAL IS THE INTELLECTUAL
PROPERTY OF SIMONINI FLYING SLR AND
MUST NOT BE REPRODUCED OR COPIED
BY ANY MEANS WITHOUT PRIOR
WRITTEN PERMISSION OF THE AUTHOR.

Important Notice
DANGER
THIS ENGINE, BY ITS DESIGN, MAY BE SUBJECT TO SUDDEN
STOPPAGE. ENGINE STOPPAGE CAN RESULT IN CRASH LANDINGS.
SUCH CRASH LANDINGS CAN LEAD TO SERIOUS INJURY OR DEATH
AND OR DAMAGE TO PROPERTY.

DO NOT FLY THE AIRCRAFT EQUIPPED WITH THIS ENGINE AT

LOCATIONS, AIRSPEEDS, ALTITUDES OR OTHER CIRCUMSTANCES
FROM WHICH A SUCCESSFUL ENGINE OFF LANDING CANNOT BE
MADE, AFTER SUDDEN ENGINE STOPPAGE, EITHER DELIBERATE OR
ACCIDENTAL OR INCIDENTAL.

WARNING
THIS ENGINE IS NOT A CERTIFICATED AIRCRAFT ENGINE. IT HAS NOT
RECEIVED ANY SAFETY OR DURABILITY TESTING NOR DOES IT
CONFIRM TO ANY AIRCRAFT STANDARDS.
IT IS FOR USE IN EXPERIMENTAL, UNCERTIFICATED AIRCRAFT AND
VEHICLES ONLY, WHERE ENGINE FAILURE WILL NOT COMPROMISE
SAFETY.
THE USER ASSUMES ALL RISK OF USE AND ACKNOWLEDGES BY HIS
USE THAT HE KNOWS THIS ENGINE IS LIABLE TO STOP SUDDENLY.
Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual May 2009

CONTENTS
SAFETY....................................................................................................................................................... 1
1. DESCRIPTION OF ENGINE .......................................................................................................................... 3
1.1 EACH ENGINE IS SUPPLLED WITH: ...................................................................................................... 3
1.2 VICTOR 2 PLUS DIMENSIONS .............................................................................................................. 3
1.3 EXPLODED VIEW OF VICTOR 2 / VICTOR 2 PLUS / Victor 2 Super ENGINE ......................................... 4
1.4 PARTS LIST FORSIMONIHI VICTOR 2 ENGINE ..................................................................................... 5
2. FUEL AND OIL ............................................................................................................................................ 6
2.1 Mixing procedure: ............................................................................................................................... 7
2.2 Oil Mixing Ratios ................................................................................................................................. 7
3. GEARBOX OIL ............................................................................................................................................ 8
4. FUEL PUMP................................................................................................................................................ 9
5. BREAKING IN PROCEDURE ...................................................................................................................... 10
6. STARTING PROCEDURE ........................................................................................................................... 11
7. NORMAL WORKING CONDITIONS........................................................................................................... 12
8. CARBURETOR ......................................................................................................................................... 13
8.1 BING CARBURETOR EXPLODED VIEW ............................................................................................... 15
9. EXHAUST SYSTEM.................................................................................................................................... 16
10. REDUCTION GEARBOX .......................................................................................................................... 17
10.1 REDUCTION RATIOS AVAILABLE ...................................................................................................... 17
10.2 Propeller Mass Moment of Inertia: ................................................................................................ 17
10.3 Propeller Mass Balance and Pitch setting for Ground Adjust Propeller: ........................................ 17
10.4 Procedure to fill gear box oil: .......................................................................................................... 19
10.5 Procedure to drain gear box oil: ..................................................................................................... 19
10.6 Exploded View of Simonini Type “C” Gearbox ................................................................................ 21
10.7 Part list for Simonini Type "C" Gear Box ......................................................................................... 22
11. IGNITION SYSTEM ................................................................................................................................. 23
11.1 IGNITION CIRCUIT DIAGRAM .......................................................................................................... 25
12. SPARK PLUGS......................................................................................................................................... 26

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual May 2009

13. ELECTRICAL STARTER ............................................................................................................................ 27

13.1 Typical Electric Wiring Schematic for Starter Motor ...................................................................... 28
14. BATTERY ................................................................................................................................................ 29
14.1 Power source: ................................................................................................................................. 29
14.2 Relay for power Supply to starter: .................................................................................................. 29
14.3 Fuse: ................................................................................................................................................ 29
14.4 Typical wiring diagram .................................................................................................................... 30
15. INSTRUMENTS ....................................................................................................................................... 31
15.1 Minimum instruments required with the engine: .......................................................................... 31
16. Special operation condition .................................................................................................................. 33
16.1 Engine mounted inside cowling: ..................................................................................................... 33
17. LIQUID COOLING SYSTEM: .................................................................................................................... 34
18. AIR FILTERATION SYSTEM ..................................................................................................................... 35
19. MAINTENENCE SCHEDULES: ................................................................................................................. 36
19.1 Description of checks ...................................................................................................................... 36
19.2 Initial Start-up Procedure:............................................................................................................... 37
19.3 Storage procedure .......................................................................................................................... 38
20. CHECK FOR CARBON BUILD-UP AND RING CONDITION ....................................................................... 38
21. GEARBOX MAINTENANCE ..................................................................................................................... 39
22. TORQUE DATA:...................................................................................................................................... 40
23. WEAR LIMITS: ........................................................................................................................................ 40
24. TECHNICAL DATA .................................................................................................................................. 41
24.1 Description ...................................................................................................................................... 41
24.2 Temperature ................................................................................................................................... 42
24.3 Ignition and Generator System ....................................................................................................... 43
24.4 FUEL SYSTEM:.................................................................................................................................. 43
24.5 OTHER INFORMATION .................................................................................................................... 44
24.6 STANDARD VERSION INCLUDE ....................................................................................................... 44
24.7 WEIGHT ........................................................................................................................................... 44
25. OPERATING LIMITATION ....................................................................................................................... 45
26. WARRANTY CONDITION ........................................................................................................................ 45

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual May 2009

ANNEX ......................................................................................................................................................... 47
DECLARATION OF QUALITY ..................................................................................................................... 47
Record no 14: Aluminum Alloy LM 25 .................................................................................................... 48
DUCATI Regulator ................................................................................................................................... 49
DUCATI Alternator .................................................................................................................................. 50

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

SAFETY

Safety is paramount and all persons using this engine must be responsible for their own safety as
well as the safety of those in the vicinity and those who may be affected.

We include some important safety information and tips; however this list is neither complete nor
comprehensive.

GENERAL SAFETY POINTERS

1. Never mix fuel in an enclosed space or area where the fumes could be accidentally ignited or
may cause self-combustion.

2. Ensure that all controls work in the correct sense and that you know ON and OFF positions of
the throttle and ignition. Make sure that these are easily accessible when in the process of
starting the engine and that you can operate them in the correct sense instinetive1y and
immediately.

3. Ensure that no fuel can be spilled on to the hot exhaust or hot engine parts. Use only safety
approved fuel containers and never transport fuel in an unsafe manner.

4. Do not refuel the aircraft or vehicle with engine running.

5. Check all engine mounts and frames regularly as well as all the drive components, fuel lines,
wiring and fuel and air filters.

6. Check for fuel contamination, air vents and exhausts. Protect engine while it is not in use from
any Contamination entering fuel or carburetor system.

7. Ensure that you remove all storage protection before starting the engine.

8. Maintain your engine in top condition and assume it is going STOP running at any time.
Ensure that you have a way out to safety in event of unexpected failure.

9. Never run the engine on the ground with the propeller turning unless you are doing so in a
designated engine run up area and can observe anyone or anything entering the danger area.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

10. If Starting by hand cranking the propeller, have an observer who is well briefed and can act
as a safety officer. Ensure Aircraft is suitably restrained.

11. Never leave your aircraft with the engine running. You may be held responsible if the aircraft
causes an accident even If you are not in the cockpit.

12. Always maintain the engine / aircraft log and enter any unusual engine behavior. Do not fly
until the problem has been corrected and the corrective action recorded in the logbook.

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

1. DESCRIPTION OF ENGINE

1.1 EACH ENGINE IS SUPPLLED WITH:

Bing carburetors (BING 54 36mm for Victor 2 and Victor 2Plus, BING 54 38mm for Victor2Super), air
filters, fuel pump, exhaust systems, electric starter, reduction gear type “C” with elastic joint on primary
gear, system to charge battery in flight.

1.2 VICTOR 2, VICTOR2PLUS AND VICTOR2SUPER ENGINES DIMENSIONS

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

1.3 EXPLODED VIEW OF VICTOR 2 / VICTOR 2 PLUS / VICTOR 2 SUPER ENGINE

Exploded view of Victor 2 engines. Part list as numbered items.

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

1.4 PARTS OF SIMONINI VICTOR 2 / VICTOR 2 PLUS / VICTOR 2 SUPER ENGINES

PART# DESCRIPTION QUANTITY

1 BOLTS FOR EXHAUST MANIFOLD x4 4
2 EXHAUST MANIFOLD x 2 2
3 EXHAUST MANIFOLD GASKET x 2 2
4 CYLINDER BOTTOM GASKET x2 2
5 CYLINDER x2 2
6 VYTON 0 RING x 2 OUTER 2 2
7 STUD FOR CYLINDER HEAD, 6 FOR EACH CYLINDER 12
8 CYLINDER HEAD x 2 2
9 CYLINDER HEAD WASHER, 6 FOR EACH CYLINDER 12
10 CAP NUTS FOR CYLINDER HEAD, 6 FOR EACH CYLINDER 12
11 VYTON 0 RING x 2 INNER 2
12 WATER OUTLETS TOP AND BOTTOM x 4 4
13 HOSE CLIPS FOR WATER OUTLET AND HOSE PIPE BENDS x10 10
14 HEAT DISSIPATER TOP I BOTTOM 1
15 HOSE PIPE HEAT DISSIPATOR TO WATER PUMP 1
16 8MM. BOLT TO HOLD WATER PUMP POSITION 1
17 WATER PUMP 1
18 ENGINE COVER PLATE, MAG END 1
19 12 MM. BOLT TO HOLD MAGNETO 1
20 6 MM. SCREWS TO HOLD ENGINE COVER PLATE 6
21 NUT TO POSITION WATER PUMP 1
22 HOSE PIPES WITH 90 DEG. BEND FROM CYLINDER HEADS TO HEAT 4
DISSIPATERS x4
23 WATER PUMP BELT 1
24 FLAT WASHER FOR WATER PUMP 1
25 WATER PUMP BELT PULLEY 1
26 8 MM. BOLT 1
27 WASHER 8MM. 1
28 ENGINE MAG END CASING 1
29 BOLT 8MM. 1
30 GASKET INLET AT REED VALVES x 2 2
31 REED VALVES x 2 2
32 RUBBER FLANGE TO HOLD CARBURETORS x 2 2
33 HOSE CLIPS TO HOLD CARBURETORS x 2 2
34 CARBUREITORS x 2 2
35 SPRING WASHERS FOR CARBURETOR BOLTS x 12 12
36 CARBURETOR BOLTS 6 MM x 12 12
37 BREATHER TUBE FOR CARBURETORS x 2 2
38 HOSE CLAMPS x 2 FOR AIR FILTERS 2
39 A IR FIL1ERS x 2 2
40 SPRING WASHERS FOR CRANKCASE 8mm 20
41 CRANKCASE 1
42 WASHER FOR DEPRESSION OUTLET FROM CRANKCASE 1

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

43 DEPRESSION OUTLET FOR FUEL PUMP 1

44 NUT FOR ELECTRIC STARTER x 2 2
45 WASHER FOR ELECTRIC STARTER x 2 2
46 SPRING WASHER FOR ELECTRIC STARTER x 2 2
47 BOLT FOR ELECTRIC STARTER x2 2
48 ELECTRIC STARTER 1
49 PISTON ASSEMBLY 2 2
50 CONNECTING ROD ASSEMBLY x 2 2
51 OIL SEAL 4
52 CIRCLIPS FOR Oil SEALS 7
53 BEARINGS 2
54 CONROD PIN 2
55 CRANKSHAFT WITH WOODRUFF KEY HOUSING SHAFT 2
56 CRANKSHAFT WITH MALE SPLINE 1
57 BEARING 2
58 CRANKSHAFT WITH FEMALE SPLINE 1
59 WOODRUFF KEY 1

2. FUEL AND OIL

The VICTOR 2 / VICTOR 2 PLUS / Victor 2 Super engine uses unleaded or leaded petrol at
least 87 octane rating. The engine requires the petrol to be premixed with two-stroke oil.

STOP: Do not run the engine without ensuring that it is correctly loaded (e.g. propeller is
mounted).

Fuel contamination can be a major cause of engine failure. Ensure that your fuel container is
clean inside before you use it to fill up with fuel or oil.

Filter all fuel that goes into the fuel container. Also use a filter when transferring fuel from fuel
container into the aircraft tanks. The Victor 2 / Victor 2 Plus / Victor 2 Super engine is designed
to run on unleaded petrol or leaded petrol or avgas mixed with 2 Semi-synthetic Oil.

The Oil to be premixed with fuel must meet or exceed the specifications API, TC, JASO, FC.

It is recommended only to use a semi- synthetic 2-stroke oil like Bardahl or MixoilSynt Api or
equivalent. Use of Semi- Synthetic Oil pre-mixed in the petrol / avgas will greatly reduce the
buildup of carbon deposits in the cylinder heads and pistons. This will increase your service
intervals.

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

2.1 MIXING PROCEDURE:

Use a clean container of known volume.

Pour Oil into container.

Pour Fuel into the can using a fine mesh filters.

Close container cap firmly and shake container for a few moments so that the oil and fuel are
mixed properly.

2.2 OIL MIXING RATIOS

Type of fuel Fuel Qty. %age of oil Oil Qty. Type of fuel Fuel Qty. %age of oil Oil Qty.
Unleaded 10 Lit. 3% 300ml. Leaded/Avgas 10 Lit. 2.5% 250ml.
15 Lit. 3% 450ml. 15 Lit. 2.5% 375ml.
20 Lit. 3% 600ml. 20 Lit. 2.5% 500ml.
25 Lit. 3% 750ml. 25 Lit. 2.5% 625ml.
30 Lit. 3% 900ml. 30 Lit. 2.5% 750ml.
33.3Lit. 3% 1lit. 40 Lit. 2.5% 1lit.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

3. GEARBOX OIL

Reduction Gearbox Oil in the Simonini Type "C" reduction gearbox. Recommended Oil is
9OWX/140EP. The quantity required to fill the gearbox is 170cc with gear box upright and
225cc with gear box down.

Warning: Do not run the engine without sufficient oil in the Gear Box.

On the side of the Gear Box there are two Allen Screws which are used to inspect and indicate
the level of oil in the gear box.

It is always the lower of the 2 screws that indicates maximum oil level. The lower Allen screw
can be carefully opened to check that the oil leve1 is sufficient. Do not over fill above this level.
When the instillation requires the gear box to be fitted with the propeller shaft below the
crankshaft, the oil filler cap and the oil drain plug are interchanged.

Max Oil Level 225cc

Max Oil Level 177cc
Gear Box Down
Gear Box UP

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

Replace the Gearbox oil after the first 10 hours of use. The next change of Gearbox Oil is at 100
hours of use or once every 12 months, whichever comes first.

Stop: Ensure before every flight that you have sufficient oil in the gearbox.

4. FUEL PUMP

The Victor 2 / Victor 2 Plus /Victor 2 Super engine comes equipped with a Mikuni Membrane
Pump. This is a pneumatic pump operated by the pressure pulses from the crankcase of the
engine.

Install the pump 3 - 4 cm higher than the crankcase pressure outlet. This will prevent a build-up
of fuel / oil mix in the lower compartment of the fuel pump, which in turn may lead to less
efficiency.

The length of the tube, which connects the engine crankcase depression to the fuel pump, should
be as short as possible, ideally less than 15 cm and not more than 30 cm long.

If your aircraft fuel tank is located more than 50/60 cm below the carburetor and fuel pump,
install an electric pump near the fuel tank. This pump will help push the fuel up to the membrane
pump and prevent vapor locks pump subsequent engine failures. Please follow the fitting
schedule of the electric pump.

Stop: The maximum fuel pressure exerted by the electric fuel pump should not exceed 0.3 bar
(4.35 psi).

When fitting an electric booster fuel pump ensure that there is fuel filter installed in line before
the pump. This will prevent the electric pump from clogging up with foreign material, which
may result in fuel starvation and resultant engine stoppage.

The electric booster fuel pump must be of the type where it allows fuel to pass through even
when it is not working.

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

Example of electric fuel pump that may be

used as a Booster pump

5. BREAKING IN PROCEDURE

EACH SIMONINI VICTOR 2 / VICTOR 2 PLUS / VICTOR 2 SUPER ENGINE IS

ASSEMBLED AND RUN IN AT THE FACTORY.

EACH ENGINE IS SUBJECTED TO A DYNAMIC TEST. THE ENGINE IS

SECURELY MOUNTED ON A TEST BENCH AND A SUITABLE PROPELLER
INSTALLED ON IT.

THE ENGINE IS STARTED AND KEPT RUNNING FOR UP TO 4 HOURS AT

VARIABLE SPEEDS. TEMPERATURES AND POWER OUTPUTS ARE

REGULARLY CHECKED WHILE THE ENGINE IS BEING RUN.

THE CUSTOMER/USER IS NOT REQUIRED TO DO ANY RUNNING OR

BREAKING IN PROCEDURES ON THE ENGINE.

THE CARBURETORS ARE SET AT THE FACTORY FOR THE IDEAL

SETTINGS.

WHEN THE ENGINE IS MOUNTED ON YOUR AIRCRAFT, ENSURE THAT

BOTH CARBURETOR SETTINGS ARE EQUAL WHEN INSTALLING THE
THROTTLE AND CHOKE OPERATING CABLES.

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

ADJUST THE CARBURETOR SLIDES UNTIL YOU GET AN 8 MM GAP UNDER

THE SLIDES WHEN VISIBLE FROM THE AIR FILTER SIDE.

TURN THE CARBURETOR AIRSCREWS FULLY CLOSE AND THEN UNSCREW

THEM BY 1 TO 1. 5TURNS.

THE ENGINE SHOULD BE RUNNING AT FULL OPEN THROTTLE WITH

6500RPM. IN THE CASE OF MAX. RPM. IS NOT DEVELOPED, CHECK
PROPELLER PITCH/SIZE AND MAIN JET SIZE.

6. STARTING PROCEDURE

NOTE: ALL SIMONINI ENGINES ARE RUN IN AT THE FACTORY AFTER ASSEMBLY.

Ensure that the engine is fitted securely to the aircraft. All electric concoctions must be checked
to be correct. All fuel lines must be securely fitted.

Stop: Ensure that there is sufficient fuel and oil in the fuel tank and enough oil in the gearbox.
Insufficient fuel and oil will cause the engine not to Start.

Ensure that there is sufficient coolant in the radiator. Insufficient coolant will cause the engine to
overheat in a matter of seconds and thereafter cause seizure of the pistons and resultant
catastrophic failure.

With the engine cold, Open fully chokes on the Bing Carburetors. Keep throttle at the idle
position.

Ensure that ignition switches are ON and that you can instantly switch them off if required.

Ensure that the aircraft brakes are on. If no brakes, ensure you have chocks under the wheels to
stop the aircraft from rolling away unintentionally.

Ensure that there is nobody near the Propeller and that the slipstream not causes damage to any
other aircraft or persons or property.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

Engage electric starter. As soon as the engine fires, open throttle so the engine runs at slightly
over 2000/2200 rpm.

Ensure that the starter motor is disengaged from the engine. Do not run the Starter motor for
more than 5 seconds at a time.

Once the engine fires, within 10 seconds close the Chokes and the engine should be running
smoothly.

Once the engine is running for about 2 minutes, increase the RPM to 3800 - 4000. Check
exhausts Gas temperatures on both cylinders. The difference should not exceed 20 ° C.

Warm up the engine until the water temperature reaches 50 ° C.

Now the engine should be ready for flight.

7. NORMAL WORKING CONDITIONS

It is recommended to use as much as gas your aircraft needs, it depends on your requirements
and as occasion may require. Reach height as soon as possible, above all if you are flying with a
delta motor.

Do not exceed maximum 6500 RPM. Do not run the engine in the climb out at Full Open
Throttle for more than 3 minutes.

Idling rpm should be 2000 rpm. Less than this may cause unnecessary vibrations. Higher idling
rpm will cause a reduction in the fuel / air mixture enrichment in the starting circuit of the
carburetor and may make cold engine start-ups difficult.

Before shut down, the engine should be run until any heat build-up from previous high power
settings (e.g. taxi back to hangar) has dissipated. Run the engine at 3000 rpm for 2 minutes and
then at 2000 rpm or smooth idle speed for a short while.

Do not idle for prolonged periods (e.g. holding point checks) as the normal rich conditions at this
carburetor setting may cause high carbon deposits on the spark plugs and piston rings causing
fouling. At low revolutions, the vibrations are high and the loads on the propeller, gearbox, and
drive train and should be avoided for longevity of the engine.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

8. CARBURETOR

The Victor 2/ Victor 2 Plus / Victor 2 Super engine is equipped with 2 Bing Double Float
Carburetors. The Bing Carburetor is a piston type carburetor with float Chamber.

The following methods and combinations can adjust the Carburetor.

1. By Main Jet / Idle Jet / Needle Jet of various sizes.

2 .The Jet Needle size and position can also be varied.

3 .The Air / Fuel Mixture screw, Carburetor piston stop height can be changed.

When anyone of the above components or settings is changed, it affects the others so that other
small adjustments may be required.

Each Carburetor must be fitted with the slide axis at right angles in relation to the crankshaft
axis, both from the top and the intake side, to ensure equal fuel distribution to both cylinders.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

When you receive the engine from Simonini Flying, the engine has been run in and the
carburetor settings checked.

NOTE: The Simonini Factory is at 600 meters above Mean Sea Level; thus when the engine is
run in at the Factory, it is set to produce maximum power at that altitude. If you are to operate
the engine at a very different altitude, you may need to retune the Carburetor mixture settings to
produce optimum power.

Stop: When you attach the throttle cable and choke cables, please ensure that you have both the
carburetor slides moving exactly equally up and down in unison. If not, it will cause the engine
to run rough or worse malfunction. The throttle control mechanism must enable the carburetor
slides to attain their full open position.

Ensure that aircraft movement or controls movement does not affect the movement of throttle
and choke cables. This may cause the throttle settings to change inadvertently.

Ensure that Air filters and Exhausts and Radiators are installed in place before starting the
engine. They must be in place to produce proper carburetion for the engine.

Special operating conditions or extreme altitude and or climatic changes will require different
Jetting. Contact your dealer for the correct carburetor jets setting. The Victor 2 engine/ Victor 2
Plus / Victor 2 Super engine is fitted With "Reed Valves" between the Carburetors and the
crankcase. These valves add to the efficiency of the engine in controlling carburetion and fuel
economy. The Reed Valves require changing of the VALVES after 400 hours of use.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

8.1 BING CARBURETOR EXPLODED VIEW

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

9. EXHAUST SYSTEM

The Simonini Engines produce a high power output to weight ratio with the help of very highly
tuned exhaust systems. The exhaust system is manufactured in the Simonini factory for each
engine type.

Stop: Do not attempt to make any changes to the Simonini Exhaust Systems.

Any changes will invalidate the warranty and may severely reduce the performance and power
output of the engine. Any changes will affect adversely the fuel economy as well as the
reliability of the engine.

Vibrations caused by incorrect mounting and fixing of the exhaust system will result in a reduced
life span of the exhaust system.

Ensure that the entire system is free from vibrations through the entire range of power settings.

Ensure that there is no harmonic resonance or vibration present due to the engine, propeller and
aircraft combination. This means that you must mount the exhaust system on shock resilient
mounts.

Ensure that the ball joints of the various exhaust system components are lined with an anti-
galling product (e.g. copper loaded grease or graphite dry lubricant).

Secure the exhaust system to the aircraft.

Secure all the springs by loosely wire locking them.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

10. REDUCTION GEARBOX

The Simonini Victor 2 / Victor 2 Plus / Victor 2 Super engine comes fitted With the Simonini
Type "C" gearbox. There are various ratios that the customer cans specify when ordering. Please
confirm and check that you have the correct reduction gear ratio for your combination of
propeller, aircraft and engine.

10.1 REDUCTION RATIOS AVAILABLE

2.54:1 2.76:1 3.06:1 3.47:1 4.00:1

The Gear Box Input Shaft is fitted with a rubber "Donut" elastic joint that acts as a vibration
damper.

The Reduction Gearbox may be fitted with the drive output propeller shaft above or below the
crankshaft axis.

10.2 PROPELLER MASS MOMENT OF INERTIA:

With the Type "C" Simonini gearbox, the propeller mass moment of inertia must not exceed
6000 kg

Before fitting the propeller, check with the propeller manufacturer if the mass moment inertia
meets these requirements. Your warranty will be invalid if the propeller exceeds the limits.

10.3 PROPELLER MASS BALANCE AND PITCH SETTING FOR GROUND ADJUST
PROPELLER:

A new propeller must be balanced to better than one gram to avoid problems and overstressing
the gearbox drive train. You must ensure that the propeller is also tracked to within 1 mm at the

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

tips. Check for balance and tracking of the propeller after the first fifty hours of operation and
100 hours thereafter.

Stop: Imbalance in Pitch causes extreme cyclic load settings, Blade to Blade should be better
than 0.1° or 6

Warning: Even though the gearbox is fitted at the factory and the engine has been run in, you
must check that it has the correct type and quantity of oil in it. The oil may have been drained
before dispatching the engine to you!

Before you start the engine, ensure that the gearbox contains oil of the correct type and
quantity.

Use gearbox oil with viscosity that meets SAE 140, API GLA. It is recommended to use Castrol
EP-140 for the Simonini type C gearbox. On first filling the dry gearbox you will require 170 cc
of oil with gear box upright. With gear box down, you will require 225 cc of oil to fill it. The oil
filler is always located on the top of the gearbox.

Max Oil Level 177cc

Max Oil Level 225cc
Gear Box UP
Gear Box Down

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

10.4 PROCEDURE TO FILL GEAR BOX OIL:

1. Unscrew and remove the 4cm tall ribbed aluminum heat exchanger plug on top of the gearbox.

2. Use an Allen key to unscrew the lower of the 2 Allen screws on the side of the gearbox. This
lower hole is your maximum oil level indicator.

3. Fill in the correct quantity of EP 140 oil from the top of the gearbox. It will take some time for
the oil to dribble down on the inside of the gearbox and start to ooze out from the oil level
indicator hole.

4. Screw in the Allen screw. Torque it to 10 Nm.

5. Screw in the heat exchanger plug on top of the gearbox Torque it to 20 Nm and wire-lock.

6. Ensure that the tiny hole on top of this heat exchanger plug is free to act as a breather hole for
the oil in the gearbox.

Stop: You must ensure that you have sufficient oil in the gearbox for every flight.

10.5 PROCEDURE TO DRAIN GEAR BOX OIL:

1. After running the engine, the gearbox should be warm and the oil inside should be warm and
have a low viscosity.

2. Place a container or pan under the gearbox. The container should be large enough to hold 250
ml of oil.

3. Remove the heat exchanger plug on top of the gearbox.

4. Unscrew the Lower Allen screw on the side of the gearbox.

5. Unscrew the drain plug at the bottom of the gearbox and let the oil dribble down into the
collection pan or bowl. It may take a while for all the oil to dram out.

6. Clean the magneto in the drain plug and check for metal fillings.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

7. After the gearbox is completely drained, screw the drain plug back in, torque is 20 Nm.

Drain and change the gearbox oil after the first 10 hours of engine use.

Thereafter drain and change gearbox oil every 100 hours of use or once every 12 months,
whichever is sooner.

You must ensure that you have sufficient oil in the gearbox for every flight. Check oil level
every 50 hours.

Please dispose of used oil in the correct oil disposal unit

Giving due consideration to the environment

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

10.6 EXPLODED VIEW OF SIMONINI TYPE “C” GEARBOX

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

10.7 PART LIST FOR SIMONINI TYPE "C" GEAR BOX

Part # Quantity
1 BOLT FOR PROPELLER 6
2 PLATE FOR PROPELLER HUB 1
3 POWER OUTPUT SHAFT 1
4 6MM ALLEN SCREWS FOR GEARBOX 12
5 GEARBOX FRONT COVER 1
6 GASKET 1
7 BEARING 1
8 PIN TO LOCATE GEARBOX FRONT COVER 1
9 BOLT 1
10 GEAR ASSEMBLY DRIVE GEAR AND DRIVEN GEAR 1
11 BEARING 1
12 OIL SEAL 1
13 WASHER 1
14 OIL DRAIN PLUG 1
15 BOLTS 8
16 SCREW TO CHECK MAX OIL LEVEL WITH GIB UP 1
17 SCREW TO CHECK MAX OIL LEVEL WITH GIB DOWN 1
18 OIL FILLER SCREW WITH HEAT DISSIPATER 1
19 WASHER 1
20 BOLTS 8 MM 8
21 OIL SEAL 1
22 BEARING 1
23 CIRCLIPS FOR OIL SEALS 1
24 BEARING 1
25 THRUST WASHER 1
26 CONE WASHER 1
27 BOLTS 6
28 PLATE 1
29 BEARING 1
30 0 RING 1

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

31 OIL SEAL 1
32 TRIANGLE FLANGE 1
33 LOCATOR BOLT 1
34 BOLTS 6
35 RUBBER DONUT 1
36 BOLT 1
37 WASHER 1
38 BOLTS 8
39 FLY WHEEL 1
40 GEAR HOUSING 1

11. IGNITION SYSTEM

The Simonini Victor 2 / Victor 2 Plus / Victor 2 Super engine is equipped with a breaker-less 12
Volts 170 w Ducati Capacitor-Discharge Dual Ignition.

The Ignition system consists of:

1. F1ywheel Magneto Generator.

2. Two twin Ignition Coils with Integrated Control Circuit.

3. Magnetic Pickups which act as Triggers for the Sparks.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

The 12 Poles f1ywheel generator is an outer rotor type with 12 integrated permanent magnetos.
The Stator is fitted with 12 coils. Out of the 12 coils, 8 Coils are used for supplying power to
Auxiliary Equipment and 4 coils are used for the Twin Ignitions. The Grey cable is to be used for
connection to a suitable tachometer.

The two pairs of charging coils fitted on the Generator Stator are independent of each other and
supply one Ignition Circuit each. The Energy supplied is stored in the Ignition Capacitor. At the
moment of Ignition, the External Triggers supply an Impulse to the Control Circuits and the
Ignition Condensers arc discharged via the Primary winding of the Ignition Coil. The Secondary
winding supplies the High Voltage for the Ignition Spark.

Before every flight, complete your pre-flight or Vital Actions Checks. Include the Checks to see
that each Ignition Circuit is working independently and together.

To check each Ignition Circuit is working, run the engine at 3000 to 4000 rpm. Ensure that the
aircraft is stationary with brakes or chocks and pointing into the wind. Now turn one (left)
Ignition Switch off. The reduction or drop in RPM must not exceed 300 RPM. Now turn the
Ignition switch on. Let the RPM rise to the previous setting (3000 - 4000 RPM). Now turn the
second (right) Ignition Switches off. The reduction or drop in RPM must not exceed 300 RPM.
Now turn the Ignition Switch on. Ensure that both Ignition switches are on before you proceed
for rake-off.

Stop: Both Ignition Circuits must be switched on before take-off! Do not carry out running tests
of the ignition without the spark plugs connected and grounded to the engine. Running the
engine without the spark plugs connected and grounded to the engine will cause damage of the
control circuits.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

11.1 IGNITION CIRCUIT DIAGRAM

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

12. SPARK PLUGS

The Victor 2 /Victor 2 Plus / Victor 2 Super is installed with 2 NGK B9ES Spark Plugs on each
Cylinder. The gap on the spark plug electrodes should be between 0.4 to 0.5 mm.

As the fuel and oil that you use may vary from time to time; check the condition of all the spark
plugs on your engine regularly. Remember to check and clean the spark plug caps. At the same
time check for evidence of shorting caused by build-up of fretting residues (powdery substance).

Clean and re-gap plugs if necessary. Gap = 0.4mm to 0.5mm

Replace spark plugs every 100 hours,

Always replace all the four plugs at the same time. When replacing spark plugs after checks, you
should put them back in the same position. This will prevent possible damage to the cylinder
head threads. Always use anti-seize paste when instilling spark plugs.

If plugs are sooty with oil deposits, the engine is running too cold (i.e. too rich). The Carburetion
and Air Filters should be checked for cleanliness.

It is recommended only to use a semi- synthetic 2-stroke oil like Bardahl or MixoilSynt Api or
equivalent. Use of Semi- Synthetic Oil pre-mixed in the petrol / avgas will greatly reduce the
buildup of carbon deposits in the cylinder heads and pistons.

If plugs have whitish deposits with evidence of melt droplets; it may be a lean mixture. If
carburetor calibration is correct and no evidence of manifold leaks neither lack of fuel nor
incorrect float settings is found, check the cooling system.

The temperature measured under the spark plugs Cylinder Head Temperature (CHT) on each
cylinder must not exceed 120° C. at full power.

The temperature of the coolant exiting the cylinder heads (water Temperature) at maximum
power must not exceed 80° C.

The Normal Operating temperature range for the Coolant / Water temperature is between 55° C
to 65° C.

Do not take-off until the Water temperature has reached 50° C.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

13. ELECTRICAL STARTER

The Victor 2 /Victor 2 Plus / Victor 2 Super engine is equipped with an electric starter motor as
standard. This is fitted on the magneto end of the engine.

The starter motor is a high performance, lightweight device that sits alongside the engine. The
starter has a ''Bendix'' clutch; which engages the ring gear fitted on the crankshaft for starting the
engine.

Once the engine has started, the ''Bendix'' clutch disengages the electric starter motor.

A "starter engaged" lamp indicator may be installed in the cockpit to ensure that the "Bendix"
clutch and solenoid switch have disengaged after the engine is running.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

13.1 TYPICAL ELECTRIC WIRING SCHEMATIC FOR STARTER MOTOR.

NOTE:
Battery, Solenoid and Starter Motor cable is 8 mm2 (160 A)
Wiring between the Battery, Master Switch and 12 V dc feed is
4 mm2 (25 A)
All other wiring is 25 mm2 (16 A)

Starter motor, Starter switch and Voltage Regulator wiring Diagram

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

14. BATTERY

The starter motor will need a Battery of 16 ampere hours with a high discharge rate.

The cables supplying power from the battery to the starter motor should be of as short a length as
practicable and should be at least 8 flexible multi-strand cables.

14.1 POWER SOURCE:

The Simonini Victor 2 /Victor 2 Plus / Victor 2 Super engine is fitted with a Ducati generator
coil, which outputs 170 watts of alternating current. The Ducati rectifier cum regulator supplied
with the engine converts this electrical power output from AC to DC The rectifier / regulator
outputs 13.8 volts DC. This output is then routed to the battery fitted into the aircraft. Ensure that
a 15 amp fuse is fitted in line between the battery and the regulator.

14.2 RELAY FOR POWER SUPPLY TO STARTER:

The starter relay (or solenoid) supplied, with the engine must be securely mounted at a suitable
place as close to the starter and battery as possible.

14.3 FUSE:

A 15 amp fuse (no fuse should be rated greater than the smallest cable in the fused circuit) must
be installed between the battery charging circuit and the main power terminal.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

14.4 TYPICAL WIRING DIAGRAM

NOTE:
All wiring is 25 mm2 (16 A) with the exemption of
the fuel pump and 12 V dc feed wiring which is 4
mm2 (25 A)

Ignition, fuel pump ancillaries wiring diagram

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

15. INSTRUMENTS

The Victor 2 / Victor 2 Plus / Victor 2 Super engine has two separate cylinders and two separate
cylinder heads inline. Each cylinder head carries 2 spark plugs. Each cylinder head feeds into the
heat dissipater/coolant carrier tubes. The coolant temperature is measured on the top heat
dissipater tube.

Each cylinder has one exhaust pipe. The Exhaust Gas Temperature is measured at the exhaust
manifold.

15.1 MINIMUM INSTRUMENTS REQUIRED WITH THE ENGINE:

RPM counter to measure Engine Speed.

Two EGT Gage to measure Exhaust Gas Temperatures at the exhaust manifold on each cylinder.

Water Temperature Gauge to measure Coolant Temperature located on the top heat dissipater.

Engine Hour Meter : This is essential to keep records of how many hours the engine has to run
before the next service or check.

Voltage / Ampere Gauge to indicate battery charge, this is necessary to ensure that the alternator
is charging the battery when the engine is running. The battery must be able to supply power to
the electric starter to start the engine when required.

We suggest you could use the Alpha Multi Function Display (MFD) instrument with this engine.
It has been specifically designed to use the connection on the 12-pole flywheel generator used on
the Ducati CDI Systems. The Tachometer on the Alpha MFD measures the frequency of the
pulses provided by one of the transducers supply winding where it is connected. This instrument
also provides all the information required in flight and on the ground after the flight for the pilot
owner to enter into the aircraft and engine log books.

Be informed you can also use a simple runs indicator, connected to the grey wire.

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16. SPECIAL OPERATION CONDITION

If you are operating from water, i.e. float planes, beware of the following risks and take adequate
protection measures:

Water ingestion into the air filters in takeoff and landing due to spray and splash. Use good
quality air filters (K and N type filter recommended for the Bing carburetors but in some
Countries they use different air filters with a large surface which increase the performance), with
the correct oil impregnation. Dry filter paper elements will absorb water causing the carburetion
mixture to become over-rich resulting in loss of power.

Corrosion due to water, salt-water operations will cause more corrosion than non-salt water, so
ensure that you wash the aircraft and engine (when cold) after salt-water operations.

Submersion in water of entire aircraft and or engine will spoil your day!

16.1 ENGINE MOUNTED INSIDE COWLING:

When the engine is mounted inside a cowling you must ensure that the cowl inlet is not restricted
and the exit area is double the inlet area. All the airflow entering the cowling should flow onto
and thru the radiator to ensure optimum cooling.

There should be no leakage of air between the inlet and exit on cowling, i.e. the radiator should
not be starved of air throughput.

There should be a minimum difference in air pressure between the air inlet and air exit.

Extreme changes in temperature and humidity due to climatic changes can cause carburetor
icing, vapor lock in fuel lines, overheating, etc. These climatic changes may cause changes in
carburetor calibration and may require a change of jets, needles, etc.

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17. LIQUID COOLING SYSTEM:

The Simonini Victor 2 / Victor 2 Plus / Victor 2 Super engine is liquid cooled. The engine is
equipped with an integral water pump, the water pump is belt driven. The coolant is pumped
around the cylinders and cylinder heads under pressure from the water pump. There are 2 finned
heat dissipaters which route the coolant water to and from the radiator. The top heat dissipater is
fitted with a thermostat designed to open at 57° C. The other end of the top heat dissipater is to
be fitted with the coolant temperature sender.

The WATER PUMP DRIVE BELT must be checked for condition and tension before every 100
hours.

WATER PUMP SHOWN WITH DRIVING BELT, COVER PLATE AND HOSE PIPES.

Radiator Filler / Expansion Bottle with Pressure Cap.

The radiator fitted to the Victor 2 /Victor 2 Plus / Victor 2 Super engine must be between 1000 to
1100 cm² radian surface areas. The radiator mountings and security must be ensured before every
flight.

The coolant should be a mixture of 70% water and 30% anti-freeze suitable for aluminum. If
necessary, change the anti-freeze percentage to ensure the effective cooling.

The maximum coolant temperature must not exceed 75°C. If on takeoff the coolant temperature
exceeds 50°C. You must reduce power until the temperature drops below 50° C.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

The radiator filler/ expansion bottle is of the pressure relief type with an over flow tube. Ensure
that the overflow tube is routed into a bottle to capture any coolant, which may overflow due to
expansion.

18. AIR FILTERATION SYSTEM

The Victor 2 / Victor 2 Plus / Victor 2 Super engine has one air filter on each carburetor intake.
The air filter is made from a special fabric enclosed inside a wire mesh cage.

The air filters must be clean and oiled with light filter oil. The filter oil prevents moisture from
clogging the filter cloth.
Check the Air Filters every 50 hours for dirt and clean with filter detergent and water and re-oil
if necessary.
Stop: Disconnect spark plugs leads for all maintenance and inspection procedures also ensure
that all ignition switches are grounded and the battery master switches are turned off.

A clogged or dirty air filter can:

1. Change the fuel / air mixture and may make starting the engine difficult.

2. Make the fuel / air mixture rich causing the plugs to foul up.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

3. Cause the engine to consume more fuel than normal.

4. Cause excessive carbon build-up.

19. MAINTENENCE SCHEDULES:

Warning: Maintenance on engines and systems requires special knowledge and tools. It is
recommended that you have a qualified person do the maintenance on the engine or take it to the
authorized service centre or dealer.

Service times are based on average use; assuming engine is run at least once per week for a
normal operation cycle or flight. Total time before tear down is determined by the frequency and
conditions of usage. The Victor 2 / Victor 2 Plus / Victor 2 Super is a very low maintenance
engine, about every 150 hours using. Use the chart below as an aid. Do not overlook anything
that you may find is necessary to check and replace on your particular aircraft and engine
combination. It is your responsibility to check that the electrical and fuel systems around the
engine are in perfect working order.

19.1 DESCRIPTION OF CHECKS

Engine Hours 10 25 50 100 150 200 250 300 350 400 450 500 550 600
Gearbox oil check X X X X X X X X X X X X X X
Gearbox oil Replace X X X X X X X
Gearbox Springs and Shim check,
X X
Replace if Required
Spark plugs, check and Re-gap X X X X X X X X X X X X X X
Spark Plugs Replace X X X X X X
Carb. Needles, Jets, Pistons check
X X X
for wear. Replace if necessary
Carb. Rubber Hoses, check and
X X X X X X
Replace if Required
Carb. Air filter Clean X X X X X X X X X X X X
Water Pump Drive Belt, check
X X X X X X X X X X X X
Condition/Replace
Rubber Coupling Drive Shaft
X X
Replace
Reed Valve Replace X X
Replace Radiator Coolant X X X X X X
Check Small End/Big End
X X X X X X
Bearing Play Within Limits

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

Carbon Build up, check, if More

X X
than 1.5mm, decoke
Major Overhaul of complete
X
engine

19.2 INITIAL START-UP PROCEDURE:

Your engine has been run in at the factory. However, after installation in your aircraft and prior
to starting for the first time please use the checklist provided for initial start-up.

1 Check Engine is secure in its mounting system. Check all bolts, washers and nuts are correctly
fastened with proper torque and wire-locked where required.
2 Check all electrical connections are secure and correctly made.
3 Check all fuel connections are secure and correctly made.
4 Check all Temperature senders are secure and correctly made.
5 Check Radiator is secure and filled with sufficient coolant. Check radiator cap is securely fastened
and safety-locking wire fitted.
6 Check Gear Box filled with sufficient oil EP 140 type.
7 Check torque of the oil level Allen screw is 10Nm
8 Check Oil filler / heat dissipater screw is Fastened and it’s torque is 20 Nm
9 Check oil drain plug is fastened with torque of 20 Nm
10 Check sufficient fuel and oil mixture is filled in the fuel tank.
11 Check both carburetors are securely fitted. Both the idle screw adjusters must be used to obtain an
8 mm gap under the throttle piston passage when viewed from the air-filter side. Refit Air filters.
12 Check the two airscrews so that they are equal at 1 to 1¼ turn open.
13 Check the battery is fully charged to enable the electric starter to turn.
14 Check aircraft is chocked and brakes applied. Ensure that the propeller slipstream will not damage
anything nor hurt anyone.
15 Prime the carburetors by either hand primer or electric fuel pump.
16 Keep throttle lever in aircraft closed. Apply full choke.
17 Engage starter motor for not more than 5 seconds.
18 When engine fires, wait for 5 seconds to close choke lever so the engine runs smoothly.
19 Warm the engine up for 2 minutes and stabilize the RPM at about 3800 - 4000 rpm.
Check exhausts Gas Temperatures on both exhausts. They should stabilize and the
difference should not exceed 20 °C between the 2 cylinders
20 Wait for the coolant temperature to reach 50°C.
21 At maximum power and rpm the exhaust gas temperature should not exceed 600/620°C.
22 Run the engine at various power settings for 10 minutes. Monitor the engine instruments
continuously. If any of the indicators go outside the permissible operating parameters, shut down

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

the engine immediately.

23 When testing is completed check everything on the engine for leaks and security of Fixing, etc.

19.3 STORAGE PROCEDURE

If the engine is not going to be used for a period of 2 months or more, use the following
procedure for storage:

1. Start the engine and remove the air filters from the carburetors.

2. Spray 2-stroke oil that you use in the petrol oil mixture directly in to the carburetor throat until
the engine stalls. This will ensure that all the parts in the crankcase and the top and bottom
conrod bearings are well lubricated.

3. Reinstall the air filters and after the engine has cooled down cover it with suitable covers. You
may also cover the exhaust opening with suitable cover to stop foreign material from entering.

20. CHECK FOR CARBON BUILD-UP AND RING CONDITION

1. After 300 hours of engine operations remove the exhaust manifolds and check for carbon
build-up around the piston rings.

2. Remove the spark plugs and shine a light thru the hole in the cylinder head to check for dark
brown color of carbon build-up.

3. You only need to de-carbonize the engine every 300 hours. This will coincide with the
gearbox service internal. If on observation you find that there is no sign of carbon forming, you
will not need to open the cylinders and decoke.

4. However, the use of mineral oil or fuels with additives may cause carbon to build-up sooner.

5. Take precautions to prevent personal injury, i.e. safety goggles, etc.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

21. GEARBOX MAINTENANCE

The Simonini "C" Type Gear Box is a very low maintenance item.

1. Change the oil in the gearbox after the first 10 hours of operation.

2. Thereafter check oil level every 50 hours or if the aircraft has not been flown for more than 2
months, before the next flight.

3. The next oil change is to be done after 100 hours of operation or once every 12 months
whichever is earlier.

4. Replace the coupling "donut" after 300 hours of operation, when the gear box is opened for
service.

Oil quantity required for gearbox:

Drive shaft above crankshaft……………………………………………………………….170CC

Drive shaft below crankshaft ……………………………………………………………….225CC

Oil type to be used is 90W / EP 140.

Stop: Please dispose of used oil in an oil disposal unit. Think about the environment!

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

22. TORQUE DATA:

M12 STARTER FLY WHEEL 70NM

M8 WATER PUMP BODY 22NM
M8 STARTING STATOR COIL SUPPORT 23NM
M8 STARTER MOTOR 23NM
M8 CYLINDER HEAD 23NM
M8 CYLINDER BASE 23NM
M6 REDUCTION GEAR BOX COVER 10NM
M8 REDUCTION FLANGE 23NM
M8 REDUCTION SEMI-BOX 23NM
M8 REDUCTION CRUSE 30NM
M10 RUBBER FLEXIBLE COUPLING (DONUT) 60NM
M12 REDUCTION GEAR NUT 70NM
M6 GEAR BOX OIL LEVEL INDICATOR 10NM
- GEAR BOX OIL FILTER / HEAT DISSIPATER 20NM
- GEAR BOX OIL DRAIN PLUG 20NM

23. WEAR LIMITS:

PISTONS WITH NEW CYLINDERS AT ASSEMBLY 0.08 -0.09 mm

WEAR LIMIT BETWEEN CYLINDER AND PISTON 0.15 mm
MAXIMUM CYLINDER CONICAL LEVEL 0.04 mm
MAXIMUM OVALISATION 0.04 mm
DATUM POINT TO MEASURE PISTON IS 12/13 mm FROM

MANTLE BASE
DRIVE SHAFT NEW AT ASSEMBLY OUT OF CENTRE 0.01 mm
DRIVE SHAFT USED, AT ASSEMBLY AFTER SERVICE 0.04 mm
AXIAL CRANKSHAFT CLEARANCE 0.03 mm
RESILIENT RUBBER "DONUT" AT ASSEMBLY 0.35-0.45mm

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

24. TECHNICAL DATA

24.1 DESCRIPTION

Two stroke, two cylinders, and oil in fuel premix lubrication, water-cooled with integrated water
pump and electric starter.

• Dual Ignition, Bing Carburetors, Reed Valves and Tuned exhaust pipes.

Specification Victor 2 Victor 2 Plus Victor 2 Super

BORE 80mm x 2 80mm x 2 82mm x 2
STROKE 72mm x 2 76mm x 2 76mm x 2
DISPLACEMENT 724cc 764cc 802cc
COMPRESSION RATIO 9.5 TO 1 9.5 TO 1 9.5 TO 1
POWER OUTPUT 92 hp SEA @ 102 hp SEA @ 110 hp SEA @
6100 rpm X 6200 rpm X 6200 rpm X
MAX TORQUE 10.80 Kgm 11.45 Kgm N/A
MAX RPM 6200 RPM 6200 RPM N/A
MAX. CYLINDER 0.4mm 0.4mm 0.4mm
CONICAL LEVEL

MAX.OVALISATION 0.4mm 0.4mm 0.4mm

ROTATION DIRECTION Counter clockwise, viewed toward PTO without

reduction gearbox
CYLINDER MATERIAL Aluminum with Nicasil Ceramic Coating
PISTON MATERIAL Aluminum with silicon
PISTON-CYLINDER
Maximum 0.15mm
CLEARANCE

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24.2 TEMPERATURE:

CHT measured under the spark plug …………………..... 80°-100°C (NORMAL)

120° C (MAXIMUM)

Difference between 2 cylinders …….……………… 20° C

EGT measured at each exhaust manifold

At cruise power ……………………. 550°-580° C (NORMAL)
At maximum power at max speed ……………………. 620° C (MAXIMUM)

Difference between 2 cylinders * ……………………. 20°C

Water / Coolant Temperature ……………………. 65°-75°C (NORMAL)

Measured at heat dissipater ……………………. 80°C (MAXIMUM)

*
The exhausts Gas Temperatures are more reliable when the engine is stabilized at full power or cruise power

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

24.3 IGNITION AND GENERATOR SYSTEM

Breaker-less DUCATI capacitor discharge dual ignition with magneto generator.

GENERATOR OUTPUT …………………... 170 W AC @ 6000 RPM, 13.5V RMS

AC RECTIFICATION …………………... DUCATI RECTIFIER REGULATOR

BATTERY CHARGING …………………... DUCATI RECTIFIER REGULATOR

IGNITION TIMING ……………...…… 1.96mm (18°) BTDC

SPARK PLUG …………………... NGK B9ES TWO ON EACH CYLINDER

24.4 FUEL SYSTEM:

CARBURETOR …………………. TWO BING 36 mm FOR VICTOR2 AND

VICTOR2PLUS, TWO BING 38mm FOR
VICTOR2SUPER WITH CABLE
CHOKES AND AIR FILTERS
FUEL PUMP * …………………. MIKUNI PNEUMATIC FUEL PUMP

FUEL …………………. UNLEADED GASOLINE OR AVGAS

LUBRICATION OF ENGINE …………………. PREMIX TWO STROKE OIL IN

GASOLINE

2.5% OIL BY VOLUME TO LEADED

FUEL

3% OIL BY VOLUME TO UNLEADED

FUEL
*
ADDITIONAL ELECTRIC FUEL PUMP MAY BE REQUIRED, SEE INSTALLATION NOTES

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

24.5 OTHER INFORMATION

LUBRICATION OF ........................... GEAR OIL API-GL4, SAE l40 EP OR

REDUCTION GEARBOX 85W-140 EP

DIRECTION OF PROPELLER ………………... CLOCKWISE VIEWED TOWARD

SHAFT PROPELLER FLANG

STARTER ………………... SIMONINI ELECTRIC STARTER

24.6 STANDARD VERSION INCLUDE

SIMONINI VICTOR 2 / VICTOR 2 PLUS /VICTOR 2 SUPER ENGINE WITH:

1. SIMONINI REDUCTION GEAR BOX TYPE "C"

2. SIMONINI ELECTRIC STARTER (INTEGRAL)

3. BING 54 (VICTOR2 AND VICTOR2PLUS) /58 (VICTOR2SUPER) CARBURETOR 2

4. AIR FILTER

S. DUCATI TWIN ELECTRONIC IGNITION SYSTEM (INTEGRAL)

6. NGK SPARK PLUGS 4

7. DUCATI RECTIFIER / REGULATOR

8. MIKUNI PNEUMATIC FUEL PUMP

9. SIMONINI EXHAUST SYSTEM

12. SIMONINI WATER PUMP (INTEGRAL)

24.7 WEIGHT

ENGINE…………………………………………………………………………………… 52 KG

INCLUDING: Reduction gearbox type "C" and oil, electric starter, 2 air filters, 2 carburetors,
exhaust system, radiator.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

25. OPERATING LIMITATION

The Victor 2 / Victor 2 Plus / Victor 2 Super engine is to be operated within the operating
limitations listed below.

DESCRIPTION LIMITATION NOT TO EXCEED

Cylinder Head Temp 120° C
Exhaust Gas Temp 580° C
Radiator Coolant Temp 80° C
Gear Box Inertia. 6000
RPM Min And Max 2200 Min – 6500 Max
Max Continuous RPM 600RPM
Max Fuel Pressure 0.3BAR / 4.35 psi
Time Between Overhaul 600 HOURS

26. WARRANTY CONDITION

1. Simonini F1ying SRL as the manufacturer warrants through their authorized distributors from
the date of sale to the first customer, every Simonini Victor 2 / Victor 2 Plus / Victor 2 Super
non-certified aircraft engine, sold as new and unused (except for running in procedures done by
Simonini Flying SRL) and delivered by an authorized Simonini Flying SRL distributor, for a
period of the earliest of:

• One year from shipment by Simonini

• The first 500 operational hours from date of first purchase for private- owners.

2. Simonini Flying SRL will, at its option, repair and or replace components defective in material
and or workmanship under normal use and service with genuine Simonini components without
charge for parts or labor during the warranty period. All parts replaced under the warranty will
become the property of Simonini Flying SRL.

3. You must present to an authorized Simonini Flying distributor or service centre the hard copy
of the Simonini Flying warranty registration card and or proof of purchase delivered to customer
from the selling dealer at the time of purchase.

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Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

4. Exclusions are not covered by warranty:

• Normal wears on all items

• Replacement parts and or accessories, which are not Simonini Flying parts and or
accessories
• Damage resulting from installation of parts other than genuine Simonini Flying parts.
• Damage caused by failure to provide proper maintenance as detailed in the Operators
Manual.
The labor, parts and lubricants cost of all maintenance services including tune-ups and
adjustments will be charged to owner.
• Aircraft engines designed and or used for racing or commercial purposes.
• All optional accessories installed on aircraft engine.
• Damage resulting from running the aircraft engine without propeller.
• Damage resulting from modification to the engine not approved in writing by Simonini
Flying.
• Damage caused by electrolysis.
• Cold seizure and piston scuffing.
• Use of a gear reduction not designed by Simonini Flying.
• Use of propellers, which exceed the inertia and balance limits as specified by Simonini
Flying.
• If engine instruments recommended by Simonini Flying have not been used.
• Losses occurred by the aircraft engine owner other than the parts and labor, but not
limited to mounting and dismounting of the engine from the aircraft, such as loss of use,
transportation, towing, telephone calls, taxis, or any other incidental or consequential
damage.
• Damage resulting from accident, fire or other casualty, misuse, abuse or neglect.
• Damage / rust / corrosion, premature wear to engine caused by water ingestion.
• Damage resulting from sand / stones infiltration.
• Damage resulting from any foreign material ingestion.
• Damage resulting from service by an unqualified mechanic.

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

ANNEX
DECLARATION OF QUALITY
Whit the present we declare that the engines that we sell are submitted to strictly controls. Every
part is singularly checked, then assembled then re-checked after the installation following the
industrial concepts of construction.

The testing engineers come from "Ferrari" schools and they are specialized on engines
constructions.

In particular:

1. Each engine is manufactured according to design.

Each engine is assembled at the factory and run for 4 hours at the factory.
2. The engine run is done with the following parameters checked:
• RPM
• CHT
• EGT
• Water Temperature
• Engines are checked for leaks of exhaust gases, coolant liquids or fuel /oil mixtures.
• After engine run is completed, all components are visually checked for leaks.
• After engine is cooled down to ambient temperature, all cylinders head bolts, gearbox
bolts, spark plugs, water-temp belt are checked for the respect of the correct torque and
tension curve parameters.
• All exhausts arc checked for possible cracks.
• Final inspection is done by testing engineers before engine is dispatched to the customer.
3. All exhausts are manufactured on jigs in the factory (avoiding differences between them).
4. All exhausts are made of mild steel using MIG welding.
5. All exhausts are welded by qualified welders at the "Istituto Professionale Statale Ferrari" in
Maranello Italy. The welders have a further apprenticeship at the factory and internal checks.
6. Each exhaust is checked by quality control manager at Simonini factory before it leaves the
factory.

Simonini Enzo

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

Record no 14: Aluminum Alloy LM 25

Additional information Heat treated castings

Specifications and information BS 1490,LM25
Tensile strength. (soft / hard) MPa 150 / 280 / precipitance
0.2% Proof / yield stress (soft / hard) MPa 100 / 200 MPa
Fracture toughness MN/m3/2 25
Density kg/m3 2700
Elongation % 2
Hardness (Vickers) (soft/hard) 70 / 150 kgf/mm2
Tensile modulus GPa 80
Melting temperature deg C 630
Fatigue limit (50 million cycles) MPa 60
Electrical conductivity %IACS (Cu=lOO) 39
Thermal conductivity W/m K 100
Coeff. of thermal expansion mm/km K 19
Specific heat J/kg K 900
Availability (1 .. 15) (1=rare, 15=common) 7
Relative cost (1 .. 9999) (Mild steel=10) 200
Corrosion (l .. 30) (Least .. Most Cathodic) 3
Corrosion resistant die casting.
Si 6.5-7.5;Mg O.2-0.45;Al rem.

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

DUCATI REGULATOR

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Simonini Flying SRL
Victor 2 / Victor 2 Plus / Victor 2 Super Operator s Manual 2009

DUCATI ALTERNATOR

50