Tiger Aircraft AA-5 TRAVELER User manual

ST
I
I
TIGER AIRCRAFT LLC
MAINTENANCE MANUAL
FOR
Gulfstream Aerospace Corporation*
MODELS:
AA-5 TRAVELER
AA-5A CHEETAH
AA-5B TIGER
ISSUED: NOVEMBER 15,1976
REVISION 5: MARCH 1, 2004
*REVISION 5 -CONTENT REVIEWED AND APPROVED BYTYPE DESIGN HOLDER
TIGER AIRCRAFT LLC
226 PILOT WAY
MARTINSBURG, WV

JfpN
TITLE
AIRCRAFT GENERAL
Time Limits/Maintenance Check
Dimensions and Areas
Lifting and Shoring
Leveling and Weighing
Towing and Taxiing
Parking and Mooring
Placards and Markings
Servicing
AIRFRAME SYSTEMS
Standard Practices — Airframe
Air Conditioning
Auto Flight
Communications
Electrical Power
Equipment/Furnishings
Flight Controls
Fuel
Ice and Rain Protection
Landing Gear
Lights
Navigation
Vacuum
STRUCTURE
Doors
Fuselage
Stabilizers
Windows
A A-5 SERIES
MAINTENANCE MANUAL
LIST OF CHAPTERS
CHAPTER NO.
5
6
7
8
9
10
11
12
20
21
22
23
24
25
27
28
30
32
33
34
37
52
53
55
56
List of Chapters
Page 1
July 15/78

TITLE
Wings
PROPELLER
Propellers
POWER PLANT
Power Plant General
Engine Fuel and Control
Ignition
Engine Indicating
Exhaust
* 0iI
$Starting
chajJts
Charts
A A-5 SERIES
MAINTENANCE MANUAL
UST OF CHAPTERS
CHAPTER NO.
57
61
71
73
74
77
78
79
80
91
List of Chapters
Page 2
July 15/78

AA-5 SERIES
MAINTENANCE MANUAL
INTRODUCTION
GENERAL
The function of this Maintenance Manual Is to acquaint maintenance personnel with the systems andtheir
components of the
AA-5, AA-5A and AA-5B aircraft and to direct them in the proper procedures for
maintaining the aircraft In an airworthy condition.
This manual contains Information on installations made in the aircraft during manufacture and optional
equipmentonly. However, information derived from applicable Single Engine Aircraft Service Kits,
Service Bulletins, and Service Letters will be included in the manual as soon as possible after the
issuance of these documents. Changes or installations made by the operator are not Included In this
manual.
The ability of maintenance personnel is recognized, and those procedures which are considered common
to
all aircraft have been either briefly referenced or omitted.
FORMAT
The chapter identification in this manual has been prepared In accordance withAir Transport Associa
tion
(ATA) Specification No. 100. A functional breakdown is employed whereby all data pertaining to a
given system, or component of a system, may be found In one chapter with a minimum of cross-refer
encing to other chapters.
The Electrical Power Chapter in this manual covers only the power sources anddistribution equipment
- for the electrical system. There is not a chapter in this
manual specifically designated for instruments.
Details of individual branch electrical or instrument systems will be found in the applicable chapter.
IDENTIFICATION OF SUBJECT MATTER
Athree-dash number system is employed to Identify subject matter. The first dash number Identifies
the chapter, the second dash number the section, and the third dash number the component or sub
section of the section. The following example illustrates how the numbering
system is used in the
NAVIGATION Chapter.
34 - l — i
•Identifies NAVIGATION Chapter.
• Identifies that section (group of related subjects) which
provides coverage for the Flight Environment Data
portion of the NAVIGATION Chapter.
•Identifies a specific subject (component) of the Flight
Environment Data. In this manual It
is assigned to the
Pitot and Static Pressure Systems.
The dash 0 (-0) is provided as a means for covering a complete system or sub-system. The chapter
number followed by a zero (34-0) will segregate that material covering the complete system; the chapter
section numbers
followed by a zero (34-1-0) is used for further details covering the sub-system or com
ponent.
PAGE NUMBER IDENTIFICATION
Page number blocks are used to separate the subject matter into the following categories:
General Coverage andUnit Description Pages 1 through
1Q0
Troubleshooting Pages 101 through 200
Maintenance Practices (See Below)
Introduction
Pagel
Nov 15/76

AA-5 SERIES
MAINTENANCE MANUAL
Maintenance Practices include as applicable the following sub-topics: Servicing, Removal/Installation.
Adjustment/Test, Inspection/Check, Cleaning/Painting, and
Approved Repairs.
If all sub-topics, under Maintenance Practices are brief, they are combined into one topic. All such com
bined topics are numbered withinpage number
block 201-300. Whenever individualsub-topics are so
lengthy thata combination requires several pages, each sub-topic is treated as an individual topic. Page
number blocks for this sub-topic arrangement are as follows:
Servicing 301 - 400
Removal/Installation 401 - 500
Adjustment/Test 501 - 600
Inspection/Check 601 - 700
Cleaning/Painting 701 - 800
Approved Repairs 801 - 900
Each
new subject starts with page 1, 101, 201, etc., and continues through the page block assignment to the
extent necessary. The first page of each block is placed on a right-hand page.
I
-FIGURE IDENTIFICATION
Figures (illustrations) are numbered consecutively within eachtopic (subject) as follows:
Figures in Description - 1, 2, 3, 4, 5, etc.
Figures in Troubleshooting - 101, 102, 103, etc.
Figures in Maintenance Practices -
When not sub-divided - 201, 202, 203, etc.
When sub-divided -
Servicing- 301, 302, 303, etc.
Removal/Installation - 401, 402, 403, etc.
Adjustment/Test - 501, 502, 503, etc.
Cleaning/Painting- 701, 702, 703, etc.
Approved Reoairs - 801, 802, 803, etc.
INDEXING
Each chapter is prefaced with a table of contents identifying the subject matter within the chapter in the
order of presentation. The table of contents is arranged with the following headings: DESCRIPTION:
TROUBLESHOOTING; and MAINTENANCE PRACTICES.
PART NUMBERS
This manual must not be used for identifying spare parts by number. Consult the Illustrated Parts
Catalog for this information. Part numbers are used in this manual only as a means of identification
when nomenclature alone is inadequate.
Introduction
Page 2
Nov
15/76

J#*N
AA-5 SbRIES
MAINTENANCE MANUAL
REVISIONS
Revisions to the original text are indicated by vertical lines in the left margin of the page, adjacent to
the revised material.
The manual is provided with a "Record of Revisions" page for recording revisions by number and the
dates on which they were inserted in the manual.
Each page revised or added to the Initial manual will be identified by the date of revision at the bottom
of the page. Pages issued with the original manual are identified with the issue date of the manual.
Each revision also contains a "Listof Effective Pages". This list contains the chapter, page number,
and date of each page which is effective since the issuance of the initial manual. This list Is updated
for each revision, with page changes indicated by the number of asterisks (*) placed adjacent to the
page number as noted below:
*Pages revised by the current revision.
♦♦Pages added by the current revision.
♦♦♦Pages deleted by the current revision.
CROSS REFERENCE
NAME, MODEL DESIGNATION AND EFFECTIVE SERIAL RANGES
Gulfstream Americanaircraft are certified under model number designations. For marketing
.purposes, each model is also given a name. The aircraft model number is used in this publication except
where the name is necessary to differentiate between versions of the same basic model. The following table
contains a listing of name, model years, model number, and
serial range.
POPULAR NAME
MODEL
YEAR
MODEL
SERIAL NOS.
BEGINNING
ENDING
AA-5 or Traveler
AA-5 or Traveler
AA-5 or Traveler
AA-5 or Traveler
AA-5A or Cheetah
AA-5 A or Cheetah
AA-5 A or Cheetah
AA- 5A or Cheetah
AA-5B or Tiger
AA-5B or Tiger
AA-5B or Tiger
AA-5B or Tiger
AA-5B or Tiger
1972
1973
1974
1975
1976
1977
1978
1979
1975
1976
1977
1978
1979
AA-5
AA-5
AA-5
AA-5
AA-5A
AA-5 A
AA-5 A
AA-5 A
AA-5B
AA-5B
AA-5B
AA-5B
AA-5B
AA5-0001
AA5-0155
AA5-0406
AA5-0641
AA5A-0001
AA5A-0283
AA5A-0523
AA5A-0671
AA5B-0001
AA5B-0111
AA5B-0400
AA5B-0693
AA5B-0906
AA5-0154
AA5-0405
AA5-0640
AA5-0834
AA5A-0282
AA5A-0522
AA5A-0670
AA5A-0900
AA5B-0110
AA5B-0399
AA5B-0692
AA5B-0905
AA5B-1323
Introduction
Page 3
January 4/80"

/I^v
jSPfev
CHAPTER 5
TIME LIMITS - MAINTENANCE CHECKS
TABLE OF CONTENTS
NUMBER
5-0
TIME LIMITS/MAINTENANCE CHECKS
Des criptlon/Operatlon
General
5-1-1 TIME LIMITS
Description/Operation
General
Service Life Limited Components
5-2-1 SCHEDULED MAINTENANCE CHECKS
Description/Operation
General
Maintenance Practices
Annual or 100-hour Inspection
Procedures
5-5-1 UNSCHEDULED MAINTENANCE CHECKS
Description/Operation
General
Maintenance Practices
Inspection Requirements
Bondline Damage, Inspection
Procedures and Repair
PAGE
1
1
1
1
1
1
1
201
1
1
201
201
204
5
Page 1
Nov 15/76

JPN
AA-5 SERIES
MAINTENANCE MANUAL
TIME LIMITS/MAINTENANCE CHECKS - DESCRIPTION/OPERATION
1. General
This chapter contains the manufacturer's recommended time limits, scheduled and unscheduled maintenance checks
and inspections.
5-0
1
July
15/78

• /S0&\
AA-5 SERIES
MAINTENANCE MANUAL
TIME LIMITS - DESCRIPTION/OPERATION
1. General
The service guide (Figure 1) contains the manufacturers' recommended time limits for inspection, main
tenance and overhaul of the airplane, its systems and units.
2. Service Life Limited Components
Recent changes in the Federal Aviation Regulations require that all new aircraft now being certified, for
which application for a type certificate, was made after September 14, 1969, have the
critical wing struc
ture components fatigue strength Investigated and that, where applicable, these components be service
life limited. Since the AA-5, AA-5A and AA-5B fall into this category, the following service life infor
mation is provided. The Model AA-5, AA-5 A and AA-5B wing and associated structure have been shown
capable of withstanding
the repeated loads of variable magnitude expected in service. This was accom
plished through a fatigue strength investigation, and as a
result of this Investigation, discrete service
lives have been established for several wing structure components. Those components and their corre
sponding service lives are listed in Figure 2.
Service life limited parts must be retired from service in accordance with the specified service life
hours listed in Figure 2.
All wing and fuselage structural components shall be subject to normal inspection, maintenance, repair
and replacement procedures. In addition, to ensure maximum
limited life, If corrosion is detected on
wing
or inboard spars, remove it as quickly as possible and protect the surface from further corrosion
in accordance with AC43.13-1A,"Acceptable Methods, Techniques and Practices - Aircraft Inspection
and Repair".
5-1-1
Pagel
Dec 15/77

AA-5 SERIES
MAINTENANCE MANUAL
SCHEDULED MAINTENANCE CHECKS - DESCRIPTION/OPERATION
1. General
The inspection procedures guideline included in this section may be used by the owner, inspector, or
mechanic to ensure complete and comprehensive coverage of the inspection requirements. The format
of the procedures canbe reproduced for ready use by the personnel performing the inspection. The
checklist includes the minimum requirements for the 100-hour or annual inspection.
5-2-1
Pagel
Nov 15/76

AA-5 SERIES
MAINTENANCE MANUAL
INSPECTION MAINTENANCE
Inspection Interval
(Operating Hours)
NOTE
50
100
1000
AIRFRAME
1. Clean aircraft.
2. Aircraft structure (especially the spar around the
inboard and outboard wing lock shoulder bolts, gear
attachments, and fuselage attach collars)
3. Windows, windshield and canopy
4.
Seats, console, interior and seat belts
5. Instrument panel, instruments and placards
6. Baggage
compartment and cargo tie downs
.. 7.
Radio antennas
|8. Nose gear torque tube assembly
i
$9. Control T-column and bearings
10. Forward empennage attachments
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
i
LANDING GEAR
1. Strut and upper and lower strut brackets, main gear
2. Strut, torque tube assy,, fork and boot
assy, nose gear
3.
Nose and main wheel bearing lubrication
4. Nose fork swivel lubrication
5. Brake linings and discs
6. Wheel fairings scraper adjustment
7. Main and nose tire pressure
r*
X
X
X
X
X
X
X
X
X
X
X
X
X
a
b
CONTROL SYSTEMS
1. Cables, turnbuckles, pulleys, guards and terminals
2. Rudder pedals and springs
3. Flaps, flap actuator, flap actuator jack screw, flap
push-pull rods, flap torque tubes, torque tube
bearings, bearing supports and position indicator
4. All control Stops
X
X
X
X
X
X
X
X
J
Service Guide
Figure 1 (Sheet 1 of 4)
5-2-1
Page 2
Dec 15/77
/-3%

AA-5 SERIES
MAINTENANCE MANUAL
I
INSPECTION MAINTENANCE
Inspection Interval
(Operating Hours)
NOTE
50
100 1000
CONTROL SYSTEMS (Continued)
5.
Elevator trim wheel, indicator, indicator shaftand
actuator shaft drive screw. Elevator trim tab free
play (AA-5A and AA-5B only).
XX1
6. Ailerons,
aileron torquetubes, aileron balance
weights, bearings and bearing brackets XX
POWERPLANT
1. Oil Change XXX
2.
Oil Screens and cooler
XXX
3. Replace oil filter
if external filter is used XXX
4. Spark plugs XX
•• 5. Ignition harness XXX
; 6. Magneto timing c
7. Exhaust system XX X
8. Throttle, carburetor heat and mixture controls
operation
XXX
9. Engine
baffles
X X X
10. Air filter
X X Xk
11. Engine
mount
XX X
12. Oil breather vent
XXX
13. All lines, flex ducts and connections X X Xd
14. Oil and fuel pressures XXX
15. Propeller and spinner XXX
16. Alternator belt
X X X
17. Cylinders, crankcase, accessory section, front
crankshaft seal
XXX
18. Engine overhaul e
Service Guide
Figure 1 (Sheet 2 of 4)
5.2-1
Paged
January
4/80

I
AA-5 SERIES
MAINTENANCE MANUAL
INSPECTION MAINTENANCE
Inspection Interval
(Operating Hours)
NOTE
50
100
1000
FUEL SYSTEM
1. Electric fuel pump filter
XXX
2.
Fuel cap gaskets
XXX
3. Fuel overboard vents
XXX
4.
Fuel tanks, fuel sumps and drains (4) XX
5; Fuel
selector and placard XX
6.
Fuel gauges XX
7. All hoses and lines
XXXd
8.
Fuel primer
XX
UTILITY SYSTEMS
| 1. Master cylinder fluid level
XXX
f 2.
Parking brake operation
XX
H
3. All hoses, lines, and connections
XX
4.
Pitot and static systems
X X
5. Pitot line drain
XX
6.
Vacuum regulator and filter
XXf
7. Flexible ducts for heating
system
XX
8. Cabin
heat control operation XX
9.
Compass check
Xg
10.
Vacuum pump
Xh
ELECTRICAL SYSTEM
1. Battery fluid level
t'
X X X
2.
Battery hydrometer check
XX
3. All connections
XX
4.
All lights for operation XXX
5.
All wiring harnesses and wires
XX
Service Guide
Figure 1(Sheet 3 of 4)
5-2-1
Page 4
Dec 15/77

/jtpfc>,
AA-5 SERIES
MAINTENANCE MANUAL
INSPECTION MAINTENANCE
Inspection Interval
(Operating Hours)
NOTE
50
100
1000
ELECTRICAL SYSTEM (Continued)
6. Stall
warning.
7. Electric flap motor.
XX
X
X
X
NOTES:
a.
b.
c.
d.
e.
f.
Remove nose gear strut from torque yoke and inspect for corrosion of the surfaces every 12 calendar months.
Remove corrosion and paint surfaces with zinc chromate primer and reassemble wet. Seal strut to yoke con
nection with RTV-102 by Dow-Corningor equivalent.
Clean and repack wheel bearings at first 100 hours. Inspect wheel bearing grease for contamination and solid
ification at each annual or 100 hour inspection. Do not exceed 500 wheel miles between repacking intervals.
Maximum time between magneto timing checks100 hours. Magneto replacementrecommended after 900
hours of service.
Recommended replacement of all flexible pressure lines at engine overhaui or every five years, whichever
comes first.
Maximum engine overhaul time 2000 hours.
Replace gyros central air filter each 400 hours. Replace vacuum relief valve filter each 1000 hours. For opera
tion in dusty climates, replace filters more frequently.
g. Check accuracy of compass every 1000 hoursor at each time that an item of equipment is installed or re
moved that could affect the accuracy of the unit.
h. Recommended replacement of vacuum pump at 1000 hours.
i. Remove the fuel tank
access covers and inspect allinternal surfaces and structure for corrosion, cracks, and
bonding separation every
2000 hours or at any time the access covers are removed.
j. Replace rudder springs every 1000 hours.
k. Recommended replacement
of 1975 and later Model AA-5 and AA-5A air filters at 100 hours, 12 calendar
months,or when 50 percent covered with foreign material, whichever comes first. AA-5B foam type air filters
at 300 hours, 12 calendar months, or when 50 percentcoveredwith foreign material,whichever occurs first.
AA-5B paper type air filters at one year, 500 hours or after 10 cleanings.
1. Measure the elevator trim tab free play every
500 hours. Refer to 27-3-1.
Service Guide
Figure 1 (Sheet 4 of 4)
5-2-1
Page 5
January 4/80

AA-5 SERIES
MAINTENANCE MANUAL
COMPONENT
AIRCRAFT
MODEL
PART NUMBER
SERVICE LIFE
(AIRFRAME HRS.)
Inboard Spar Assembly
AA-5 & 5A
5102310-501 12,000
AA-5B
5102310-502 12,000
Shoulder Bolt
AA-5 & 5A
901044-1/-2
7,250
AA-5B
901044-2
7,250
Wing Spar Assembly
AA-5 & 5A
*5201002-501 12,500
AA-5A & 5B
♦5201004-501
12,500
Wing Outboard Spar
Assembly
AA-5 & 5A ♦5201189-501
12,500
AA-5B
♦5201189-501
12,500
♦Retiring of wing spars from service will generally require simultaneous re-
moval of corresponding wing panel assemblies from service.
Service Life Limited Components
Figure 2
5-2-1
Page 6
Dec 15/77

AA-5 SERIES
MAINTENANCE MANUAL
SCHEDULED MAINTENANCE CHECKS - MAINTENANCE PRACTICES
1. Annual
or 100-hour Inspection Procedures
A. Perform Annual or 100-Hour Inspection
Complete the inspection by performing each of the procedures detailed on the checklist, Figure 201.
Indicate completion by sign-off in the appropriate column.
B. In addition to the Servicing Guide and Annual or 100 Hour Inspection Procedure, the following steps
should be adhered to when performing an inspection or overhaul:
(1) Check any FAA Airworthiness Directive or Gulfstream American Service Bulletins/ Letters
for compliance at the time specified thereon. Also, appropriate sections
of this maintenance
manual.
(2) Check that all aircraft documents are present and In order:
Aircraft Airworthiness Certificate (Form FAA 8100-2)
Aircraft Registration Certificate (Form FAA 8050-1 or FAA 8050-3)
Weight and Balance Sheet
Aircraft Equipment List
Any Repair and Alteration Forms if applicable (Form FAA 337)
Aircraft Radio Station License If applicable (Form FCC 566 or FCC 453B)
Aircraft and Engine Log Books
NOTE: All of the above items except the log books must be carried in the aircraft at all
times. Form FAA 8100-2, FAA 8050-3 and FCC 556 (FCC 453-B) must be visually
displayed.
(3) Check that operating limitations placards (reference Chapter 11) are displayed.
5-2-1
Page 201
January 4/80

I
AA-5 SERIES
MAINTENANCE MANUAL
MODELS AA-5, AA-5A & AA-5B
ANNUAL OR 100 - HOUR INSPECTION PROCEDURE
ANNUAL OR 100 HOUR INSPECTION PROCEDURE GUIDELINE
FAR 43.15 (C) (1) states: "Each person performing an annual or 100 hour inspec
tion shall use a check list while performing the inspection. The check list may be
of the person's
own design, one provided by the manufacturer of the equipment
being Inspected, or one obtained from another source. This checklist must include
the scope and detail of the Items contained In appendix D to this part and paragraph
(b) of this section." The following pages contain acomprehensive annual or 100
hour inspection procedure check list. This check list has been prepared to assist
a mechanic in performing a detailed inspection of such scope and detail that when
the Inspection is completed, the mechanic is absolutely
sure that he has not over
looked any areas, even though he may not have previous experience on this parti
cular model aircraft. Once a mechanicbecomes familiar with this aircraft, he
may
wish to prepare his own check list, which must be within the scope of appendix
D
of FAR part 43.
OWNER'S NAME
STREET ADDRESS
CITY STATE ZIP CODE
IDENTIFICATION NUMBER SERIAL NUMBER
HOURS DATE INSPECTION COMPLETED
SERVICING AGENCY
CITY
Check for conformity with FAA Specifications,
Airworthiness Directives and Gulfstream American
Corporation and Supplier's Service Bulletins
and Letters.
NOTE
It is recommended that reference be made to
the applicable maintenance handbook, service
bulletins, letters, Installation instructions,
and vendor specifications for torque
values,
clearances, settings, tolerances and other
specification data.
Inspection Procedure Guideline
Figure 201 (Sheet 1 of 13)
STATE
5-2-1
Page 202
January 4/80

/^S
AA-5 SERIES
MAINTENANCE MANUAL
MODELS AA-5, AA-5A & AA-5B
ANNUAL OR 100 - HOUR INSPECTION PROCEDURE
PRE-INSPECTION ENGINE RUN UP
Prior to beginning the Annual or 100 hour inspection, an engine
run up is to be made to facilitate oil drainage and to observe the
following, noting any discrepancies:
MECH
INSP.
1. Fuel Pressure (0.5 to 8 PSI)
Electric Pump only prior to engine start up
Engine Pump only after engine start up Both , »
2.
Oil Pressure (60 to 90 PSI) (Approx. 25 PSI idling)
Actual. Actual
c. 3. Magneto RPM Drop (175 RPM maximum drop on either magneto;
|, no more than 50 RPM difference between magnetos.)
I
1! Actual Drop
Left Right
4. Static RPM: AA-5 & AA-5 A AA-5B
(2250-2375) (2150-2275)
Actual , • Actual
5. Idling Speed: AA-5 & AA-5A AA-5B
(600 to 650 RPM) (500 to 650 RPM)
Artiml Anhml
6. Ammeter (no steady discharge in normal operating range)
7. Suction Gauge (4.6 to 5.4 In. Hg.)
8.
Fuel Selector (check operation in all positions)
9. Carburetor Heat Control
10. Engine Response to change in power
11. Idle cut-off
Inspection Procedures Guideline
Figure 201 (Sheet 2 of 13)
5-2-1
Page 203
Nov
15/76

AA-5 SERIES
MAINTENANCE MANUAL
MODELS AA-5, AA-5A & AA-5B
ANNUAL OR 100 - HOUR INSPECTION PROCEDURE
A.
PROPELLER GROUP
MECH.
INSP.
1Remove spinner and check for cracks, scratches,
2.
Inspect blades for erosion, scratches, nicks and cracks.
Dress out nicks as required
1 '
Inspect spinner back plate, bulkheads and doubier for cracks
and secure mounting.
4.
*5.
ml.
Check propeller mounting bolt torque:
F^ftt pounds or inrh pounds.
Resafety propeller, mounting bolts
J-'
Reinstall spinner. Check spinner run out inch maximum
B.
ENGINE GROUP
MECH.
INSP.
1.
Remove engine cowL Clean and check for cracks, wear, dis
tortion,
loose or missing fasteners and landing light attach-
2.
Drain oil sump. Remove oil screens, clean and Inspect for
metal particles. Reinstall and resafety. Replace oil filter
(If installed). Cut apart and inspect old filter for metal
3.
Check oil temperature sending unit, oil Unes, cooler, and fit
tings for leaks, chafing, dents, cracks, and secure mounting.
4.
Fill engine with oil per lubrication chart.
5.
6.
Check engine cylinder compression #1. #2. #3. #4
7.
Clean and regap or replace spark plugs as required
(See latest revision of Lycoming Service Instruction No. 1042)
Iapplicable to
your aircraft for
quick reference during inspection.
Inspection Procedures Guideline
Figure 201 (Sheet 3 of 13)
5-2-1
Page 204
January 4/80
•^^s

AA-5 SERIES
MAINTENANCE MANUAL
MODELS AA-5, AA-5A & AA-5B
ANNUAL OR 100 - HOUR INSPECTION PROCEDURE
B. ENGINE GROUP (Continued)
MECH.
INSP.
9. Check magnetos to engine timing, oil seal leakage, and
distributor block for cracks, burned areas and corrosion
10. Remove and service air filter (see Chapter 73 for details).
Inspect carburetor heat control valve plate, shaft, valve plate
to shaft screws and bearings for signs of wear and security.
Replace filter and/or gasket if damaged or defective. Reinstall
11. Check induction air intake seals for leaks, deterioration and
Lhardness. Check flex ducts for broken or loose strings, loose
or displaced supporting wire and general overall condition
f. 12. Drain carburetor bowl. Reinstall drain plug. Remove and clean
carburetor fuel inlet screen with acetone. Reinstall screen ....
13. Remove and clean electric fuel pump filter. Reinstall and
14. Check fuel pump for proper operation and secure mounting.
Pressurize fuel system with electric pump and inspect fuel
system and lines for leaks. Check fuel primer for operation
16. Check security of throttle arm on carburetor. Check throttle,
carburetor heat, and carburetor mixture controls for proper
travel, security, operating condition and control cushion
17. Remove exhaust shroud and check muffler tailpipe, risers, clamps,
gaskets and exhaust system for cracks, leaks and secure mounting.
Inspection Procedures Guideline
Figure 201 (Sheet 4 of 13)
5-2-1
Page. 205