Remos G-3 /600 User manual

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Maintenance Manual
July 1st 2008

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Note: Changed pages are indicated by the marking “changed” at the top of
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Dates of issue for original and changed pages are:
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Changed… 6 July 1st 2008
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Table of Contents
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Appendix 1
Appendix 2
General Description………………………………………………
Ground Handling, Servicing, Cleaning,
Lubrication and Inspection………………………………………
Structures – Fuselage……………………………………………
Structures – Wings and Empennage…………………………..
Structures – Landing Gear and Brakes………………………..
Structures – Aileron Control System…………………………...
Structures – Wing Flap Control System……………………….
Structures – Elevator Control System…………………………
Structures – Elevator Trim Control System…………………..
Structures – Rudder Control System………………………….
Engine…………………………………………………………….
Fuel System………………………………………………………
Propeller…………………………………………………………..
Utility Systems……………………………………………………
Instruments and Instrument System…………………………...
Electrical Systems……………………………………………….
Electronic Systems – included in Appendix 1
Structural Repair…………………………………………………
Exterior Painting…………………………………………………
Wiring Diagrams…………………………………………………
Safety Directives and Safety Monitoring System…………….
1-1
2-1
3-1
4-1
5-1
6-1
7-1
8-1
9-1
10-1
11-1
12-1
13-1
14-1
15-1
16-1
18-1
19-1
20-1
21-1
Attachments Page
A
B
C
Annual/100 hour Inspection Form…………………………….
Operational Safety Feedback Form…………………………..
Owner/Operator Responsibility Commitment Form…………
22-1
23-1
24-1

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ii
Imprint
Published by REMOS Aircraft GmbH Flugzeugbau
Franzfelde 31
D-17309 Pasewalk/Germany
Distributed by REMOS Aircraft GmbH Flugzeugbau
All rights reserved. No part of this manual may be reproduced,
stored in a retrieval system or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording or
otherwise, without the prior permission of REMOS Aircraft.
Editior, Designer and Graphics:
Hans Fuchs
All correspondence concerning the content of this volume
should be adressed to REMOS Aircraft GmbH.
Foreword
This maintenance manual contains factory-recommended
procedures and instructions for ground handling, servicing and
maintaining Remos G-3 /600 Series aircraft. Besides servicing
as a reference for experienced mechanic, this manual also
covers step-by-step prodcedures for the less experienced man.
This book should be kept in a handy place for ready reference.
If properly used, it will better enable the mechanic to maintain
Remos G-3 /600 Series aircraft and thereby establish a
reputation for reliable service.
All information contained is based on data available at the time
of publication and is supplemented and kept current by service
letters published by Remos Aircraft Company. These are sent to
all Remos Aircraft Dealers so that they have the latest
authoritative recommendations for servicing Remos aircraft.
Therefore it is recommended that Remos owners utilize the
knowledge and experience of the factory-trained Dealer Service.
This manual is designed to meet the standard of maintenance
manuals for Light Sport Aircraft as prescribed in the ASTM
document F2483-05. According to the ASTM standard each
task does contain the type of maintenance “Level of
Maintenance” and the minimum level of certification needed to
accomplish the task “Certification Required”.
The REMOS G-3 /600 complies to the rules of the Light Sport
Aircraft airworthiness standards and does not conform to
standard category airworthiness requirements.

Changed 1
iii
Common conversions and abbreviations
1 mm = 0.03937 in
1 in = 25.4 mm
Unit of length
1 ft = 0.3048 m
1 cm2= 0.155 sq inUnit of area
1 sq in = 6.4516 cm2
1 cm3= 0.06102 cu in
1 cu in = 16.3871 cm3
Unit of volume
1 gal (US) = 3.7854 l (dm3)
1 kg = 2.2046 lbUnit of mass
1 lb = 0.45359 kg
1 N = 0.224809 lbfUnit of force
1 lbf = 4.4482 N
1 bar = 1000 hPa
1 bar = 14.5037 lbf/in2 (psi)
1 lbf/in2 (psi) = 0.0689 bar
Unit of pressure
1 in HG = 33.8638 hPa
°C = (°F – 32) / 1.8Unit of temperature
°F = (°C x 1.8) + 32
1 m/s = 3.6 kph
1 ft/min = 18.288 m/s
1 m/s = 0.0555 ft/min
1 kts = 1.852 kph
1 kph = 0.53996 kts
Velocities
1 mph = 1.609 kph
1 Nm = 8.848 In.lb.
1 in.lb. = 0.113 Nm
Torques
1 ft.lb. = 1.356 Nm

Changed 1
Section 1-1
Section 1
General Description
Table of Contents Page
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.8.1
1.8.2
1.9
1.10
1.11
1.12
Aircraft Description…………………………………………………..
Aircraft Specifications…………………………………………………
Torque Values…………………………………………………………
Tire Inflation Pressures……………………………………………….
Approved Oils and Capacities……………………………………….
Engine Specifications…………………………………………………
Equipment List…………………………………………………………
Weight and Balance Information…………………………………….
Center of gravity determination………………………………
CG-Calculation………………………………………………...
Sources to Purchase Parts…………………………………………..
Disposable Replacement Parts……………………………………...
General Safety Information…………………………………………..
Reporting possible Safety of Flight Concerns During Inspection
1-1
1-1
1-2
1-3
1-3
1-4
1-5
1-6
1-6
1-6
1-8
1-8
1-9
1-10
1.1 Aircraft Description
REMOS G-3 Series aircraft, described in this manual, are highwing monoplanes of all
composite monocoque construction. These aircraft are equipped with a fixed tricycle
landing gear. All models are equipped with composite (glass fiber) main landing gear
struts including wheel fairings and a steerable nose gear. Two place seating is
standard. Each aircraft is equipped with a 4-stroke, four cylinder, horizontally
opposed, water cooled Rotax 912 UL or 912 UL/S aluminum alloy engine, driving a
fixed pitch propeller.
1.2 Aircraft Specifications
Primary specifications of the aircraft, with dimensions based on gross weight, are
given in figure 1-1. If these dimensions are used for constructing a hangar or
computing clearances, remember that such factors as tire pressure or load
distributions may result in some dimensions that are somewhat different from those
listed.

Changed 1
Section 1-2
Figure 1-1.
Gross Weight………………………………………………..
Fuel Capacity………………………….…………………….
Oil Capacity………………………………………………….
Engine Model (Refer to Section 11 for Engine Data)……
Propeller (Fixed Pitch)………………………………………
Main Wheel Tires……………………………………………
Pressure……………………………………………...
Nose Wheel Tire…………………………………………….
Pressure………………………………………………
Aileron Travel
Up……………………………………………………..
Down………………………………………………….
Wing Flap Travel…………………………………………….
Rudder Travel
Right…………………………………………………..
Left…………………………………………………….
Elevator Travel
Up……………………………………………………..
Down………………………………………………….
Elevator Trim Tab Travel
Up……………………………………………………..
Down………………………………………………….
Principal Dimensions
Wing Span…………………………………………….
Length (Carbon Spinner)………………………...…
Length (Plastic or Aluminum Spinner)…………….
Vertical Stabilizer Height……………………………
Track Width..…………………………………………
Tail Span……………………………………………..
Battery Location……………………………………..
1320 lb
21 gal.
0.75 gal.
Rotax 912 Series
66.7" Tonini GT
6.00 x 4, 6-Ply Rating
29 - 34 psi
4.00 x 4, 6 Ply Rating
29 - 34 psi
20°, +/- 1°
12°, +/- 1°
0° to 40°, +/- 3°
27°, +/- 2°
27°, +/- 2°
25°, +/- 1°
19°, +/- 1°
19°, +/- 1°
19°, +/- 1°
32.3'
21.4'
21.7'
7.5'
6.9'
9.1'
Firewall
1.3 Torque Values
A Chart of recommended nut torque values is shown in figure 1-2. These torque
values are recommended for all installation procedures contained in this manual,
except where other values are stipulated. They are not to be used for checking
tightness of installed parts during service.
Figure 1-2.
M4…………………………………………………………….
M5…………………………………………………………….
M6…………………………………………………………….
M8…………………………………………………………….
M10…………………………………………………………...
4 Nm / 35 in.lb.
6 Nm / 53 in.lb.
10 Nm / 88 in.lb.
24 Nm / 212 in.lb.
35 Nm / 310 in.lb.

Changed 1
Section 1-3
Caution
DO NOT REUSE SELF-LOCKING NUTS.
1.4 Tire Inflation Pressure
Maintain tire pressure at the air pressure specified in figure 1-1. When checking tire
pressure, examine tires for wear, cuts, bruises and spillage. Remove oil, grease and
mud from tires with soap and water.
1.5 Approved Oils and Capacities
In general we recommend referring to the latest ROTAX 912 Series engine operator's
manual to check for a suitable engine oil. Nevertheless, general recommendations
about lubricants are shown in figure 1-3.
Caution
If engine is mainly run on AVGAS more frequent oil changes will be required. See
ROTAX Service Information SI-18-1997, latest edition. At the selection of suitable
lubricants also refer to the ROTAX Service Information SI-18-1997 latest edition.
The use of multi-grade oils is recommended. Multi-viscosity grade oils are less
sensitive to temperature variations than single-grade oils. They are suitable for use in
all seasons, ensure rapid lubrication of all engine components at cold start and multi-
viscosity oils get less fluid at higher temperatures.
Figure 1-3.
Oil specification
Motorcycle oil of a registered brand with gear additives. No aircraft engine oil should
be used.
-
-
-
-
-
Use only oil with API classification "SF" or "SG"
Due to high stresses in the reduction gears, oils with gear additives such
as high performance motorcycle oils are required.
Because of the friction clutch incorporated in the gearbox, oils with
friction modifier additives are unsuitable as this could result in a slipping
clutch during normal operation.
Heavy duty 4-stroke motorcycle oils meet all the requirements. These
oils are normally not mineral oils but semi- or full-synthetic oils.
Oils primarily for Diesel engines are generally unsuitable due to
insufficient high temperature properties and additives which favor
clutch slipping.

Changed 1
Section 1-4
Table of lubricants
Since the temperature range of neighboring SAE grades overlap, there is no need for
change of oil viscosity for a short duration of ambient temperature fluctuation.
Climatic conditions Multi-grade oils
Tropical……………………………………
Temperate………………………………..
Arctic………………………………………
SAE 20W-50, SAE 20W-40
SAE 15W-50, SAE 15W-40
SAE 10W-40
SAE 5W-50, SAE 5W-40
SAE 20W-50, SAE 20W-40
SAE 15W-50, SAE 15W-40
SAE 10W-40
SAE 5W-50, SAE 5W-40
SAE 10W-40
SAE 5W-50, SAE 5W-40
1.6 Engine Specifications
The ROTAX 912 Series engines are 4-stroke, 4 cylinder horizontally opposed, spark
ignition engines, featuring one central camshaft with push rods – OHV. Cylinder
heads are liquid cooled. Lubrication system is a dry sump forced type. It is equipped
with dual breakerless capacitor discharge ignition and two constant velocity
carburetors. Prop drive is via reduction gear with integrated shock absorber and
overload clutch. Specific engine datas are given in figure 1-4.
Figure 1-4.
Description
Dimensions
Bore………………………………………………….
Stroke………………………………………………..
Displacement……………………………………….
Compression ratio……………………………….....
Weight (without exhaust, radiator, air intake System)….
Speed
Takeoff speed………………………………………
Continuos speed (max.)…………………………...
Idle speed (approx.)………………………………..
Gear Ratio…………………………………………………..
Performance
Takeoff performance……………………………….
Continuos performance…………………………….
Acceleration
912 UL
3.13 in
2.40 in
73.9 in3
9.0 : 1
132 lb
5800 rpm
5500 rpm
1700 rpm
2.27 : 1
80 hp
77 hp
912 UL/S
3.31 in
2.40 in
82.5 in3
10.5 : 1
134 lb
5800 rpm
5500 rpm
1700 rpm
2.43 :1
100 hp
92 hp

Changed 1
Section 1-5
Max. negative "g" for 5 seconds……………………
Oil Pressure
Max. for short period at cold start…………………
Min. (below 3500 rpm)……………………………..
Normal (above 3500 rpm)…………………………
Deviation from Bank Angle max………………………….
Oil Temperature
Max…………………………………………………..
Min…………………………………………………...
Normal……………………………………………….
Cylinder Head Temperature
Max. (observation at hottest cylinder, #2 or #3)…
Normal……………………………………………….
Engine Start, Operating Temperature
Max…………………………………………………..
Min……………………………………………………
Fuel Pressure
Max…………………………………………………..
Min…………………………………………………...
Electric Starter………………………………………………
Generator……………………………………………………
-0.5 g
100 psi
12 psi
29 - 73 psi
40°
285° F
120° F
190-230° F
300° F
167-230° F
120° F
-13° F
5.8 psi
2.2 psi
12V, 0.6 kw
12V, 20A
- 0.5 g
100 psi
12 psi
29 - 73 psi
40°
285° F
120° F
190-230° F
300° F
167-230°F
120° F
-13° F
5.8 psi
2.2 psi
12V, 0.6 kw
12V, 20A
1.7 Equipment List
In figure 1-5 a list of factory installed equipment is provided. Additional installed
equipment and alterations have to be considered when performing weight and
balance calculation. If a ballistic recovery system is installed from the factory, this is
already included in the factory weight and balance calculation form.
Figure 1-5.
Factory Installed Equipment
Airspeed Indicator, Altimeter, Vertical speed indicator, Compass, Slip indicator
RPM gauge (Rotax Flydat)
Oil pressure gauge (Rotax Flydat)
Oil temperature gauge (Rotax Flydat)
CHT gauge (Rotax Flydat)
Exhaust gas temperature gauge (Rotax Flydat)
Manifold temperature
Electric fuel gauge
Position lights
ACL (Anti Collision Light)
Master-, avionics and engine kill (ignition) switch
Electrical system including circuit breakers
4-Point safety belts (pilot and passenger)
Ballistic recovery system (optional factory equipment)

Changed 1
Section 1-6
1.8 Weight and Balance Information
To perform a successful weight and balance calculation, the center of gravity "C.G."
has to be determined with all installed equipment, including engine oil, cooling liquid,
but without fuel. Figure 1-6. shows how to conduct the C.G. determination. All
measurements including a listing of all installed equipment have to be noted in the
separate weight and balance calculation form (an example is given in figure 1-7.).
This form has to be placed in the aircraft, so every pilot will be able to conduct his
specific weight and balance calculation prior to each flight.
1.8.1 Center of gravity determination
Required Tools: Weighing scales, flexible clear hose, plummet, pocket-rule.
Parts required: None
Level of Maintenance: Line
Certification required: A&P Mechanic or LSA Repairman Maintenance
To get the correct values, it is necessary to put the aircraft on three weighing
scales located on a level surface. Before conducting the weighing procedure, it
is important to achieve a level wing main chord, outlined as “Reference Line
R.L.” in figure 1-6. (use suitable pads between main wheels and scale beneath
to hoist aircraft). A check-mark (“Reference Point R.P.” in figure 1-6.) on the
leading edge of the left wing, adjacent to the wing root is provided to ease
examination that wing main chord is level (check-mark and trailing edge has to
be level) - use a flexible clear hose, filled with water as spirit level.
To get the total weight G you have to add weight G1 and G2. The center of
gravity has to be calculated using this value. The C.G. is located at the
distance (X) behind R.P. (leading edge check-mark) near the fuselage (see
figure 1-6.).
1.8.2 CG-Calculation
A specific C.G.-calculation recommendation which has to be carried out prior
to each flight is provided in the Pilot Operating Handbook, Section 4.

Changed 1
Section 1-7
Figure 1-6.
Figure 1-7.

Changed 1
Section 1-8
1.9 Sources to Purchase Parts
In figure 1-8. sources to purchase spare parts and disposable parts are given. When
in doubt, ask your distributor or contact the factory first.
Figure 1-8.
Part Description
Airframe and Engine Components……………
Engine Components…………………………
Source to buy
REMOS Aircraft GmbH Flugzeugbau
Franzfelde 31
D-17309 Pasewalk / Germany
Phone: [phone]
e-mail: [email protected]
web: www.remos.com
997 Happy Trails Dr
Hangar A1
Rogers AR. 72758
USA
Phone: [phone]
e-mail: [email protected]
web: www.remos.com
Refer to ROTAX Engine Operator´s
Manual 912 Series, Section 14
1.10 Disposable Replacement Parts
A listing of disposable replacement parts which shall be replaced if necessary at
regular servicing intervals is given in figure 1-9. A listing where to purchase
replacement parts is shown in figure 1-8. When damage is determined to any part of
the aircraft please contact your REMOS distributor when in doubt about replacement
or repair. No repairs must be done to any of the listed parts due to flight safety!
Figure 1-9.
Part Description or Location
Engine Compartment…………………………
Part Description
Oil Filter Element
Gasket for Oil Filter
Gasket for Oil Drain Screw
Air Cleaner Element
All Gaskets in General
Exhaust System
Retaining Springs
Self-Locking Nuts in General
Propeller Screws

Changed 1
Section 1-9
Other specific Engine Components…………
Propeller……………………………………….
Landing Gear………………………………….
Airframe……………………………………….
Engine Mount Screws
Engine Shock Mounts
Throttle Control Cables
Refer to ROTAX Engine
Maintenance Manual.
Refer to TONINI Operators Manual
Tires and Tubes
Cotter Pins in General
Hydraulic Line Fittings
Self Locking Nuts in General
Brake Pads
Brake Discs
All Wheel and Landing Gear
Components when damaged in
General.
Self Locking Nuts in General
Cotter pins in General
1.11 General Safety Information
This aircraft shall never be operated at locations, airspeeds, altitudes or other
circumstances from which a successful no-power landing cannot be made, after
sudden engine stoppage. This aircraft must only be flown at VFR (daylight)
conditions and it is not suitable for acrobatics.
Whether you are a qualified pilot or a novice, complete knowledge of the aircraft, its
controls and operation is mandatory before venturing solo. Flying any type of aircraft
involves a certain amount of risk. Be informed and prepared for any potentially
hazardous situation associated with flying.
A recognized training program and continued education for piloting an aircraft is
absolutely necessary for all aircraft pilots. Make sure you also obtain as much
information as possible about your aircraft, its maintenance and operation from your
dealer.
Respect all government or local rules pertaining to flight operation in your flying area.
Fly only when and where conditions, topography and airspeeds are safest.
Select and use proper aircraft instrumentation -- only approved instrumentation may
be installed.
Before flight, ensure that all engine controls are operative. Make sure all controls can
be easily reached in case of emergency.
Unless in a run up area, never run the engine with the propeller turning while on the
ground. Do not operate engine if bystanders are close.
In the interest of safety, the aircraft must not be left unattended while the engine is
running.
Keep an aircraft log and respect engine and aircraft maintenance schedules. Keep
the engine in top operating condition at all the times. Do not operate any aircraft
which is not properly maintained or has engine operating irregularities which have not
been corrected.

Changed 1
Section 1-10
Since special tools, equipment and certification may be required, servicing shall only
be performed by repairmen specified in this manual.
To eliminate possible injury or damage, ensure any loose equipment or tools are
properly secured before starting the engine.
When in storage, protect the engine and fuel system from contamination and
exposure.
Certain areas, altitudes and conditions present greater risk than others. The engine
may require carburetor recalibration or humidity or dust/sand preventive equipment,
or additional maintenance may be required.
Never operate the engine and gearbox without sufficient quantities of lubricating oil.
Periodically verify level of coolant.
Never exceed maximum rated rpm. Allow the engine to cool at idle for several
minutes before turning off.
1.12 Reporting possible Safety of Flight Concerns During Inspection
If any concerns about safety of flight are determined during inspection or
maintenance this must be reported in the inspection form (refer to Section 2). If in
doubt about the airworthiness of the aircraft, it is strongly recommended to contact
your REMOS distributor. The aircraft must not be flown unless concerns about flight
safety are cleared completely.

Section 2-1
Section 2
Ground Handling, Servicing, Cleaning, Lubrication and Inspection
Table of Contents Page
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.6.1
2.1.7
2.1.7.1
2.1.7.2
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
2.4
2.5
2.5.1
2.5.2
2.5.3
Ground Handling………………………………………………………
Towing………………………………………………………….
Hoisting…………………………………………………………
Jacking………………………………………………………….
Parking………………………………………………………….
Tie-Down……………………………………………………….
Flyable Storage………………………………………………..
Returning Aircraft to Service…………………………
Temporary Storage……………………………………………
Inspection During Storage……………………………
Returning Aircraft to Service…………………………
Servicing……………………………………………………………….
Fuel……………………………………………………………..
Fuel Drains……………………………………………………..
Engine Oil………………………………………………………
Engine Induction Air Filter……………………………………
Battery………………………………………………………….
Tires…………………………………………………………….
Hydraulic Brake System………………………………………
Cleaning………………………………………………………………..
Windshield and Windows…………………………………….
Plastic Trim…………………………………………………….
Painted Surfaces………………………………………………
Aluminum Surfaces……………………………………………
Engine and Engine Compartment…………………………...
Upholstery and Interior………………………………………..
Propeller………………………………………………………..
Wheels………………………………………………………….
Lubrication……………………………………………………………...
Inspection………………………………………………………………
Inspection Requirements……………………………………..
Inspection Charts……………………………………………...
Inspection Guide Lines………………………………………..
2-1
2-1
2-2
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-3
2-4
2-4
2-4
2-4
2-5
2-5
2-6
2-9
2-9
2-9
2-9
2-10
2-10
2-10
2-10
2-11
2-11
2-11
2-11
2-11
2-12
2-12
2.1 Ground Handling
2.1.1 Towing
Moving the aircraft by hand is accomplished by using the wing struts and landing
gear struts as push points. Since there is no tow bar applicable at the nose gear, you
have to press down the tail cone adjacent to the fin to raise the nose wheel off the
ground. With the nose wheel clear of ground, the aircraft can be turned by pivoting it
about the main wheels.

Section 2-2
2.1.2 Hoisting
The aircraft may be lifted with a hoist of at least 1000 lb (0.5 tons) capacity by using
suitable slings. To apply the slings, the wings have to be folded back first (refer to
Pilot Operating Handbook, chapter 8). Now the wing main bolt brackets at the
fuselage are accessible. Using a suitable securing bolt the slings can be hooked in at
those brackets.
2.1.3 Jacking
Refer to paragraph 2.3. The aircraft does not feature further jacking points except for
changing main wheels. Doing so requires one person to lift the aircraft by pushing up
the wing at the wing tip, while a second person has to put a jack beneath the main
wheel strut adjacent to the fuselage. A piece of foam must be inserted between jack
and fuselage so that no damage will occur to the paint.
2.1.4 Parking
Parking precautions depend principally on local conditions. As a general precaution,
set parking brake or chock the wheels and lock the controls. In severe weather and
high wind conditions, tie down the aircraft as outlined in paragraph 2.6. if a hangar is
not available.
Caution
Do not set parking brakes during cold weather (when accumulated moisture may
freeze the brakes) or when brakes are overheated.
2.1.5 Tie-Down
When parking the aircraft in the open, head into the wind if possible. Secure control
surfaces by using suitable locks and set brakes.
After completing the preceding, proceed to moor the aircraft as follows:
Tie ropes to the wing tie-down fittings (upper end of each wing strut). Secure
the opposite ends of ropes to ground anchors.
Secure a tie-down rope (no chains or cables) to the exposed propeller shaft
and secure the opposite end of the rope to a ground anchor.
Secure the middle of a rope to the tail tie-down ring. Pull each end of rope
away at a 45-degree angle and secure to ground anchors at each side of tail.
Secure controls to the rearward position by using the seat belts.
2.1.6 Flyable Storage
Flyable storage is defined as a maximum of 30 days non-operational storage and/or
the first 20 hours of intermittent engine operation.

Section 2-3
During the 30 day non-operational storage or the first 20 hours of intermittent engine
operation, every seventh day the propeller shall be rotated through 10 revolutions,
without running the engine. If the aircraft is stored outside, tie-down in accordance
with paragraph 2.1.5. In addition, the pitot tube, static airvents, air vents, openings in
the engine cowling, and or similar openings shall have protective covers installed to
prevent entry of foreign material. After 30 days, aircraft should be flown for 30
minutes or ground run-up until oil has reached operating temperature.
2.1.6.1 Returning Aircraft to Service
After flyable storage, returning the aircraft to service is accomplished by performing a
thorough pre-flight inspection. At the end of the first 20 hours of engine operation,
drain engine oil and replace external oil filter element. Service engine with correct
grade and quantity of engine oil. Refer to figure 1-3. and paragraph 1.5 for correct
grade of engine oil.
2.1.7 Temporary Storage
Temporary storage is defined as aircraft in a non-operational status for a maximum of
90 days. The aircraft is made from composite materials and epoxy resin. This
construction will allow to store the aircraft for long periods without damage to the
airframe. Nevertheless we recommend to store the aircraft in a dry hanger to keep
paintwork and metal parts in good condition. For storage periods not to exceed 90
days, the following methods of treatment are suggested:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Fill fuel tank with correct grade of gasoline.
Clean and wax aircraft thoroughly.
Clean any oil or grease from tires and coat tires with a tire preservative. Cover
tires to protect against grease and oil.
Rotate wheels every 30 days to change supporting points and prevent flat
spotting the tires.
Seal or cover all openings which could allow moisture and/or dust to enter.
Remove battery and store in a cool dry place, charge battery as required.
Seal all engine openings exposed to the atmosphere using suitable plugs or
none-hygroscopic tape. Attach a red streamer at each point that a plug or tape
is installed.
If the aircraft is to be stored outside, perform the procedures outlined in
paragraph 2.1.5. In addition, the pitot tube, static ports, air vents, opening in the
engine cowling and other similar openings should have protective covers
installed to prevent entry of foreign material.
Attach a warning placard to the propeller to the effect that the propeller shall not
be moved while the engine is in storage.
2.1.7.1 Inspection During Storage
Remove dust accumulations as frequently as possible, clean and wax as required.
2.1.7.2 Returning Aircraft to Service
After temporary storage, use the following procedures to return aircraft to service:

Section 2-4
a.
b.
c.
d.
e.
f.
g.
Check tires for proper inflation.
Check battery and install.
Check the oil sump has proper quantity of engine oil (Refer to Pilot Operating
Handbook and/or Rotax Operator´s Manual for instructions).
Service induction air filter and remove warning placard from propeller.
Remove materials used to cover openings.
Check fuel tank and fuel lines for moisture and sediment, drain enough fuel to
eliminate moisture and sediment.
Perform a thorough pre-flight inspection, then start and warm-up engine.
2.2 Servicing
Servicing requirements are shown in figure 2-2. The following paragraphs
supplement this figure by adding details not included in the figure.
2.2.1 Fuel
Fuel tank should be filled immediately after flight to lessen moisture condensation.
Tank capacity is listed in Section 1. The recommended fuel grade to be used is given
in figure 2-2.
2.2.2 Fuel Drains
A fuel drain is located is located at the bottom of the fuel tank. The drain valve is
accessed from beneath the fuselage adjacent to the main landing gear. To activate
push up the white plastic tube. To drain all fuel from the tank without holding the
valve depressed a lock mechanism is built in. To activate the lock mechanism, push
up the white plastic tube and rotate it until it locks.
2.2.3 Engine Oil
Check engine lubrication oil with the oil dipstick located in the oil tank, located on the
right hand side of the firewall, immediately after engine has been stopped. To check
the oil level, it is important to turn the propeller a few times in operating direction until
you can hear some kind of bubbling noise coming out of the oil expansion tank.
Please be sure to remove the key from the ignition switch before turning the
propeller. This is the only way to check the engine oil level correctly. (Refer also to
the ROTAX Engine Operator's Manual).
Engine oil should be drained while the engine is still hot so that more positive
draining is obtained. Refer to the inspection charts for required intervals for oil and
filter changes. Change oil at least every 12 months even if less than the specified
hours have accumulated. Reduce this period for prolonged operation in dusty areas,
in cold climates where sludging conditions exist, or where short flights and long idle
periods are encountered, which cause sludging conditions.
Caution
Do not operate with less than the minimum engine oil level on dipstick marking.

Section 2-5
2.2.4 Engine Induction Air Filter
The induction air filter keeps dust and dirt from entering the induction system. The
value of maintaining the air filter in a good clean condition can never be
overstressed. More engine wear is caused through the use of dirty or damaged air
filter than is generally believed. The frequency with which the filter should be
removed, inspected and cleaned will be determined primarily by aircraft operating
conditions. A good general rule however, is to remove, inspect and clean the filter at
least every 50 hours of engine operating time and more frequently if warranted by
operating conditions. Due to reasons of flight safety the filter should be replaced after
using 100 hours of engine operation time or one year, whichever should occur first.
Note
The aircraft is equipped with an oiled K&N Pre-Charger Filter Element, which can be
cleaned and re-oiled when necessary. Its special design provides extended servicing
intervals. For proper cleaning and re-oiling the use of K&N air filter cleaner is
recommended and K&N air filter oil is required.
Caution
The filter has to be replaced if damaged, if in doubt filter has to be replaced as a
precaution to flight safety. Be sure air box is clean before installing a new filter.
2.2.5 Battery
The installed battery needs no further servicing, except checking cable connections.
It is important to check battery voltage when the aircraft is out of service for more
than two weeks. Battery voltage has to maintain at least 12.0 volts without engine
running and all equipment switched off, master switch in "off" postion (regular voltage
12.5 volts). If voltage does indicate 12.2 volts or less it has to be charged and
maintaining charge instructions are found on the battery. If battery voltage is less
than 11.8 volts a replacement battery is required.