AMD Zodiac 601XL SLSA User manual

ZODIAC 601XL / 601XLi / 650LS / 650LSi
SLSA
Continental 0-200 Engine
MAINTENANCE
MANUAL
Aircraft Manufacturing & Design, LLC.
P.O. Box 639 Eastman, GA 31023 USA
Tel: [phone]
Fax: [phone]
July 09

AMD ZODIAC 601XL / 601XLi / 650LS / 650LSi SLSA MAINTENANCE
MANUAL
_______________________________________________________________________
TABLE OF CONTENTS
SECTION I INTRODUCTION SECTION VI POWERPLANT
SECTION II HANDLING AND SERVICING SECTION VII SURFACE CONTROLS
SECTION III INSPECTION SECTION VIII FUEL SYSTEM
SECTION IV STRUCTURE SECTION IX INSTRUMENTS
SECTION V LANDING GEAR AND BRAKES SECTION X ELECTRIC SYSTEM
SECTION XI HEATER /VENTILATION
SECTION XII PROPELLER
LIST OF EFFECTIVE PAGES
Section Page Date Section Page Date
0 0.1 Nov. 09 7 7.1 Nov. 09
0 0.2 Nov. 09 7 7.2 Nov. 09
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1.1
July 09
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7.3
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1 1.2 July 09 7 7.4 Nov. 09
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1.3
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2 2.1 July 09 8 8.1 July 09
2 2.2 July 09 8 8.2 July 09
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3 3.1 July 09 9 9.1 July 09
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3 3.4 Nov. 09 9 9.4 July 09
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3 3.6 July 09 9 9.6 July 09
3 3.7 July 09 9 9.7 July 09
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3 3.9 July 09 9 9.9 July 09
3 3.10 Nov. 09 10 10.1 July 09
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4 4.2 July 09 10 10.3 July 09
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5 5.2 July 09 11 11.1 July 09
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Copyright AMD
The data and information contained in the document is the property of AMD. This
document may not be reproduced or transmitted to a third party, in any form or by any
means. Any unauthorized copy, distribution is illegal as per international agreements
relating to property rights.
NOV 2009 0.1

AMD 601XL / 601XLi / 650LS / 650LSi SLSA MAINTENANCE MANUAL
_______________________________________________________________________
SERVICE MANUAL UPDATE LOG
REV. NO. DATE ISSUED DATE
INCORPORATED
INSERTED BY
0 July 2009 AT ISSUE
1 November 2009
Note: 0.1 and 0.2 with Update sheet(s) are replaced for each new update.
0.2 NOV 09

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
SECTION 1
GENERAL
INTRODUCTION
This manual contains service and maintenance instructions for the ZODIAC 601XL /
601XLi / 650LS / 650LSi, designed and manufactured as a versatile two-seat aircraft
In the text, reference is made to the following publications:
- Pilots’ Operation Handbook
- Airframe drawings. These drawings must be used when doing major repairs to the
airframe as to make sure that proper material and material thickness is used etc.
Airframe drawings do not come with the aircraft but must be purchased separately.
Contact the manufacturer.
- Parts Manual. Airframe parts are listed in the parts assembly drawings.
- Engine: Operator’s Manual from the engine manufacturer
- Engine: Maintenance and overhaul Manual from the engine manufacturer
- Propeller: Prop. book (instructions for use and care) from the propeller
manufacturer
- Pre-Flight Check List. Contact the manufacture for this list. It is to be used when
putting an aircraft back into service, when major work was performed, annual
inspection, etc.
FAA AC-43.13.-1B and 2A Acceptable Methods, Techniques, and Practices -
Aircraft Inspection and Repair is a useful handbook.
The description of the aircraft included in this section is limited to general information;
however, the figure gives specific external dimensions.
Before performing maintenance on the aircraft, make sure that you are authorized to do so.
See Appendix 2.
When disassembling and reassembling the aircraft, see Appendix 1.
July 09 1.1

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
DESCRIPTION
The ZODIAC is a single engine, two-seat, low-wing monoplane of all-metal construction.
WING: The wing is of all-metal stressed-skin, full cantilever, low-wing design, consisting
of two wing panels bolted to a spar box assembly in the fuselage. The ailerons are cable
and push rod controlled. The wing trailing edge hinged flaps are electrically operated.
EMPENNAGE: The empennage consists of the rudder, stabilizer, and elevator trim tab.
FUSELAGE: The fuselage consists of three basic sections: the engine section, the cabin
section, and the sheet-metal tail cone.
LANDING GEAR: The tricycle landing gear is of the fixed type, consisting of a nose
wheel and two main wheels.
HYDRAULIC SYSTEMS: The optional dual brake system is operated by master
cylinders.
ENGINE: The aircraft is powered by one horizontally opposed Continental 0-200 four-
cylinder air-cooled engine.
PROPELLER: The propeller used is a two blade wood fixed pitch propeller.
FUEL SYSTEM: The fuel system on the ZODIAC consists of aluminum tanks in the
wings, one engine-driven pump, and one electrical auxiliary pump.
FLIGHT CONTROLS: The flight controls are conventional equipment, consisting of a
center Y stick that control ailerons and elevator, and pedals which operate the rudder.
Duplicate rudder controls are provided for the co-pilot. Dual sticks are optional.
RADIO: Provisions for radio installations consist of microphone and headset jacks and
mounting brackets, necessary wiring, and panel space for extra radios.
CABIN HEATER, AND FRESH AIR SYSTEM: Heated air for the cabin is obtained
directly from the exhaust system muffler shroud. Fresh air is supplied to the cabin through
two individual and orientable air inlet vents in the right and left fuselage sides.
INSTRUMENTS: Provisions for optional instruments are provided.
1.2 July 09

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
GENERAL DIMENSIONS
AMD 601XL / 601XLi / 650LS /650LSi
July 09 1.3

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
SECTION II
HANDLING AND SERVICING
GENERAL
This section provides ground handling and servicing instructions.
Recommended ground handling procedures, and recommended methods of servicing
are provided in following paragraphs. If trouble or damage to the aircraft is discovered
during ground handling or servicing, refer to the appropriate section for the system
concerned. Lubrication is treated as a separate function.
ACCESS PROVISIONS
Access door on rear fuselage is located on the bottom of the aircraft. Aileron belcrank
access doors are located on the bottom– center of each wing, fuel strainer access panels
are located beside left and right wing fuel drain valves. Oil door is located on the top
engine cowling. Engine top and bottom cowlings must be removed for engine access.
Seats and cabin side upholstery can be removed. Access doors provide access for purposes
of service and maintenance.
GROUND HANDLING
GENERAL. The aircraft must not be pushed, pulled, or lifted by any other means than
those described. Procedures are given for the proper execution of all necessary handling
operations and, if the instructions are followed, damage to the aircraft or its equipment
will be prevented.
Caution: Use the utmost care at all times during ground handling operations.
STEP AND WALKWAYS
A fixed step is located on each side, below and aft of the inboard end of the wing trailing
edge. The walkway is made up of a non-skid compound applied to the wing surface.
Caution: Walk on the walkways only, to avoid damage to the wings.
WEIGHT & BALANCE AND EQUIPMENT LIST
See Flight Manual
July 09 2.1

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
HOISTING
Nose Gear Hoisting - Remove the cowl and lift the aircraft with a hoist attached to the
metal loop on top of the engine.
Main Gear Hoisting - Lift the aircraft one side at a time and insert a padded sawhorse or
equivalent under wing at main wing spar and rib rivet line.
LEVELING
The aircraft may be leveled while the wheels are on the ground or during the weighing
procedure while the wheels are on scales. Leveling the aircraft for purposes of reweighing
or rigging is accomplished as follows:
Position the level on the canopy sill (upper fuselage longeron). See Weight & Balance
drawing in Pilots Operating Handbook.
To put the airplane in a longitudinally level position, either on scales or on the floor,
deflate the nose wheel tire until the proper position is reached (or add shims under the two
main wheels ).
To level the airplane laterally, place a level across the cabin on the right and left
longerons, shim one main wheel as required. (repeat longitudinal leveling).
WEIGHING PROCEDURE - See Pilots Operating Handbook.
TYING DOWN
Secure tie-down ropes to the wing tie-down rings and the tail skid at approximately 45°
angles to the ground. Leave sufficient slack to avoid damage to the aircraft when the
ropes contract due to moisture.
TOWING
Move the aircraft using the nose wheel optional tow bar hooked into the nose gear strut
rings.
Caution: Remove the tow bar when not in use as the propeller may hit it when engine is
started.
July 09 2.2

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
SERVICING
FUEL SYSTEM
The fuel tanks and sumps are drained through the push-to-drain valves under the wings
just rear of the wheels.
The fuel strainers at the tank outlets are accessed for removal and cleaning through the
access panels beside the push-to-drain valves.
Gascolator is located under the fuselage near the firewall.
LUBE OIL SYSTEM
FILLING ENGINE SUMP
Fill the oil tank with the specified lubricating oil. (Engine Manual.)
BRAKE SYSTEM
FILLING BRAKE CYLINDER RESERVOIRS
The brake cylinder reservoirs are an integral part of the master cylinders on pilot side.
They must be checked at every 50-hour inspection and replenished when necessary. No
adjustment of brake clearance is necessary on the brakes.
DRAINING BRAKE SYSTEM
To drain the brake system, disconnect the hydraulic brake lines from the brake assembly
of the main gear, and place the end of each line in a suitable container. Slowly pump the
brakes until fluid ceases to flow. To clean the brake system, flush with denatured alcohol.
LUBRICATION
Airframe must be lubricated every 100-hours, at annual or after washing. This includes all
moving parts including but not limited to ailerons-flaps-elevator and trim piano hinges, all
control bearings such as nose wheel bearing strut top and bottom, aileron bellcranks, etc.
Wheel bearings need to be repacked and greased, each time new tires are installed.
LIST OF WEARABLE REPLACEMENT PARTS:
-Oil filter – Cessna 150 type. Order from AMD, Aircraft Spruce & Specialty, etc.
-Carb. air filter – Cessna 150 type. Order from AMD, Aircraft Spruce & Specialty, etc.
-Spark plugs – Auto type. Order from AMD, Aircraft Spruce & Specialty, etc. See
engine manual for type.
-Wheels and brakes – Cessna 150 type. Order from AMD, Aircraft Spruce & Specialty,
etc.
2.3 Nov. 09

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
SECTION III
INSPECTION
GENERAL
This section provides instructions for conducting scheduled inspections, unscheduled
inspections, replacement of time limited parts and corrosion control. Repair or
replacement instructions for those components found to be unserviceable are in the
sections covering the applicable aircraft system.
Lubrication and servicing intervals should be adjusted to take into account the aircraft
operating conditions.
All of the inspections are generally visual inspections unless otherwise specified. They
are to be performed by trained and qualified personnel using appropriate tools and
adequate lighting.
Prior to commencing the scheduled inspections listed in Table 1:
a. Thoroughly clean the aircraft and engine;
b. Remove and or open the necessary inspection and access panels, the engine cowlings,
the spinner and the optional wheel fairings; and
c. Review the aircraft records for outstanding “SAFETY ALERTS”, “SERVICE
BULETINS” and “NOTIFICATIONS”. You must contact the manufacture for the
latest list of above documents.
Manufacturer can be contacted by telephone at 478-374-2759 or by fax at 478-
374-2793 or by mail at 415 Airport Road, Eastman GA, 31023 USA.
For engine and propeller Service Bulletins, Airworthiness Directives, and Service
Letters, contact the original manufacturers.
Section F2295 of the ASTM SLSA lists the Owner/Operator Responsibilities for
Continued Operational Safety Monitoring of a Light Sport Airplane. Complete and
submit Form #1 for maintenance, service and safety difficulties.
Note: In addition to the tasks specified in Table 1, do the preflight inspections described
in the Owner’s Manual. For mechanics who are not familiarized with the aircraft, use the
+40 page Pre-Flight check list as an extra guide. Available from the manufacturer.
SCHEDULED INSPECTIONS
Scheduled inspections include the items listed in Table 1 Inspection Form, the
overhaul requirements for the engine and propeller, the calendar time inspections and the
one-time inspections done following specified tasks. Do the following:
Inspection Form Requirements
Perform the tasks in Table 1 at the intervals shown.
Overhaul Requirements
a. Overhaul the engine (Continental 0-200). See engine manuals
b. Overhaul the propeller. See propeller manufacturers instructions
Replacement of Airframe Time Limited Parts
No parts listed at this time.
July 09 3.1

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
UNSCHEDULED INSPECTIONS
Unscheduled inspections must be performed anytime that unusual operating
conditions are encountered which may affect the integrity or airworthiness of the aircraft.
Actions to be taken following the reporting of such events are as follows:
Hard Landing
a) Check ELT for inadvertent activation.
b) Check main gear spring for deformation.
c) Check nose gear and firewall for damage.
Propeller Strike a) Check propeller for damages.
b) Check prop flange re crankshaft damage.
C) Check engine manufacturers Service Manual
Lightning Strike
a) Check ELT for inadvertent activation.
b) Check skins for damages.
c) Check control connections for damages.
Bird Strike
Check the area for damages
Exceedence of Operational Limits
Do not fly the aircraft. Contact the manufacturer immediately.
Tire Change Replace tires when required. Do not wait until next scheduled
inspection if tire(s) need to be changed.
CORROSION CONTROL
To avoid the deterioration of the ZODIAC aircraft due to the effects of corrosion,
monitor the condition of protective coatings on exterior and interior surfaces. If damage
to coatings is found, restore surfaces prior to the occurrence of damage caused by
environmental effects.
INSPECTION SCHEDULE
The required inspection tasks and their intervals are listed in Table 1. The tasks
are placed in seven groups: Propeller, Engine, Cabin, Landing Gear, Wing, Fuselage and
Empennage.
The first column of Table 1 states the task to be performed; the second column
states the applicable references(s). The third column is divided into four sub-columns,
each of which corresponds to an inspection interval. The last column may be used to
verify that a task has been completed. Perform the stated tasks at the intervals shown
when a plus (+) symbol is shown in an interval column. A minus (-) symbol indicates no
maintenance action is required. Tasks may be performed sooner but not later than the
stated intervals. If done sooner, tasks must next be performed at the stated interval (e.g. at
790 flight hours airframe time, a 100 hour task is performed 10 flight hours before it is
due. It must next be performed 100 hours later, at 890 flight hours (or sooner).
Operational checks are tasks that determine that an item is fulfilling its intended
purpose. No verification of meeting tolerances is required.
Functional checks are tasks which determine if one or more functions of an item
are performing within specified limits. Quantitative checks must be performed.
Useful Note: The 50 hour inspection has a tolerance of + 16% (i.e. between 42
and 58 hours). An Annual condition Inspection is identical in scope and detail as a 100
hour inspection. Perform inspections as per section VII of Engine Operators Manual. In
order to assist A&P mechanics with the annual inspection or when reassembling the
aircraft, the Pre-Flight Check List must be used with Table 1.
Nov. 09 3.2

TABLE 1 – ZODIAC INSPECTION FORM
Make / Model
____________________ Serial No.
_____________________
Airframe Hours
___________________ Type of Inspection
(Circle One)
Registration No: _________ Engine Hours: __________ 50 100 500 1000
Symbols: + Indicates perform task,
-
Indicates do not perform task
Task Refer to Intervals (Flight Hours) Initials
50
100
500
1000
Propeller Group
1. Check propeller bolts for torque and safeties.
2. Inspect blades and hub for cracks, corrosion,
damage, etc.
3. Inspect spinner and backing plate.
Engine Group Danger
Ground magneto primary circuit before
working on engine.
1. Check for oil/fuel leaks.
2. Check for particles on oil suction screen and
sump drain plug.
3. Drain oil and refill. Safety plug.
4. Perform cylinder compression test.
5. Clean the spark plugs. Adjust gap
6. Check and set magneto timing. See 29.
7. Check magneto breaker points and lubricate
breaker point felt.
8. Clean oil suction and oil pressure screens
9. Inspect the wet type foam air filer.
10. Inspect the exhaust manifold for cracks
(carb and cabin heat shroud removed).
11. Inspect the heat shrouds for cracks, etc.
12. Inspect the motor mount fuselage and
engine attachment points and braces.
13. Inspect the rubber engine vibration
isolating mounts for cracks damage, etc.
First bolt torque is at 5
hours.
Sensenich Continued
Airworthiness
Requirements. Also see
Appendix 1 of this
manual.
See Engine Operators
Manual.
Section 6.5
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July 09 3.3
Inspection page 1 of 8

TABLE 1 – ZODIAC INSPECTION FORM
Type of Inspection
(Circle One)
50 100 500 1000
Symbols: + Indicates perform task, - Indicates do not perform task
Task Refer to Intervals (Flight Hours) Initials
50 100 500 1000
14. Inspect engine for security of all attaching
hardware (nuts, bolts, screw, etc.)
15. Perform valve clearance check
16. Inspect the ignition harnesses for general
condition.
17. Inspect the carburetor air intake box for
leaks.
18. Drain carburetor and clean carburetor fuel
strainer and strainer bowl.
19. Inspect engine cowlings for cracks,
damage, loose rivets, etc.
20. Inspect the vacuum pump, lines and
separator, if installed.
21. Change the Oil filter.
22. Inspect the oil radiator, oil lines and
attaching brackets (if installed).
23. Clean and flush oil radiator (if installed).
24. Inspect engine, firewall and firewall seals
for deterioration, cracking, etc.
25. Inspect cabin heat control box for cracks,
condition, etc.
26. Inspect engine controls for defects,
safeties, etc. Check control travels.
27. Check starter, alternator, fuel pump and
vacuum pump for proper mounting, security
and defects
28. Perform operational checks of all systems
(fuel, oil, heating, etc.)
29. Run engine and check:
- Magneto drop:
- Full power RPM
- Idle RPM
30. Check and adjust magnetos only if
discrepancies were noted in step 29.
N/A on 0-200 model
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Nov. 09 3.4
Inspection page 2 of 8

TABLE 1 – ZODIAC INSPECTION FORM
Type of Inspection
(Circle O
ne)
50 100 500 1000
Symbols: + Indicates perform task, - Indicates do not perform task
Task Refer to Intervals (Flight Hours) Initials
50 100 500 1000
CABIN GROUP
1. Inspect the control stick(s), linkages,
column and torque tube assemblies for
cracks, distortion, excessive play etc.
2. Check controls for ease of operation and
correct travel.
3. Check operation lights.
4. Check operation of all circuit breakers and
switches.
5. Check flight control cables for routing,
fraying, corrosion and tension.
5a Inspect flight control turnbuckles,
pulleys and guides for wear, damage
and safeties.
6. Check elevator trim tab switch/ indicator
for correct operation.
7. Inspect the flap motor actuator, extension
tube, actuator lever, interconnect tubes,
control levers and control rods for cracks,
distortion, security, etc.
7a Inspect flap indicator cable and
indicator for security and correct
Operation.
8. Perform functional check of the flap
system.
9. Inspect windshield for cracks, cleanliness,
etc.
10. Check cabin finish for damage,
deterioration, etc.
11. Perform operational check of the fuel
selector valve and safety lock.
12. Inspect canopy fit and latching
mechanisms.
13. Check upholstery for condition
See AMD Safety Alert of
October 2008
See AMD Safety Alert of
October 2008
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July 09 3.5
Inspection page 3 of 8

TABLE 1 – ZODIAC INSPECTION FORM
Type of Inspection
(Circle One)
50 100 500 1000
Symbols: + Indicates perform task, - Indicates do not perform task
Task Refer to Intervals (Flight Hours) Initials
50 100 500 1000
14. Inspect safety belts, attaching hardware,
etc. for condition security.
15. Verify appropriate compass correction
card is in aircraft.
16. Clean or replace filters in the gyro
vacuum system (if installed).
17. Inspect radio installations and mounting
hardware for security, condition. etc.
18. Inspect electrical wiring for condition,
security, routing, damage, etc.
19. Check condition and security of all
bonding wires.
20. Inspect antenna installations for
condition, security, etc.
21. Inspect instruments for security,
markings, condition and perform
operational check.
22. Inspect fuel sender units for security,
leaks, etc.
23. Inspect fuel primer (if installed) for
security, condition, leaks, etc.
24. Check brake fluid level.
25. Inspect the aft side of the firewall from
inside the cabin for cracks around any
rivets.
Landing Gear Group
1. Inspect the main landing gear mainspring
attachment bolts for safeties, etc.
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3.6 July 09
Inspection page 4 of 8

TABLE 1 – ZODIAC INSPECTION FORM
Type of Inspection
(Circle One)
50 100 500 1000
Symbols: + Indicates perform task, - Indicates do not perform task
Task Refer to Intervals (Flight Hours) Initials
50 100 500 1000
2. Check security, condition, etc., of lateral
stop and bolts and axle bolts.
3. When removing wheels, inspect the brake
assemblies, axles, pins and spacers for
security, condition, leaks, etc.
4. Check the brake pads and brake discs for
excessive wear.
5. Inspect the main wheels for cracks,
corrosion, etc.
6. When removing wheels re-pack wheel
bearings.
7. Inspect the master and slave brake cylinders,
brake lines, connections for damage,
corrosion, leaks, etc. Service the master
brake cylinders.
7a Inspect the rubbers at the main landing
gear attachments for condition and
abrasion damage, and position
8. When removing wheel, the airplane hoisted
remove the nose wheel and inspect wheel for
cracks, corrosion, etc.
9. Inspect the nose gear lower front bearing
plate, cam centering, steering connections
strut, strut supports and stop plate for cracks,
distortion, corrosion, etc.
10. Inspect the steering rods for security,
distortion, etc.
11. Inspect the shock cord for damaged threads
and weakness.
12. Inspect the lower shock ring support for
cracks, distortion, etc.
13. Check tire pressure. (30 PSI)
14. When removing wheel, inspect the nose
wheel axle bolt, spacers and axle for wear,
damage, corrosion, etc.
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July 09 3-7
Inspection page 5 of 8

TABLE 1 – ZODIAC INSPECTION FORM
Type of Inspection
(Circle One)
50 100 500 1000
Symbols: + Indicates perform task, - Indicates do not perform task
Task Refer to Intervals (Flight Hours) Initials
50 100 500 1000
Wing Group
1. Check the torque and safeties of the front
spar, main spar and rear spar wing to
fuselage attachment bolts.
2. Inspect the external surfaces of the
ailerons and flaps for cracks, deformation,
etc.
3. Inspect the aileron and flap hinge pins for
corrosion, wear, safeties and adequate
lubrication.
4. Inspect flap and aileron rods and rod
attachment bolts for wear, damage
safeties, etc.
5. Inspect aileron bellcranks, stops, cable
ends and pulley assembly for cracks,
damage, corrosion safeties, etc.
6. Inspect upper and lower wing skins and
leading edges for cracks, loose fasteners,
damage, etc.
7. Lubricate the aileron and flap hinges,
control rod ends, bellcranks, etc.
8. Inspect the dual landing/taxi lights for
security, clean lenses, etc.
9. Drain water from wing fuel tanks (if
applicable) using sump drains. Check
sump drains for leaks. Clean fuel
strainers.
10. Check fuel tank filler caps (if installed)
for security, condition, etc.
11. Perform an operational check of the stall
warning system (option).
AC 43-13-1B Section 3
See AMD Safety Alert of
October 2008
See AMD Notification
letter of January 2009
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+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
3-8 July 09
Inspection page 6 of 8

TABLE 1 – ZODIAC INSPECTION FORM
Type of Inspection
(Circle One)
50 100 500 1000
Symbols: + Indicates perform task, - Indicates do not perform task
Task Refer to Intervals (Flight Hours) Initials
50 100 500 1000
12. Perform operational check of the pitot
static heater (if installed).
13. Perform operational check of fuel quantity
indicating system.
Fuselage Group
1. Inspect the outer fuselage skin for cracks,
corrosion, loose rivets, damage, etc.
2. Inspect fuselage bulkheads, stiffeners and
internal structure for cracks, corrosion,
damaged fasteners, etc.
3. Inspect flight control cables for routing,
fraying, corrosion and tension.
4. Inspect flight control turnbuckles, pulleys
and guides for wear, damage and safeties.
5. Check flight control torque tube bearings
for wear.
6. Inspect electrical wiring for condition,
security, routing, damage, etc.
7. Inspect fuel lines for security, damage,
and leaks.
8. Inspect the battery for condition, fluid
level and clean terminals
9. Clean gascolator fuel filter. Check for
debree and water.
10. Check fuel tank filler caps for security,
condition, etc.
Empennage Group
1. Inspect the rudder, stabilizer, and
elevator, and trim tab skins for cracks,
loose fasteners, damage, etc.
-
-
-
-
-
-
-
-
-
-
-
-
-
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
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+
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+
+
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+
+
+
+
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+
July 09 3-9
Inspection page 7 of 8

TABLE 1 – ZODIAC INSPECTION FORM
Type of Inspection
(Circle One)
50 100 500 1000
Symbols: + Indicates perform task, - Indicates do not perform task
Task Refer to Intervals (Flight Hours) Initials
50 100 500 1000
2. Inspect elevator trim lever/fork for security,
wear, damage, etc.
3. Perform operational check of elevator trim
system.
4. Inspect rudder, elevator/stabilator and trim tab
hinges for wear and excessive play.
5. Lubricate the rudder bearings, elevator hinges,
and elevator trim tab hinges.
6. Inspect the elevator deflection stops for
condition, damage, etc.
Deflections / Cable Tensions
1. Check elevator deflections up 30°, down 15
o
or 20°, ± 2°
2. Note: early models may have 30° up and
down. Change to 15
o
or 20°, ± 2
3. Check aileron deflections 10.5°, ± 2° up &
down
4. Check flap deflections up 0° down 20°, ± 2°
5. Note: early models may have 30° down.
Change to 20°, ± 2°
6. Check rudder deflection is stop to stop
7. Check elevator cable tensions 30 lbs ± 5
8. Check aileron cable tensions 20 lbs ± 5
Based on UK LAA MOD/162B/004
9. Check Rudder cable tensions 22 lbs ± 5
10. Check that flap is tight at flap stop when
flaps are up. Left and Right wing.
11. Check that flaps have no play (movement)
when in the up position by lightly pushing up
and down on flaps Left and Right.
12. Check that ailerons have no play (movement)
when holding control stick tight and lightly
pushing up and down on ailerons Left and
Right.
-
-
-
-
-
-
-
-
-
-
-
+
+
+
+
+
+
+
+
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+
+
+
+
3-10 Nov. 09 Rev.
1 Inspection page 8 of 8

AMD 601XL / 601XLI / 650LS / 650LSi SLSA MAINTENANCE MANUAL
________________________________________________________________________
SECTION IV
STRUCTURE
GENERAL
No structural repairs are recommended without contacting the manufacturer, however,
minor repairs such as patching the skin, etc., may be made in accordance with AC43-13-
XX for the airframe. It may be necessary to cut access holes to make skin repairs in some
areas of the aircraft.
Caution: Skin repairs must result in a surface which is as strong as, or stronger than, the
original skin. However, flexibility must be retained so that the surrounding areas will not
receive extra stress.
The rivets used on most parts are of the blind rivet type, reference #A4 (1/8” dia.) or A5
(5/32” dia.); to be set with the hand tool, reference #HP-A4-A5. Aircraft quality
aluminum “Cherry” rivets are an approved substitute. Standard MS20470 rivets may be
used where access is possible.
Repair Fiberglass parts with standard / typical Fiberglass type resin and woven Fiberglass
cloth. Using AC43-13-XX Chapter 3 is also acceptable.
When nylon locknuts are removed, the installation of new locknuts is highly
recommended.
Bolt torque valves are given in AC-43-13-1B Section 3
July 09 4.1