BOOSTER MK1

PARTS CATALOGUE-ISSUE 1

Pegasus Aviation, Elm Tree Park, Manton, Marlborough, Wiltshire SN8 1PS, UK
Telephone: +44 (0)1672 861578 Fax: +44 (0) 1672 861550
email: info@pegasusaviation.co.uk www.pegasusaviation.co.uk
CONTENTS
GENERAL ARRANGEMENT 2

AIRFRAME
UNDERCARRIAGE ASSEMBLY 3-4
STRUT ASSEMBLY 5-6
TOP SHELL ASSEMBLY 7-8
BOTTOM SHELL ASSEMBLY 9-10
BOOSTER SIDE WIRE ASSEMBLY 11-12
STIRRUP ASSEMBLY 13
HAND THROTTLE ASSEMBLY 14-15
CRUISE CHEESE ASSEMBLY 16
HARNESS PLATES ASSEMBLY (SHORT) 17
HARNESS PLATE ASSEMBLY (LONG) 18
AIR BOX ASSEMBLY 19

POWERPLANT

ENGINE ASSEMBLY 20-23

FUEL, THROTTLE & CHOKE SYSTEM 24-25
STARTER CABLE ASSEMBLY 26
THROTTLE CABLE ASSEMBLY 27
CHOKE CABLE ASSEMBLY 28
PROPELLER ASSEMBLY 29-30
AFTER MUFFLER ASSEMBLY 31
FUEL TANK SUPPORT TUBE ASSEMBLY 32
BOOSTER DRIVE SHAFT 33
SHAFT ASSEMBLY 34-35
PARACHUTE IGNITION CUTOUT 36

GENERAL
BOOSTER PLACARD 37-38
BOOSTER PROPELLER BLADE REPLACEMENT
AND BALANCING 39-40
GENERAL ARRANGEMENT

1. SIDE LIMIT CABLE

2. SIDE LIMIT CABLE BUNGEES
3. TORQUE TUBE
4. ARRESTER CABLE
 UNDERCARRIAGE ASSEMBLY

BST-101

ITEM PART NUMBER DESCRIPTION

1 FNM5-NT M5 NYLOCK NUT T TYPE

2 FW3-12 3/16 × 3/4 × 1/16 M/S WASHER
3 ZMS-092 ELBOW
4 EFTC-10 O-RING 1.7/8 × 3/16
5 FBM5-45 M5 × 45 HEX HT BOLT
6 ZMA-145 UPPER LEG
7 FR6-12-002 3/16 DIA × 3/8 RIVET
8 RM-1 DECK EYE
9 FMSST-001 NO 12 × 3/4'’ PAN HD POS S/TAP SCREW
10 ZMA-147 RIGHT DOWN LEG
11 ZSP-292 BUSH
12 WW-011 BOOSTER WHEEL
13 FNU4-NT ¼ T EX/THIN TYPE NYLOCK NUT
14 FW4-T4 ¼’’ TALP WASHER
15 END-CAP NO4 END-CAP NO 4
16 FBU4-24 2.1/2 × ¼ UNF HEX BOLT
17 RP-1 R 1550 SINGLE BLOCK/MICRO
18 BST-002 UNDERCARRIAGE RETRACTION WIRE
19 BST-001 SPREADER WIRE
20 ZMA-146 LEFT DOWN LEG

Page 4
 STRUT ASSEMBLY
BST-010 STRUT
BST-004 ROPE

ITEM PART NUMBER DESCRIPTION

1 WEBB-002 STRUT CONNECTION STROP

2 ZKN-124 STRUT UPPER CASTING
3 ZSP-289 STRUT SPACER
4 PMC-SB6 6mm SKIFFY RING
5 FBM6-50 M6 × 50 HEX HT BOLT
6 BST-004 KEEL ROPE
7 BST-010A STRUT COMPLETE
8 FNM6-NT M6 NYLOCK NUT T TYPE
9 PMC-RSC6 6mm RAISED SKIFFY CAP ONLY

Page 6
TOP SHELL ASSEMBLY
STG-BST-004

ITEM PART NUMBER DESCRIPTION

1 COM-006 SHELL WITH HARNESS BEARINGS

2 EFT-9 FUEL TANK
3 ZMS-299 EYE BOLT
4 FBM6-25 M6 × 25 HEX HT BOLT
5 FNM6-NT M6 NYLOCL NUT T TYPE
6 BST-101 UNDERCARRIAGE ASSEMBLY
7 ZMP-104 LEG BEARING
8 ZCH-028 STRUT MOUNT
9 FW4-T4 ¼’’ TALP WASHER
10 BST-102 STRUT ASSEMBLY (COMPLETE)
11 RT-185 5/16 HOLE L/WT SUP TANG SS2004
12 BST-012 FUEL TANK SUPPORT TUBE ASSEMBLY
13 FSM6-20 M6 × 20 HX HT SET SCREW
14 FPSR-003 SAFETY RING
15 VSC3-001 3 MM SHOCK CORD (1500 MM LONG)
16 FBA4-17 AN4-17 A/C HEX BOLT
17 FMS6-25 M6 × 25 C/SNK SLOTTED
18 BST-003 SIDE WIRES ASSEMBLY
19 HTW-001 CABLE TIE 140MM × 3.6 MM
20 FWP-001 PLASTIC WASHERS
21 FNU4-WN ¼ UNF WING NUT
22 FP-003 SAFETY PIN
23 HCC-003 ½ NYLON P CLIP
24 FW4-T3 ¼ T3LP WASHER
25 VW50-004 SMOOTH VELCRO (275MM LONG)
26 DT116-001 WALK TAPE (320MM LONG)

Page 8
BOTTOM SHELL ASSEMBLY

STG-BST-005
ITEM PART NUMBER DESCRIPTION
1 FBM6-25 M6 × 25 HEX HT BOLT
2 FW4-18 ¼’’ 1 ½ × 1/16 MS WASHER
3 ZSP-013 SPACER
4 BST-011 STIRRUP ASSEMBLY
5 FBM6-70 M6 × 70 HEX HT BOLT
6 PMS6-001 SADDLE WASHER
7 ZMA-141 BOOMERANG TUBE
8 ZSP-293 SPACER
9 FW4-12 ¼ × ¾ × 16 M/S YELL. WASHER
10 FNM6-NT M6 NYLOCK NUT T TYPE
11 VSC3-001 3 MM SHOCK CORD (1M LONG)
12 FNM5-NT M5 NYLOCK NUT T TYPE
13 LT-028 CRIMP TERMINAL
14 COM-009 SHELL END PLATE
15 FMS5-20 M5 × 20 HT PN HD SET
16 FMSR-001 BLACK SCREW PLASTIC
17 FW4-T4 ¼’’ 4 WASHER
18 FNM6-NT M6 NYLOCK NUT T TYPE
19 PTM6-001 6 MM ENOTS TUBE (250MM LONG)
20 HTW-004 CABLE TIE 300 MM × 4.8 MM
21 FPSR-003 SAFETY RING
22 HCJ-004 JUBILEE CLIP
23 FW4-T3 ¼ T3LP WASHER
24 HTM-001 TY-WRAP MOUNT
25 PMM-008 GROMMET
26 HCC-003 P-CLIP
27 VW50-004 SMOOTH VELCRO
28 FSM6-20 M6 × 20 HX HT SET SCREW
29 FW5-14 5/16 × 1.1/4 WASHER
30 FWM5-B 5 MM M/S FORM B WASHER
BOOSTER SIDE WIRE ASSEMBLY

BST-003

ITEM PART NUMBER DESCRIPTION

1 BST-003A BOOSTER SIDE CABLE COMPLETE

2 RM-4 50mm WICHARD TACK HOOK
3 VNR-BL3 3mm HIBRITE – 500 mm LONG (BLUE)

Page 12
ITEM PART NUMBER DESCRIPTION

1 ZMS-297 LEFT STIRRUP SPRING

2 ZMP-108 STIRRUP BEARING
3 RF2.5-CCU 2.5 mm ZN PLT CPR FERRULE
4 FR4-12-001 1/8 × 3/8 POP RIVET
5 ZMS-298 RIGHT STIRRUP SPRING
6 ZMA-151 STIRRUP TUBE

Page 13
HAND THROTTLE ASSEMBLY
STG-BST-008

ITEM PART NUMBER DESCRIPTION

1 COM-010 HAND THROTTLE PLATE

2 ZMP-106 BOOSTER THROTTLE LEVER
3 BST-016 CRUISE CHEESE ASSEMBLY
4 VW50-004 50 MM ADHESIVE LOOP VELCRO (200 MM)
5 LS-017 MINI TOGGLE SWITCH
6 FMS5-20 M5 × 20 MM PN HD SET
7 FW4-T4 ¼’’ T4LP WASHER
8 ZSP-013 SPACER
9 LS-018 COVER FOR MINI TOGGLE SWITCH
10 HTW-004 TY-WRAP (BLACK 300 × 4.8 MM)
11 BST-013 ACCELERATOR CABLE ASSEMBLY

Page 14
 HAND THROTTLE ASSEMBLY

ITEM PART NUMBER DESCRIPTION

12 FNM6-NT M6 NYLOCK NUT T TYPE

13 FNM5-NT M5 NYLOCK NUT T TYPE
14 DTI16-001 NON SLIP (150MM LONG) USE TEMPLATE 3
15 EVI-003 BONDED FEET-M6
16 FCM6-20 M6 × 20 MM SCKT CAP SCREW
17 WEBB-003 HAND PLATE STROP
18 HCJ-013 MICROFLEX NO 1 JUBILEE CLIP

Page 15
CRUISE CHEESE ASSEMBLY

BST-015

Page 16
HARNESS PLATES ASSEMBLY (SHORT)

STG-BST-009

ITEM PART NUMBER DESCRIPTION

1 ZPL-142 INSIDE HARNESS PLATE

2 ZPL-143 OUTSIDE HARNESS PLATE
3 FSCM6-18 M6 × 30 MM C/SNK HD CAP
4 PMC-SB6 6 MM SKIFFY RING
5 FNM6-NT M6 NYLOCK NUT T TYPE
6 PMC-RSC6 6 MM RAISED SKIFFY CAP

Page 17
HARNESS PLATES ASSEMBLY (LONG)

STG-BST-010

ITEM PART NUMBER DESCRIPTION

1 ZPL-144 INSIDE HARNESS PLATE

2 ZPL-145 OUTSIDE HARNESS PLATE
3 FSCM6-18 M6 × 30 MM C/SNK HD CAP
4 PMC-SB6 6 MM SKIFFY RING
5 FNM6-NT M6 NYLOCK NUT T TYPE
6 PMC-RSC6 6 MM RAISED SKIFFY CAP
7 FPWP-001 PIN
8 GEN-OG SIZE

Page 18
ITEM PART NUMBER DESCRIPTION

1 FMS5-20 FMS5-20 SCREW

2 PMC-SB6 6 MM SKIFFY RING
3 COM-007 AIR BOX PLATE DRILLED (BOOSTER)
4 ZMP110 AIRBOX JOINER ROD
5 PF-008 AIR BOX FOAM
6 COM-008 AIR BOX SHELL DRILLED (BOOSTER)
7 PMC-RSC6 6 MM RAISED SKIFFY CAP

Page 19
ENGINE ASSEMBLY

STG-BST-001

ITEM PART NUMBER DESCRIPTION

1 FNM8-NT M8 NYLOCK NUT T TYPE

2 FWM8-B 8 MM FORM B WASHER Z & Y
3 EVI-008 AVM209/9
4 WEBB-001 STROP
5 FSM8-20 M8 × 20 HEX HT SET SCREW
6 FSM8-25 M8 × 25 HEX HT SET SCREW
7 ZSP-286 SPACER
8 FBM6-45 M6 × 45 MM HEX HT BOLT
9 FNM6-NT M6 NYLOCK NUT T TYPE
10 FWP-002 10.5 × 32 MM NYLON WASHER
11 ZCH-026 FRONT ENGINE BEARER CHANNEL
12 FWM10-B 10 MM M/S FORM B WASHER
13 FWM10-SW 10 MM SPRING WASHER Z/Y
14 FBM10-55 M10 × 55 HT HEX BOLT
15 ZCH-027 REAR ENGINE BEARER CHANNEL
16 ZMS-300 CABLE BRACKET
17 FNM4-BX M4 BRASS BINX NUT
18 FSM4-16 M4 × 16 PAN HD BRASS SCREW
19 PP-120/1 ENGINE PARTS
Refer to RADNE 12 AERO ENGINE MANUAL
20 FCM5-16 M5 × 16 SCKT CAP SCREW
21 FWM5-B 5 MM M/S FORM B WASHER
22 HCC-003 (350 3328) ½’’ NYLON P CLIP
23 FNM5-NT M5 NYLOCK NUT T TYPE
24 FNM8-TN M8 NUT THIN TYPE
25 FMS8-15 M8 × 15 MM SKT BNT SET
26 ZPL-139 PLUG PROTECTOR
ITEM PART NUMBER DESCRIPTION

27 BST-006 AFTER MUFFLER ASSEMBLY

28 EVI-009 EXHAUST MOUNT
29 HS-014 EXHAUST SPRING (SHORT TYPE)
30 HCJ-003 70-90 MM JUBULEE CLIP
31 HCJ-006 50-70 MM STEEL HOSE CLIP
32 ZMS-294 EXHAUST CONNECTOR
33 HS-015 EXHAUST SPRING (LONG TYPE)
34 HCM14-001 14 MM HOSE CLIP
35 BST-009 STARTER CABLE ASSEMBLY
36 RW1.5-SS 1.5 MM WIRE
37 RF2-CCU 2 MM FERRULE
38 RW1.5-SS 1.5 MM WIRE
39 FW4-T3 ¼ T.3 L.P M/S WASHER
40 FNU4-NT ¼ ‘T’ EX/THIN TYPE NYLOCK NUT
41 FBM6-30 M6 × 30 HEX HT BOLT Z/Y
42 RP-11 ALUMINIUM PULLEY
43 RP-12 ALUMINUM PULLEY BUSH
44 ZPL-141 PULLEY GUARD
45 ZPL-140 STARTER PLATE
46 ZMS-302 STARTER PLATE BOLT
47 ZMP-031 ROPE STOPER
48 FDM6-15 M6 × 15 DOME BOLT
49 FR61202 3/16’’ MONOBOLT
50 ZMA-154 RECOIL STOP

Page 23
ITEM PART NUMBER DESCRIPTION

1 FNM6-NT M6 NYLOCK NUT T TYPE

2 FW4-12 ¼ × ¾ × 16 M/S Z/YELL. WASHER
3 ZSP-288 STOP MOUNT SPACER
4 FW4-T4 ¼’’ TALP WASHER
5 FBM6-30 M6 × 30 HEX HT BOLT Z/Y
6 ZMP-109 PROP BRAKE HOSE
7 FDM6-15 M6 × 15 DOME BOLT
Page 24
FUEL, THROTTLE AND CHOKE ASSEMBLY

STG-BST-007

ITEM PART NUMBER DESCRIPTION

8 ZPL-032 PROP BRAKE PLATE

9 ZMS-280 EYE BOLT
10 ZMS-285 M6 HOSE NIPPLE
11 HTW-002 CABLE TIE (3.6 140 MM)
12 EFLH-7 FUEL HOSE BLUE (440 MM)
13 PT12-001 BREATHER PIPE (1270MM LONG)
14 PMM-008 694-15090 RUBBER GROMMET
15 HCM10-001 9-11 MM SCREW CLIP
16 EFLC-6 ART 1450 PRIMER BULB ¼ BORE
17 HTW-004 CABLE TIE
18 EFLH-7 FUEL HOSE BLUE
19 SEE HAND THROTTLE ASSEBLY
20 SEE TOP SHELL ASSEMBLY
21 “ “ “ “
22 “ “ “ “
23 BST-014 CHOKE CABLE ASSEMBLY
24 EFF-2 FUEL FILTER 90 DEG
25 HCC-033 ½ ‘’ NYLON P CLIP
26 HS-004 RETURN SPRING MF 4412
27 EFLH-7 FUEL HOSE BLUE
28 FNU4-NT ¼ T EX/THIN TYPE NYLOCK NUT
29 ATUO-1-1 SOFT ALUMINIUM TUBE SPOUT
30 STG-BST-011 PARACHUTE IGNITION CUTOUT ASSY.

Page 25
25
PROPELLER ASSEMBLY

STG-BST-006

ITEM PART NUMBER DESCRIPTION

1 FBM5-35 M5 × 35 MM HEX HT BOLT

2 COM-004 COMPOSITE SPRING (FOLD. PROP)
3 FWM5-B 5 MM M/S FORM B WASHER
4 FNM6-NT M6 NULOCK NUT T TYPE
5 FW4-T3 ¼ T3 L.P M/S WASHER
6 EVI-003 BONDED FEET-M6 AVM-191
7 ZMA-090 FOLDING PROP HUB
8 FNU4-NT ¼ T EX/THIN TYPE NYLOCK NUT
9 KIT-BST-001 WASHER KIT
10 FBA4-27A AN4-27A A/C HEX BOLT
11 BST-022 FOLDING PROP BLADE KIT
12 HTW-002 CABLE TIE 140 × 3.6 MM
13 VSC5-001 5 MM SHOCK CORD (0.5M LONG)
14 ZMP-102 NYLON PROP DRIVER
15 FP-003 SAFETY PIN
16 PMC-SB6 6 MM SKIFFY RING
17 ZMS-296 DRIVE PIN
18 FWM5-B 5 MM M/S FORM B WASHER
19 FNM5-NT M5 NYLOCK NUT T TYPE
20 EVI-010 FOLDING PROP STOPPER
21 ZMS-301 PROPELLER BUSH
22 ZMP-013 WASHER
23 DP-063 PLACARD
24 DTM12-001 LEADING EDGE TAPE

Page 30
SHAFT ASSEMBLY

STG-BST-002

ITEM PART NUMBER DESCRIPTION

1 FNM10-G8 10 MM PLAIN NUT

2 FWM10-B 10 MM M/S FORM B WASHER
3 ZMA-088 EXPANDER SLEEVE
4 ZMS-089 EXPANDER CONE
5 FCM5-16 M5 × 16 SCKT CAP SCREW
6 FWM5-SW 5 MM S. COIL SQ. SEC.SPR. WASHER
7 ZMS-091 47 TOOTH SPROCKET
8 ZMA-089 SPROCKET HUB
9 CHN-001 DID TYPE 209 CHAIN (66 LINKS, O-RING)
10 BEA-BB-8 BEARING
11 ZMP-103 BEARING CARRIER
12 (SEE PAGE 38/39) DRIVESHAFT FOR BOOST2ER
13 HCJ-003 70-90 MM JUBILEE CLIP
14 ZSP-290 PROP BEARING THRUST WASHER
15 BEA-BB-9 BEARING
16 ZSP-291 PROPELLER BEARING SLEEVE
17 ZSP-287 PROPELLER THRUST SPACER
 BOOSTER PLACARD

DP071

ON RH SIDE HANDLE

PULL LOOP HANDLE TO

RETRACT GEAR

ON PROP BLADES (1 SPARE) ON LEFT HAND SIDE ABOVE HANDLES

BLADE DRAWING EPB-010 PULL VELCRO HANDLE

STAGE 1 FOR BRAKE, STAGE
ISSUE:
BALANCE FACTOR: 2 FOR CHOKE.
PITCH:
SERIAL NO: PULL LOOP HANDLE TO
INSPECTION/TEST:
RETRACT GEAR

FRONT CENTRE OF SHELL ON IGNITION SWITCH

WARNING - Do not attempt to rig the ON OFF

aircraft, start the engine or operate
the aircraft or its equipment until
you have read and fully understood
the Operator’s and Engine Manual.

WARNING - This aircraft is not
aerobatic. No whip stalls, wing
overs, tail slides, loops, rolls or
spins. Maintain positive g loading at SHELL DRAWING COM-006
all times.
ISSUE:
SERIAL NO:
INSPECTION/TEST:

Page 37
 ON SHELL ABOVE EXHAUST AREA ON SHELL BY FUEL TANK

WARNING FUEL CAPACITY 5 LTR

Do not touch the engine when UNLEADED 90+ OCTANE
running - some rotating engine parts MIX RATIO 40:1
are exposed. Some parts remain hot SYNTHETIC RACING 2 STROKE OIL.
for a considerable time after the
engine has been switched off. Allow DRIVE CHAIN MUST BE
to cool before inspection and before LUBRICATED BEFORE FLIGHT
filling tank. USING NON-FLING AEROSOL
CHAIN LUBRICANT.

SPARES

WARNING - Hot
WARNING - Hot
WARNING - Hot
WARNING - Hot
BOOSTER PROPELLER BLADE REPLACEMENT & BALANCING

Root
Pivot Return
Bolt Bolt

Replacement Propeller Blades:

Before replacing a blade, check:

1) The condition of the hub for distortion, wear at the bolt holes, cracks.
2) The driveshaft for straightness.
3) Condition and security of the nylon prop. driver, pin, and shaft attachment sleeve.
4) The condition of the other blade – cracks, splits etc.
5) Condition of mylar washers and bungees.

Balance:

Correct balance is absolutely vital. A correctly set up Booster is vibration-free.Vibration

causes pilot discomfort as well as causing structure damage through fatigue.
The Booster propeller is balanced by using unequal length return bolts and balancing
washers. The return bolts are 6mm diameter, ranging from 35mm to 90mm long. To get an
extra balancing range, the short bolt may be titanium and the long 90mm bolt may be
increased to ¼” diameter. (Aluminium must not be used because of corrosion in the carbon
blade). The bolt must be degreased with acetone or cellulose thinners and bonded securely
in position using 5 minute epoxy (e.g. Devcon or Araldite rapid) coating the entire length of
the bolt. 6-8mm shank must protrude for the return bungee.

So that replacement blades can be supplied for any propeller, blades are supplied without
the return bolt fitted so that the propeller can be balanced.

Page 39
Procedure:

Assemble the propeller and carefully chock the blade stops using equal weight washers so
that the blades are square to the hub. Use the balancing tool part ZMA-155A in calm
conditions. See the procedure in the drawing “balancer” below.
Use the unequal weight return bolts to balance the propeller along the blade axis. Fine
tuning can be by using up to 2 washers under the blade stop nuts.
Use up to 2 washers under the root pivot bolt nuts to balance across the blade axis. Note
the washers MUST be on the threaded end of the bolt so that the 700kg centrifugal force is
taken by the plain bolt shank. Turn the bolt round if necessary.
The pivot bolts are NOT intended to rotate. The blades pivot on the stainless steel sleeve.
Some light lubricant e.g. WD40 can be used. Mylar face washers must be fitted.

After balancing, test run the propeller in a clear area, away from people, to check rpm and
vibration levels. Check the propeller afterwards for security of all fasteners and condition of
parts.

If the propeller balance is perfect and vibration still exists, ensure the shaft is straight and
the chain is not worn. All shaft bearings must be secure with no play on the shaft. Varying
chain tension as the engine turns causes vibration accompanied by a “vibrato” engine note.
The correct static rpm is 2250-2400 with a cold engine, falling by around 50rpm warm.
At this rpm range, static thrust is approximately 39-44kg.
PARTS KIT NO: KIT-BST-001