Jabiru j120 User manual

TECHNICAL MANUAL
FOR
JABIRU AIRCRAFT MODELS:
J120 Variants
J160 Variants
J170 Variants
J200/J400 Variants
J230/J430 Variants
J250/J450 Variants
DOCUMENT No. JTM001-1
DATED: 6th April 2012
This Manual has been prepared as a guide to correctly maintain Jabiru Aircraft Models.
It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for
applicable Service Bulletins and have them implemented as soon as possible. Manuals are also
updated periodically with the latest revisions available from the web site. Failure to maintain the
engine or aircraft with current service information may render the aircraft un-airworthy and void
Jabiru’s Limited, Express Warranty.
This document is controlled while it remains on the Jabiru server. Once this no longer applies
the document becomes uncontrolled.
Should you have any questions or doubts about the contents of this manual, please contact
Jabiru Aircraft Pty Ltd.

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 2 of 233
1Table of Contents
1TABLE OF CONTENTS.......................................................................................................2
1.1 TABLE OF FIGURES...................................................................................................................................... 6
1.2 LIST OF TABLES...........................................................................................................................................10
2SECTION 2 –SERVICE MANUAL ....................................................................................11
2.1 FOREWORD / APPLICABILITY.....................................................................................................................11
2.2 LIST OF EFFECTIVE PAGES / ISSUE STATUS...........................................................................................14
2.3 INTRODUCTION............................................................................................................................................14
2.4 READING THIS MANUAL..............................................................................................................................14
2.5 DEGREE OF DIFFICULTY............................................................................................................................14
2.6 CALIBRATIONS.............................................................................................................................................15
2.7 USE-BY DATES & STORAGE.......................................................................................................................15
2.8 GENERAL DESCRIPTION ............................................................................................................................15
2.9 OWNER MAINTENANCE ..............................................................................................................................16
2.10 AIRCRAFT SPECIFICATIONS ......................................................................................................................16
2.11 CENTRE OF GRAVITY LIMITATIONS..........................................................................................................16
2.12 TORQUE VALUES (IN FIBREGLASS)..........................................................................................................16
2.13 STANDARD PRACTICES..............................................................................................................................17
2.14 AIRCRAFT STRUCTURE..............................................................................................................................17
2.15 ENGINES.......................................................................................................................................................18
2.16 AIRCRAFT SPECIFICATIONS ......................................................................................................................19
3GROUND HANDLING & STORAGE .................................................................................27
3.1 TOWING........................................................................................................................................................27
3.2 JACKING .......................................................................................................................................................27
3.3 HOISTING......................................................................................................................................................28
3.4 LEVELLING ...................................................................................................................................................28
3.5 PARKING.......................................................................................................................................................28
3.6 TIE DOWN.....................................................................................................................................................28
3.7 STORAGE .....................................................................................................................................................29
4INSPECTION & SERVICING.............................................................................................31
4.1 BASIC INSPECTION PROCEDURE..............................................................................................................31
4.2 MANDATORY INSPECTIONS & LIFED ITEMS ............................................................................................31
4.3 INSPECTION CHART....................................................................................................................................32
4.4 SERVICING...................................................................................................................................................36
4.5 GENERAL INSPECTION GUIDELINES ........................................................................................................36
4.6 ENGINE PRE-INSPECTION RUN-UP:..........................................................................................................37
4.7 PROPELLER 100-HOURLY ..........................................................................................................................37
4.8 ENGINE COMPARTMENT 100-HOURLY .....................................................................................................37
4.9 FUEL SYSTEM 100-HOURLY.......................................................................................................................39
4.10 LANDING GEAR 100-HOURLY.....................................................................................................................39
4.11 AIRFRAME 100-HOURLY .............................................................................................................................40
4.12 CONTROL SYSTEMS 100-HOURLY ............................................................................................................41
4.13 LUBRICATION...............................................................................................................................................41
4.14 SPECIAL INSPECTIONS –PROPELLER.....................................................................................................42
4.15 SPECIAL INSPECTIONS –WEIGHING........................................................................................................42
4.16 SPECIAL INSPECTIONS –CONTROL CABLES..........................................................................................44
4.17 SPECIAL INSPECTIONS –CONTROL SURFACES.....................................................................................45
4.18 SPECIAL INSPECTIONS –MAIN WHEEL ALIGNMENT..............................................................................49
4.19 SPECIAL INSPECTIONS –FUEL GAUGE DECAL SETUP..........................................................................52
4.20 SPECIAL INSPECTIONS –FUEL SENDER CALIBRATION.........................................................................54
5CLEANING........................................................................................................................57
5.1 WINDSHIELD AND WINDOWS.....................................................................................................................57

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 3 of 233
5.2 INTERIOR SURFACES .................................................................................................................................57
5.3 EXTERIOR SURFACES................................................................................................................................57
5.4 ALUMINIUM SURFACES ..............................................................................................................................57
5.5 ENGINE AND ENGINE COMPARTMENT.....................................................................................................58
5.6 PROPELLER .................................................................................................................................................58
5.7 WHEELS........................................................................................................................................................58
6FUSELAGE .......................................................................................................................59
6.1 FUSELAGE....................................................................................................................................................59
6.2 WINDSHIELD AND WINDOWS.....................................................................................................................59
6.3 J160-TYPE CABIN DOORS...........................................................................................................................61
6.4 J160-TYPE CABIN DOOR LATCHES............................................................................................................61
6.5 J200 TYPE CABIN DOORS...........................................................................................................................65
6.6 J200-TYPE CABIN DOOR LATCHES............................................................................................................66
6.7 SEATS...........................................................................................................................................................68
6.8 UPHOLSTERY...............................................................................................................................................69
6.9 SOUNDPROOFING.......................................................................................................................................69
6.10 SAFETY PROVISIONS..................................................................................................................................69
7WINGS & EMPENNAGE ...................................................................................................70
7.1 GENERAL......................................................................................................................................................70
7.2 J120 WINGS..................................................................................................................................................70
7.3 J160 WINGS..................................................................................................................................................71
7.4 J170 WINGS..................................................................................................................................................75
7.5 J200 WINGS..................................................................................................................................................77
7.6J230 WINGS..................................................................................................................................................78
7.7 J250 / J450 WINGS .......................................................................................................................................80
7.8 WING STRUTS..............................................................................................................................................81
7.9 LANDING LIGHT(S).......................................................................................................................................82
7.10 LANDING LIGHT ADJUSTMENT (NIGHT-VFR MODELS)............................................................................82
7.11 DYNON PITOT ..............................................................................................................................................84
7.12 WING INSPECTION WINDOW......................................................................................................................85
7.13 FIN.................................................................................................................................................................86
7.14 HORIZONTAL STABILISER..........................................................................................................................86
8LANDING GEAR & BRAKES............................................................................................87
8.1 GENERAL DESCRIPTION ............................................................................................................................87
8.2 MAIN UNDERCARRIAGE REMOVAL (JACKING) ........................................................................................87
8.3 MAIN WHEEL FAIRING (SPATS)..................................................................................................................88
8.4 MAIN GEAR TOP FAIRING (SPEED FAIRING)............................................................................................89
8.5 MAIN WHEELS..............................................................................................................................................89
8.6 MAIN WHEEL STUB AXLE............................................................................................................................92
8.7 WHEEL BALANCING.....................................................................................................................................93
8.8 MAIN GEAR LEG...........................................................................................................................................93
8.9 TROUBLE SHOOTING –MAIN UNDERCARRIAGE.....................................................................................94
8.10 NOSE WHEEL SPEED FAIRING (SPAT)......................................................................................................96
8.11 NOSE WHEEL...............................................................................................................................................96
8.12 NOSE WHEEL STEERING / CENTRING SYSTEM.......................................................................................98
8.13 NOSE UNDERCARRIAGE LEG ....................................................................................................................99
8.14 TROUBLE SHOOTING –NOSE LEG..........................................................................................................101
8.15 NOSE WHEEL BALANCING .......................................................................................................................102
8.16 NOSE LEG HOUSING.................................................................................................................................104
8.17 BRAKE MASTER CYLINDER......................................................................................................................105
8.18 HYDRAULIC BRAKE LINES........................................................................................................................108
8.19 WHEEL BRAKES.........................................................................................................................................108
8.20 PARKING BRAKE........................................................................................................................................109

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 4 of 233
8.21 BRAKE LINING INSTALLATION .................................................................................................................109
8.22 BRAKE SYSTEM BLEEDING......................................................................................................................109
8.23 BRAKE PAD ADJUSTMENT .......................................................................................................................110
8.24 BRAKE DISC WEAR LIMIT .........................................................................................................................110
8.25 TROUBLE SHOOTING - BRAKES ..............................................................................................................111
9AILERON CONTROL SYSTEM.......................................................................................113
9.1 AILERON CONTROL SYSTEM...................................................................................................................113
9.2 CONTROL COLUMN...................................................................................................................................115
9.3 CONTROL CABLES ....................................................................................................................................117
9.4 AILERONS...................................................................................................................................................120
9.5 AILERON RIGGING.....................................................................................................................................120
10 WING FLAP CONTROL SYSTEM...................................................................................123
10.1 WING FLAP CONTROL SYSTEM...............................................................................................................123
10.2 MANUAL FLAP LEVER ASSY.....................................................................................................................125
10.3 ELECTRIC FLAP DRIVE ASSEMBLY.........................................................................................................125
10.4 FLAP CROSS SHAFT ASSEMBLY .............................................................................................................131
10.5 FLAP POSITION INDICATOR .....................................................................................................................133
10.6 EXTERNAL FLAP PUSH ROD ....................................................................................................................135
10.7 FLAP............................................................................................................................................................135
10.8 FLAP RIGGING (AS PER TEMPLATE) .......................................................................................................136
11 ELEVATOR CONTROL SYSTEM ...................................................................................137
11.1 ELEVATOR CONTROL SYSTEM................................................................................................................137
11.2 CONTROL COLUMN...................................................................................................................................139
11.3 ELEVATOR..................................................................................................................................................139
11.4 ELEVATOR CONTROL CABLES ................................................................................................................141
11.5 RIGGING .....................................................................................................................................................142
11.6 ELEVATOR TRIM –CONTROL LEVER ASSY ...........................................................................................143
11.7 ELEVATOR TRIM –AFT ASSEMBLY.........................................................................................................145
11.8 TRIM CONTROL CABLES...........................................................................................................................146
12 RUDDER CONTROL SYSTEM........................................................................................148
12.1 RUDDER PEDAL SYSTEM .........................................................................................................................148
12.2 RUDDER CENTRING SYSTEM ..................................................................................................................151
12.3 RUDDER......................................................................................................................................................154
12.4 RUDDER CONTROL CABLE ......................................................................................................................155
12.5 RUDDER BALANCE....................................................................................................................................156
12.6 RIGGING .....................................................................................................................................................156
13 ENGINE & ENGINE INSTALLATION..............................................................................157
13.1 ENGINE COWLS.........................................................................................................................................157
13.2 ENGINE.......................................................................................................................................................159
13.3 FLEXIBLE HOSES.......................................................................................................................................159
13.4 COOLING AIR BAFFLES.............................................................................................................................161
13.5 ENGINE MOUNT.........................................................................................................................................162
13.6 ENGINE FUEL SYSTEM .............................................................................................................................163
13.7 ENGINE THROTTLE CONTROL.................................................................................................................163
13.8 CHOKE CABLE ...........................................................................................................................................166
13.9 AIR INTAKE SYSTEM & CARBURETOR HEAT .........................................................................................167
13.10 EXHAUST SYSTEM ....................................................................................................................................168
13.11 CABIN HEATER SYSTEM...........................................................................................................................171
13.12 EXTREME CLIMATIC CONDITIONS...........................................................................................................173
14 FUEL SYSTEM................................................................................................................176
14.1 DESCRIPTION ............................................................................................................................................176
14.2 FUEL LINES ................................................................................................................................................180

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 5 of 233
14.3 FUEL TANKS...............................................................................................................................................182
14.4 FUEL VENTS...............................................................................................................................................184
14.5 FUEL SHUT-OFF VALVE............................................................................................................................185
14.6 FUEL GAUGES ...........................................................................................................................................186
14.7 FUEL FILTERS............................................................................................................................................189
14.8 FUEL PUMPS..............................................................................................................................................189
15 INSTRUMENTS & INSTRUMENT SYSTEMS..................................................................191
15.1 GENERAL....................................................................................................................................................191
15.2 INSTRUMENT PANEL.................................................................................................................................191
15.3 INSTRUMENT PANEL MOUNT...................................................................................................................193
15.4 INSTRUMENTS...........................................................................................................................................194
15.5 PITOT & STATIC SYSTEMS .......................................................................................................................195
15.6 ALTERNATE STATIC SOURCE..................................................................................................................202
15.7 ANALOGUE TACHOMETER.......................................................................................................................203
15.8 ANALOGUE ENGINE GAUGES..................................................................................................................205
15.9 DIGITAL DISPLAYS.....................................................................................................................................206
15.10 MAGNETIC COMPASS...............................................................................................................................207
15.11 GYRO INSTRUMENT PACKAGE (OPTION)...............................................................................................207
16 SECTION 14 –ELECTRICAL SYSTEMS........................................................................208
16.1 ELECTRICAL POWER SUPPLY SYSTEM..................................................................................................208
16.2 MINOR ELECTRICAL EQUIPMENT............................................................................................................211
16.3 BATTERY SYSTEM.....................................................................................................................................212
16.4 ELECTRICAL LOAD ANALYSIS (ELA)........................................................................................................213
16.5 RADIO INSTALLATION...............................................................................................................................213
16.6 TRANSPONDER..........................................................................................................................................215
18 PAINTING & FINISHING .................................................................................................216
18.1 EXTERIOR...................................................................................................................................................216
19 PLACARDS.....................................................................................................................218
19.1 MODEL-SPECIFIC DECALS .......................................................................................................................218
19.2 PLACARDS GENERAL................................................................................................................................220
20 FAIRINGS........................................................................................................................225
20.1 DESCRIPTION ............................................................................................................................................225
22 APPENDIX IV –PROPELLER SERVICE MANUAL........................................................226
22.1 CERTIFIED PROPELLER MODELS............................................................................................................226
22.2 APPROVED INSTALLATIONS ....................................................................................................................226
22.3 IDENTIFICATION STAMPINGS...................................................................................................................226
22.4 DESCRIPTION ............................................................................................................................................227
22.5 INSTALLATION ...........................................................................................................................................227
22.6 TO REMOVE EXISTING PROPELLER .......................................................................................................229
22.7 TO ASSEMBLE AND REPLACE PROPELLER ASSEMBLY.......................................................................229
22.8 SERVICING AND REPAIRS........................................................................................................................229
22.9 PROPELLER BALANCING PROCEDURE..................................................................................................230
23 APPENDIX –AIRWORTHINESS LIMITATIONS.............................................................231
23.1 GENERAL....................................................................................................................................................232
23.2 INTERIOR FLAME RETARDANT MAINTENANCE LIMITATIONS..............................................................232
23.3 COMPOSITE INSPECTION & MAINTENANCE ..........................................................................................232
23.4 CONTROL SURFACE BALANCING............................................................................................................233

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 6 of 233
1.1 TABLE OF FIGURES
Figure 1 –J120-C General Arrangement ...................................................................................................................20
Figure 2 –J160 General Arrangement.......................................................................................................................21
Figure 3 –J170-C & Variants General Arrangement..................................................................................................22
Figure 4 –J170-D General Arrangement ...................................................................................................................23
Figure 5 –J200 / J400 General Arrangement............................................................................................................24
Figure 6 –J230 / J430 General Arrangement............................................................................................................25
Figure 7 –J250 / J450 General Arrangement............................................................................................................26
Figure 8 –Undercarriage............................................................................................................................................31
Figure 9 –Weighing Diagram.....................................................................................................................................43
Figure 10 –Normal and Jammed Control Illustration.................................................................................................45
Figure 11 –Rudder Gap Cross Section .....................................................................................................................46
Figure 12 –Aileron Clearance....................................................................................................................................47
Figure 13 –Test Load Application..............................................................................................................................47
Figure 14 –Elevator Gap Cross Section....................................................................................................................47
Figure 15 –Scratches on Rudder...............................................................................................................................48
Figure 16 –Wheel Alignment Set Up .........................................................................................................................49
Figure 17 –Alignment Straight Edge In Position........................................................................................................49
Figure 18 –Alignment Measurements........................................................................................................................50
Figure 19 –Camber / Toe-In Adjustment...................................................................................................................51
Figure 20 Max Empty (Left) and Acceptable Empty (Right) Indications.....................................................................52
Figure 21 - Fuel Gauge Calibration Decal Parts.........................................................................................................53
Figure 22 –20L Indication on Sender & Decal to Match............................................................................................53
Figure 23 –EMS Fuel Calibration Screens ................................................................................................................54
Figure 24 –Fuel Line Clamps.....................................................................................................................................55
Figure 25 –EMS Calibration Screen #1.....................................................................................................................56
Figure 26 –EMS Calibration Screens #2 and #3 .......................................................................................................56
Figure 27 –J160-Type Door Hinge Assy ...................................................................................................................62
Figure 28 –J160-Type Door Assembly......................................................................................................................62
Figure 29 –J120-Type Door Assembly......................................................................................................................63
Figure 30 –J200-Type Door Assembly (J160-Type) .................................................................................................63
Figure 31 –J160-Type Rear Door Assy.....................................................................................................................64
Figure 32 –J160-Type Door Latch Mechanism Assembly.........................................................................................64
Figure 33 –Top Door Catch Assy ..............................................................................................................................65
Figure 34 –J200-Type Door Hinge Assy ...................................................................................................................66
Figure 35 –J200-Type Front Door Assembly.............................................................................................................67
Figure 36 –J200-Type Rear Door Assy.....................................................................................................................67
Figure 37 –J200-Type Door Latch Mechanism Assembly.........................................................................................68
Figure 38 –J160 Wing Assembly Sheet 1 (Ser X).....................................................................................................73
Figure 39 –J160 Wing Assembly Sheet 2 (Ser X).....................................................................................................73
Figure 40 –J160 Wing Assembly Sheet 1 (Ser XIV) .................................................................................................74
Figure 41 –J160 Wing Assembly Sheet 2 (Ser XIV) .................................................................................................74
Figure 42 –J160 Wing Assembly Sheet 3 (Ser XIV) .................................................................................................75
Figure 43 –J170 Friese Aileron Installation ...............................................................................................................76
Figure 44 –J170-UL Wing Assy Sheet 1 (Ser IX)......................................................................................................76
Figure 45 –J170-UL Wing Assy Sheet 2 (Ser IX)......................................................................................................77
Figure 46 –J230 Wing Assembly Sheet 1 (Ser 13) ...................................................................................................78

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 7 of 233
Figure 47 –J230 Wing Assembly Sheet 2 (Ser 13) ...................................................................................................79
Figure 48 –J230 Wing Assembly Sheet 3 (Ser 13) ...................................................................................................79
Figure 49 –J250 Family Wing Assy (SP-I Type)........................................................................................................80
Figure 50 –J250 Family Wing Assy (SP-III Type)......................................................................................................81
Figure 51 –Light Installed (Left) & Slotted Hole In Housing ......................................................................................82
Figure 52 –Night-VFR Lighting Aim Diagram ............................................................................................................83
Figure 53 –Night-VFR Landing / Taxi Light Assy ......................................................................................................83
Figure 54 –Day-VFR Light Assembly ........................................................................................................................84
Figure 55 –Dynon Pitot Installation............................................................................................................................85
Figure 56 –Wing Inspection Panel.............................................................................................................................86
Figure 57 –Wheel Spat Installation............................................................................................................................88
Figure 58 –Main Wheel to Leg Assy..........................................................................................................................91
Figure 59 –Main Wheel Assembly.............................................................................................................................91
Figure 60 –Directional Brake Disc Installation...........................................................................................................92
Figure 61 –Main Undercarriage (Type 1) ..................................................................................................................95
Figure 62 –Main Undercarriage Assembly (Type 2)..................................................................................................95
Figure 63 –Nose Wheel Hub Assembly.....................................................................................................................97
Figure 64 –Nose Leg Soft Link Assy (J160 Family) ..................................................................................................98
Figure 65 –Nose Leg Soft Link Assy (J200 Family) ..................................................................................................99
Figure 66 –Nose Leg Housing & Assembly.............................................................................................................101
Figure 67 –4” Wheel Nose Leg Assy.......................................................................................................................102
Figure 68 –Nose Leg Assy ......................................................................................................................................103
Figure 69 –Nose Leg Assy –Long Trail (J160 Family) ...........................................................................................103
Figure 70 –Fabricated Nose Wheel Yoke Assy.......................................................................................................104
Figure 71 –Machined Nose Leg Housing ................................................................................................................105
Figure 72 –Brake Master Cylinder & Lever Assy (Type 1)......................................................................................107
Figure 73 –Brake Master Cylinder & Lever Assy (Type 2)......................................................................................107
Figure 74 –Dual Calliper Brake Assy (Quick Change Pads)...................................................................................111
Figure 75 –Single Calliper Detail (Non Quick Change)...........................................................................................112
Figure 76 –Single Calliper (Legacy Brake System).................................................................................................112
Figure 77 –Aileron Controls –Type 1......................................................................................................................113
Figure 78 –Aileron System Schematic –Type 2. ....................................................................................................114
Figure 79 –Aileron System Schematic –Type 3. ....................................................................................................114
Figure 80 –Control Column Assy –Type 1..............................................................................................................115
Figure 81 –Control Column Assy –Type 2..............................................................................................................116
Figure 82 –Control Column Assy –Type 3..............................................................................................................116
Figure 83 –Clamp Comparison (Primary Cable Clamp Upper on Right Picture) ....................................................117
Figure 84 –Clamp Comparison & Installation (Rudder Cable) ................................................................................118
Figure 85 –Clamp Installations (Elevator & Aileron)................................................................................................118
Figure 86 –Trim Cable Clamp Installation ...............................................................................................................118
Figure 87 –Cable & Clamp Comparison..................................................................................................................119
Figure 88 –Correct and Incorrect Clamp Installation...............................................................................................119
Figure 89 –Aileron Stops –Type 1..........................................................................................................................121
Figure 90 –Aileron Stops –Type 2..........................................................................................................................122
Figure 91 –Aileron Stops –Type 3..........................................................................................................................122
Figure 92 –Manual Flap Control System.................................................................................................................123
Figure 93 –J200 Family Manual Flap System Sheet 1............................................................................................124
Figure 94 –J200 Family Manual Flap System Sheet 2............................................................................................124
Figure 95 –Linear Actuator Disassembled ..............................................................................................................126

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 8 of 233
Figure 96 –Commutator Ring Close-Up ..................................................................................................................127
Figure 97 –Flap Controls –Sheet 1 (Fibreglass Motor Mount) ...............................................................................128
Figure 98 –Flap Controls –Sheet 1 (Aluminium Motor Mount)...............................................................................128
Figure 99 –Flap Controls –Sheet 2.........................................................................................................................129
Figure 100 –Flap Controls –Sheet 3 (Fibreglass Motor Mount).............................................................................129
Figure 101 –Flap Controls –Sheet 3 (Aluminium Motor Mount).............................................................................130
Figure 102 –J200 Family Electric Flap System Sheet 1..........................................................................................130
Figure 103 –J200 Family Electric Flap System Sheet 2..........................................................................................131
Figure 104 –Flap Cross Tube Assy J160 Family.....................................................................................................132
Figure 105 –Flap Cross Tube Assy J200 Family, Electric.......................................................................................133
Figure 106 –Flap Position Indicator –Type 1..........................................................................................................134
Figure 107 –Flap Position Indicator –Type 2..........................................................................................................134
Figure 108 –Flap Position Indicator Drive Cable Assembly....................................................................................135
Figure 109 –Elevator Control System –Type 1, Sheet 1........................................................................................137
Figure 110 –Elevator Control System –Type 1, Sheet 2........................................................................................138
Figure 111 –Elevator Control Assy Type 2..............................................................................................................138
Figure 112 –J160 Models –Horizontal Tail & Elevator Assy ..................................................................................140
Figure 113 –Wide-Span Models –Horizontal Tail & Elevator Assy –Type 1.........................................................140
Figure 114 –Wide-Span Models –Horizontal Tail & Elevator Assy Type 2 ............................................................141
Figure 115 –Elevator Travel Limits..........................................................................................................................142
Figure 116 –Trim Lever Assy –Type 1 ...................................................................................................................144
Figure 117 –Trim Lever Assy –Type 2 ...................................................................................................................144
Figure 118 –Elevator Trim Handle Assy –Type 3...................................................................................................145
Figure 119 –Trim Controls –At Tail.........................................................................................................................146
Figure 120 –Typical Rudder System Schematic .....................................................................................................148
Figure 121 –Rudder Pedal - Non-Adjustable...........................................................................................................149
Figure 122 –Adjustable Rudder Pedal Assy –Type 1.............................................................................................150
Figure 123 –Adjustable Rudder Pedal Assy –Type 2.............................................................................................150
Figure 124 –Steering/Rudder Centring Assy –Type 1............................................................................................151
Figure 125 –Steering/Rudder Centring Assy –Type 2............................................................................................152
Figure 126 –Steering/Rudder Centring Assy –Type 3 (Sheet 1)............................................................................152
Figure 127 –Steering/Rudder Assy –Type 3 (Sheet 2) ..........................................................................................153
Figure 128 –Steering/Rudder Centring Assy –Type 3 (Includes Soft Link)............................................................153
Figure 129 –Typical Rudder Installation (Alloy Hinges) ..........................................................................................154
Figure 130 –Typical Rudder Installation (Steel Hinges)..........................................................................................155
Figure 131 –Typical Upper Cowl Assy ....................................................................................................................158
Figure 132 –Typical Lower Cowl Assy ....................................................................................................................158
Figure 133 –Fuel Hose Assy –Engine Bay.............................................................................................................160
Figure 134 –Air Duct Hard Point Reinforcement.....................................................................................................162
Figure 135 –Throttle Assy (Seat Mounted)..............................................................................................................164
Figure 136 –Throttle Assy (Panel Mounted)............................................................................................................165
Figure 137 –Throttle Assy (Large Panel Mount)......................................................................................................165
Figure 138 –Control Cable End Fitting Installation..................................................................................................166
Figure 139 –Carburettor Heat Box ..........................................................................................................................167
Figure 140 –Hot Air Duct Assy ................................................................................................................................168
Figure 141 –2200 Exhaust System .........................................................................................................................169
Figure 142 –3300 Exhaust System Type 1 .............................................................................................................170
Figure 143 –3300 Exhaust System Type 2 .............................................................................................................170
Figure 144 –Cabin Heat Mixer Assembly................................................................................................................172

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 9 of 233
Figure 145 –Cabin Heat Exchanger Assy ...............................................................................................................172
Figure 146 –2200 Engine Installation......................................................................................................................173
Figure 147 –2200 Engine Installation......................................................................................................................174
Figure 148 –2200 Engine Installation, Long Engine Mount.....................................................................................174
Figure 149 –J200 Family Engine Installation Type 1...............................................................................................175
Figure 150 –J200 Family Engine Installation Type 2...............................................................................................175
Figure 151 –In-Cabin Fuel System..........................................................................................................................177
Figure 152 –Fuel System Schematic –Type 1........................................................................................................177
Figure 153 –Fuel System Schematic –Type 2........................................................................................................178
Figure 154 –Fuel System Schematic –Type 3........................................................................................................178
Figure 155 –Fuel System Schematic –Type 4........................................................................................................179
Figure 156 –Schematic............................................................................................................................................180
Figure 157 –Sample Fuel Line Details ....................................................................................................................181
Figure 158 –Fuel Lines Showing Typical “U” Requiring Correction ........................................................................181
Figure 159 –Corrected Fuel Lines...........................................................................................................................181
Figure 160 –Header Tank Installation –Type 1 ......................................................................................................183
Figure 161 –Header Tank Installation –Type 2 (Sheet 1) ......................................................................................183
Figure 162 –Header Tank Installation –Type 2 (Sheet 2) ......................................................................................184
Figure 163 –Vented Fuel Cap Assy.........................................................................................................................185
Figure 164 –Single Line Fuel Tap ...........................................................................................................................186
Figure 165 –Fuel Gauge –Electric Sender Installation...........................................................................................188
Figure 166 –Fuel Gauge –Electric Sender Assembly.............................................................................................188
Figure 167 –Fuel Gauge –Sight Glass ...................................................................................................................188
Figure 168 –Instrument Panel Layout Type 1 .........................................................................................................192
Figure 169 –Instrument Panel Layout Type 2 .........................................................................................................192
Figure 170 –Instrument Panel Layout Type 3 .........................................................................................................192
Figure 171 –Instrument Panel Layout Type 4 .........................................................................................................193
Figure 172 –Instrument Panel Mount Installation....................................................................................................194
Figure 173 –Pitot Assembly.....................................................................................................................................195
Figure 174 –Static Probe System Assembly...........................................................................................................196
Figure 175 –Pitot / Static Water Trap ......................................................................................................................197
Figure 176 –Pitot-Static System –Water Trap Locations .......................................................................................197
Figure 177 –Static System Test...............................................................................................................................202
Figure 178 –Alternate Static Source Assy...............................................................................................................203
Figure 179 –Hall Effect Sensor Wiring (For Tach with Jabiru Logo on Face).........................................................204
Figure 180 –Hall Effect Sensor Inst. (For Tach with Jabiru Logo on Face) ............................................................205
Figure 181 –Wiring Diagram Sheet 1. .....................................................................................................................209
Figure 182 –Wiring Diagram Sheet 2. .....................................................................................................................210
Figure 183 –Night-VFR Lighting Sheet 1.................................................................................................................210
Figure 184 –Night-VFR Lighting Sheet 2.................................................................................................................211
Figure 185 –VHF Antenna Installation.....................................................................................................................213
Figure 186 –Second VHF Antenna Installation (J120 / J160 Families)...................................................................214
Figure 187 –Second VHF Antenna Installation (J230 Families)..............................................................................214
Figure 188 –Transponder Antenna Installation .......................................................................................................215
Figure 189 –Propeller Installation............................................................................................................................228

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JTM001-1
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REVISION
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Dated: Nov 2011
Issued By: SW
Page: 10 of 233
1.2 LIST OF TABLES
Table 1 –Recommended Bolt Torque Values............................................................................................................17
Table 2 –J120-C Specifications.................................................................................................................................20
Table 3 –J160 Specifications.....................................................................................................................................21
Table 4 –J170 Specifications.....................................................................................................................................22
Table 5 –J200/J400 Specifications............................................................................................................................24
Table 6 –J230/J430 Specifications............................................................................................................................25
Table 7 –J250/J450 Specifications............................................................................................................................26
Table 8 –Inspection Chart..........................................................................................................................................32
Table 9 –Control Free Play Limits .............................................................................................................................44
Table 10 –Trouble Shooting –Main Undercarriage...................................................................................................94
Table 11 –Trouble shooting –Nose Leg. ................................................................................................................101
Table 12 –Trouble Shooting –Brakes.....................................................................................................................111
Table 13 –Trouble Shooting –Fuel System............................................................................................................179
Table 14 –Trouble Shooting –Fuel Gauge .............................................................................................................187
Table 15 –Trouble Shooting –Pitot-Static System..................................................................................................199
Table 16 –Trouble Shooting –Airspeed Indicator...................................................................................................200
Table 17 –Trouble Shooting –Altimeter..................................................................................................................200
Table 18 –Trouble Shooting –Vertical Speed Indicator..........................................................................................201
Table 19 –Trouble Shooting –Tachometer.............................................................................................................203
Table 20 –Trouble Shooting –Engine Gauges .......................................................................................................205
Table 21 –Trouble Shooting –Digital Instruments Gauges.....................................................................................206
Table 22 –Model-Specific Decals............................................................................................................................218
Table 23 –General Decals.......................................................................................................................................220
Table 24 –Approved Propeller Installations.............................................................................................................226
Table 25 –Control Surface Balancing Limits ...........................................................................................................233
Table 26 –Mandatory Inspection Times ..................................................................................................................233
Table 27 –Mandatory Replacement Times..............................................................................................................233

Aircraft Service Manual
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JTM001-1
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REVISION
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2Section 2 –Service Manual
2.1 FOREWORD / APPLICABILITY
This manual contains JABIRU recommended procedures and instructions for ground handling,
servicing and maintaining the following Jabiru aircraft models:
J120 - Kit-built J120 aircraft.
J120-C - Factory-Built Light Sport Aircraft
J160 - Kit-built J160 aircraft
J160-C - Factory-Built Primary Category Aircraft
J160-D - Factory-Built Light Sport Aircraft
J170 - Kit-built aircraft
J170-C - Factory-Built Light Sport Aircraft
J170-D - Factory-Built Light Sport Aircraft
J200/J400 - Kit-built aircraft
J230/J430 - Kit-built aircraft
J230-C - Factory-Built Light Sport Aircraft
J230-D - Factory-Built Light Sport Aircraft
J250/J450 - Kit-built aircraft
Model
MTOW (kg)
Category
J120-C
500
LSA /
Experimental LSA
All other J120 variants
500
Experimental
J160-C
540
Primary
J160-D
540
LSA /
Experimental LSA
All other J160 variants
544
Experimental
J170-C
600
LSA /
Experimental LSA
J170-D
600
LSA /
Experimental LSA
All other J170 variants
544
Experimental
J200
544 –RA-Aus
700 –CASA
Experimental
J400
700 –CASA
Experimental
J230-C
600
LSA
J230-D
600
LSA
All other J230 variants
544 –RA-Aus
700 –CASA
Experimental /
Experimental LSA
J430 variants
700
Experimental
J250 variants
544 –RA-Aus
700 –CASA
Experimental
J450 variants
700
Experimental
Some specialised variants are not shown. In these cases maintain the aircraft as detailed for the
nearest corresponding model shown herein unless customised data is available.
It is the owner’s responsibility to become fully aware of the particular maintenance requirements and
limitations applicable to the appropriate registration.

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IMPORTANT
All maintenance should be undertaken with careful regard for the procedures outlined in this
manual. A detailed record of maintenance undertaken should be recorded in the Aircraft Log
Books.
Factory-built models must be maintained by an Authorised Person (LAME for CASA-registered
aircraft, refer to Operations Manual for owner-maintenance levels allowed for RA-Aus-registered
aircraft).
Factory-built Light Sport Aircraft have a Special Certificate of Airworthiness which remains in
force provided:
- Only modifications and repairs approved by the manufacturer are incorporated on the
aircraft;
- The aircraft complies with all safety directions issued by the manufacturer;
- The aircraft has been maintained in accordance with the manufacturer’s requirements;
and
- The continuing airworthiness functions are performed by the manufacturer (or a person
appointed by CASA).
If the aircraft no longer complies with one or more of these conditions, the C of A becomes void.
Continued operation with an invalid C of A is a criminal offence. It is permissible, however, for
the registration holder of a non-compliant aircraft to apply for an Experimental Certificate.
For Experimental Category aircraft, builders remain able to conduct maintenance on aircraft for which
they are the registered builder. This area of regulations varies across different countries and operators
must ensure that they are complying with all local requirements.
In the interests of product development, we encourage owners to make suggestions related to design
improvements. However, the final decision on their adoption or otherwise rests with JABIRU AIRCRAFT
Pty Ltd.

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REVISION
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WARNING:
Jabiru Aircraft Pty Ltd has devoted significant resources and testing to develop the different
Jabiru aircraft models for recreational flying and flight training. Any other uses or applications
not approved by Jabiru Aircraft P/L may be extremely hazardous, leading to property damage, or
injury or death of persons on or in the vicinity of the vehicle. Jabiru Aircraft Pty Ltd does not
support the use of this aircraft in any applications which do not meet the requirements of the
appropriate Pilot Operating Handbook or Flight Manual. Any non-compliant operation may
render the aircraft un-airworthy and will void any warranty issued by Jabiru.
Jabiru Aircraft are designed to be maintained only in strict accordance with the appropriate
Technical Manual. Any variation of any kind, including alteration to any component at all,
whether replacement, relocation, modification or otherwise which is not strictly in accordance
with these manuals may lead to dramatic changes in the performance of the aircraft and may
cause unexpected engine stoppage, loss of control or have other detrimental effects on the
aircraft which may lead to injury or death. Jabiru Aircraft Pty Ltd does not support any
modifications to an aircraft, its parts, or components. Any such actions may render the aircraft
un-airworthy and will void any warranty issued by Jabiru.
Maintenance and modification cannot be supervised by the manufacturer. Maintenance requires
extreme cleanliness, exact parts, precise workmanship and proper consumables. It is your
responsibility to ensure absolute attention to detail no matter who may become involved in work
on this engine. Your safety, your life and your passenger’s lives rely on precise and accurate
following of instructions in this manual.
In exchange for the technical manual provided by Jabiru Aircraft Pty. Ltd. (“Jabiru”) I hereby
agree to waive, release, and hold Jabiru harmless from any injury, loss, damage, or mishap that I,
my spouse, heirs, or next of kin may suffer as a result of my use of any Jabiru product, except to
the extent due to gross negligence or willful misconduct by Jabiru. I understand that proper
skills and training are essential to minimize the unavoidable risks of property damage, serious
bodily injury and death that arise from the use of Jabiru products.

Aircraft Service Manual
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JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
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Dated: Nov 2011
Issued By: SW
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2.2 LIST OF EFFECTIVE PAGES / ISSUE STATUS
This manual is revised as a whole. All pages retain the revision status of the overall document.
Issue Notes:
1
Initial Issue
2.3 INTRODUCTION
The information in this manual is based upon data available at the time of publication, and is
supplemented and kept current by Service Bulletins & Service Letters published by JABIRU
AIRCRAFT Pty Ltd. These are distributed directly to owners of factory-built aircraft in addition to
being posted on the JABIRU website or provided to your local distributor. New owners of pre-owned
aircraft should ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty
Ltd or your Jabiru representative so that our owner databases can be updated. Existing owners
should ensure that they update Jabiru with their new contact details when they move or details
change.
This Technical Manual has been developed to cover a range of different Jabiru Aircraft models.
Many components and systems are common between these models; for example the main
undercarriage legs are common between the J160, J170, J200/J400, J230/J430 and J250/J450
models and consequentially the procedures in this Manual apply equally to each of these aircraft.
Where there are differences between the models this manual supplies guidance for each variant.
Before working on an aircraft the technician must be fully conversant with the appropriate technical
manual, engine instruction & maintenance manual, propeller manual and any relevant Service
Bulletins, Service Letters or other manufacturer’s data. Current information is available from the
Jabiru Aircraft (Australia) web site –www.jabiru.net.au .
Maintenance must only be carried out by an approved person. Depending on the country and the
category of the aircraft this may be a Licensed Aircraft Maintenance Engineer, an RA-Aus Level 2 or
equivalent. The responsibility for determining what qualifications are necessary to carry out an
overhaul belongs to the person carrying out the work.
2.4 READING THIS MANUAL
If you are reading this manual on a computer and want to be able to quickly zoom in and out: Hold
down the Ctrl key while rotating the wheel button on your mouse. In most programs this will instantly
zoom in or out.
To do the same thing on a modern laptop either plug in a wheel mouse as detailed above or use the
built-in track-pad. Put two fingers on the pad close together then move then apart diagonally. To
reverse, put two fingers on the pad at opposite diagonal points on the pad and bring them together
diagonally. This works on most modern PC-laptops.
This document has been created with hyperlinks between referenced items. So, when reading the
manual on a computer you can click on the page number of an item on the table of contents and the
computer will skip to that page. If a paragraph says “refer to Section 8.6” –then you can click on the
“8.6” and automatically skip to that page. Similarly, if Figures or Tables are referenced. On some
computers it may be necessary to hold the “Ctrl” key while clicking on the link.
To open a search window press “Ctrl-f”. Depending on the program, this will normally open a small
search window where you can enter keywords. For example, searching for the word “life” will allow
you to quickly find all reference to lifed maintenance items.
2.5 DEGREE OF DIFFICULTY
This manual is intended for use by experienced technicians and while all processes will be explained
as clearly as possible, some knowledge is assumed. This manual is not intended to be sufficient
reference for a person with no other training to safely maintain an aircraft.

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
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Dated: Nov 2011
Issued By: SW
Page: 15 of 233
In this manual we have used a “spanner scale” to help technicians approach a job. Anyone
considering undertaking a task in this manual must realistically assess themselves against this scale
and not attempt any task for which they lack knowledge or the required tools.
The Spanner Scale
Translation
Simple, basic, straightforward. A careful layman, with guidance, can
achieve this.
Straightforward, but with some technical bits. Basic knowledge, care
and guidance needed.
Straightforward, but requires special tools, training and/or judgement.
Sound basic knowledge guidance and a careful approach are required.
A technical job. Take your time, double-check everything. Only for the
experienced maintainer.
A difficult job. Requires special tools, solid skills, good judgement.
Only for experts.
2.6 CALIBRATIONS
While all Jabiru Aircraft are designed to be as simple to maintain as possible some professional tools
are required:
- An accurate, calibrated torque wrench is required. The wrench must have a suitable scale for
use on the fasteners typically found on Jabiru Aircraft –for example a wrench with a scale from
20 –100 lb.ft is unsuitable.
- An accurate tyre pressure gauge is required.
- Accurate scales and spirit level if the aircraft is to be weighed.
- Other tools as required to maintain the engine and propeller –refer to the applicable manuals for
these products.
Specialist tools such as the torque wrench and scales are required to be calibrated regularly –a
minimum of once a year or more often if they are being used frequently.
In addition, CASA requires that calibrations be carried out in a way which is traceable to a NATA
laboratory.
2.7 USE-BY DATES & STORAGE
Some products called for by this manual –including thread locking compound, resins and glues –
have a use-by date. Care must be taken to ensure all such compounds are within their shelf life
before applying them to an aircraft.
Loctite products typically do not have their use-by date marked on the bottle. For these products it is
necessary to note the batch number on the bottle and contact the distributor for shelf-life information.
Similarly, for many products the shelf-life assumes a certain type of storage –i.e. sealed,
temperature controlled etc. Maintainers must ensure that such products are stored appropriately.
2.8 GENERAL DESCRIPTION
The JABIRU aircraft described in this manual are 2-seat, high-wing monoplane composite aircraft of
monocoque construction. They are equipped with fixed tricycle landing gear of composite
construction. The steerable nose gear is a welded metal, trailing link assembly with rubber springs.
The aircraft are equipped with a JABIRU, 4 cylinder, 4 stroke engine of around 80hp or a JABIRU 6-
cylinder, 4-stroke engine of around 120hp. Both engines are optimised to drive a 2-bladed, wooden,
fixed pitch propeller.

Aircraft Service Manual
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JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
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Dated: Nov 2011
Issued By: SW
Page: 16 of 233
2.9 OWNER MAINTENANCE
2.9.1 FACTORY-BUILT MODELS
All Jabiru Aircraft, including factory-built models, have been specifically designed as simple aircraft
which can be maintained by owners to a large degree. Jabiru Aircraft allows normal maintenance up
to 100-hourly servicing to be carried out by the owner wherever this is allowed by the aircraft’s
operating category. This servicing includes:
- Oil & oil filter changes
- Fuel filter changes
- Brake pad changes
- Tyre changes
- Spark plug changes
- Normal engine maintenance between 100-hourly maintenance. Refer to Engine Maintenance
Manual for details.
Every 100 hours or Annually (whichever happens first) a 100-hour inspection must be carried out by
an Authorised Person (such as a LAME. Refer to the RAAus Operations Manual for RAAus aircraft
Australia). CAUTION
It is the operator’s responsibility to ensure that the factory-built aircraft is correctly maintained
for the intended use.
2.9.2 KIT-BUILT MODELS
Many models discussed in this manual can be registered under a variety of different categories
worldwide, at a variety of different weights and operating requirements. The owner must consult their
local airworthiness authority to determine what level of owner maintenance is allowed. As an
example, in Australia aircraft registered in the “Experimental” category may be maintained
exclusively by the owner/builder, or by authorised aircraft maintainers.
CAUTION
It is the operator’s responsibility to ensure that the kit-built aircraft is correctly maintained for the
intended use.
2.10 AIRCRAFT SPECIFICATIONS
Leading particulars of the aircraft discussed in this manual are given in Section 2.16. If these
dimensions are used for constructing a hangar or computing clearances, remember that such factors
as tyre pressure, tyre size and load distribution may result in some dimensions that may be
somewhat different from those listed.
2.11 CENTRE OF GRAVITY LIMITATIONS
All JABIRU models are relatively light weight. The installation of equipment may significantly alter the
approved CG limits of the aircraft. Therefore, all proposed fixed installations must be approved by
JABIRU AIRCRAFT Pty Ltd or a person authorized to revise an aircraft’s weight and balance
information (such as the holder of a CASA Weight Control Authority)
2.12 TORQUE VALUES (IN FIBREGLASS)
Unless noted otherwise, all bolt torque settings detailed within this manual are for clean, dry threads.
When checking fastener torque, use the following procedure:
- Ensure the fastener to be checked is clean and dry before proceeding.
- Where a reversible wrench is being used, set the torque to a value slightly below the target
torque and LOOSEN the fastener slightly (approx 1/3 or a turn). The wrench should “click” –
indicating that the fastener had maintained its set torque. If the fastener torque has reduced
significantly it may be an indication of damage or degradation to the assembly and should be
investigated.

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- The fastener is first loosened slightly to ensure that it is free to move on its threads. If this step is
not carried out it is possible for the fastener to corrode in place. If that happens, the friction of the
corrosion will seize the fastener, ensuring that it appears to “pass” torque checks but in fact has
lost tension and is no longer holding the assembly correctly.
- Tighten the fastener smoothly to the set torque. Any jerks or bumps when tightening can cause
the reading to be obtained prematurely.
- The torque must be obtained while the nut is turning. If you stop to reposition the torque wrench
and then the required torque reading is obtained without the nut turning, the nut needs to be
loosened a little and then tightened again so the torque reading is obtained while turning.
Table 1 –Recommended Bolt Torque Values
Bolt Size
Torque (Inch.lb)
(Core-mat or thin laminate)
Torque (Inch.lb)
(Thick, glass-only laminate)
AN3
20 - 25 (1.7 –2.1lb.ft)
Up to 4 lb.ft
AN4
50 - 70 (4.2 –5.8lb.ft)
Up to 8 lb.ft
AN5
100 –140 (8.3 –11.7lb.ft)
Up to 18 lb.ft
AN6
N/A
Up to 24 lb.ft
AN4 Propellor
72 (6lb.ft)
N/A
These values relate only to steel nuts on oil-free cadmium plated threads.
For Engine Bolt Torque Values see Engine Instruction & Maintenance Manual.
The above values are recommended for all installation procedures contained in this Manual, except
where other values are stipulated.
The above values are not to be used for checking tightness of installed parts during service.
2.13 STANDARD PRACTICES
Do not over tighten bolts
Ensure a minimum of 1 full thread is clear of nuts.
Do not exceed 3 threads clear on nuts (use extra washers).
Ensure nuts are not thread-bound (i.e. the thread on the nut has hit the end of the thread on the bolt.
All spherical bearings must be fitted with a large washer on the outside of the through-bolt to prevent
the bearing case and cable releasing in the event of a bearing failure. i.e. a ¼” washer must be fitted
to 3/16” bolts or a 5/16” washer to ¼” bolts.
AC43 or similar approved data gives guidance on accepted means for carrying out typical aircraft
maintenance tasks –such as safety-wiring etc.
WARNING
Thread bound nuts can carry far less load and are much more susceptible to failure.
WARNING
DO NOT REUSE SELF-LOCKING NUTS
2.14 AIRCRAFT STRUCTURE
In all Jabiru Aircraft, due to the monocoque construction the majority of the structure is primary. The
components of the aircraft which are secondary structure can be identified by the fact that they are
designed as fairings and are generally removable. Examples of secondary structure are the engine
cowls, speed fairings, ventral fin and wheel spats.

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
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Issued By: SW
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2.15 ENGINES
The engines used in Jabiru Aircraft are not discussed within this manual. For details of installation,
maintenance and overhaul refer to the engine manuals appropriate to the engine model.
Up-to-date engine manuals are available from the Jabiru Aircraft website; www.jabiru.net.au.

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
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REVISION
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2.16 AIRCRAFT SPECIFICATIONS
2.16.1 UNIVERSAL SPECIFICATIONS
Item
Specification
Fuel Type
AVGAS 100LL or 100/130.
MOGAS with Octane Rating 95 RON (AKI 90) or above
Fuels blends containing up to 10% Ethanol may be used only
where the aircraft is equipped with appropriate fuel tank sealant
and fittings. Refer to Service Letter JSL007, the Pilot Operating
Handbook or Flight Manual for details.
CAUTION
CASA-certified models may not use fuel containing alcohol.
Operators who choose to use MOGAS do so at their own risk.
Operators who choose to use fuel containing alcohol do so at their
own risk.
REFER TO SERVICE LETTER JSL007 FOR DETAILS
Battery Location
In Engine Compartment
Propeller Type
Jabiru
2-bladed Wooden
Propeller Diameter
60” dia (1524mm)
Target Wheel Alignment
(at gross weight)
0° Camber, 0° Toe-in.
Engine Oil Type
Refer Engine Manuals

Aircraft Service Manual
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2.16.2 J120-C
Table 2 –J120-C Specifications
Model
J120-C
Other J120 Variants
Aircraft Maximum Weight
500kg
(1102lb)
500kg
(1102lb)
Fuel Capacity
65 litres
65 litres
Oil Capacity
2.3 litres
2.3 litres
Engine Model
Jabiru 2200B
Jabiru 2200A
Propeller Pitch
Jabiru 42” pitch (1067mm)
Sensenich 43” pitch (1092mm) or
Sensenich 46” pitch (1168mm)
Jabiru 42” pitch (1117mm)
Nose Wheel Size
260 x 4” rim
260 x 4” rim
Main Wheel Size
400 x 4” rim
400 x 4” rim
Tyres Standard
4” wide, 4 Ply
4” wide, 4 Ply
Tyre Pressures Standard - Mains
228 kpa (33 psi)
179 kpa (26 psi)
Tyre Pressures Standard - Nose
193 kpa (28 psi)
137 kpa (20 psi)
Figure 1 –J120-C General Arrangement