MAULE Star Rocket M-8-235 User manual

7/99
FOR
MAULE M-8-235
Star Rocket
TLC-M-8-235
7/99
PERFORMANCE THAT COUNTS!
2099 Georgia Hwy 133 South ~ Moultrie, GA 31788
Tel: [phone] ~ Fax: [phone] ~ www.mauleairinc.com

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
i
FOREWORD
Ahead of you are many hours of flying pleasure. The more you fly your M-8 the more
you will realize that flying this aircraft is a stimulating sensation that will never grow old.
The Maule M-8 is designed and built to give you the airplane you have always want-
ed. It is fast, comfortable, and easy to fly, yet no light airplane is safer than the Maule M-8.
Its sturdy construction means you will not have to pamper it to enjoy long years of trouble-
free service.
Our dealers and distributors are anxious to serve you and will gladly furnish advice as
to proper servicing methods. You may also address requests for information on any items
not covered in this manual to Maule Parts - Service Department of Maule Air, Inc. (Telephone
912-985-2045, Ext. 239). In correspondence, please be certain to give complete information
on serial number, engine make and model, etc.
WARRANTY
Maule Air, Inc. warrants each new airplane manufactured by it to be free from defects
in material and workmanship under normal use and service, provided, however, that this war-
ranty is limited to making good at the Maule factory any part or parts thereof which shall,
within ninety (90) days after delivery of such airplane to the original purchaser, be returned to
Maule with transportation charges prepaid, and which upon Maule's examination shall dis-
close to its satisfaction to have been thus defective; this warranty being expressly in lieu of all
other warranties expressed or implied and all other obligations or liabilities on the part of
Maule, and Maule neither assumes nor authorizes any other person to assume for it any oth-
er liability in connection with the sale of its airplane.
This warranty shall not apply to any airplane which shall have been repaired or al-
tered outside Maule's factory in any way so as, in Maule's judgment, to affect the airplane’s
stability or reliability, or which airplane has been subject to misuse, negligence or accident.
Certain items of equipment are warranted separately by their manufacturer. The en-
gine and accessories are warranted by Textron Lycoming, Williamsport, PA. The Hartzell
Propeller is warranted by Hartzell Propeller, Inc., Piqua, OH; the McCauley Propeller is war-
ranted by McCauley Propeller, Inc., Dayton, OH. Avionics items are warranted by their man-
ufacturers. Manufacturers of separately warranted item of equipment request that warranty
claims be made through your nearest authorized Distributor or authorized Service Center.
Maule Air will be glad to help you find that facility nearest to you.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
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TABLE OF CONTENTS
ITEM PAGE
Forewor
d
...................................................................…… i
Warranty
...............…................................................……
i
Table of Con-
tents…..................................................…… ii
Log of Revi-
sions…................................…....................… iii
SECTION I - GENERAL DATA
General Descrip-
tion..................................……………….. 1
Design Specifica-
tions..................................................….. 1
Fluid Capacities and Specifica-
tions...........................…… 2
SECTION II - GENERAL MAINTENANCE
Cleaning and Care of Air-
craft.....................................…... 3
nspection Guides
........................................................….
5
Rigging Proce-
dures.....................................................….. 10
Lubrication
..........................................................………… 12
Fabric Re-
pairs……………………………………………….. 13
SECTION III - MAJOR COMPONENT PARTS
Wings
..........................................................................…..
14
Lift Struts
...................................................................…...
14
Fuselage
..............................................................…....….. 14
Surfaces and Con-
trols................................……………… 15
Landing Gear, Wheels and
Brakes........................……… 16

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
Maule
Tailwheel…………………………………………….. 19
Figure
One…………………………………………………… 20
Power Plant Sys-
tem........…...................................……… 21
Fuel Sys-
tem....................….............................……….….. 23
Electrical Sys-
tem................…...................................…… 24
Electrical Schematic - 14
Volt..........…......................…… 25
Electrical Schematic - 28
Volt...............................….…… 26
Door Latch Adjustment Proce-
dure....………..........…….. 27

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
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7/99
SECTION I
GENERAL DATA
GENERAL DESCRIPTION:
Type: Five place high wing cabin monoplane.
Engine Installation: Single tractor engine in nose of fuselage.
Wing: Strut braced, two spar, metal covered, modified USA 35-B airfoil. Fiberglass
wing tips.
Fuselage: Welded steel tube structure.
Fuselage and tail group covered with Ceconite synthetic fabric. Fiberglass
engine cowl. Aluminum skin on forward fuselage and doors.
Landing Gear: Spring aluminum main gear. Hydraulic Brakes. Steerable tailwheel
(Automatic locking)
Control Systems: Dual controls wheels, rudder pedals and brakes. All controls direct-
ly cable driven. Fuel control/shut off valve is at the left lower side
panel. Mechanical flap and trim controls are at the center on the
floor. All other controls, switches, etc., are instrument panel mount-
ed.
DESIGN SPECIFICATIONS:
Wing Span 32 feet 11 inches
Length 23 feet 7½ inches
Height 6 feet 4 inches
Gross Weight 2500 lbs.
Empty Weight Approx. 1535 lbs.
Wing Loading 15.1 lbs./sq. ft.
Power Loading 10.6 lbs./HP
Useful Load Approx. 965 lbs.
Seats Four/Five
Flaps Neg. 7°, 0°, 24°, 40°
Baggage Allowance 250 lb. Structural Limit
Baggage Compartment Dimensions 35½ H x 30W x 21L

MAULE AEROSPACE TECHNOLOGY, INC.
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Wings:
a. Airfoil Modified USA 35-B
b. Chord 63 inches
c. Incidence +30 minutes
d. Dihedral 1.2 degrees
e. Sweepback None
Areas:
a. Wing, Aileron and Flaps 165.6 sq.ft.
b. Ailerons (total) 14.2 sq.ft.
c. Flaps (total) 23.9 sq.ft.
d. Horizontal Stabilizer 18.1 sq. ft.
e. Elevators (including tab) 14.1 sq. ft.
f. Vertical Stabilizer 13.1 sq. ft.
g. Rudder 6.2 sq. ft.
h. Elevator Trim tab 1.03 sq. ft.
i. Rudder Tab .34 sq. ft.
FLUID CAPACITIES AND SPECIFICATIONS:
a. Main Fuel Tanks - Inboard - 100 Octane
Right Main Tank 21.5 or 23.8 gallons total
Left Main Tank 21.5 or 23.8 gallons total
Note: 1.5 gallons unusable fuel per 21.5 gallon main tank
2.3 gallons unusable fuel per 23.8 gallon main tank
b. Auxiliary Fuel Tanks - Outboard - 100 Octane
Right Auxiliary Tank 15.0 gallons or 21.0 gallons
Left Auxiliary Tank 15.0 gallons or 21.0 gallons
c. Engine Oil (SAE 50 above 60°F, SAE 40 at 30°to 90°F, SAE 20 below
10°F ambient air temp, at sea level. Refer to Engine Manual for
AD Oil grades.)
O-540: 12 qt. Maximum IO-540: 8.0 qt. Maximum
9 qt. Minimum 5.0 qt. Minimum
d. Brakes (Texaco Aircraft Hydraulic Oil 15, MIL-H-5606E or equiv.)
1 pint

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
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SECTION II
GENERAL MAINTENANCE
CLEANING AND CARE OF AIRCRAFT
Keeping the performance, speed and durability that was built into your aircraft at the
factory requires more than casual attention. The accumulation of dirt and oil on the outside
and debris inside does affect these factors and can be a fire hazard as well. The first step to
proper maintenance is a clean aircraft.
EXTERIOR
Frequent washing is good for your aircraft finish, especially during the first few
months. Use any quality car wash with a soft cloth or sponge and plenty of clean water-do
not use dishwashing detergent. Drying should be done with a chamois. Accumulation of oil,
grease and exhaust carbon deposits should be removed frequently by using a soft cloth
soaked in mineral spirits or other neutral cleaner.
For general polishing, apply a good quality car polish or wax according to instructions.
Clean Plexiglas with plenty of soap and water using grit free soft cloth, chamois or sponge.
Use of a dry cloth on Plexiglas will not only cause scratches but will also build up an electro-
static field which will attract dust to the surface. Blotting with a clean damp chamois will re-
move the charge and the dust. After cleaning, polishing with a good Plexiglas cleaning prod-
uct such as "Mirror Glaze" will keep the glass clean and help polish out minor scratches.
Experience has shown that airplanes based at coastal airports or where there is an
otherwise corrosive atmosphere require special treatment to prevent corrosion, specifically
"electrolyte corrosion". Salt water and chemicals act as an electrolyte between dissimilar
metals and can start a strong corrosive action over a short period of time. Maule makes eve-
ry effort to separate dissimilar metals with primers and coatings during manufacture, but
there are some locations (such as rivets in wing skins) where this is impossible. To combat
corrosion it is important that the external painted surfaces be kept clean and well waxed.
Wash the airplane with fresh water frequently to remove any salt or chemical film. Periodical-
ly, coat the wings, flaps and ailerons internally with a quality corrosion preventative, several
of which are available. Floatplanes require more extensive preservation techniques which
are well known in the field.
INTERIOR
Floorboards should be vacuumed frequently and can be cleaned with any good rug
cleaner.

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Cont’d
Care should be taken in the disposal of candy wrappers, paper scraps, cigarette
butts, etc. These can work their way under the floorboards and become a fire hazard, mois-
ture trap and could jam the control cables.
NOTE: While washing the aircraft, ascertain that all drain holes are open. Clean out
any debris blocking them. Accumulated water can be dangerous, so check behind the bag-
gage compartment frequently.
Textile upholstery may be cleaned using a vacuum cleaner. Grease and oil spots on
the upholstery should be treated with a spot remover or dry cleaning fluid. Do not use soap
and water on textile materials.
Vinyl upholstery may be cleaned using soft whiskbroom or suds of any mild soap
(castile or olive oil base) in lukewarm water. Use water sparingly as the upholstery otherwise
requires a long time to dry if water trickles through the seam stitches.
For best results, stains, especially those caused by grease or paint, should be re-
moved from upholstery as soon as possible or they may become "set" and hard or impossible
to remove. "Set" stains should be removed carefully with a clean cloth dampened in dena-
tured alcohol. Stains caused by shoe polish can best be removed with turpentine. However,
such cleaning agents are liable to affect the dust-repellent finish of the vinyl if used in excess
of the actual requirements. Never use volatile solvents such as lacquer thinner, acetone, etc.
on upholstery.
The cleaning should be completed by wiping the surface of the vinyl dry with a clean
cloth, particularly in the seam. No attempt should be made to apply preservatives such as
wax, polish, or varnishes, as these will not be absorbed by vinyl, but will merely collect dust.
There are protective treatments made especially for vinyl that are commercially available and
quite satisfactory.
Leather upholstery should be cleaned by leather cleaning methods using leather-
cleaning products.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
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INSPECTION GUIDES
At 25 Hour Total Time, perform 50 Hour Inspection as described below:
At 50 Hour Total Time and every 50 hours thereafter:
A. POWER PLANT
1. Perform appropriate inspection as called for in the engine manufacturer's
Operator's Manual.
2. Perform appropriate inspection as called for in the propeller manufacturer's
Installation, Operation and Service Manual.
3. Remove the outer muffs from the mufflers and inspect the mufflers and tubes for
cracks. Inspect muffs for cracks before reinstalling.
4. Inspect gascolator, clean if necessary.
5. Inspect engine controls for security and proper operation.
6. Clean or replace air filter. (See page 23 for Brackett air filter.)
7. Inspect all engine and engine mount attach bolts.
8. Inspect all engine fuel and oil lines for general condition and security.
9. Check all engine compartment electrical connections and wires for security and
chafing.
B. AIRCRAFT
1. Check battery for general condition and electrolyte level, (in wet cell batteries only).
2. Check all main electrical connections.
3. Check fluid level in brake reservoirs.
4. Check the entire fuselage, tail surfaces and wing skins for cracks, security of fair-
ings and general condition.
CAUTION: If airplane is subject to excessive stress, i.e., heavy loads, adverse wind
conditions, rough landings, etc., take special care in examining wing skins for any
cracks. If any are found, repair before further flight in accordance with AC 43:13 and
factory drawings. (Do not replace any countersunk rivets with buttonhead rivets in wing
because it is not approved.)

MAULE AEROSPACE TECHNOLOGY, INC.
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5. Check the aileron and flap skins for cracks.
6. Check the security, operation and general condition of all control surfaces.
7. Check general condition of tailwheel, leaf springs and spring attachment. Leaf
springs should have 45°angle with no weight on the wheel. Check all bolts and
nuts holding the tail springs to the fuselage. Tighten nuts, if needed, so that there is
no play or side movement in the springs or their attachment.
8. Drain sumps of fuel tanks.
9. Check tires for inflation and cuts.
At 100 Hours Total Time and every 100 Hours thereafter, perform the 50-hour inspection
plus the following:
A. POWER PLANT
1. Perform appropriate inspection as called for in the engine manufacturer's Operator's
Manual.
2. Perform appropriate inspection as called for in the propeller manufacturer's Installa-
tion, Operation and Service Manual.
3. Clean the engine with any good engine cleaner (Gunk, etc.) Be sure to protect
magneto from getting wet.
4. Examine baffles and baffle extensions for security and cracking.
5. Clean gascolator screen.
6. Retorque bolts attaching engine mount-to-fuselage and engine-to-engine mount.
Visually inspect mount structure for condition. See "Engine Mount" under "Power
Plant System".
7. Inspect induction system and airbox for cracks and security.
CAUTION: For carbureted engine only: If rubber seal on air valve is in poor condition,
replace seal with black nitrile rubber with cotton insert and/or if valve plate is loose, re-
pair per SB#16. (Check compliance to Maule SB#16.)
B. AIRCRAFT
1. Remove right and left kick panels in cockpit, windshield side post covers and panels
below seat fronts. CAUTION: If cable guide tubes are not installed and if backside
of kick panel shows evidence of rudder cable rub and tape has not been placed,
comply with Maule SB#14 and #17.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
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Examine protective rudder cable guide tubes, (located behind kick panels), if in-
stalled, and attaching clamps, bolts and nuts for security and general condition.
2. Examine all front cockpit electrical connections and wires, fuel lines and fittings,
control cables attachments and pulleys for security, leaks, chafing, etc.
3. Remove rear seat, rear floorboard and panel behind baggage compartment.
4. Inspect all control cables, pulleys, fairings and electrical connections and wires for
security and chafing.
5. Open zippers in headliner and inspect all control cables, pulleys, fairleads and elec-
trical connections and wires for security and chafing.
6. Remove wing root fairings and inspect control cables, fairleads, fuel lines and con-
nections, and electrical wires and connections for security, chafing and leaks.
7. Remove wing strut fairings, top and bottom, and inspect attaching fittings and bolts
for security, corrosion and cracks. Carefully inspect both sides of lift struts for abra-
sion, corrosion, pin holes and punctures. Any paint loss or minor corrosion should
be sanded down to bare metal with fine sandpaper and metal primer should be ap-
plied. After the primer is dried, a finish coat of the desired color may be added.
Powder coating is recommended if complete strut is being refinished.
WARNING: Any unrepairable dents or punctures in strut are cause for replacement of
the strut.
CAUTION: If aircraft has original unsealed struts comply with Maule Service Bulletin
No. 11 (and AD# 98-15-18) as required. (New sealed struts are identified by two weld
spots located at upper end. Removal of the upper cuff is needed to locate the weld
spots). Also, do not replace lift struts with older M-4 struts with the 7/16” dia. lower fork
thread. 1/2” dia. is required for later models.
CAUTION: Item (a)(4) of AD# 98-15-18 is very misleading as Maule never drills holes
in struts to attach cuffs, door clips or any hardware and it is illegal to do so since there
are no approved holes in the wing struts under the TC data. If aircraft has a modifica-
tion added requiring a drilled hole in strut under a #337, refer to AD for inspection re-
quirements at the 24-month intervals. Also, inspect the area around the holes(s) fre-
quently for corrosion or cracking (ref. SL#58).
8. Remove wheels and inspect wheels, tires, brake disc, bearings, brake lines and
brake pad for wear, cuts, chafing, leaks and general condition. Repack wheel bear-
ings.
9. Remove landing gear top fairings and inspect attaching fittings and bolts for securi-
ty, corrosion and cracks and inspect brake hose for security, chafing and leaks.

MAULE AEROSPACE TECHNOLOGY, INC.
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FOR M-8-235
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10. Remove inspection hole cover in fuselage bottom inboard main landing gear (spring
gear) attach points. Visually check bolt/nut attachment for security, both from below
and above. Check fuselage square tube truss for cracks or bending. Carefully in-
spect both sides of the spring gear itself at the inboard attachment and along its en-
tire length for abrasion, cracking, corrosion, exfoliation, mechanical damage, or any
other adverse conditions. Remove any corrosion and prime and paint the affected
area. Spray entire inboard area of spring gear, attachment points, and truss with
LPS-3 Rust Inhibitor (LPS Laboratories, Inc.) or equivalent. The torque on the in-
board attach bolts must be 240-300 inch pounds and on outboard clamp bolts 160-
190 inch pounds.
CAUTION: Use Steps 9 and 10 above as a guide for inspection after an unusually
hard landing or any time there is concern about the condition of the main landing
gears or their attachments.
11. Remove all inspection covers/plates and inspect all visible control cables, pulleys,
bellcranks, electrical wires and connections, fuel lines and fittings, nuts, bolts, etc.
for security, chafing, leaks, etc.
(CAUTION: If a wing has been removed and reinstalled, or a new wing installed, visual-
ly inspect the routing of aileron cables through the inspection hole cover located on un-
derside of wing, aft of rear spar and outboard of wing strut attach brackets. Ascertain
that cables are not over the strut attach bracket and are properly routed through the
fairleads and around the pulleys. Ref. Maule Service Bulletin No. 12.)
12. CAUTION: At inspection hole in tail, visually check the pivoting action at the control
cable attachment points over the full range of rudder and elevator travel. This ac-
tion should be such that there are no bending loads imparted to the turnbuckles,
(which are designed for straight tension load only). Any binding which causes
bending of the turnbuckles should be removed. Any cable attachment parts which
display appreciable corrosion must be replaced before further flight. NOTE: Pivot
points must be cleaned and lubricated with any lightweight lubricating oil. Following
lubrication, the cable attachments, including the turnbuckles, must be heavily coat-
ed with a good preservative such as:
Black Bear Paralketone Preventative LPS 3, Heavy Duty Rust Inhibitor
Black Bear Co. (preferred) LPS Laboratories, Inc.
Long Island City, NY Tucker, GA
NOTE: Maule Service Bulletin No. 9 covers corrosion resistant parts replacement and is
particularly recommended for airplanes operating in a potentially corrosive environment.
Compliance to this SB provides for larger stainless steel turnbuckles and corrosion re-
sistant steel fasteners and attachment details for the elevator cables.
13. CAUTION: Special attention should be given to the horizontal stabilizer strut lower
attach tubes which are welded to the lower longerons. The seal on the inside of the
lower strut attach stub tubes can deteriorate with age which could cause corrosion
on the interior of the attach stub tubes, especially on floatplane models. It is rec-

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
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ommended that the stabilizer struts be removed to inspect attach stub tubes at each
annual. If there is visible external corrosion around the attach stub tubes, or the in-
ternal seal appears loose or cracked, remove the seal, clean the inside of the tube
and visually inspect the inside for corrosion. (Note: earlier model Maule airplanes
used a hard seal filler material, which may crack or lose adhesion with the tube.
Later Models used silicone rubber as a seal, which is more compliant and durable.)
If corrosion is found, repair in accordance with AC 43.13-1B. After repair, or if no
corrosion is found, fill entire tube with silicone rubber to seal tube from moisture.
Inspect the struts for dents, corrosion, or punctures and replace if necessary. Rein-
stall struts with new hardware and document in aircraft records.
NOTE: Double struts, available through Maule, are recommended for floatplanes and
banner and glider-towing planes.
14. Lubricate all chains and points of rotation on sprockets, pulleys and bellcranks,
15. Inspect and lubricate all control surface hinges and control horn connections.
16. Inspect and lubricate door hinges and latches and seat tracks.
CAUTION: Carefully inspect all door hinge bolts and nuts for condition and security. If
using elastic nuts on door hinges, they must be replaced with castle nuts and cotter pins.
Refer to Maule Service Letter No. 61.
17. Lubricate rudder pedals and rudder bar points of rotation.
18. Check control rigging and cable tensions.
19. Check and clean vacuum system regulator valve filter and intake filter.
20. Check the pitot static system for leaks.
21. Ensure that all applicable Airworthiness Directives and Maule Service Letters and
Bulletins that are mandatory have been complied with.

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RIGGING PROCEDURES
1. LEVELING:
Laterally: The airplane can be accurately leveled laterally using the front spar attach
bolts. Turn these two bolts so that a flat on the head is "up". Fabricate two
equal length spacers (1½ inch minimum length) which can be placed on the
bolt heads. Place a 48 inch level across the two spacers and block under the
landing gear to center the bubble.
Longitudinally: Using a level thirty-six (36) inches long or longer, place it on the leveling
lug and leveling mark thirty-one (31) inches to the rear of the leveling lug
on the bottom of the right wing root. Raise the tail to bring bubble to cen-
ter.
2. DIHEDRAL ANGLE:
To check dihedral angle at the front spar, remove both top wing root fairings to ex-
pose the front spar attach bolts. Stretch a string along the top of the wing above the front
spar, from wingtip to wingtip, and draw it tight. String can be attached to tie down fittings
underneath the wing to hold tautness. Be careful to protect the edges of the wingtips
from string chafing.
Find the row of flush rivets on the top of each wing from wingtip to wingtip at the front
spar location. Measure from the forward wing to fuselage attach bolt centerline, for both
left and right wings, outboard 127.5 inches along the top of each front wing spar. Using
masking tape or equivalent, tape the string down on the rivet centerline at this point.
At the inboard end of the front spar, measure the distance from the top rear edge of
the spar cap to the string for both wings. Adjust the front wing struts so as to have a
measurement of 2 3/4 inches on each wing (plus or minus 1/8 inch) at this location. It is
recommended that the rear struts be removed while adjusting dihedral. The wing must
be supported while the front strut is being adjusted. For rear strut adjustment, see sec-
tion on Washout.
CAUTION: Be sure that the strut fork is not extended more than 1 inch of threads from
the strut end to the end of the fork threads (not including the jam nut). There must be at
least 1 3/8 inch of thread engagement into the strut.
3. WASHOUT:
To adjust the washout in the wings, proceed as follows:
Put a leveling protractor chordwise on the underside of the wing root and adjust it to a
zero degree reading. Now put the protractor chordwise just inboard of the wing tip and
adjust the rear strut to give ½°trailing edge up, difference from the wing root angle.

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4. TAIL ASSEMBLY:
With the airplane in level position, the stabilizers should be leveled at their rear spars.
The hinge line should be straight from tip to tip. The vertical stabilizer should be plumb at
the hinge.
5. AILERONS:
Adjust the ailerons to streamline position by placing a straight edge on the bottom of
the wing, chordwise, at the inboard end of the aileron. Then adjust the turnbuckles in the
aileron system so the control wheels are centered and there is a gap of zero to ¼ inch
between the straight edge and the trailing edge of the aileron.
Check the aileron travel for 20°±1°up and 20°±1°down. Adjust turnbuckles to stay
within these limits. Proper cable tension is 15 to 25 lbs.
6. FLAPS:
Adjust the first notch flap position to be aligned with the aileron trailing edge with the
ailerons centered. Check the flap travel with flap handle at fully retracted (handle down)
position for negative 7°±1°up, and 24°±3°down for second notch, 40°±3°down for
third notch. Adjustment, if needed, may be accomplished by adjusting turnbuckles locat-
ed above front seats through headliner. Proper cable tension is 60 lbs. ±10 lbs.
. RUDDER:
Check the rudder travel for 21°±1°right and left. Rudder cable tension is controlled
by springs, and the cables should not be slack with the rudder centered. Rudder trim
may be accomplished by adjusting the tension of the rudder centering springs located
behind the rear bulkhead. Keep springs as short as possible but never less than 4 ½
inches from end coil to end coil with the rudder centered.
8. ELEVATORS:
Elevator control movements are up 30°±1°, down 20°±1°. Stops are located on the
vertical tail rear spar just inside the inspection plate. Proper cable tension is 25 to 45 lbs.
9. ELEVATOR TRIM:
Elevator trim tab movement is 12°±2°up, 38°±2°down. If adjustment is needed, it
may be done at the turnbuckles located just aft of the trim control. Proper cable tension
is 15 to 25 lbs.

MAULE AEROSPACE TECHNOLOGY, INC.
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10. RUDDER TAB:
This tab is interconnected with the aileron system to automatically coordinate aileron
and rudder controls for simplified handling in the air. (It may be used as a rudder trim tab
to make the airplane trim in cruise.) This tab may be ground adjusted by changing the
position of the tab cables where they attach to the aileron cables located just over the
front doors on the inside of the airplane. Normally, the tab should be streamlined with the
rudder when the aileron and rudder controls are centered, using the centering spring for
rigging adjustments (See 7 above).
The tab travel is 48°±4°right or left. Proper cable tension is 5 to 10 lbs.
CAUTION: Make sure tab is free at extreme aileron travel.
NOTE: The “Rudder Trim Control” on the instrument panel pulls on a spring attached to
the right rudder pedal. It is not connected to the tab on the rudder.
LUBRICATION
1. Main wheel bearings - Use good quality wheel bearing grease.
2. Control Column - Apply light coat of graphite base lubricant to aileron balance chain,
torque tube and control guide. Use lightweight lubricating oil on all other bearings.
3. Control pulley bearings and control surface hinges - Use lightweight lubricating oil.
4. Flap bellcrank and mechanism - Use lightweight lubrication oil.
5. Aileron and flap hinge - Use lightweight lubricating oil.
6. Elevator and trim tab - Use lightweight lubricating oil.
7. Tailwheel - Good quality wheel bearing grease to tailwheel bearings through zerk fitting.
Same for fork spindle roller bearings, if necessary. See tailwheel maintenance section
under "Landing Gear, Wheels and Brakes".

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FABRIC REPAIRS:
(Applicable to polyurethane paint on Ceconite fabric only)
REPAIRS:
1. Small holes and damaged areas can easily be repaired without removing the existing
paint topcoat.
2. Trim the damaged area to a rectangular or circular shape.
3. Lightly scuff sand with #320 or #400 wet/dry sandpaper approximately 2 inches around
the repair area.
4. Mix one part gray urethane primer catalyst with two (2) parts gray urethane primer (2:1
ratio - 2 parts paint/1 part catalyst), mixing a very small amount only for coating the sand-
ed area around the repair.
5. Apply one coat (this may be brushed) to the sanded area slightly larger than the size of
the patch to be applied. This application aids in total adhesion to the topcoat and offers a
fresh chemical adhesion base for the repair patch.
6. Allow prime to dry for 4 hours.
7. Apply a coat of urethane adhesive (thinned one to one (1:1) with urethane adhesive thin-
ner by volume) to the primed area slightly larger than the repair patch size. Allow this to
dry for approximately 15 minutes.
8. Apply a second coat of the thinned urethane adhesive and lay the patch in the wet bed of
adhesive, smoothing the edges while applying a topcoat of the thinned urethane adhe-
sive, working he edges down. Allow to dry at least 8 hours prior to any shrinkage.
SHRINKING THE REPAIR AREA:
1. When using an iron to shrink the patch, always use a piece of aluminum foil over the area
to be tautened and the surrounding undamaged topcoat. This is to prevent any scorching
of the topcoat. Follow the procedure previously mentioned (primer and finish coat appli-
cation). Take care to feather sand as required during primer procedure to feather the re-
pair patch and blend in prior to topcoat spraying.
SPECIAL PRECAUTIONS:
1. For any repair or damaged area larger than 16 inches in any direction refer to FAA AC
43.13 1B paragraph 169. Only use equal or next heavier weight fabric for repair patch.
Do not substitute any other products or brands in this procedure.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
14
SECTION III
MAJOR COMPONENT PARTS
WINGS:
The complete wing is of metal construction (2024-T3 aluminum) with a fiberglass wing-
tip.
Spar root end strut fittings are made of 2024-T4 aluminum.
LIFT STRUTS:
The lift struts are streamlined tubes attached to the wing and fuselage by means of steel
bolts. When inspecting the struts, check for nicks and dents and see that all bolts are snug
(not tight).
In handling the airplane on the ground, care should be take to prevent damage to the lift
struts by pushing or lifting in the middle of the strut. Frequent inspection of the struts should
be made and any paint loss or minor corrosion should be sanded down to bare metal with
fine sandpaper and metal primer should be applied. After the primer is dried, a finish coat of
the desired color may be added. Powder coating is recommended if complete strut is being
refinished.
WARNING: Any unrepairable dents or punctures are cause for replacement of the strut.
When replacing a sealed strut with an unsealed strut, insure compliance with AD No. 98-15-
18 (Maule SB No. 11) (See also page 7, item 7.)
FUSELAGE:
The fuselage is a welded truss type structure having an integral vertical tail fin. Chrome
molybdenum steel (4130) is used for all tube members, control fittings, floor supports and
seat members. Door frames and other nonstructural parts are made of cold rolled steel
(1008 to 1015) or stainless steel (per customer’s request).
If it becomes necessary to replace any fuselage members, sleeve type splices should be
made in accordance with practices outlined in FAA AC 43.13-1B, Aircraft Inspection and Re-
pair.
The forward fuselage section is aluminum covered (2024-T3). The firewall is made of
.018 galvanized sheet steel or stainless steel.
The aft fuselage section is covered with Ceconite fabric and standard dope and paint fin-
ish as per Maule Specification S-17. Later models are finished with polyurethane or acrylic
urethane paint in accordance with Maule Specifications S-40 or S-41, respectively. This fab-
ric need not be pulled or punch tested.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
15
SURFACES AND CONTROLS
AILERONS AND FLAPS:
The ailerons and flaps are aluminum alloy structures covered with 2024-T3 skin.
The aileron control system consists of a chain drive connecting the two control wheels
and is attached to the necessary cables which are routed over pulleys through the fuselage
and into the wing section to the aileron horns.
The flap control system consists of a control lever, which has four active positions, (-7°,
0°, 24°, and 40°). This is connected to the control cables (and spring cartridge located direct-
ly behind cargo area) which are routed over pulleys through fuselage and connected to chain
drive located directly above the cabin area. This chain drive is connected to a torque tube,
which operates the flap through a push-pull rod attached to the inboard hinge fittings.
ELEVATORS:
The elevator has chrome molybdenum (4130) internal structure covered with Ceconite
fabric. Inspect for corrosion. Drain grommets should be kept open. The hinge attachments
should be lubricated with light engine oil. Accumulations of dust and dirt on hinges should be
removed.
STABILIZERS:
The stabilizers have chrome molybdenum steel (4130) internal structures covered with
Ceconite fabric. Inspect for corrosion including elevator hinges and struts.
RUDDER:
The rudder structure is very similar to the elevators. No maintenance other than inspec-
tion for corrosion is needed. The hinges should be cleaned and lubricated with light engine
oil at frequent intervals. The cable attachment points should be checked for wear and corro-
sion.
TRIM AND RUDDER TABS:
These surfaces have low carbon steel frames with aluminum alloy skin (2024-T3).
These surfaces need no maintenance other than inspection for corrosion. The hinges
should be lubricated at frequent intervals using light engine oil.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
16
LANDING GEAR, WHEELS AND BRAKES
MAIN LANDING GEAR:
The main landing gear consists of separate left and right side heat-treated (7075-T651)
aluminum spring legs, which are bolted to a square tube truss in the bottom of the fuselage
structure. No maintenance is required. However, since the landing loads are taken on these
members, they are stressed and should be inspected frequently for damage and corrosion.
See Section II, “Inspection Guides”.
MAIN WHEELS AND BRAKES:
See Equipment Lists for items installed and options.
To change a tire, follow these steps:
1. Chock opposite main wheel and tailwheel.
2. Raise wheel with a light scissors jack or a small bottle jack placed under the lower end of
the spring gear leg.
3. Remove brake calipers by removing two (2) brake bolts.
4. Remove hub cap, cotter pin and retainer nut.
5. Remove wheel.
6. Deflate tire by removing valve core.
WARNING: Failure to fully deflate the tire prior to separating the wheel halves (Step 8) may
result in personal injury.
7. Break tire bead on both rim halves.
8. Remove wheel rim through-bolts.
9. Clean rims thoroughly.
10. Remove bearings and check for scoring, galling and corrosion. Replace as required.
11. Regrease and assemble. (Tire and wheel rims are prebalanced. Balance points are
usually marked by a colored dot.)
12. Lightly inflate to prevent pinching of tube when tightening through-bolts.
13. Inflate tire to 35 psi to seat tire on rims and back off to 25-26 psi normal pressure. (16-
18 psi for oversize tires.)
14. Thoroughly inspect landing gear and axle; check that axle attach bolts are torqued.
15. Reinstall wheel, tighten retaining nut until all play is removed, back off nut to first availa-
ble cotter pin hole, and install new cotter pin.
16. Inspect brake pads. Replace if necessary.
17. Replace brake calipers and hub cap.